In recent years, polished concrete has become a trendy choice for homes, businesses, and industrial areas because these floors are simple to care for, easy to clean, and more budget-friendly than other flooring types.
While some home and property owners may opt to polish their floors, many projects are better left to professionals with the right tools and experience to help you achieve the desired results. In this article, we'll cover various types of concrete floors, the steps involved in the polished concrete flooring process, and the benefits of polished concrete floors.
Polished concrete is the technique of strengthening, grinding, and sealing concrete to make it long-lasting and resistant to damage. The process of polished concrete flooring involves grinding and polishing machines equipped with industrial diamonds to smooth out imperfections and restore and repair concrete floors. After the grinding and preparation process, hardeners, sealers, and densifiers are applied to the concrete to enhance and finalize the finish. Polished concrete can have varying levels of reflectivity. Reflectivity is simply an aesthetic feature, while the exposure of aggregates varies depending on how deep the grinding is done into the floor.
There are five distinct polished concrete types listed below:
Mechanical Polishing is a detailed, multi-step method that provides both durability and design flexibility, making it ideal for industrial and commercial environments.
Grind and Seal is a budget-friendly technique where the concrete is ground and then sealed with a top layer. It works well for residential properties and outdoor areas.
Burnished Concrete is created by polishing the surface with a high-speed floor buffer. It is commonly seen in warehouses or spaces with minimal foot traffic.
Honed Concrete provides a non-slip, matte look and is frequently used in moist environments, such as around poolside areas or bathrooms.
Concrete Overlays are thin coatings applied over existing concrete. They provide surfaces and offer quick installation customization options for personalizing the design.
The procedure begins with rough diamond pieces carefully bonded into a metallic matrix. These diamond segments are coarse enough to remove small pits, imperfections, stains, or light coatings from the surface in preparation for the final smoothing process. Depending on the condition of the floor, this preliminary rough grinding typically involves three to four steps to complete the task fully.
The following stages involve finely grinding the concrete surface with diamond abrasives embedded in a plastic or resin-based matrix. Workers use increasingly finer polishing disks (lapping) until the floor reaches the desired shine. A final grit, such as 1500 or finer, may be used to achieve an extremely high-gloss finish. Skilled polishing teams know when to move to the next finer grit by closely observing the floor's surface and how much material has been removed.
An internal sealer that penetrates the concrete is applied during the polishing procedure. The sealer seeps into the concrete and remains invisible to the naked eye. Not only does it protect the concrete from within, but it also hardens and densifies the material. This removes the need for a surface coating, which significantly reduces maintenance (as compared to having a coating applied). Some contractors apply a commercial polishing compound to the surface during the final polishing step, which adds extra sheen to the floor. These compounds also assist in cleaning any leftover residue from the polishing process and provide a dirt-resistant finish.
You can smooth concrete using either wet or dry techniques. While both methods offer benefits, the dry polishing technique is preferred today because it's quicker, more practical, and more eco-friendly. Wet polishing uses water to help cool down the diamond abrasives and wash away the grinding dust. The water helps reduce friction and serves as a lubricant, extending the lifespan of the polishing abrasives. The main downside of this method is the cleanup process. Wet polishing generates a huge amount of slurry, which crews must gather and dispose of in a safe, environmentally responsible manner. With dry polishing, no water is needed. Instead, the floor polisher is connected to a dust-collection system that sucks up almost all of the debris.
Many contractors rely on a mix of wet and dry polishing techniques. Dry polishing is usually the method of choice for the first grinding stages when a larger amount of concrete needs to be removed. As the surface gets smoother and workers transition from metal-bonded abrasives to finer resin-bonded diamond abrasives, they typically switch to wet polishing.
1. Start by removing any existing coatings (if the coatings are thick, use a 16- or 20-grit diamond abrasive or a stronger tool made specifically for coating removal, like a T-RexTM tool).
2. Fill any cracks and joints using epoxy or semi-rigid filler to ensure a solid surface.
3. Grind the surface using a 30- or 40-grit metal-bonded diamond for an initial smooth surface.
4. Follow up by grinding with an 80-grit metal-bonded diamond to refine the surface further.
5. Continue grinding using a 150-grit metal-bonded diamond (or a finer grit if you prefer a smoother finish).
6. Apply a chemical hardener to the surface to help densify the concrete and strengthen it.
7. Start polishing with a 100- or 200-grit resin-bond diamond or a combination of both to enhance the surface.
8. Polish the surface further with a 400-grit resin-bond diamond to achieve a finer finish.
9. Polish again using an 800-grit resin-bond diamond to get a smoother, more refined look.
10. Complete the process by finishing with a 1500- or 3000-grit resin-bond diamond (depending on your desired sheen level).
You can optionally apply a stain guard, which helps protect the polished surface and makes it much easier to maintain.
