Concrete

Polished concrete is a process which enhances the natural beauty of existing concrete by hardening and applying a sheen to the concrete.
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Polished Concrete Standards

“Polished concrete is a process which enhances the natural beauty of existing concrete by hardening and applying a sheen to the concrete. There are two primary methods to create this sheen: Topical or Mechanical.” While both methods will provide a sealed floor, mechanical polished concrete is preferred in most applications due to its extended longevity, low maintenance, sustainability, and stunning esthetic. Just as every slab of marble or granite is unique, each polished concrete floor contains its own characteristics. This stone-like, mottled appearance is very appealing, and adds character to the floor. Being a leader in the industry is defined by our contributions to our predecessors, which in turn Benefits everyone, not just ourselves.

Topical Polishing

A Topical Polish is a product treatment rolled or sprayed onto the surface of the concrete to seal it. Examples of this are wax coatings and buffed hardeners. If a higher sheen is preferred, many applications require a buffing or burnishing step to create a shine. While the concrete will have a coated, sealed appearance, the concrete will retain its coarse texture, and any inconsistencies in the surface will remain visible.

Sheen Level/Finish Options

  • Topical-Sheen Level 1: Matte finish: Scrub and Seal
  • Topical-Sheen Level 2: Low Sheen: Scrub, Buff, and Seal
  • Topical-Sheen Level 3: High Sheen: 4-Step Resin Polish

Mechanical Polish

A mechanical grinding & polishing process that utilizes industrial diamonds & impregnating hardeners and sealers to level, densify, polish & finally seal the floor from within the interior of the floor surface.

  • Wet Polish: Extends the life of diamond tooling by using water to cool, however, creates a slurry which much be disposed of.
  • Dry Polish: A preferred polishing method as it does not create a slurry, and can be performed with no production down time.

Sheen Level/Finish Options

Level 1: Matte Finish: 100 grit
Level 2: Low Sheen: 400 grit
Level 3: High Sheen: 800 grit
Level 4: Gloss Shine: 3000 grit

Decorative Polished Concrete

Abundant options including colorants, saw cuts, engraving, even stenciled art create an aesthetically appealing floor that is durable and lasting without breaking the budget. Often compared to marble, granite, and terrazzo, decorative polished concrete can be performed to achieve the same high-end look, without the cost. From stenciled designs and tile layouts, to custom logos and integral color, decorative polished concrete offers endless customization.

Sheen Level/Finish Options

  • Colorants
  • Exposed Aggregates
  • Patterns
  • Logos/Engraving
  • Acid Staining

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Benefits of Polished Concrete

Whether new construction or a 100 year old slab, most concrete floors can benefit greatly from the aesthetic, durability, and longevity of polishing.
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Elimination of Dusting from Efflorescence
In ordinary unpolished concrete, tiny particles of dust are pushed to the surface through an upward force called hydrostatic pressure, resulting in efflorescene, Efflorescene leads to dusting, which forces epoxies off of the surface of concrete floors, and can make maintenance a costly priority.
Stain-Resistant
By densifying and sealing the surface, polished concrete transforms a porous concrete floor into a tightened floor that is dense enough to repel water, oil, and other contaminants, preventing them from penetrating the surface.
Improved Reflectivity and Ambient Lighting
The reflective properties of a polished concrete floor increases the lighting in facilities. Increased ambient lighting will reduce the energy bill as well as look beautiful.
Increased Slip Resistance
Polished concrete, though quite shiny, does not create a slippery floor. In fact, the benefits of mechanically grinding and flattening the floor will increase the coefficient of friction when compared to ordinary concrete. Polished concrete often exceeds OSHA standards for floors. (ASTM C 1028)
Less Maintenance
Most floor systems, including tile and linoleum, require aggressive scrubbing to maintain a clean environment and nice appearance. Polished concrete surfaces are tightly compacted, reducing stains, and do not require any waxing or stripping to maintain the sheen.
Cost-Effective
Polished concrete will reduce energy and maintenance costs significantly through reflectivity and ambient lighting, reduction in upkeep (such as waxing), and reduced tire wear.
LEED Friendly
Polished concrete not only utilizes existing concrete surfaces, eliminating additional materials such as coverings/coatings and moving towards sustainable building, it typically contains no noticeable VOC’s, making it friendly for any USBGC LEED project.
Improved condition for old floors
As concrete ages, surface stress, delamination, curled cold joints, and other problems can arise. Mechanically grinding the floor will remove the top surface of the old concrete and polishing will then strengthen it, increasing it’s impact and abrasion resistance. (Mechanical Polish Only)
Reduced Tire Wear
The rough, uneven texture of natural concrete causes tires to abrade, adding to their wear. A polished concrete floor system will level the joints and make the entire surface smooth, preventing this abrasion (Mechanical Polish)
No Production/Plant Shutdowns
Dry-Mechanically polished concrete can be put into service immediately after the process is complete. Due to the cleanliness of the process and the lack of toxic or hazardous chemicals, floors can often be serviced while the plant is in full production. (Dry-Polish Mechanical)

Concrete Specifications

Preferred Flatwork Finishing Specs

  • Preferred Floor Flatness (FF) of 50
  • Preferred Floor Levelness (FL) of 35
  • Alternative to FF/FL is the strike-off method:
    • 0″ – 1/8″ is favorable
    • 1/8″ – 1/4″ is wavy/unfavorable
  • Bull-floated, smooth, pan-finished floor from edge to edge, with no rough areas
  • Concrete Compressive Strength: 3,500psi to 5,000psi
  • Lightweight Concrete: Not allowed if aggregate exposure is required.
  • Concrete Curing: Minimum 8 days water cured or dissipating curing compound applied.
  • Laser screeding is good for ensuring flatness.

Preferred Mix Design Specs

  • 3500 psi minimum
  • Pozzolans – No more than 15% cement replacement is recommended
  • Admixtures – in moderation, admixtures are ok for use with polished concrete. Superplasticizers will require removal with a stripper before attempting to grind and polish

Sustainable Polished Concrete Flooring

Polished Concrete and LEED

Polished concrete benefits align with the economic benefits of green building through reduced operating costs (maintenance), optimized life cycle, and reduced first costs (polished concrete is much cheaper to install than terrazzo, granite, or marble, yet sustains the polished stone aesthetic.) Below is a listing of points polished concrete may contribute to according to the standards outlined in LEED-NC v 2.2 (new construction).

Conserving the earth’s natural resources and reducing the environmental impact of construction are huge endeavors that have taken on a global focus. Using polished concrete as the floor finish is one of the most sustainable flooring options available. As a concrete slab is a required element for almost all construction projects, polishing that slab to provide a finish will not require the harvest, manufacture, and transport of additional material. There is no material sitting on top of the slab that will end up in a land-fill when it comes time to replace it. Should a repolish be desired, it can be completed with very little waste at a fraction of the initial installation cost.

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