Is my slab a good candidate for polished concrete?
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Whether your slab is a good candidate for polished concrete comes down to 5 things: how flat it is, how hard it is, how much water comes up through it, what the last floor left behind, and how much of it has been patched. Once we know those 5 things, we can tell you straight whether a polish is worth paying for.
Polishing doesn’t put a new surface on top, because it opens up the one you already have. The machines start with coarse diamonds, around 30 grit, and work up to fine ones at 1500 grit. Every one of those steps takes a little concrete off, and nothing goes over the top to hide a choice somebody made years ago.
Think of a board of wood. We can sand it and finish it and make it beautiful, but it’s still that same board. Concrete tends to work the same way.
How flat does the slab need to be?
It needs to be flat enough that a normal cut reaches the whole floor. Flatness sets how deep we grind, and how deep we grind sets the look, so it’s really one question.
On a flat slab, a normal cut takes off the cream, the thin top layer of cement paste. Under it sits fine rock and sand, and showing just that gives the salt-and-pepper look most people picture. A floor that isn’t flat can’t get it. The high spots have to come down before we touch the low spots at all, and cutting deeper into the high spots shows bigger rock as a side effect. You didn’t pick that look. The floor picked it for you.
Joints are where this gets costly. Say two separate pours meet with a lip between them. Grinding the high side down to match shows big rock right along the seam, and then the low side needs another 1/8 inch or more to catch up. That change tapers out over about 4 feet on each side. One lip can put 8 feet of floor in a different look from the rest of the room.
Is a harder slab better?
No. Too hard and too soft both cost you money, so hardness is a Goldilocks problem.
A very hard slab with the rock sitting deep is slow to cut, so it wears out diamond tools and eats up hours. If you want the full rock look, the grinding can cost more than the look is worth. At that point we’d rather talk you out of it than send you a bill you’ll resent.
A soft slab goes wrong the other way. It grinds fast, which sounds like a savings until it starts soaking things up. On one job the floor ground so fast that the crew knew, before they even finished, that it would drink far more coating than normal.
What does moisture do to the answer?
We check every slab. We test for moisture when the check shows a warning sign, or when you ask us to. The test measures how many pounds of water come up through 1,000 square feet of slab in 24 hours. On a bid, you may see it called ASTM F1869. The line is 3.5 pounds. Above it, a coating doesn’t go down, and below it, we talk it through with you.
Three things are warning signs:
- There’s no vapor barrier, the plastic sheet that goes under the slab.
- The slab sits below grade, lower than the ground outside.
- The heat and air in the building have never run.
If we see any of those, we want a number before anybody picks a product.
Polishing has one big plus here, because it doesn’t trap water. A coating seals the top like a lid, and a polish leaves it open. So when nobody knows the moisture yet and the schedule can’t wait, a polish is often the safer choice.
One warning about young slabs. Concrete dries fast at first and then slower and slower. So a reading this month tells you where the slab is today, but almost nothing about when it will be ready.
What do old tile, VCT, and carpet leave behind?
Whatever was on the floor before still shows up in some way. We call that faint outline ghosting, and each kind of covering leaves a different mark.
Ceramic tile leaves a ghost of its pattern. It’s worst where the tile setter ground the concrete first to help the tile stick.
VCT (vinyl composition tile) leaves its glue, called mastic, plus old sealer. Both have to come off with diamond grinding, and the tile pattern often lives through the grinding anyway. The pattern comes from porosity, which means some spots in the concrete soak up more than others. It often runs at least 1/4 inch into the slab, so grinding, staining, and sealing won’t make it go away.
Carpet is the sneaky one. Pulling up the tack strips tears out holes the size of a quarter every few inches, all the way around the room. Those holes get patched, but patch cement isn’t as dense as the slab, so it takes stain in a different way. You can still see the patches as a dotted line around the edge of the floor.
Walls that came out leave the outline of the bottom board they sat on. A deeper cut gives us a better chance of losing it. That’s better odds, but it’s no promise.
Will the repairs still show?
Yes, every one of them. We put this in writing, and every customer reads it before anyone signs:
“…any and all repairs, fills, pour-backs from plumbing work, etc, will show in the finished floor.”
A pour-back is concrete poured back into a trench after plumbing work. Polished concrete is tough, but by its nature every flaw shows.
What a good crew can do is blend. We work color into each patch until it matches the concrete around it and your eye stops catching on it. Then the floor looks like a floor with a history instead of a floor with damage. That takes real work, and getting the best match on a single patch can take 3 or 4 hours of trying rock and tint before anyone touches the repair itself.
When the pattern truly has to go
If a tile ghost or a field of patches is something you can't live with, polishing is the wrong tool. A resurfacing overlay puts a new top layer over the old slab and starts the look fresh.
The 4 things you still control before the pour
If your concrete isn’t in the ground yet, you’re in a much better spot than someone reading this about an old floor. These 4 things set the limits on everything above, and you still control all of them:
- The mix design. That’s the recipe for the concrete, and it includes how much cement goes in.
- The aggregate. That’s the rock: what kind it is and which plant it comes from.
- The cure. How the slab dries sets how hard it ends up and how it takes color.
- How it’s placed and finished. This is where flatness is won or lost.
Before the pour, you can plan the ready-mix recipe the concrete crew will use, how the slab gets cured, and what rock goes in it. That gives you a lot more say in how the floor looks.
On jobs like that, we talk to the ready-mix plant and the pour crew ahead of time. Then we show up on pour day to watch. We’re not there to boss somebody else’s crew. We’re there to see what went in the ground, because nobody can measure that later.
One check before the pour has nothing to do with the finish, and it costs more than all the rest when it’s missed. Everybody needs to double and triple check the stub-outs. Those are the plumbing and electrical lines that stick up where the slab will go. Make sure every one is in the right spot, and measure two or three times.
Picture what happens if one is wrong. The cabinets show up for the kitchen island, and the water line is 1 foot off. Now somebody is running a jackhammer through your new floor to move it. If you’re already there, our page on plumbers cutting a finished floor shows the order of work that keeps the damage small.
Mixed answers call for a mock-up
Some slabs are easy to read from photos, but plenty aren’t. On those, the honest answer is that nobody knows yet, and that includes us.
That’s what a mock-up is for. We grind and finish a small test area on your actual slab, so everyone sees what that concrete does before the whole floor is on the line. It takes real time, around 5 hours even on a patch of about 150 square feet. That’s why it shows up as a line on the bid instead of a favor. On a slab we’re not sure about, we treat it as a must, not an upsell. It’s the cheapest insurance you can buy on a floor nobody can read from pictures.
If the mock-up comes back and you’re still torn, back up one step. The question stops being what this slab can do and becomes what you really want out of a floor, and that has its own way to work through it.
Read the slab first. Then decide.