There are four basic methods used today to create a shine on natural stone floors: Buffing with polishing powders and compounds, grinding with diamond abrasives, crystallization and applying barrier coatings. Each method may not be effective on all stone types and the use of more than one may be necessary.
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Polishing Powders and Compounds are fine grains of aluminum or tin oxide abrasive powder that are buffed or rubbed on the surface of the stone to create the shine. This process is actually the same as sanding with diamonds except that the powder is a much finer abrasive. This process is most often augmented by the addition of oxalic acid or oxalate to create a reaction similar to crystallization. The powder is put on the surface and wet with water to make a paste or slurry that is buffed into the stone with a 175 rpm weighted floor machine and a hogs hair or white pad.
Grinding with diamond abrasives is done by grinding the surface of the stone with various grits of industrial grade diamonds that are usually in three to four inch diameter pads or discs. Three to six discs are placed on the bottom of a floor machine drive plate and held on with Velcro. A low speed (175 rpm) floor machine is used to drive the plate and sand the stone surface with the diamonds to remove scratches. The process is repeated with finer and finer grits of diamonds until a mechanical shine is achieved.
Coatings are commonly known as 'waxing' the surface to create an artificial shine. A liquid or semi-liquid form of wax, acrylic, urethane or other polymer is applied or 'coated' on to the surface with a mop, roller, lambs wool applicator or sprayer. Some are left as applied and others must be 'buffed out' to achieve the shine. This is generally done with a high speed burnishing floor machine and fiber or hogs hair pads. This process is not recommended for porous stone.
Crystallization is a process in which a chemical called fluorosilicate is sprayed onto the stone and buffed in with steel wool pads causing new, glassy like, crystals to be formed on the surface. A standard 175 rpm floor machine with a special heavy drive plate is used to create the heat and friction needed to form and polish the crystals.
The following pros and cons are presented from the view point that polished marble, granite and limestone are chosen for use on floors because of their 'natural' appearance and beauty. When cost is shown as an advantage or disadvantage, it is only to compare one method with the others. Most often the owner's expect the cost of maintaining natural stone floors to be higher than that of other resilient floors.
Polishing Powders and Compounds
ADVANTAGES:
1. Gives a natural appearance with a high gloss and sheen.
2. Produces a relatively durable finish.
3. Never requires stripping.
4. Can be applied with a standard low speed weighted floor machine.
5. If oxalic acid or oxalate is included in the powder, it will remove fine to medium scratches.
6. Only done periodically, not daily or weekly.
7. Compounds composed of aluminum oxide will not etch floor.
DISADVANTAGES:
1. A messy process, requiring additional work to clean up.
2. If oxalic acid is included in the powder, it can cause etching or blistering of marble and limestone depending on the skill of the person using it.
3. Requires equipment (i.e., a floor machine, wet vac, mop, mop bucket, etc.).
Grinding with Diamonds
ADVANTAGES:
1. Is the most natural method.
2. Very durable, long lasting finish.
3. Never requires stripping.
4. Will remove all scratches.
5. Works well on marble and granite.
DISADVANTAGES:
1. Requires an initial restoration of the floor to remove or bevel the lippage that can/will damage the fine grit diamonds used.
2. Highest cost method in both material and labor.
3. The final polish and clarity vary depending on the stone and generally have to be augmented by using powder, polish or compound.
Coatings
ADVANTAGES:
1. Most janitorial maintenance personnel are familiar with this method.
2. Can be lowest cost method if not concerned about the appearance.
3. Generally provides good slip resistance.
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DISADVANTAGES:
1. Does not provide a natural appearance.
2. Most coatings do not adhere well to polished stone.
3. Scuffs and dulls very rapidly.
4. Requires daily buffing or burnishing.
5. Requires periodic stripping that is messy and damages the stone.
6. Blocks the pores of the stone which, coupled with stripping, can cause spalling.
7. Can be a high cost method if done properly to maintain the best possible shine.
Crystallization
ADVANTAGES:
1. Gives a natural appearance with a high gloss and sheen.
2. Very durable, long lasting finish.
3. Easy to use and does not require any special skills.
4. Very clean, no mess.
5. Will remove fine scratches and polish heavy scratches.
6. Do not have to polish the entire floor. Can 'touch-up' high traffic areas.
7. Can be applied with a standard low speed floor machine.
DISADVANTAGES:
Polished Concrete, when professionally done, is a perfect no-wax flooring material that gives spaces a minimalistic, professional, and sophisticated look. It is a low-maintenance, cost-effective, durable and an incredibly hard-wearing surface option that can be effectively remodelled for areas that have heavy foot traffic or that need to withstand constant movement of heavy items. With the proper floor grinding equipment, expert professionals can grind concrete surfaces, whether new or old, to a flawless, high-gloss finish. Concrete can also be coloured in many tones which largely expands its aesthetic and decorative scope.
