What Is The Process Of Polishing Concrete?
What Is The Process Of Polishing Concrete?
Polished concrete is a multi-step process in which a concrete floor is mechanically ground, honed, and polished using bonded abrasives to cut the surface of the concrete floor. It is then tweaked with each cut until it achieves the desired level of attractiveness.
A penetrant chemical known as a hardener is also used in this procedure. The concrete densifier/hardener penetrates the concrete and causes a chemical reaction that aids in hardening and dust-proofing the surface.
During concrete polishing, the surface is treated in a series of phases using increasingly finer grinding tools (in general, a minimum of four grinding steps of processing is called polished concrete).
The procedure starts with coarse diamond segments joined in a metallic matrix.
In preparation for ultimate smoothing, these segments are coarse enough to remove tiny pits, flaws, stains, or light coatings from the floor.
This initial rough grinding is often a three- to four-step operation, depending on the quality of the concrete.
Following that, the concrete surface is finely ground with diamond abrasives contained in a plastic or resin matrix.
Crews employ ever-finer grits of polishing disks (a process known as lapping) to achieve the proper gloss on the floor.
A final grit of 1500 or finer may be utilized for an exceedingly high-gloss finish. Polishing workers with experience know when to transition to the next-finer grit by evaluating the floor surface and the quantity of material removed.
An interior impregnating sealer is used during the polishing process. The sealant penetrates the concrete and is imperceptible to the naked eye. It not only preserves the concrete from within, but it also hardens and densifies it.
This removes the need for a topical coating, which considerably minimizes maintenance (versus if you had a coating on it).
To give the floor a bit extra gloss, some contractors apply a professional polishing compound to the surface during the final polishing stage.
These chemicals also aid in the removal of any polishing residue from the surface and provide a dirt-resistant finish.
Concrete may be polished using either wet or dry processes. Although each has merits, dry polishing is the most generally utilized process in the industry today since it is faster, more convenient, and less harmful to the environment.
Water is used in wet polishing to cool the diamond abrasives and remove grinding dust. Water extends the life of polishing abrasives by reducing friction and acting as a lubricant.
Cleaning is the main downside of this strategy.
Wet polishing generates a large volume of slurry, which workers must collect and dispose of in an ecologically responsible manner.
Instead, the floor polisher is connected to a dust-containment system, which vacuums up almost all debris.
Many contractors employ a combination of wet and dry polishing techniques. When more concrete is removed, dry polishing is often employed for early grinding operations.
Wet polishing becomes more common as the surface grows smoother and crews convert from metal-bonded to finer resin-bonded diamond abrasives.
Is Polished Concrete Cheaper?
There are many factors to consider when determining whether polished concrete is cheaper than other flooring options.
The initial cost of the concrete itself is often cheaper than other materials, but installation and ongoing maintenance costs must also be considered.
Polished concrete is also more durable than many other materials, so it may last longer and require less maintenance.
Because tile has high material and labour expenses, polished concrete is frequently much less expensive than tile in new home construction and restoration.
Polished concrete is a unique flooring solution because it is primarily a labor-intensive procedure.
The principal material utilized is the house’s concrete base. As a result, the polished concrete prices may be established long in advance with no chance of cost variations.
