Polished Concrete Consulting

What is Polished Concrete?

Polished Concrete is a multi-step process of mechanically refining the floor through grinding, honing, and polishing of a concrete surface. This process is continued until the desired "gloss level" or appearance is reached. Polished Concrete is an environmentally friendly, low-cost, and low-maintenance flooring solution for all types of facilities.

What are the steps to Polish Concrete?

The steps of polished concrete are broken into three phases called grinding, honing, and polishing.

Grinding

The first phase in the process of polishing concrete is called grinding. This step consists of selecting several metal bond tools (in succession) to "open" the concrete surface. This phase is the most important as it sets the foundation for the entire refinement process. It is important to note maximum refinement and the removal of scratches during this early phase is a must.

Honing

The next phase of polishing concrete is honing. This is the process of evenly refining the concrete beginning with a higher metal bond tool and swapping over to a lower grit resin bond tool. This phase typically begins around a 100 grit and can be refined up to a 400 grit. This process leaves a smooth matte finish with a low to medium gloss finish. This finish is the low maintenance industrial look that everyone loves.

Polishing

The last phase in the process is polishing. This phase consists of refining the floor utilizing an 800 grit resin bond tool and can be refined up to the owner's desired level (typically 1500 or 3000 grit). This phase leaves a mirror like finish and brings a high clarity and detailed glass like appearance to the floor. This is the highest level of refinement you can achieve in this process.

How Expensive is Polished Concrete?

The price of Polished Concrete is based on the square footage, scope, and complexity of the project. Typically it is priced between $3.00 and $15.00 per square foot. The price varies because of many different factors. Here are some examples:

  • Is this a new construction or existing remodel?

  • Is demolition of existing flooring required?

  • Is there mastic (glue) on the floor?

  • Is the concrete substrate in need of patching/resurfacing?

  • Are walls already in place or is the space an open floor plan?

  • What is the owner's expectations of gloss level & appearance?

  • Does the owner want the concrete stained?

  • Does the owner want a sealer?

What do I need to Polish Concrete?

  • Proper PPE:

      • Safety Glasses

      • Steel-Toed Boots

      • Respirator or N95 dust mask

      • Hard-hat

      • Hearing Protection

  • Diamond grinder

  • Preseparator

  • Industrial HEPA Vacuum

  • Generator

  • Standup Edger

  • Hand-Grinder & HEPA Vacuum

  • Diamond Tooling

  • Densifier

  • Sealer (not always necessary)

  • Stain/Dye

  • Acetone

  • Microfiber Mop

  • Rags

Equipment Information

Diamond Grinders

Diamond Grinders are the most important piece of equipment for polishing. They typically have a frame with controls, ventilated computer system, motor, drum, heads, and plates to attach the tooling. In most commercial applications, the specs call for a planetary diamond grinder. This means the drum of the grinder spins independently in one direction, while the heads holding the tooling spins in the opposite direction.



Planetary Diamond Grinder

Example of a Planetary Diamond Grinder Rotation

Here are some examples of some diamond grinder manufacturers:

SASE Company

Werkmaster

HTC

Dust Extractor Systems

Dust Extraction Systems are vital to productivity and safety when polishing concrete. These systems are designed to extract the dust from the floor that is left behind from grinding the surface. With OSHA's new silica dust laws, it is more important than ever to ensure you are compliant and safe while grinding silica particles. The Dust Extractor Systems typically have 2 main components:

  1. Pre-Separator

  2. Industrial HEPA Vacuum

These components are attached with a long wide hose to allow for silica particles to pass through unobstructed.

Pre-Separator

With OSHA's new silica laws everyone needs to make sure their dust extractor systems are compliant, while still finding a way to maintain efficiency. Pre-separators filter out the majority of particles (80+%) before they hit the dust extractor's filters. This allows for longer grind times and also reduces the buildup and damage to the dust extractor filters. Pre-Separators ultimately increase productivity and keep your dust extractor systems running more efficient and longer.

Industrial HEPA Vacuums

Industrial HEPA vacuums are a critical component in the dust extractor system and polished concrete process. Put simply, it removes dust left behind from the grinder. This is very important from a safety standpoint as it cuts down on airborne silica particles and helps decrease an individual's exposure to silica dust. The vacuum also reduces the dust left on the surface, decreasing the amount of cleanup/scrubbing in-between steps. Typically these vacuums have a large HEPA filter and also secondary filters inside the cylindrical housing. These filters need to be checked for tears/holes and cleaned/purged on a regular basis. All of these types of vacuums require power of some sort: 240v, 480v, or Propane. With today's technologies these systems are getting more efficient enabling longer grind times, increasing productivity.

Tooling

There are many different types of tooling used for polishing concrete. Each type of tooling brings a unique application to the process. Here are some types:

  • Metal Bond

  • Resin Bond

  • Hybrid Bond

  • Removal Bond

  • Diamond Impregnated Pads

  • Cupwheels

Different Types of Tooling