Floors that are dusty, scuffed, greasy or oily can be costly and create hazardous working conditions. Clean, durable floors streamline operations, improve health and safety outcomes, and promote a positive work environment.
Concrete floor polishing is a process of grinding and refining the concrete using increasingly finer grit diamonds until the desired level of finish is achieved. This process can also include applying a chemical densifier to the slab. Contact Concrete Floor Polishing Orange County for professional help.
Before you can get a polished concrete floor, it is important that the slab is in sound condition. If there are cracks, repair them with a concrete patching compound. A new floor should be free of any dirt, oil, and other debris that may prevent adhesion to the surface.
The preparation process starts with rough grinding with metal-bonded diamond segments to eliminate pits, blemishes, and light coatings from the concrete surface. Then, an etching solution is applied to the surface for 30-60 minutes to open up the concrete for final smoothing.
After etching, the floor is rinsed thoroughly to remove any residual chemical and prepare it for the next step. At this point, the choice is made between dry and wet polishing. Dry polishing is done with large corded electrical machines and can be used on large areas, but it can cause dust contamination. Wet polishing is performed with a variety of hybrid and resin abrasives that are progressively finer. Depending on the desired sheen and finish, pads ranging from 400-grit to 800-grit are used. At the first stage of wet polishing, a densifier is added to advance the concrete’s preparation.
This is a chemical that penetrates into the concrete and hardens it from within. This eliminates the need for a topical coating, and reduces maintenance costs. The final step is to spread a commercial polishing compound over the surface of the concrete. This gives the concrete a little bit more sheen, and makes it easier to maintain. A clean, well-prepared floor provides many benefits to your facility and its occupants. Dirty, dusty floors are inefficient, increase health and safety risks, and can lower morale. However, clean, polished concrete floors streamline your operations, minimize maintenance and repair costs, and improve indoor air quality, safety, and overall morale.
Grinding
The grinding stage of concrete floor polishing removes the top layer of dirt and old coatings from a surface, revealing a more uniform, less bumpy finish. It can also expose aggregate, depending on the needs of a particular building or client.
Contractors use industrial strength diamond tools layered in plastic or resin to grind a floor, beginning with the roughest grit available. It’s important to inform your concrete contractor about what your expectations are for the finished product, so they can begin with a grit that will provide you with an attractive sheen and leave a smooth surface.
After the initial grinding, finer abrasives are used to achieve an even more smooth and glossy surface. During this process, it’s common to see contractors wear respirators in accordance with new OSHA regulations regarding crystalline silica. A water recirculating system is also often employed, since it can prevent dust from accumulating in the air while polishing and helps keep the work environment safe.
Once the final polish is achieved, a chemical densifier may be applied. This step is typically taken once the concrete has opened up and is in a condition to readily accept the chemical, which increases the density of the concrete and reduces its porosity.
Some companies will also spread a commercial polishing compound over the final polished concrete surface, which adds an extra sheen to the floor and makes it easier to clean and stain. This is an optional step, but it’s one that can be very helpful in reducing the need for future maintenance and protecting the floor from premature wear. A sealant is then applied, which can be any type of concrete protectant ranging from basic water-based solutions to high-performance epoxies and polyurethanes.
Honing
Concrete polishing is an intricate process that transforms your concrete floor into a stunning, highly reflective surface. It can make any room in your building more appealing, while providing a durable and easy to clean work surface.
The first step in a successful polishing project involves making sure your concrete surface is clean and dry. This means removing any dirt or debris and using a degreaser to remove any grease or oil that may be on the floor. It is also important to repair any cracks or holes in the concrete before beginning the process.
Once the concrete is clean and dry, it is time to begin the grinding process. Choosing the right diamond grit is crucial for this stage. Depending on the level of sheen you want to achieve, you will need to select from a range of diamond grits.
Starting with a coarse grit, the initial rough grinding smooths the concrete floor. This step is critical to the final result, as it helps eliminate minor pits, blemishes, or light coatings from the concrete surface. Often, these are caused by improper construction techniques or a lack of adequate curing time for the concrete.
Moving up to a medium grit, the concrete begins its transformation from rough ground to polished canvas. This step is a delicate balance of removing the coarse scratches while not over-grinding the concrete. It is also essential to maintain consistency with this phase, ensuring that every area of the floor is treated equally.
When the grit moves up to a high-level polish, the concrete begins to shine and become more reflective. The sheen of a high-level polish is so bright that it can reflect light from different directions and almost look wet. Observing the sheen from different vantage points is vital for determining whether the concrete is truly at a high-level polish.
Staining
A concrete floor stain is an alternative to polished concrete and may be more appropriate for a space where there’s little expected foot traffic or wear on the surface. It works in the same manner as polishing but is a topical chemical spray or roll-on application.
The stain can be acid- or water-based. The stain seeps into the concrete and creates a color that won’t fade or peel. This allows the flooring to have a natural look and offers a wide range of color options from earth tones to bold hues.
Stains also provide the opportunity to highlight concrete’s natural porosity and variablility. For example, a turquoise acid stain can create a mottled effect for a beach-themed store. The color can also be used to highlight concrete that has been stamped and colored to look like wood or stone, such as this emerald green stained concrete floor.
Once the floor is stained, it’s important to apply a concrete sealer that will protect the floor and bring out its shine. A good concrete sealer will protect against abrasion, dirt, oil and water stains. It should be applied with a sprayer or pump garden sprayer to ensure that the sealant is evenly distributed over the entire surface.
Once the concrete is sealed, it’s important to clean the floor regularly. Regular cleaning will keep the concrete looking clean and help prevent odors from building up. In addition, an anti-slip conditioner can be added to the concrete to improve traction and make the floor safer in wet conditions. When properly installed and maintained, a stained-and-polished concrete floor can last for decades. It’s an affordable and durable option for many spaces.
Sealing
Concrete floor polishing is a multi-step process that involves mechanically grinding and honing the concrete to achieve a desired level of sheen or gloss. A concrete sealant is then applied to the concrete, protecting it from oil spills and changes in weather. This helps the concrete last significantly longer than if it were not sealed.
Once the concrete is polished and sealed, it requires very little maintenance beyond a pH-neutral cleaner and water. The floor will maintain its sheen for years and if it dulls, a light re-polishing with a fine grit abrasive will restore the shine.
In the initial grind and hone stages, the concrete is machined with metal-bonded diamond abrasives to remove the surface coatings and expose the aggregate. Concrete floor grinders use multiple levels of increasingly fine abrasives, gradually refining the grind and creating a high-gloss finish.
The next step is patching the concrete to ensure that any cracks and chips are filled, then the floors are prepared for a stain. Concrete hardener and densifiers are sprayed onto the concrete, which helps the sealant adhere better to the surface. Stain is then sprayed or scrubbed on the concrete to create a color that matches the customer’s design preferences.
A concrete floor can be stained in a wide range of colors and patterns, which opens up the space and adds style to any building. The stains and dyes are sealed with concrete sealant, which protects the concrete from damage by harsh chemicals, water, and UV rays. It also prevents the etching of the concrete that can happen if oil spills are not cleaned up quickly, as well as mold, mildew and rebar expansion.
