Architectural concrete elements used in interiors, residential, and garden design have become a very interesting trend in recent years.
Indeed, we are frequently contacted by clients with questions focused on the surface treatment of classic, cast, or smoothed concrete. One day, while recording an instructional video, I discovered the beauty of polished concrete myself and gradually applied the experience gained to both corporate and private spaces.
In the beginning, there was just concrete in a warehouse
We were preparing new, larger warehouse spaces and needed a smooth and durable floor. The choice was clear very quickly: smoothed "armored concrete." The composition of this material is very similar to all common concrete structures—reinforcement and a high-quality concrete mix enriched with "micro-fibers" (fine metal hairs) that significantly increase the material's strength.
After pouring and leveling the concrete surface, it was time for power troweling with a hardener shake and finishing with a special lacquer. After the evaporation and curing of all components, we were left with a nice, unified, and extremely durable floor that is easy to maintain.
What would happen if we polished such a large concrete area?
We asked ourselves this exact question during the construction work in the part of the building that is currently the DiaSegment showroom and pickup point. We decided to take the risk and use the exact same floor structure, with the difference that we would polish it to a high gloss while keeping visible aesthetic defects and cut expansion joints. The result thrilled the architect, the floor polishing crew, and, of course, us.
Polished armored floor in the DiaSegment s.r.o. premises.
Polished concrete floor in an apartment? Who can advise you when almost nobody has one?
The third phase of the project was an apartment located on the upper floor, above the company premises. I had long played with the idea of a large polished concrete floor in private living spaces, but I didn't have much courage.
They say: "Don't take advice from people who comment on situations they haven't experienced." Since this idea had been proven right to me several times, I didn't let myself be discouraged.
I like uniqueness, being different, and results with a story. Therefore, I didn't want to repeat the same scenario as with the floor in the warehouse or showroom; I wanted to push the knowledge a bit further. In this concrete mix, we added glass fibers instead of steel fibers. But that wasn't the most significant change. I decided that we would not cut expansion joints and would let the relatively large concrete area cure naturally, even at the high risk of cracks forming.
"Let's turn a mistake into an ornament" was the challenge in case the concrete surface cracked too much. To our great surprise, after two months of curing, only three one-meter-long, very thin cracks appeared. Before grinding and polishing, we filled these with a mixture of epoxy and gold dust. Thus, we gained subtle gold veins in the floor.
Since this concrete structure was essentially a subfloor for further floor coverings, we didn't risk much. If it hadn't worked out, we would have applied a self-leveling compound followed by tiles, parquet, etc.
What are the advantages of a polished concrete floor in the interior?
- High hardness and durability similar to a stone floor.
- Beautiful shine and simple maintenance.
- Very long lifespan.
The owner's opinion after years of use
Even after more than 5 years of use, our opinion on the polished concrete floor in the apartment, warehouse, and showroom hasn't changed. It is still just as shiny, without damage, and very easy to maintain.
However, you must keep in mind that the basis of this project was power-troweled cast concrete. This means it is, in principle, a manually leveled concrete and therefore not perfectly flat. It is a surface whose unevenness you won't notice while walking or with the naked eye. The unevenness reveals itself when placing a large furniture piece or by letting a golf ball roll across the floor.
Concrete elements in architecture are not just a current trend or a whim of architects. Modern technologies push the boundaries of processing concrete surfaces to a much higher level compared to previous decades.
What procedure did we choose for polishing the concrete floor?
In all three cases, it was the same floor structure regarding the surface. This means we polished a smoothed concrete surface with a shake-on hardener. Since we wanted to level the floor first, this meant grinding this thin layer deeper into the material in some places.
- For the coarser grinding needed for leveling, we used metal-bond grinding segments. A metal grinding wheel with #30 grit worked very well for us.
- Coarse marks from the first grit were smoothed out with the same tool as in the first step, just with a finer #100 grit.
- This was followed by #400 and #800 grit in a ceramic bond.
- For a higher shine, we used polishing pads with 2000 and 3000 grit.
- After thoroughly cleaning the floor of grinding slurry and drying, we applied STRONG 2000 impregnation from the Italian brand Bellinzoni in three layers. For more information on impregnation, you can read the article "How to protect stone?..."
A moment captured during work with the floor polisher.
How to keep the floor in top condition?
Polished concrete floors are among the most durable and long-lasting. By following a few simple rules, it will serve you for decades without major interventions.
- Do not use acidic cleaners; avoid acidic environments. We recommend using cleaners suitable for concrete or marble surfaces.
- To increase, revive, or maintain the shine, we recommend using suitable waxes, such as the RR/1 product.
- To maintain high gloss even in more demanding conditions, use the product Dural Brill.
Conclusion
Bold ideas and their realizations carry a strong story with them. Do not let yourself be discouraged from your visions by people who only have an opinion but lack relevant experience. Seek advice from experts and try to capitalize on their experience. You will achieve unique results and be a role model for others. Because uniqueness carries with it experience, risk, and courage. And that is not for everyone.
Pavol Šáray
CEO & Technical Specialist, DiaSegment
I spend most of my time in the field with customers, searching for the best solutions for their specific tasks directly on construction sites or in stonemasonry workshops. These field trips are my greatest inspiration – I then process insights from practice into professional articles to help you navigate the subject. Since I am often in full work mode, you might not reach me immediately, but I will be happy to devote my full attention to your questions.
✉️ E-mail: diamantovenastroje.cz@gmail.com
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