Any slab that is soft needs extra densification. Do not believe for one second that different bonds of diamond tools will overcome a soft matrix of concrete. Yes, a different bond of tool will last more or less time based on its bonding but it has NOTHING to do with making the matrix of the concrete stronger or the floor to be cut more flat by overcoming the hardness disparity between matrix and aggregates. Soft floors need more densifier; usually double, if not more.

Diamond Tools

Any tool that is used before the first coat of densifier should be of the sort that can handle the abrasive nature of a soft concrete slab. Whether it be your first metal tool or up to your last metal tool (if something is prohibiting using densifier after your first cut) plan that tool consumption will be higher until that slab is densified unless you switch to a hard bond tool.


mock-upDuring the "Mockup Phase" – (always, always, ALWAYS perform a mock-up when a project like this is to be done!) – grind the floor with a tool that can remove the top layer of concrete to a uniform exposure and does not cut uncontrollably. In the case of STI's offering, a #0H on a P/M Machine with all the weights on the top handle works perfectly for this.

The floor should be consistently scratched and have no variation or low spots that have not been touched by the process. Then clean the surface thoroughly and apply your favorite densifier at one and a half times the manufacturer specified rate.

After the densification, whether using STI's or other diamond products, begin your polishing with your first metal polishing step. In the case of STI's offering, the EGT or CLC #1 will be the first step. Proceed on through the polishing process and then apply the densifier again after your first resin step. Finish by completing each successive step to whatever final grit the project requires to meet the specified shine.

There is much more that can be offered on this topic of "Polishing Soft Concrete." My advice is always to consult the people that make the products first before considering any other sources for what actions you should take. At least by now knowing how to accommodate soft concrete, you will have confidence to proceed as expected or to stop work and get in touch with some help.


© 2016 Substrate Technology, Inc.

The above is a general guideline to determine if densifier should be applied once or twice. For any clarification of the above or to discuss your unique situation, please do not hesitate to contact STI or any of its authorized dealers for more help and advice. We are all here to supply you solutions that save you time and make you money.