Milling
Milling substrate preparation: Effective material removal for concrete & screed
Sometimes simple cleaning or sanding is not enough to optimally prepare a concrete or screed floor for the next phase. If thick old coatings need to be removed, severe unevenness removed or a defined material removal is required, substrate preparation by milling comes into play. This powerful mechanical process enables the targeted and efficient removal of surface layers and is often an indispensable step in demanding renovations or special preparations for new builds. As your nationwide specialists for screed and flooring systems, we have the modern milling technology and expertise to professionally prepare even difficult substrates for subsequent work.
When is milling the right choice? Areas of application
Milling is an intensive method of substrate preparation that we use specifically when other methods reach their limits:
- Removal of thick or hard coatings: For removing old, thick synthetic resin coatings (EP, PU), tough adhesive beds (e.g. from parquet or tiles), thick fillers or hard cement slurries where sanding or shot blasting would be too slow or ineffective. Keyword: removing thick coatings.
- Removal of severe unevenness: For leveling significant height differences, steps or heavily undulating surfaces on concrete or screed. Keyword: Removing unevenness.
- Roughen / profile the substrate: To create a very rough surface with high grip, which ensures optimum mechanical bonding for subsequent thick layers (e.g. repair mortar, industrial coatings).
- Removal of contaminated layers: For the superficial removal of screed or concrete layers soaked with oil or chemicals as part of a floor renovation.
- Milling grooves: For technical purposes, e.g. to prepare for the underfloor heating milling system (although this often requires specialized machines).
The floor milling technique: How it works
We use special floor milling machines for screed milling or concrete milling:
- The machine: These devices have a rotating drum equipped with many small carbide or diamond tools (milling blades, chisels).
- The operating principle: The rotating tools strike the floor surface and remove the material chip by chip. The removal depth per pass is adjustable.
- Low-dust work: Modern professional milling machines are connected to powerful industrial vacuum cleaners that collect the milling dust directly. This enables largely dust-free milling.
Advantages of substrate preparation by milling
- High material removal: Enables even thick and hard layers to be removed quickly and efficiently. Keyword: Remove substrate.
- Effective leveling: Can eliminate significant unevenness.
- Targeted profiling: Creates a very rough surface for maximum adhesion.
- Low-dust process: Professional equipment minimizes dust exposure.
Limits & considerations when milling
- Surface appearance: Milling produces a naturally rough, often linear structure. If a smooth surface is required for the subsequent layer (e.g. thin coating), additional sanding is often necessary after milling.
- Noise & vibrations: The process is louder and more vibration-intensive than grinding.
- Substrate stability: The concrete or screed to be milled must be sufficiently strong and stable to withstand the mechanical action.
- Edge processing: Corners and edges are difficult to reach with large routers and usually require the use of smaller edge routers or grinders.
Quality factors: Recognizing professional milling
The quality of the result depends on:
- Correct machine and tool selection (suitable lamellas for the material).
- Correct setting of the milling depth and feed speed.
- Functioning dust extraction system.
- Systematic working method for a uniform result.
- Experience of the operating personnel.
Costs for milling concrete & screed: A classification
The costs for milling are project-related. The price per square meter for the milling process alone is often higher than for sanding or blasting, as it involves more intensive removal. However, if thick layers need to be removed, milling can be more economical overall than many sanding passes. The costs depend heavily on the depth of removal, the hardness of the material, the surface area and the disposal costs for the removed material. An offer after inspection is necessary.
Your nationwide expert for substrate preparation by milling
We offer you:
- Expert assessment of whether milling is the right method for your substrate.
- Modern floor milling machines with effective dust extraction.
- Experienced teams for precise and efficient material removal - nationwide.
- Integration into comprehensive concepts for floor renovation or new installation.
Conclusion: Milling - Powerful preparation for demanding substrates
Substrate preparation by milling is the method of choice when it comes to significant material removal, the elimination of severe unevenness or the removal of thick old coatings. When carried out professionally, concrete milling or screed milling creates a stable base for subsequent work, even under difficult conditions.
Difficult substrate? We mill the solution!
Are you facing a challenge with substrate preparation? Contact us for advice on floor milling and a customized quote for your project - anywhere in Germany. By phone, e-mail or WhatsApp.
Frequently asked questions (FAQ)
Milling is the method of choice when thicker layers (> 2-3 mm) need to be removed (e.g. old coatings, adhesive beds), severe unevenness needs to be leveled or deeper removal is required (e.g. in the case of contamination). Sanding or blasting is often sufficient for lighter preparations.
With professional floor milling machines connected to powerful industrial vacuum cleaners, the process is low-dust. However, a certain amount of dust cannot be completely avoided during this intensive removal process. Appropriate protective measures are important.
The surface is relatively rough and often has visible milling marks (grooves). This provides good mechanical bonding for thick subsequent layers. If a smooth surface is required (e.g. for thin coatings), sanding is often necessary after milling.
Chipping or damage can occur if the work is carried out incorrectly (too low a setting, incorrect tools, too high a speed) or if the substrate is unsuitable or weak. It is therefore important that the work is carried out by experienced specialists.
The pure costs per square meter for the milling process are often higher than for grinding or shot blasting. However, if a lot of material has to be removed, milling can be faster and more economical overall than, for example, a large number of grinding passes. The costs depend heavily on the removal volume and material.
Sanding, on the other hand, is gentler on the material and a good preparation for plastering. Sanding produces an aesthetically pleasing result, especially with exposed screed. In many cases, milling and sanding complement each other, so that the two jobs are carried out one after the other.