The Step-by-Step Process of Concrete Polishing for Sydney Construction Sites

Concrete polishing has become one of the most requested flooring solutions across Sydney construction sites—and for good reason.

It delivers exceptional durability, low maintenance, and a long lifespan, making it ideal for residential builds, commercial fit-outs, warehouses, garages, and large industrial projects.

In this guide, we break down the exact step-by-step technical process used on real Sydney sites, ensuring builders and project managers understand what’s involved and how to prepare.

1. Site Inspection & Concrete Assessment

Every successful polished concrete floor begins with a thorough site assessment. During this stage, we:

• Test concrete hardness

• Inspect surface conditions such as cracks, glue, paint, coatings, and uneven areas

• Check slab age, moisture levels, curing history, and potential contaminants

• Determine whether extra grinding steps will be required—common in older Sydney warehouses where slabs are soft or heavily worn

This assessment ensures accurate planning, proper tooling selection, and smoother workflow on site.

2. Initial Heavy Grind (Metal Bond Diamonds)

The first grind removes surface imperfections and exposes a clean, workable base.

• We start with coarse metal-bond diamonds (16–30 grit)

• Remove glue, paint, surface damage, trowel marks, and high spots

• Use dedicated edge grinders for corners, walls, and tight areas

• Employ commercial-grade H-class dust extraction to comply with Sydney safety standards and minimise airborne silica

This stage often reveals the true condition of the slab and sets the foundation for all following steps.

3. Surface Repair & Patching

Next, all visible defects are repaired to ensure a structurally sound and visually consistent surface.

• Fill cracks, chips, holes, and control joints using epoxy, grout slurry, or polymer repair systems

• Address common imperfections found in older Sydney commercial buildings

• Once repaired materials cure, they are ground flush to level the surface uniformly

Proper patching prevents weak points and guarantees a clean finish during polishing.

4. Refining the Floor (Progressive Grit Stages)

After heavy grinding, the floor is refined through multiple stages:

Metal Bond Grits

• 60 grit → 120 gritCreates a smoother, scratch-free base.

Resin Bond Grits

• 50 → 100 → 200 → 400 → 800 → 1500 → 3000

  Exact progression depends on the desired finish:

• Matte: 200–400 grit

• Satin: 400–800 grit

• High Gloss: 1500–3000 grit

This gradual refinement builds clarity, levelness, and reflectivity.

5. Densifier Application

A densifier is one of the most critical parts of the process.

What it does:

• Hardens and strengthens the slab

• Reduces dusting

• Enhances polish clarity

• Improves long-term durability for high-traffic Sydney sites

When it’s applied:

• Typically between 120–200 grit, depending on slab condition

Common types:

• Sodium

• Potassium

• Lithium (most popular for high-end commercial work)

Densifiers ensure the slab reaches its maximum hardness before the polishing stages.

6. Polishing Stages (Resin Pads)

This is where the floor begins to shine. Resin-bond diamonds create clarity, reflection, and evenness across the entire surface.

• 400+ grit → satin finish

• 1500–3000 grit → high-gloss architectural finish

Consistency is essential:Proper machine weight, clean tooling, and precise overlapping passes ensure a uniform, high-quality finish.

7. Sealing & Protection

Once the floor reaches the desired sheen, it is sealed for protection.

Common Sydney-used sealers:

• Penetrating sealers

• Protective guard coatings

• Stain-resistant commercial sealers

Benefits:

• Increased stain resistance

• Easier cleaning and maintenance

• Protection against tyre marks, spills, foot traffic

• Suitable for warehouses, retail, commercial kitchens, and garages

Seal is usually applied after the final polish or between high-grit stages.

8. Final Buffing & Burnishing

Using a high-speed burnisher, the floor is further refined and sealed.

• Locks sealer into the surface

• Adds additional gloss and hardness

• Enhances the overall aesthetic—especially important for large commercial projects aiming for premium visual results

9. Curing Time & Handover

Before handing over, we ensure the slab is ready for traffic and future works.

• Provide curing and drying times depending on the sealer type

• Recommend neutral-pH cleaners only for maintenance

• Supply care instructions, warranty details, and long-term maintenance guidelines

This helps builders protect the surface during the rest of the construction timeline.

10. Special Considerations for Sydney Construction Sites

Sydney conditions often require special planning:

• High humidity can affect curing times

• Soft old slabs often need more densifier and more grinding stages

• Tight deadlines on large builds require efficient scheduling

• Coordination with other trades is essential to avoid delays or surface damage

These factors influence workflow, pricing, and result quality.

Conclusion

Concrete polishing is a detailed, technical process that requires experience, preparation, and the correct equipment. Following each step precisely ensures a durable, flawless finish that performs in both residential and heavy commercial environments.

For builders and contractors in Sydney, AusGrind delivers precision concrete grinding, polishing, and sealing for residential, commercial, and industrial

projects. Contact us today for a free site assessment and tailored project advice.