What’s your full process for a floor like this?
Walked onto a job with a floor like this — looks like a fine exposed aggregate / polished concrete base, not super glossy yet but already pretty dense.
Curious how you guys would run the full process start to finish. Here’s how I usually approach it:
Step 1 – Heavy cut
Start with 30/50 grit metal bonds to open it up and flatten everything. If the slab’s uneven, I’ll do a couple cross passes. This is where you decide how much aggregate you actually want to expose.
Step 2 – Transition
Move up to 100/150 grit. Sometimes still metal, sometimes hybrid depending on how the floor reacts. Just trying to clean up scratches and even things out.
Step 3 – Densifier
Apply densifier once the surface is prepped (usually after 100–200 grit). Let it soak properly — makes a big difference later on.
Step 4 – Resin polishing
200 → 400 → 800 grit resins.
At this stage the floor starts tightening up and you can really see the consistency coming through.
Step 5 – Finish
1500 → 3000 if the client wants higher gloss. Sometimes I stop at 800/1500 for a more matte/satin look.
Equipment-wise:
Main machine: planetary grinder (I usually stick to mid-large size for open areas, way more stable)
Edges: small edge grinder (no way around it)Dust: decent vacuum is a must if you’re running dry (most of the time I do)
I’ve done both wet and dry, but honestly dry + good vacuum is just cleaner and faster for most jobs.
Biggest variables for me:
how hard the concrete is
how deep I cut at the start
and how early I densify
#construction #industrial #flooring #epoxy #concrete
What would you guys do differently on a floor like this?
Having worked extensively with polished concrete floors, I’ve found that the key to a flawless finish lies not just in the steps but in attentiveness to material-specific variables. For example, the hardness of the concrete slab can greatly affect how aggressively you start with your cut. Softer concrete requires a lighter touch to avoid over-exposing the aggregate, which can compromise structural integrity and aesthetics. In contrast, harder concrete can handle deeper initial grinding with 30/50 grit metal bonds, allowing more aggregate to come through for a beautiful texture. One of the tricks I’ve learned is to really let the densifier soak as specified after the initial grinding stages—usually post 100–200 grit preparation. This chemical treatment hardens the surface and fills micro-pores, making subsequent polishing smoother and improving the floor’s durability. I usually prefer dry grinding combined with a quality vacuum, especially in commercial or industrial settings where speed and cleanliness are priorities. Dry grinding not only reduces mess but also quickens the drying process so you can move faster through the polishing phases. For finer finishes, stepping up through resin grits (200, 400, 800) gradually tightens the surface and produces that signature sheen typical of polished concrete. Edge work requires special attention. Although it might seem tedious, I always use a smaller edge grinder to ensure consistency and avoid missed spots near walls or corners. Skimping here can detract from the overall professionalism of the job. Finally, the finish stage varies based on client preferences. Some want a glossy high-shine achieved by going up to 3000 grit, while others prefer the subtle sophistication of an 800 to 1500 grit satin look. In any case, it’s about balancing aesthetics, maintenance expectations, and the floor’s intended use. I’m curious to hear how others adjust these techniques based on the unique challenges of each job, such as varying concrete hardness, moisture conditions, or specific aggregate types. Sharing these personal insights can help all of us improve our craft and deliver outstanding polished concrete floors every time.
