What is Polished Concrete?
Polished concrete is the science and art of processing a cast-in-place slab or concrete topping to achieve the sheen or reflective degree of finish you want.
Concrete polishing technology provides one of the best no-wax flooring solutions for concrete spaces that encounter high-volumes of foot traffic every day. Polished concrete is also one of the most cost-efficient floors in the market because it is easy to maintain and can reduce the need for artificial lighting systems. Its technology can also turn any concrete space, whether old or new, into a floor with a high-gloss finish.
Typically, newly constructed concrete slabs are rough, dusty, and dull. Old concrete floors, on the other hand, have multiple cracks that may need large-scale repairs. In both cases, these concrete floors are prone to the accumulation of dust. They also have rough and uneven surfaces, and residue from coatings or flooring material used during its initial placement or construction.
With the use of heavy-duty equipment, concrete polishing contractors aim to harden and grind down the concrete surface gradually to make it shiny, smooth, and durable.
What are the uses of polished concrete?
In the Philippines, polished concrete is used for areas like:
- Warehouses
- Commercial stores
- Hotels
- Sports Complex
- Gymnasiums
- Chapels
- Showrooms
- Private residences
How is polished concrete flooring created?
There are six basic stages involved in polishing a concrete floor.
Preparing the concrete floor
Not all concrete floors are fit for the polishing process. At this stage, the concrete flooring is cleaned and cleared of unnecessary materials that can damage the machines used for polishing. The concrete slab is also examined to ensure that it has an even and level surface. Its hardness is also tested. A hardness reading below 4000 psi means the slab is soft and will crack easily under pressure.
This picture below is from a client whose flooring was uneven, soft, and prone to cracks. We had to prepare their floor to make it suitable for the concrete polishing process.
Grinding the concrete floor material
At this stage, the initial grinding of concrete is for making the flooring surface flat, level, and even. Grinding also exposes underlying pinholes and micro-pits. Pinholes are tiny voids formed by air bubbles trapped in the concrete during its placement and curing. Micro-pits are microscopic damages on a floor’s surface that eventually become visible cracks.
In this picture, our team worked to make the flooring flat and even.
Patching up cracks and holes in the concrete floor
The next step in the concrete polishing process is sealing cracks and filling holes. Grout is used to fill spaces created by cracks and holes. Patching also deals with pinholes and micropits. Grout pushes out air from these voids before the concrete polishing process continues.
In this image below, our worker is applying a special grout solution to fill in cracks in the concrete floor.
Applying densifiers to harden the concrete slab
After sealing the floor, the next step is applying densifiers to harden the concrete. High-quality densifiers make concrete stronger and protected from rust, mold and mildew, and rebar expansion. If needed, this stage is where stains are applied to achieve the color or design you prefer.
In this picture, our team applies several coatings of densifiers to strengthen the concrete until the standard hardness needed for the concrete polishing process is met.
Honing the concrete floor
After the densifier has dried, the floor is now ready for more grinding with a 200- or 400-grit resin.
Polishing the concrete floor
The final stage in the concrete polishing process is achieving the desired level of polish. A 400- or 800-grit resin is used to achieve a semi-polished floor. For a highly polished flooring surface, concrete polishing contractors use higher grit resin.
This picture is from our finished work at the Bukidnon State University. The client wanted a high-gloss finish so we processed the floor using 1,500- and 3,000-grit resin.
The Benefits of Polished Concrete
The final stage in the concrete polishing process is achieving the desired level of polish. A 400- or 800-grit resin is used to achieve a semi-polished floor. For a highly polished flooring surface, concrete polishing contractors use higher grit resin. Visit this article to learn more about the advantages of polished concrete.
- Cost-efficiency – polished concrete floors will last much longer than traditional flooring materials. DARIV Concrete Polishing Philippines provides affordable polished concrete floors. Actual prices will vary depending on the condition of your concrete floor and the outcomes you want to achieve. With the right methods, materials, and management, a polished concrete floor can last for decades. This will translate to more savings in the long-term because you won’t have to repair or replace your flooring often.
- Durability – polished concrete is sturdier than popular flooring materials like tiles, vinyl, wood, and carpets. Even in high-traffic commercial spaces, polished concrete flooring can withstand the impact of human and light vehicle traffic.
- Style – polished concrete can achieve high reflectivity and make the floor project a bright, clean, and professional ambiance. With our technology, you can avail of a wide range of color and texture for your concrete floor. We can also provide you with stunning engravings and images you want stencilled on the concrete floor surface.
- Ease of cleaning – polished concrete is super easy to clean. There is no need for additional cleaning chemicals, like wax, to keep it shiny. Sealed correctly, polished concrete floors are impervious to fluids (especially water) and harmful chemicals that can penetrate and weaken concrete.
