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Polished Concrete And Stone The Process

  • The concrete floor is cut with a sander 3-4 times depending on the finished surface and the desired aggregate exposure. This can be done wet or dry depend on the site situation, This process will remove 3-5mm of concrete thickness. If it is a new slab the cutting should occur before any walls are erected to ensure the best finish (it is harder to work around walls). Note: sanding before the walls are constructed keeps the mess to a minimum.
  • The surface is then grouted with cement to allow imperfections and air bubbles to be filled.
  • Two more cuts are done after grouting.
  • A clear liquid hardener (densifier) is then worked over the surface with a window squeegee. The densifier will provide a very glossy look to the finished floor and gives the floor extra strength. The densifier is worked into the slab for about 1 hour and will soak into the slab 5-10mm. This will require overnight curing before more cutting is done.
  • The concrete floor is then cut another three times - this is the final polishing stage.
  • Lastly all the concrete floors are to be sealed. There are two main types of sealing processes: Diamond finish is where the concrete is sanded 3-4 for times with varying grades of sanding paper and sealed with a standard stone or tile sealer. Epoxy finish is applied in two layers with sanding over both layers with varying grades of sandpaper. Both sealing systems reduce any oil staining and reduce mould build-up in wet areas. A standard floor sealer for stone and tiles can be used or you may like to use an epoxy finish.