Overcoming Concrete Issues in 2024 – Surface Prep

A Closer Look at Portland-Limestone Cement
and the Questions It Raises

In the race toward reducing carbon emissions and building a more sustainable future, the construction industry has placed significant emphasis on material innovation. One of the most talked-about shifts in recent years is the rise of 1L concrete, also known as Type 1L Portland-limestone cement (PLC). While its environmental intentions are clear, the execution and field performance of this material have sparked deep concerns among contractors, finishers, and construction professionals across the country.

What Is 1L Concrete?

1L concrete is a blended cement product made by intergrinding Portland cement clinker with up to 15% finely ground limestone. It falls under ASTM C595 and was promoted as a more sustainable option than traditional Type I or Type II cement, with a claimed reduction in embodied carbon of about 10%.
This transition is part of a broader movement toward lowering the construction industry’s carbon footprint. However, for many professionals working in the field every day, the reality of 1L’s performance has not aligned with its promise.

Why the Push—And Why the Pushback?

Advocates of 1L cement cite decades of successful use in Europe and a growing need for climate-conscious practices. Major producers in the U.S. began shifting almost entirely to Type 1L in 2022 and 2023, often with little consultation or consideration for the practical realities faced by contractors and specialty finishers.
This sudden change, often framed as a “drop-in replacement,” has led to a number of serious challenges:
Surface Defects & Finish Failures
Many contractors have reported inconsistent finish quality, scaling, dusting, and difficulty achieving color uniformity in decorative and exposed applications. In some cases, these issues have led to litigation over failed installations.

Lack of Field Testing & Support

Although some densifiers and admixtures are being promoted as compatible with 1L, most have not undergone sufficient independent testing to ensure reliable long-term performance. Contractors are left to troubleshoot on their own, often at their own expense.

Distrust from the Field

For many in the construction world, especially those working on architectural concrete, decorative finishes, or high-performance surfaces, the lack of transparency and technical support has created a deep sense of frustration and mistrust.

What Industry Experts Are Saying

While many material producers remain committed to 1L cement, an increasing number of contractors, specifiers, and consultants are raising red flags. Some are now avoiding 1L altogether in high-exposure projects or are specifying additional treatments, sealers, or surface hardeners to compensate for performance issues.
Yet even these remedies come with asterisks: most haven’t been thoroughly tested alongside 1L, and results vary based on climate, substrate, and finishing practices. While some contractors are beginning to find combinations that work, there is no universally endorsed solution at this time.

Proceeding with Caution

There’s no question that sustainability is an urgent priority—but true sustainability must also account for durability, performance, and constructability. When cement fails in the field, the environmental impact of replacement materials and labor far outweighs any initial carbon savings.
As the industry continues to explore lower-carbon alternatives, many experts are calling for a more thoughtful, transparent, and inclusive approach—one that includes rigorous testing, real-world data, and support for the contractors on the front lines of implementation.

The Bottom Line

1L concrete may represent a step toward sustainability, but for now, it’s a step that should be taken with full awareness of its limitations. The current landscape demands caution, continued evaluation, and an honest dialogue between producers and practitioners.
Until field data improves and manufacturers take stronger accountability for performance, the use of 1L cement should be considered on a case-by-case basis, especially in projects where finish quality, color uniformity, or long-term durability are critical.

When admiring a stunning epoxy floor, it’s easy to appreciate the skillful craftsmanship and the way the seamless design elevates the room’s aesthetics. However, the most vital factor in a floor’s performance is the quality of the surface it adheres to. In Florida, we face unique challenges such as soft concrete, cracking, moisture migration, salt intrusion, and more, each capable of undermining a project if not properly addressed. Often, multiple issues can arise simultaneously, necessitating additional care during the surface prep phase to ensure a successful outcome.

The team at Top Coat Epoxy of Central Florida understands that thorough surface preparation is essential for achieving the best results in every project. During a recent multi-car garage job, an extensive multi-step surface preparation process was necessary due to a cream coat on the concrete slab that was compromised by spalls, embedded dirt, and grime.

The Most Vital Factor In A Coatings Success

To address this, the TCE team utilized diamond grinding to achieve a Concrete Surface Profile of 2/3, effectively removing the damaged outer layer and establishing a solid foundation for the new coating to adhere to. However, the surface preparation did not stop there. Luis from TCE then focused on rectifying the cracks and addressing moisture migration. His expertise led him to carefully chase out the cracks, creating openings that could be filled with a fast-setting, two-part liquid crack repair solution. After allowing this repair to cure, the team applied a pigmented epoxy to the floor.

This base coat is vital for three key reasons. Firstly, it establishes a strong mechanical bond to the concrete, enabling it to withstand both vehicular traffic and hydrostatic pressure. Secondly, it effectively seals the pores of the concrete, reducing imperfections in the finish coat. Finally, the incorporation of pigment signals to the applicator that the entire floor has been adequately prepared and is primed for the coating application.

Surface Prep Is The Key To A High-Quality Floor

Epoxy Flake Floor

In this project, TCE installed an epoxy flake floor with a top coat, utilizing a resinous pigmented coating. These coatings can be either a Epoxy, Polyurethane, Polyaspartic or a combination. The application process involved coating the surface and immediately broadcasting the flake onto the still-wet material. Once the coating cured, according to the manufacturer’s specified timeline, TCE conducted a thorough inspection to confirm that all flakes had adhered properly. Finally, a clear coat is applied to encapsulate the flake, enhancing the floor’s durability and making it easier to maintain.

When considering a new decorative concrete floor, it is essential to inquire about how the contractor plans to address the necessary surface preparation for your project. The old adage holds true: you get what you pay for, and this applies to all types of concrete flooring. Often, lower prices result from omitting crucial steps in surface preparation and using subpar materials.

Property owners select companies like Top Coat Epoxy because they understand that quality workmanship reflects a solid reputation. The team takes pride in creating and installing durable decorative concrete floors that are designed to endure the test of time.

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