Milling Pads Archives - South Cumbria Tile Doctor

200-Year-Old Black Flagstone Floor Restored at Kendal Gaol

Earlier this year I was asked to improve this tired looking Black Flagstone floor which was at a house in Kendal that dates back over 200 years. The property used to be the Prison Wardens house and was part of the House of Corrections which was situated in Kendal on the Hill on the road up towards Windermere. The old Stone walls, in what is now the car park, are still present but the Gaol has long gone with new houses built in its place around 120 years ago.

Black Flagstone Floor Before Renovation Kendal

The flagstones formed the floor of what is now a Kitchen and Pantry and sometime in the past a red cement base was put on top of the stone to level it and was then covered in a wooden Parquet floor. The trouble with this was that it stopped the stone from breathing leading to damp spreading into the walls which in turn encouraged mould to grow. Certainly not what you want in a house and certainly not in the Kitchen.

The customer had removed all the old Parquet floor which was rotten anyway and knocked out a lot of the leveller but the stone was very rough and he was unable to get it clean as it would shred mops and the dirt would get trapped in the pits and build-up.

I went over to look at the Flagstones and recommended that we mill the stone which would remove what remained of the levelling compound allowing the stone to breathe again and remove the roughness of the stone allowing it to be cleaned easily. I came up with a restoration plan to do that, address the pointing and then seal the stone with a breathable sealer. Happy with the quote and relieved they now had a practical solution we were given the go ahead to do the work.

Milling a 200-Year-Old Black Flagstone Floor

We used a series of coarse DRB milling pads to grind off a thin layer of stone off the flagstones. This exposes new stone underneath and removes the contaminates in the process. The work starts with the very coarse 50-grit DRB milling pad and is applied to the floor using a heavy-duty buffing machine that has weights added to improve traction. Water is used to lubricate the process and this slowly turns to a slurry as work progresses. The slurry is then rinsed and extracted from the floor and the process repeated with the 100 and then 200-grit DRB milling pads.

Once done we moved onto the pointing which was knocked out with a Hammer Drill and replaced with a breathable pointing product called VDW in a stone-grey colour. Work continued into the next day where the sandstone was cleaned again with the 200-Grit milling pad and focus turned to cleaning all the edges and corners where the pads struggle to reach. Once done the floor was given another rinse and extraction and left it to dry overnight.

Sealing a Black Flagstone Tiled Basement Floor

To return the dark Black colour to the stone I decided to use a breathable oil-based sealer called Tile Doctor X-Tra seal that leaves a low satin finish. This product is rated for internal and external use and being breathable it will allow moisture to rise through the floor and evaporate at the surface. Old floors like this don’t have a damp proof membrane so it is important to choose a sealer that can allow the floor to breath and this will resolve the damp issues the property was experiencing previously.

Black Flagstone Floor After Renovation Kendal

This was not an easy job for us, but luckily it was quite a small floor. I’m not sure the photographs really do it justice but our work certainly made a difference and my customer was very happy with the result. They even left the following 5-star feedback on our website.

Brilliant job, our flagstone floor is completely transformed!
By Helen M, Kendal, 11 March 2024

Black Flagstone Floor After Renovation Kendal

For aftercare I recommended Tile Doctor Neutral Tile Cleaner which will clean the floor without impacting the sealer which can be a problem with many of the stronger products you find in supermarkets.

Professional Restoration of a Black Flagstone Basement in Cumbria

200-Year-Old Black Flagstone Floor Restored at Kendal Gaol Read More »

Old Black Slate Floor Restored Grange-over-Sands

200-Year-Old Black Slate Floor Restoration in Grange over Sands

The customer from Grange Over Sands had taken up a musty smelling carpet that had been in place for many years over a Black Slate tiled floor. After taking to the internet to do some research he had worked out that the pointing would need to be re-done, the stone deep cleaned and then a breathable sealer put in place. Using a breathable sealer on an old floor is very important as it won’t have a damp proof membrane and so must be allowed to breathe. If the moisture can’t rise through the floor, it will accumulate and reach out to the walls causing rinsing damp which can be most unpleasant and result in mould.

Black Slate Floor Before Cleaning Grange-Over-Sands

Realising this was a lot of work to do on his own we were asked to quote for renovating the whole floor including sealing. Whilst I was there surveying the floor, I also noticed the slate slabs were slightly uneven with small height differences between the stone tiles, something we call lippage which can be a trip hazard.

Speaking with the owner I discussed the lippage problem and how it could be resolved using a process Tile Doctor invented called milling which uses very coarse diamond encrusted pads to grind away up to 4mm of unwanted stone and then refinish the surface. Happy to go with my suggestion out quote was accepted and a date arranged for the work to begin.

Milling Black Slate Flooring Level

We use a heavy weighted buffing machine to mill the stone, it weighs about 55kg when fully loaded and the extra weight ensures the coarse diamond pads make good contact. The process starts with a 50-grit DRB Milling pad to cut into the stone and remove the lippage, only water is used to help lubricate the process and once done the floor is rinsed and the soiling removed with a wet vacuum.

