Grout is usually mixed with a very thick cement, and there are many ways to achieve a grout material that is very sticky, and causes the level of concrete to sink and push up against the grout. Grout is not always easy to remove from the concrete surface because the grout and cement mixture is very flexible. There are several techniques that are used to remove grout that do not involve sanding or chipping away the grout.
Grout is made from various ingredients such as cement, gypsum, asphalt, silica, and mixtures of one or more of these. Grout can be colored as well. The most common method of cement grouting is using a single solid layer of clay and aggregate. A variety of methods have been used to produce grout using cement in the past, but most have been abandoned in favor of today’s polyurethane foam injection technique. This is a very simple process and is useful for solving many of the problems associated with grout.
Using the polyurethane foam injection method for concrete grouting involves injecting small pellets of polyurethane foam into the grout. The foam fills the cracks and other spaces between the grout and the concrete surface. The foam softens and mixes with the grout, making it easy to remove from the concrete. A grout knife or other tools can be used to cut away the foam and the grout, while leaving the concrete and mortar behind.
Often times, during the mixing of the concrete, the cement material used in the grouting mix may contain metallic particles that are difficult to remove. The problem is that they make the cement somewhat heavier than normal. This can cause the weight of the concrete to “bounce off” the grout particles and cause them to sink into the grout more deeply, which results in unevenness and lower cement strength.
One method of removing these metallic particles is to fill the cavity between the grout and the concrete surface with a special compound that will inhibit the movement of the metallic particles and keep them where they belong, within the concrete. Concrete leveling is often required when the grout is removed from a well-finished concrete surface. It is also used on concrete that has cracked or that needs to be refinished.
Concrete leveling is done by applying an uneven amount of a grout thinner to each of the cracks and depressions in the concrete. After the cracks have been filled, a concrete layer is applied over the grout. The concrete layer is left on the concrete until it becomes loose enough to be easily removed. When the concrete is being broken up for finishing purposes, there is nothing to stop the process from proceeding.
Another method of grouting that is quite similar to the foam-injection method is the use of a grout insert. Using a grout insert is similar to the use of a grout knife, except that the injection gun is used to blast the grout into the hole. Using a grout insert requires mixing a special grout mixture that is designed to allow it to mix with the grout below it, and then applying it with a grout knife or other tools to the area to be grouted.
The grout filler that is injected into the area is placed in the hole in the concrete and allowed to set. Once the concrete has cured for at least 24 hours, the grout is removed and the new grout layer is laid. Grout is often cut away from the hole by scraping or chipping with a grout knife or other tools. Once the entire grout removal process is complete, the concrete surface is sanded smooth and any joint compound is sanded away.