At Superfloor Australia, we’ve seen a surge in demand for polishing existing concrete slabs. This trend reflects the growing appreciation for the beauty and practicality of polished concrete floors.
Transforming an old, dull concrete surface into a gleaming, durable floor is an art we’ve mastered over years of experience. In this guide, we’ll walk you through the process of polishing an existing concrete slab, from preparation to the final shine.
How to Prepare Your Concrete Slab for Polishing
Assessing Your Concrete Slab
The first step in preparing your concrete slab for polishing involves a thorough evaluation. Inspect the surface for damage such as cracks, chips, or spalling. Identify areas where the concrete appears softer or more porous, as these might need special attention.
We recommend using a Mohs hardness test to determine the concrete’s strength. This test is commonly used to measure the hardness of concrete surfaces and will guide your choice of diamond abrasives and help predict the final outcome of the polishing process.
Cleaning the Surface
Once you’ve assessed the slab, start the cleaning process. Start by grinding to remove any existing coatings or adhesives. This often requires aggressive grinding with 16-30 grit diamond tools. For stubborn materials, you might need to use chemical strippers. However, exercise caution as these can weaken the concrete surface.
Repairing Imperfections
After cleaning, address any imperfections in the concrete. Fill cracks and chips with a high-quality epoxy or similar filler. For larger repairs, consider using a concrete patching compound. It’s important to match the repair material’s strength to that of the existing concrete to ensure even wear and polishing.
Choosing Your Desired Finish
The final preparation step involves deciding on your desired level of shine and aggregate exposure. This decision will influence the entire polishing process, from the initial grinding to the final polishing steps.
For a salt-and-pepper look with minimal aggregate exposure, you might start with a 40-grit diamond tool. If you want a terrazzo-like finish with significant aggregate exposure, begin with a more aggressive 16-grit tool.
The level of shine isn’t just about aesthetics. Higher gloss levels often correlate with increased durability and easier maintenance. However, they also require more intensive grinding and polishing steps.
This meticulous preparation sets the stage for the actual polishing process. In the next section, we’ll explore the step-by-step procedure of transforming your prepared concrete slab into a gleaming, polished surface. The final polishing steps typically include adding a sealant to make the surface impervious after allowing it to dry for at least 45 minutes.
How We Polish Concrete
At Superfloor Australia, we have refined our concrete polishing process to achieve stunning results. Our method involves several key steps, each essential for creating a durable, glossy finish that transforms ordinary concrete into an extraordinary surface.
Grinding: The Foundation of Polish
We start with aggressive grinding, using diamond-embedded tools with a grit of 30 to 40. This initial step removes major imperfections and opens up the concrete’s pores. We then progress through finer grits, typically 80, 150, and 300. Every pass refines the surface further. This gradual progression ensures a uniform, smooth finish.
Densifying: Strengthening the Surface
After the initial grinding stages, we apply a concrete densifier. This liquid penetrates the opened pores and reacts with the free lime (calcium hydroxide) in the concrete to form calcium silicate hydrate crystals. This chemical reaction significantly hardens the surface, making it more resistant to abrasion and staining. We allow the densifier to cure for 24 hours before we proceed.
Fine Polishing: Creating the Shine
With the surface hardened, we resume grinding with even finer grits. We use resin-bonded diamond pads in a sequence of 400, 800, and higher grit levels. Every step increases the surface’s reflectivity. Higher grit levels (800+) create that coveted glass-like finish.
Sealing: The Final Protection
To complete the process, we apply a high-quality sealer. This step protects the polished surface from stains and enhances its longevity. We use penetrating sealers that bond chemically with the concrete, providing protection without changing the surface’s appearance or slip resistance. There are five main types of penetrating concrete sealers: Silane, Siloxane, Siliconate, Silicate or Silica, and Fluorinated.
Our process typically takes 3-5 days for an average-sized room, depending on the concrete’s condition and the desired finish. While DIY enthusiasts might attempt this process, professional results require specialised equipment and extensive experience. Our team’s expertise ensures a flawless finish that will enhance your space for years to come.
Now that we’ve covered the polishing process, let’s explore the numerous advantages of choosing polished concrete for your flooring needs.
Why Choose Polished Concrete?
Polished concrete floors transform spaces with their unique blend of durability and style. This flooring option offers numerous benefits that make it an increasingly popular choice for property owners. Let’s explore the advantages of polished concrete.
Exceptional Durability
Polished concrete floors exhibit remarkable toughness. They withstand heavy foot traffic, machinery, and even chemical spills without showing signs of wear. The National Ready Mixed Concrete Association reports that a well-maintained polished concrete floor can last over 100 years. This longevity results in significant cost savings over time, as you won’t need to replace your flooring every decade or so.
Low Maintenance Requirements
One of the most appealing aspects of polished concrete is its minimal upkeep. Unlike carpet or hardwood, which demand regular deep cleaning or refinishing, polished concrete maintains its appearance with simple routine care. A quick sweep and occasional damp mop usually suffice to keep these floors gleaming. This ease of maintenance saves time and reduces long-term costs associated with floor care products and professional cleaning services.
Enhanced Energy Efficiency
Polished concrete floors brighten up spaces significantly. High-gloss finishes reduce lighting needs by up to 30% in commercial settings. Brighter surfaces enhance ambient illumination, cutting electricity costs. This enhanced reflectivity leads to reduced lighting needs, potentially lowering energy costs. In commercial spaces, this translates to substantial savings over time.
Environmentally Friendly Solution
For those prioritising environmental impact, polished concrete stands out as an excellent choice. It utilises the existing concrete slab, eliminating the need for additional flooring materials. This approach reduces resource consumption and waste. Moreover, the polishing process doesn’t involve volatile organic compounds (VOCs), resulting in better indoor air quality. The U.S. Green Building Council recognises polished concrete as a sustainable flooring option, contributing to LEED certification points.
Versatility in Design
Polished concrete offers remarkable versatility in design. It accommodates various finishes (from matte to high-gloss), colours, and patterns. This flexibility allows for customisation to suit any aesthetic preference or architectural style. Whether you prefer a sleek, modern look or a more rustic appearance, polished concrete adapts to your vision.
Final Thoughts
Polishing an existing concrete slab transforms ordinary floors into extraordinary surfaces. The process involves thorough assessment, preparation, progressive grinding, and sealing to achieve a durable, glossy finish. Polished concrete floors offer exceptional longevity, potentially lasting over 100 years with proper maintenance, which translates to significant cost savings over time.
These floors require minimal upkeep and enhance energy efficiency through improved light reflectivity. As an environmentally friendly option, polished concrete utilises existing materials and contributes to better indoor air quality. Its versatility in design allows for customisation to suit any aesthetic preference or architectural style.
We at Superfloor Australia specialise in delivering high-quality polished concrete flooring in Brisbane. Our expertise ensures that your floors will look stunning while providing long-lasting durability and easy maintenance. For professional assistance with polishing your existing concrete slab, contact us today.