Concrete floor polishing is a multi-step process where a concrete surface is mechanically ground, honed and polished with bonded diamond abrasives to achieve a specific level of sheen or gloss. The first step is patching and applying a chemical hardener or densifier to the concrete to prepare it for grinding.
Concrete floor polishing is a cost-effective way to give an old or new concrete surface a modern, shiny finish. It is an excellent choice for a variety of commercial and industrial spaces, including offices, warehouses, retail stores and schools. It can also be used in residential homes, as polished concrete is a durable and stylish flooring option that resists moisture damage, mold growth, stains, and odors. Contact Concrete Floor Polishing Orange County for professional help.
Before a concrete surface can be polished, it must be prepared. This includes removing any existing flooring and making sure that the concrete slab is level. It is also important to repair any cracks and fill in any pits or divots on the surface.
Once the concrete is ready, the grinding process begins with coarse diamond segments bonded in a metal matrix. The crew grinds the concrete to remove any blemishes, scratches and coatings on the surface. The crew then moves on to finer grits, gradually working toward a high-gloss finish. Experienced crews know when to move on to the next grit by observing the sheen on the surface.
A chemical hardener can then be applied to the floor to densify it. This step is an important one because it prevents the concrete from becoming softer over time and reduces maintenance costs by eliminating the need for a topical coating. There are many products on the market that claim to work for this purpose, but we recommend using RetroPlate. This product is unique in that it penetrates the concrete and chemically reacts with it to create a dense surface. This is vital for the long-term durability of a concrete floor. It also eliminates the need for waxing, which can be abrasive and damaging to the floor.
Grinding
Concrete polishing is a mechanical process that involves grinding the floor with a variety of diamond pads to achieve the level of sheen you want. It’s similar to sanding wood, with heavy-duty grinders and a progression of increasingly finer grits.
This process allows you to expose decorative aggregate and creates an even surface that’s free of tripping hazards, cracks and other imperfections. It also reduces the need for carpet or tile that requires expensive replacement and harsh cleaning chemicals.
The grinding process can be done wet or dry, depending on your preferences and the condition of the concrete. Typically, a wet grind method is used because it eliminates dust and keeps the diamond abrasives from becoming airborne. This helps to prevent respiratory problems for your employees and customers.
Once the surface is smooth, a chemical densifier can be applied to fill in pores and create an even finish. A good quality densifier will also help to make the concrete more durable and resistant to abrasions, oil and water damage.
A full mechanical concrete polish can take 10 or more stages to achieve a high-sheen finish that’s reflective and attractive. This finish is often referred to as a “level 3” or “satin sheen” and is ideal for commercial and industrial environments.
Some contractors may advertise a “half-polish” method that only involves one or two stages and leaves the surface less shiny. This type of floor isn’t as resistant to dirt and oil, doesn’t have the same clarity and won’t meet national safety standards. It’s important to use a contractor that uses the full mechanical grinding process for your floors. This will ensure that your floor is safe, long-lasting and beautiful.
Honing
Concrete floor polishing transforms a porous concrete surface into a tightened, dense surface that resists water, oil and other contaminants from penetrating. The polished concrete also has an elegant, attractive appearance and can be dyed to match the color scheme of any facility.
The first step in full mechanical concrete floor polishing is removing any existing coverings or coatings such as vinyl tile, carpet and paint. Once the coverings are removed, the grinding and hone process can begin. This process is performed with large planetary head machines that have one main head that rotates in one direction and smaller satellite heads that spin in the opposite direction.
During the grinding stage, the concrete is processed through a series of progressively finer diamond grits in order to create the desired level of sheen. The grinding is done using a variety of equipment ranging from standard heavy-duty grinders with abrasive pads to lightweight walk behind and ride on machine with diamond-tipped blades. The contractor can choose to grind the entire floor or simply specific areas of interest.
After the initial grinding and honing steps, the concrete is densified to further harden the surface, making it more resistant to wear and staining. After the densifier is applied, a stain guard/concrete sealer may be used to further protect the floor.
For a more “natural” look, hybrid polishing utilizes a combination of grinding and friction rubbing (honing) to achieve the desired sheen and consistency. This is accomplished by running the grinder with a coarse diamond, followed by a medium grit and finally a fine grit, working through all of the grits until the final sheen and consistency are achieved.
Staining
Stained concrete is a popular flooring option, with a wide variety of color options available. Concrete stain seeps into the material’s pores to produce a deep color that is resistant to fading. It is also a durable protective surface that, when properly sealed, can last for decades.
Before stains are applied, it is important to fully clean the floor and remove any paints, coatings, glues, or sealers that might be present on the concrete. This can be done with a commercial floor cleaner and degreaser, like Brickform’s E-Etch. It is also a good idea to mask off areas that you do not want colored, such as thresholds, walls, or floor fixtures. Lastly, dampening the surface can help to create more uniform color and reduce dark spots or streaking.
There are two main types of stain used for concrete floors, water-based and acid-based. Water-based stains work in much the same way as traditional acrylic paints, and they are typically less expensive than acid-based stains. However, water-based stains do not hold up well in direct sunlight and may need to be resealed on occasion.
Acid-based stains are more permanent than water-based stains, but they are more expensive and require special equipment to apply. They are often used for high-end commercial and industrial applications, as they provide a unique visual impact.
A full mechanical polish involves 10 or more stages of grinding, honing and polishing the concrete with a series of diamond metals / pads, moving to a finer grit each time. This process leaves a floor with a beautiful sheen that is resistant to forklift marks and fluid staining. It is also dust-free, a big benefit considering new OSHA regulations on crystalline silica.
Sealing
Concrete floor polishing is a multi-step process where a concrete surface is mechanically ground, honed and polished with bonded diamond abrasives to achieve a desired level of sheen or gloss. The surface is then sealed. This protects the surface from staining, abrasion, and damage. It also makes the surface easier to clean and maintain.
The concrete can be sealed with a solvent-based, water-based, or acrylic sealer. The type of sealer used will depend on the application and environment of the floor. It is important to understand that different sealers have a different service life and will perform differently in various environmental conditions.
A concrete floor is typically sealed at the end of the construction process, before carpeting or tiling is installed. This is to prevent spills, paint overspray and drywall mud from damaging the polished concrete.
Sealing is an important part of the concrete polishing process, as it helps to extend the life of the flooring. A properly cured sealer will help to prevent stains, premature wear, and water penetration. It will also make the floor more resistant to chemicals, oils and other spills.
Tip: When choosing a concrete floor sealer, be sure to consider the desired level of aggregate exposure and the clarity of sheen. While exposed aggregate may look great in a retail space, it can be unsuitable for a manufacturing environment where dropped fasteners need to be easily spotted.
A dry polishing system uses large, corded electrical machines to grind the concrete and is ideal for larger areas. It produces a low-luster finish and is not considered to be a true concrete polish, but it can be suitable for some applications. The wet polishing system uses water at each step of the grinding process and is best suited for smaller areas that are less accessible to equipment.
