Four Common Problems of Polished Concrete

Concrete flooring has become a popular option for commercial and industrial spaces due to its low cost, ease of maintenance and a beautiful appearance. However, this beautiful finish can be marred by four common problems.

These problems are easily prevented and can be addressed by a professional. Learn more about how to achieve a high-quality polished concrete floor by eliminating these four critical flaws: aggregate stacking, surface porosity and surface imperfections.

Honing

Concrete polishing is a multistep process that transforms raw concrete into a smooth, reflective surface that’s both functional and visually appealing. The first step, grinding, uses coarse diamond grits to eliminate imperfections and prepare the surface for honing.

The next step, honing, uses progressively finer abrasives to refine the concrete’s surface and enhance its aesthetic appearance. The level of sheen a honed concrete floor achieves depends on the type of abrasive used and how long the abrasives are exposed to the concrete, according to a study by T. K. Jiang et al.

After a honed concrete floor is completed, it’s typically sealed with an acrylic, polyurethane, or epoxy coating to protect the surface from staining and moisture. The sealant can also be coloured to match the space’s overall design scheme. An anti-slip product can be added to the sealant to improve slip resistance. When honed and properly sealed, concrete floors are easy to clean and maintain.

Grinding

Grinding is the process of using diamond abrasives to remove the top layer of concrete, leaving a smooth surface. This is typically the first step in a new construction project and can also be performed on existing concrete. It creates a non-slip surface and improves paint adhesion.

The finish of a polished concrete floor is determined by a number of factors, including aggregate exposure, clarity of reflection and dyed color. The final result can dramatically change the performance characteristics and cost of the floor. For example, exposing aggregate may be attractive in a restaurant but could be unsuitable in a manufacturing space where dropped fasteners need to be easily spotted.

The grinding, honing and polishing of concrete is very technical in nature and requires real craftsmanship. Obtaining maximum “clarity of reflection” and durability is dependent on following strict procedures, such as the proper grit sequence and moving to the next finer abrasive only when the previous grit has completely refined the concrete surface.

Sealing

A sealer is applied to polished concrete, filling the pores and protecting the surface from damage. Options include epoxies, polyurethanes and penetrating concrete sealers. Selecting a sealer depends on the desired durability and appearance.

Commercial polished concrete is a durable flooring option that holds up well to heavy foot traffic and other stressors, making it ideal for office spaces or retail stores. Its high-end look complements modern design elements like minimalist furniture and open spaces.

Polished concrete requires less upkeep than sealed floors, and the sheen amplifies lighting to brighten a space. However, if the concrete is exposed to chemicals or water, it needs periodic resealing.

For example, acidic cleaners may dissolve the protective sealer. Resealing is also necessary if the reinforcing steel within the concrete corrodes, which can compromise the concrete and create safety hazards. If your business is considering installing or repairing industrial concrete flooring, be sure to consider all of the costs involved, including sealant and resealing fees.

Finishing

Concrete polishing utilises the structural slab itself rather than adding additional materials, which minimises waste and environmental impact. This also aligns with green building practices and can contribute to LEED certification for environmentally conscious projects. The natural material is also easy to maintain and provides a durable and stylish finish that lasts for years.

A variety of finishes are available for polished concrete, from matte to high-gloss. The best option for your project depends on your needs and design goals. A polished concrete specialist can help you choose the right look and provide advice on maintenance.

Unlike some flooring materials, which can harbour dust and allergens, polished concrete is an ideal choice for a healthy environment. The seamless surface prevents the accumulation of dust and mould, making it a safe and healthy alternative for those with respiratory issues. It also contributes to improved indoor air quality, which is a bonus for any home or office.

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