The Process of Polishing Concrete: What to Expect
The initial phase of constructing your house demands the most attention. From thinking about using the right layout to choosing the superior quality flooring, everything becomes the top priority in creating a beautiful house.
Amongst all the prevalent options, polished concrete in Geelong is becoming an increasingly popular flooring choice for residential, commercial, and industrial spaces due to its durability, low maintenance, and modern aesthetic.
However, many people are unfamiliar with the process involved in polishing concrete. This blog will provide an in-depth look at the steps involved, what you can expect, and the benefits of choosing polished concrete for your flooring needs.
Understanding Polished Concrete
Polished concrete is not just a regular concrete slab. It involves a series of mechanical grinding and polishing steps using specialised equipment and diamond abrasives. The process transforms a plain concrete surface into a smooth, glossy finish that can mimic the appearance of polished stone.
Step-by-Step Guide to Polishing Concrete
1. Assessment and Preparation
The first step in the process of polished concrete in Geelong is assessing the existing condition of the concrete slab. A professional will inspect the surface for cracks, stains, or any other imperfections that need to be addressed before polishing. The preparation phase is crucial as it sets the foundation for a successful polishing job.
Repairs:
Contractors firstly fill any cracks or holes in the concrete with a suitable patching material. This ensures a uniform surface for polishing.
Cleaning:
The concrete surface is then thoroughly cleaned to remove any dirt, grease, or existing coatings. Professionals use a combination of chemical cleaners and mechanical methods such as shot blasting for efficient cleaning.
Surface Grinding:
The initial grinding step involves using coarse diamond segments bonded in a metallic matrix. This step removes any existing coatings and levels the surface. The goal is to create a flat, even surface, which is essential for achieving a high-quality polished finish.
2. Initial Grinding
Once the surface is prepared, the initial grinding begins for concrete resurfacing. This step uses a series of diamond grinders starting with coarse grits and progressively moving to finer grits.
Coarse Grinding:
The first grinding pass typically uses a 30- or 40-grit metal-bonded diamond. This removes any remaining imperfections and opens the concrete surface.
Fine Grinding:
Subsequent passes use finer grits, such as 80- or 150-grit diamonds. The goal is to refine the surface and remove the scratch patterns left by the coarser grits.
This is repeated multiple times depending on the condition of the concrete and the desired level of smoothness.
3. Densifying the Concrete
After the initial grinding, a chemical hardener (also known as a densifier) applies to the concrete surface. The densifier penetrates the concrete and reacts with the calcium hydroxide to form calcium silicate hydrate (CSH), which fills the pores and increases the surface hardness and density.
Application:
The densifier is applied evenly across the surface using a sprayer. It is then allowed to dry and cure, which typically takes a few hours.
Benefits:
Densifying the concrete enhances its durability, making it more resistant to staining and abrasion. It also helps achieve a higher gloss during the final polishing stages.
4. Polishing
With the concrete now densified, the polishing process and concrete resurfacing can begin. This involves using progressively finer grits of resin-bonded diamond abrasives to achieve the desired level of gloss and smoothness.
Intermediate Polishing:
The first polishing step typically uses a 200-grit resin-bonded diamond. This refines the surface further and begins to impart a slight sheen.
Finer Polishing:
Subsequent passes use increasingly finer grits, such as 400-, 800-, and 1500-grit diamonds. Each pass refines the surface further and enhances the gloss.
Final Polishing:
For a high-gloss finish, the final polishing steps may use grits as fine as 3000. This produces a mirror-like shine that is highly reflective and aesthetically pleasing.
5. Sealing and Protecting
Although polished concrete is already highly durable, applying a protective sealer can further enhance its performance and longevity.
Sealer Application:
A suitable concrete sealer is applied to the polished surface. This can be a penetrating sealer that soaks into the concrete or a topical sealer that forms a protective layer on the surface.
Benefits:
Sealing the concrete enhances its resistance to stains, water, and chemicals. It also helps maintain the glossy finish and makes cleaning and maintenance easier.
What to Expect During the Polishing Process?
● Noise and Dust
Polishing concrete is a noisy and dusty process, especially during the initial grinding stages. Concrete resurfacing professionals use industrial vacuums and dust extraction systems to minimise dust, but some level of disruption is inevitable. It’s important to be prepared for this, especially in occupied spaces.
● Time Frame
The time required to polish concrete depends on several factors, including the size of the area, the condition of the concrete, and the desired finish. A typical residential project may take anywhere from two to five days, while larger commercial projects can take longer.
● Cost
The cost of polishing concrete varies based on the complexity of the job, the condition of the existing concrete, and the level of finish required. Generally, polished concrete is cost-competitive with other high-end flooring options, especially considering its longevity and low maintenance requirements.
● Maintenance
Polished concrete is easy to maintain. Regular cleaning with a dust mop and occasional wet mopping with a neutral cleaner are usually sufficient to keep the floor looking its best. It’s also important to reapply the sealer periodically, depending on the level of traffic and wear.
Benefits of Polished Concrete
● Durability
Polished concrete is one of the most durable flooring options available. It can withstand heavy foot traffic, abrasion, and impact, making it ideal for both residential and commercial spaces.
● Low Maintenance
Once polished and sealed, concrete floors require minimal maintenance. They are resistant to stains, spills, and chemicals, and regular cleaning is straightforward.
● Aesthetic Appeal
Polished concrete offers a sleek, modern look that complements a wide range of interior design styles. It can be customised with stains, dyes, and patterns to create unique and attractive finishes.
● Eco-Friendly
Polished concrete is an environmentally friendly flooring option. It makes use of the existing concrete slab, reducing the need for additional materials. The reflective surface also enhances natural light, reducing the need for artificial lighting.
● Cost-Effective
Despite the initial investment, polished concrete is cost-effective over the long term due to its durability and low maintenance requirements. It also improves indoor air quality by reducing the presence of dust, allergens, and mould.
Final Words
Polished concrete is a versatile, durable, and aesthetically pleasing flooring option that offers numerous benefits for both residential and commercial spaces. Understanding the process of polishing concrete can help you appreciate the transformation that takes place and set realistic expectations for your project.
Whether you are renovating your home or upgrading a commercial space, polished concrete from a concrete resurfacing company like Premium Concrete Resurfacing is a smart investment that will provide lasting value and beauty.