It is eco-friendly so for businesses focusing on their carbon footprint, opting for polished concrete is a great way to be sustainable. Polishing existing concrete surfaces minimizes waste by using materials at hand instead of installing completely new flooring. The process does not require many additional products or materials thus reducing unnecessary waste.
Moreover, polished concrete has reflective properties that maximize lighting in facilities. Improved ambient lighting not only improves the space's appearance aesthetically but also increases safety and significantly reduces energy consumption. With its versatility, sustainability and long-lasting durability that rivals floorboards and carpets, it's not surprising that retail, commercial as well as residential spaces are incorporating this smooth, trendy and long-lasting option.
Polished concrete involves mechanically polishing a concrete surface using diamond-encrusted floor grinding shoes, to the desired degree of shine and smoothness, similar to sanding wood. A common misconception is that every kind of concrete floor finish is polished concrete. When in fact, in the industry, there are multiple types of finishes. There are different methods and finishes to choose from ' ranging from high-gloss minimal appearance to a speckled matte look which involves exposing a lot of aggregate in the concrete slab. The different methods and finishes include: grind and seal, mechanically polished concrete, cream-matte, semi-gloss, high-gloss finish and so on.
One of the most common finishes our clients look for is 'grind & seal'. The grind & seal finish gives a smooth satin matte finish to the floor and is perfect for those clients that are looking for a rustic industrial finish which is popular and currently trending in cafes and restaurants. The advantage of this finish is that it's cost-effective and helps to protect the concrete slab from stains and spillages.
Cream concrete finish requires the concrete to be well cured, at no less and preferably more than 32 MPA of strength, having been laid very straight with a highly burnished finish. The difference between a cream concrete finish with a polished concrete finish is that a cream finish is achieved by not exposing any aggregate and switching from metal bonded diamonds to resin bonded earlier in the process. Being economical, the 'cream' finish is perfect for industrial areas where extreme floor strength is required. It is also the obvious choice for large commercial areas subject to high traffic.
Polished concrete is more expensive than 'grind & seal' finish as there are a lot more steps and processes involved. Depending on the finish you are looking for, polishing concrete can involve between 12 to 18 passes with the floor grinders. The diamond discs need to be changed while increasing the grit of the diamonds for each pass. In between the passes, a chemical hardener must be applied and allowed time to seep and densify into the slab. This is an intricate and time-sensitive process and the main reason why polished concrete is much more expensive.
As with any other specialized technique, polishing is a multi-step process requiring use of the proper tools and equipment to achieve high-quality results. Polishing concrete is quite similar to sanding wood. The process is usually carried out by large floor grinding machines that have diamond-encrusted cup wheels installed on a spinning disc. These diamonds (akin to sandpaper) are used to grind down concrete surfaces to the desired degree of shine and smoothness. Similar to sanding wood, you gradually progress from coarser grit to finer grit (in this case, grit is the particle size of the diamond) abrasives to eventually achieve a glossy, mirror-like finish.
Concrete can be polished using wet or dry methods. Although each has its advantages, dry polishing is the method most commonly used in the industry today because it's faster, more convenient, and environmentally friendly. Wet polishing uses water to cool the diamond abrasives and eliminate grinding dust. Because the water reduces friction and acts as a lubricant, it increases the life of the polishing abrasives. The key disadvantage of this method is the clean-up. Wet polishing creates a tremendous amount of effluent that crews must collect and dispose of in an environmentally sound manner. With dry polishing, no water is required. Instead, the floor polisher is attached to a dust-containment system that vacuums up virtually all the mess.
There are many different types of Diamond Cup Wheels, which will have various effects. Generally, Cup Wheels are measured in grits. The higher the grit ratio the finer finish it will leave on the concrete. For a more polished effect, a Cup Wheel with a high grit ratio would be used. The types of diamonds used are as follows:
A concrete sealer is essential for protecting surfaces from water damage caused by freeze/thaw cycles, stains from dirt, dicing salts, oil and other contaminants, and much more. There are two main types of concrete sealers: film-forming sealers and penetrating sealers.
Film-forming sealers include acrylics, epoxies, and urethanes that form a coating on the surface of the concrete. Film-forming sealers, especially acrylics, are more susceptible to wear and will need to be reapplied frequently. This type of sealer is sometimes referred to as a topical concrete sealer or a coating. You should opt for a film-forming sealer if you want a wet look or high gloss finish that enhances the colour of your concrete.
Penetrating sealers include silanes, siloxanes, silicates and siliconates that penetrate the concrete to form a chemical barrier. Penetrating sealers have a longer lifespan and are a great choice for exterior applications. They don't peel, delaminate or wear away. This type of sealer is sometimes referred to as an impregnating concrete sealer. You should opt for a penetrating sealer if you prefer a natural finish that will not change the look of your concrete.