When polishing concrete, grits are referred to as the benchmark for smoothness and light reflection. Lower grits usually produce a soft and less reflective look. The higher the grit, the smoother and more reflective a polished concrete floor will be. The finish grits are usually between 100 and 3000, with higher numbers producing a higher gloss.
100-200 grit—Low-gloss honed finish. There should be no visible scratches and a smooth industrial look with uniform color and texture. These are good where exterior polished concrete is specified, or the client requests a low-sheen alternative.
400 grit—This is where the floor starts getting glossed. It should have no imperfections and a smooth, consistent sheen across the surface. This finish is a good warehouse option and will look the same longer than a high sheen due to the amount of sheen maintained from regular wear and foot traffic.
800 grit—Floors with this finish should be glossy and have good reflectivity across the surface. Many retail stores and warehouses are a good fit for this grit as they look clean and have high reflectivity in low-light situations. Owners will need a maintenance plane at this sheen and above to achieve longevity and performance from the high gloss.
1500 and 3000 grit: These floors are high in reflectivity and clarity and are typically used in retail and office projects. A high gloss and ease of cleaning make this choice ideal for high-traffic situations. Owners will need a plan to maintain the finish, or you may see traffic patterns in busy areas.
Choose a reliable polished concrete installer for your project to achieve a top-notch, long-lasting flooring finish. Professionals like us at Floor Doctor provide reliable polished concrete installation services in Central Texas, offering professional skills and advanced tools.
Here's what you need to think about when selecting a polished concrete contractor:
Proper Training: Choose teams that have extensive concrete polishing methods, ensuring they are fully knowledgeable about the process's complexities and detailed steps.
Specialized Equipment: The contractor must own top-quality grinding machines and all the necessary tools to produce the desired outcome with precision.
Quality Materials: Verify that the contractor uses premium materials like high-grade concrete and trustworthy sealants to ensure a durable and lasting finish.
Insurance: Always select a contractor with the correct insurance coverage to protect against any possible risks or damages during the project installation process.
There are many reasons we are seeing more polished floors, including that they are:
If you work with your existing concrete floor, you won't need to pay for tile, wood, linoleum, carpet, or other available floor coverings. Since polished concrete is so durable, you won't need to worry about the cleaning, repair, or replacement expenses associated with other surfaces, including having the carpets steam cleaned, hardwood floors waxed, or chipped ceramic tiles swapped out.
Simply put, polished concrete is more resilient to damage and daily wear and tear. While various factors can influence the service life of your floors, polished concrete should last at least 20 years and can last a lifetime with proper care and maintenance.
In most cases, you only need a broom or dust mop to keep your polished concrete floors clean and clear of debris and dirt. Once a week, using a damp mop will help remove scuffs, smudges, and watermarks and bring back the shine of your floor surface. For high-traffic facilities, less time cleaning means less downtime and increased productivity.
Concrete floors offer nearly limitless design opportunities. Mix as many stains, dyes, and decorative touches as you like to create a distinctive look that beautifully matches your aesthetic.
Unlike other floors, polished concrete will not chip or scratch under normal conditions. This surface works well in spaces with heavy equipment and foot traffic. Under demanding circumstances, coatings can make your concrete more resilient to different types of damage.
Adding a non-slip epoxy coating to your surface can avoid injuries and falls in commercial settings. Other coatings can protect your floor from chemicals, heat, static, moisture, and other contaminants.
While raw concrete may not be a blank canvas, you can't compare the aesthetics of a concrete slab to a polished concrete floor. With polished concrete floors, you can choose from any degree of sheen, like many home and business owners who prefer more reflective surfaces. These help brighten up your space, reducing the amount you spend on utilities. Whether you choose an understated color or invest in an elaborate pattern, you'll get a visually appealing end product.
No hazardous coatings, cleaners, or adhesives are needed to protect or maintain polished concrete, depending on your choice of coatings and sealants. In most cases, polished concrete projects qualify for LEED certification.
In the era of do-it-yourself remodeling projects, ripping out carpet and polishing your concrete floor may sound like a good idea. However, attempting to take on a concrete polishing project alone may end in disaster like many other home projects. One of the biggest initial roadblocks is the specialized equipment needed. Concrete grinders and polishers are not only heavy and expensive but also difficult to operate if you need to know what you're doing. Then, you'll have to decide what color, stain, dye, and other aesthetic elements to incorporate, which can take a lot of work. Ultimately, your best option is to hire a pro for the job. That way, you'll ensure your residential project is done for you for the first time.
Polished concrete projects, like many flooring solutions and flooring options, require unique skills and expertise to guarantee the finished product matches your design preferences. We at Floor Doctor have years of experience installing concrete flooring systems in commercial settings, industrial facilities, and residential applications. Our expert decorative concrete contractors have built a reputation for exceeding client expectations. When you work with us, you can expect beautiful, high-quality results on time and within budget. Please reach out to us today!
