Why More Commercial Buildings Are Moving to Polished Concrete

The general definition of polished concrete is a concrete that has been treated. Usually, the concrete is polished using a chemical densifier along with being ground using grinding tools. These tools are usually progressive grits that go up in grit level. As a rule of thumb, concrete is not considered “polished” until at least a 400 grit is used. Normally, the concrete is then finished to either an 800, 1500, or 3000 grit level. During the process, stains and dyes may be applied to enhance the final look of the concrete.

When considering floor design and future plans for that flooring, polished concrete is a great, sustainable, and green option as you are already making use of something that is already there. These days, most buildings are already built on a slab, and polishing that eliminates costly energy and materials to apply a floor cover.

• When it comes to the overall level of maintenance, polished concrete is extremely low level. Most floors only need a neutral stone soap once per week.
• It is more durable, easier to clean, and will not chip or dent like softer surfaces such as wood.
• Its high friction level makes it non-slippery.
• Concrete reduces dust mite and allergen
• It improves natural lighting.
• Tile floors may only last 10–20 years, but a polished concrete floor can last 100+ years.

Diamond-polished concrete

A diamond polished concrete floor is time-consuming, and if done correctly, is due to the fact that there are numerous steps involved. However, the results are undeniable. The general rule of thumb is to start the initial grinding with a coarse 30-grit diamond and finish with a 1,500 or 3,000-grit diamond. These diamonds are impregnated inside a metal or resin-bonded segment. Typically, the diamonds’ grit size will double once the first grind has been carried out. The use of 30-grit size diamonds, then use 60/80-grit diamonds followed by the 120-grit metal bond segments.

The polishing process begins with a 50-grit diamond resin pad instead of a metal segment. When using the resin pads, the steps may be 100, then 200, 400, 800, 1500, and finally 3000 grit. Throughout the process, a densifier is used to harden the concrete surface, which allows the concrete to be polished. A number of densifiers can be used; these consist of lithium, potassium, or sodium silicates. A grouting chemical is also used throughout the process to fill in any holes, cracks, or imperfections that were exposed from the initial grinding step. The concrete is then sealed with a natural-look impregnating sealer. This sealer penetrates 2–5 mm inside the pores of the concrete, preventing any deep staining from oils and spills.

Grind-and-seal polished concrete

This system is the standard polished concrete system where the concrete surface is ground to the desired level using coarse 30-grit, metal-bonded diamonds. When the desired grind level is achieved, the surface is reground usually a 60-grit diamond to remove any visible scratching. Grouting and patching may be required to fill any holes, cracks, or imperfections. The surface is then cleaned and prepared for the application of either a gloss or matte surface coating or an impregnating enhancing sealer.

Repairing etched floors

Often times, you may encounter etching or stains, and using a fine-grit diamond polishing pad is adequate for this job. Be sure to start off with an 800-grit pad. If you are doing an excessive amount of scrubbing, try moving to a coarser 400-grit pad. The goal is to remove the stain or etching damage without harming the concrete itself. If you encounter a large, etched area, this will need to be either honed or wetly polished. Once the etching marks are removed from the surface, you can reseal it.