This process is followed with a 100-grit DRB pad and then a 200-grit DRB which hones the stone and gives it a smooth texture. The other advantage of using these pads is by removing the top layer it also takes the dirt with it leaving a new clean surface.

Next step was to knock out the old pointing with a Titan Breaker tool, it’s a noisy process but much of was already loose or missing so it was easier than it sounds. The old pointing was replaced using a modern flexible product that is also breathable.

The new pointing was allowed to cure overnight and then we called back to finish that stage of the restoration by working in a dilution of Tile Doctor Remove and Go with a 200-grit milling pad. This step is designed to remove any sticky texture left over for the pointing and then we give the floor a final rinse with water and vacuum off the excess.

Sealing Black Slate Tiled Floor

The floor was left to dry off overnight and we came back for a 3rd day to seal the slate which was the final stage in the restoration. Before doing so though we like to check the moisture levels of the stone to make sure its dry enough. We don’t recommend applying a sealer to damp tile as it the results can be patchy.

To seal this floor two coats of Tile Doctor X-Tra Seal were applied, this product is oil based which is perfect for Black Slate as it helps restore the colour and adds texture to the stone. X-Tra Seal is also breathable and so will allow moisture from under the floor to rise through the stone and evaporate at the surface so no more musty damp smell.

Black Slate Floor After Cleaning Grange-Over-Sands

Once the sealer dried the room was transformed, additionally the newly milled finish will make the stone a lot easier to clean and maintain unlike the rough texture it had before. This was a great result when you consider this is an original slate floor over 200 years old; original features like this are very much sought after so a good investment that’s a natural fit within the older building.

I always mention to my customers the importance of using a PH neutral tile cleaning product for aftercare cleaning and not to use a bleach-based cleaning products which are simply too strong and will prematurely damage the sealer given time reducing its protective qualities and appearance.

Professional Slate Floor Restoration in South Cumbria

200-Year-Old Black Slate Floor Restoration in Grange over Sands Read More »

Slate Hallway Floor Renovation Grange-over-Sands

Old Black Slate Hallway Floor Renovated in Grange over Sands

1 Comment / Grange-Over-Sands Tile Cleaning, Slate Tile Cleaning, Work by Category, Work by Location, Work History / Heidi Taylor

I recently completed the renovation of a Black Slate Floor at a property in Grange over Sands. The Slate floor was in the hallway which as you can imagine is one of the busiest areas in any house. The Slate had been down for many years and was now in need of an upgrade.

Black Slate Floor Before Renovation Grange over Sands

After surveying the Slate floor, I recommend using a method we have developed at Tile Doctor called Milling. This doesn’t just clean the stone but cuts through the rough texture and old shaling leaving a much smoother finish. This It is a bit like sanding a wooden floor using various grits of sandpaper to resurface the wood and then add a polish. In the case of stone of course sandpaper wouldn’t long, so when Milling we use coarse heavy duty floor pads encrusted with industrial diamonds.

I gave my client a quote for the work, which was happily accepted, and we scheduled a date for the work to be done the following month.

Resurfacing a Black Slate Tiled Hallway Floor

For Milling we use three different grits of pad applied in sequence with a weighted heavy duty floor buffer, the extra weight is needed to ensure a strong contact with the floor. Work starts with the 50-Grit Milling pad, then 100-grit and finally a 200-grit. Water is used to help lubricate the process and a wet vacuum is used after each pad to remove the slurry generated, the water also helps keep down the dust.

The mortar between the Slate was also in a poor state so this was broken out using a hammer drill and new pointing was applied, we like to use VDW800 for this purpose as it is available in 5 different colours. The natural tone looks very similar to lime pointing, but unlike lime pointing this product sets fully hard after 48 hours and it’s fully breathable so it is perfect for using with old floors like this without a damp proof membrane.

Black Slate Floor During Renovation Grange over Sands

Once the stone was milled and pointed, it was left to dry for 48 hours so it would be ready for sealing. I don’t recommend applying a sealer to a damp floor as the seal will struggle to cure and this can lead to an uneven result.

Sealing a Black Slate Tiled Hallway Floor

Returning later in the week, we then gave the floor one last light clean before applying two coats of Tile Doctor X-tra seal. This is a very effective and modern oil-based impregnating sealer the leaves a nice satin finish and breathable. Oil based sealers are essential for black stone as black stone is only black because of its oil content. In fact, Tile Doctor developed X-tra Seal in 2021 for exactly this type of job. The sealer can also be used outside as it comes with UV light protection unlike most sealers on the market which are really designed for internal use.

Black Slate Floor After Renovation Grange over Sands

My client was very happy with the work and even left the following feedback.

“Excellent service by both”

For aftercare cleaning I recommended the use of Tile Doctor Neutral Tile Cleaner which will keep it looking in great condition.

Professional Restoration of a Black Slate Tiled Hallway in South Cumbria

Old Black Slate Hallway Floor Renovated in Grange over Sands Read More »