- Health – concrete polishing does not require hazardous chemicals to achieve the required shine and reflectivity. Maintaining a polished concrete floor only requires basic cleaning materials. While polished concrete surfaces can get slippery when wet, this can be solved by using non-slip epoxy coatings for added texture.
- Environment-friendly – the non-toxic nature and durability of polished concrete make it less harmful to the environment. Because materials like carpets, vinyl, and wood, are damanged easily when exposed to high-volume traffic, you have to replace them regularly, resulting in more waste and pollutants. Polished concrete, on the other hand, is so durable that you don’t have to worry about replacing it time and time again.
Disadvantages of polished concrete
- Moisture – When polished concrete floor is not sealed and polished properly, it is vulnerable to moisture, and subsequently to development of mold and mildew on your flooring. Thus, when going for polished concrete, chose a polished concrete contractor in the Philippines who have proven experience with working with large firms.
- Hard – polished concrete is a hard flooring. It can be uncomfortable to stand on its surface for long periods. A solution to this problem is the use of anti-fatigue mats or rubber shoes for workers who will frequent the polished concrete floors.
- Cold – polished concrete cannot store a lot of heat and energy. This means, a polished concrete floor will be very cold during rainy or chilly months. In the Philippines, the coldest months are from December to February. During these months, always use warm foot coverings before stepping on a polished concrete floor.
- Loud – Due to its lack of cushioning properties, polished concrete flooring can be noisy and will bounce loud sound around your space. Prevent this by using materials that absord sound easily like rugs, acoustic panels, and thick drapes.
Sheen levels of polished concrete floors
Polishing concrete is done with special machines and pads designed to grind, hone, and polish the concrete floor until it emits the desired gloss. There are two often interchanged terms used to describe the shine of a polished concrete floor: sheen and gloss. In the polished concrete industry, sheen often refers to the level of gloss, or shine. Gloss is the measure of light reflected by a surface. Based on definition from the American Society of Concrete Contractors, gloss measurement is the “determination of specular gloss,” which could “also incorporate distinction of image, haze, and Rspec.”
The gloss is measured in gloss units (GU) using a glossmeter. When placed on a polished concrete floor, this special instrument emits light at specific angles and then measures the amount of light being reflected back by the surface. The GU value of that reflect is displayed on the glossmeter’s screen.
There are four levels of sheen available for your concrete floor:
Matte Finish
In a matte finish, objects reflected on the floor are hazy. Although the floor is smooth , it only reflects a minimal amount of light. Matte finish is achieved using 100-grit resin bond or lower. This finish is preferable for physical locations where the high-degrees of light and object reflections are not important.
Satin Finish
In a satin finish, the objects reflected on the floor have low-luster matte appearance. A satin finish is achieved by reaching the 400-grit resin bond. When you look down directly at the polished floor, at least from a distance of 100 feet, you will observe slight overhead reflections.
Semi-Gloss
In a semi-gloss finish, the objects reflected on the floor are easily identifiable. An 800-grit or higher diamond abrasive is required for this type of finish. When you look at the polished floor, at least from a distance of 30 to 50 feet, it will reflect both side and overhead lighting.
High-Gloss
In a high-gloss finish, the objects reflected on the floor are highly identifiable. This finish is achieved using up to 3,000-grit resin bond diamond combined with special buffing pads. In a high-gloss finish, the polished floor looks wet when it is viewed from various positions.
Can all floors be polished?
Nearly all concrete floors can be polished. But there are exceptions. Here are key issues you need to consider before calling a polished concrete contractor.
- New concrete floor curing time. For new concrete floors, the concrete placement should be at least 28 days old before it can be polished.
- Concrete floor surface and density. Before the concrete polishing process, the concrete polishing contractor will inspect aspects like concrete density, flatness, and cracks. Floors that are too wavy or uneven, or those that are highly porous may require extensive surface preparation before polishing commences.
Design options for concrete flooring polishing
Polished concrete is one of the most versatile flooring options. In the Philippines, concrete polishing contractors can use the following designs:
- Stained polished concrete.
- Dyed polished concrete.
- Plain concrete-gray flowing.
- Scored and patterned design.
- Polished concrete overlay.
For best results, only work with polished concrete contractors with reputable experience in handling both large concrete polishing projects and construction projects. Unlike small-scale projects where problems with concrete floors can be minimal, large-scale projects have different challenges in their concrete flooring. Only the best concrete polishing companies in the Philippines can take on these projects and produce the best possible results.
Want to know how much this project costs or how much you will spend to have a polished concrete floor in your property? Send us details about your concrete polishing project and we’ll give you a FREE estimate of its cost.
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