Polished Concrete Finishes Course

Lesson 1 • Concrete Mix Design Essentials

Covers water-cement ratio, aggregate selection, and admixtures as they relate to surface density. Establishes the link between mix design and long-term finish performance.

Lesson 2 • Concrete Curing and Hydration

Explains hydration stages and curing methods that determine surface hardness. Students connect curing decisions to downstream grinding and polishing outcomes.

Lesson 3 • Common Concrete Defects

Catalogs cracks, delamination, honeycombing, and surface voids with their root causes. Defect recognition is prerequisite to repair and preparation work in Chapter 2.

Lesson 1 • Project Scheduling and Resource Planning

Addresses sequencing of trades, equipment lead times, and crew sizing for efficient project flow. Students build a realistic Gantt-style schedule for a sample project.

Lesson 2 • Safety Planning and Hazard Identification

Identifies silica dust, slip, electrical, and chemical hazards specific to concrete polishing. Students draft a job-site safety plan aligned with occupational health standards.

Lesson 3 • Pre-Project Site Inspection

Teaches visual and instrument-based inspection methods to assess slab condition. Findings directly inform repair scope and tooling choices covered later.

Lesson 4 • Moisture Testing and Vapor Barriers

Covers calcium chloride, relative humidity probe, and mat tests for moisture quantification. Excess moisture is the leading cause of finish failure and must be addressed first.

Lesson 1 • Void and Spall Patching

Covers cementitious and polymer-modified patching compounds for surface voids and spalls. Proper bonding and feathering prevent visible patch lines in the finished floor.

Lesson 2 • Crack and Joint Repair Methods

Compares epoxy injection, polyurea, and semi-rigid fillers for structural and cosmetic crack repair. Material selection depends on crack width, movement, and traffic load.

Lesson 3 • Existing Coating and Adhesive Removal

Teaches shot blasting, scarifying, and chemical stripping to remove coatings without damaging the substrate. Residue-free surfaces are essential before diamond tooling begins.

Lesson 1 • Equipment Maintenance and Troubleshooting

Covers daily inspection, belt and pad replacement, and diagnosing chatter, swirl, and uneven cut. Preventive maintenance reduces downtime and protects finish quality.

Lesson 2 • Diamond Segment Metallurgy

Explains how diamond grit size, concentration, and metal bond hardness interact with concrete hardness. Mismatched tooling causes premature wear or glazing.

Lesson 3 • Tooling Progression and Grit Sequences

Defines metal-bond, transitional, and resin-bond grit sequences from coarse to fine. Skipping grits leaves scratches that densifiers and polishing cannot hide.

Lesson 4 • Grinding Machine Types and Mechanics

Covers planetary, single-head, and hand-held grinders, including head pressure and RPM relationships. Machine selection determines productivity and edge-work capability.

Lesson 1 • Post-Densification Grinding

Covers the transition from densifier application back to resin-bond tooling to develop reflectivity. This step locks in hardness gains before final polishing passes.

Lesson 2 • Reaction Time and Environmental Factors

Explains how temperature, humidity, and slab porosity affect densifier penetration and cure time. Students adjust application timing to avoid surface crystallization.

Lesson 3 • Densifier Chemistry and Types

Compares lithium, sodium, and potassium silicate densifiers by particle size, penetration depth, and reactivity. Chemistry choice affects both hardness gain and whitening risk.

Lesson 1 • Resin-Bond Pad Progression

Details the 50-, 100-, 200-, 400-, 800-, 1500-, and 3000-grit resin pad sequence and pass patterns. Each stage removes the previous scratch pattern and builds reflectivity.

Lesson 2 • Gloss Measurement and Specification

Introduces gloss meters, gloss units, and industry-standard finish classifications. Objective measurement replaces subjective judgment and supports client sign-off.

Lesson 3 • Edge and Perimeter Polishing

Addresses hand grinders, angle grinders, and detail pads for edges, columns, and tight corners. Edge work must match the field finish to avoid visible transition lines.

Lesson 4 • Troubleshooting Gloss Defects

Diagnoses haze, ghosting, swirl marks, and uneven sheen with corrective action for each. Early defect identification prevents costly rework at project completion.

Lesson 1 • Acid Staining Chemistry and Application

Explains the metallic salt reaction with calcium hydroxide that produces variegated color. Students apply, neutralize, and rinse acid stains safely and consistently.

Lesson 2 • Scoring, Sawing, and Pattern Creation

Teaches angle grinder scoring and diamond saw cutting to create geometric patterns and borders. Precise layout and controlled depth prevent cracking and uneven lines.

Lesson 3 • Water-Based Dye Systems

Covers acetone-based and water-based dye penetration, color mixing, and layering for custom hues. Dyes offer predictable color versus the variability of acid stains.

Lesson 4 • Aggregate Exposure and Seeding

Covers broadcast seeding of glass, stone, and shell aggregates into fresh concrete for decorative exposure. Grinding depth determines the aggregate reveal level.

Lesson 1 • Guard Coat Chemistry and Selection

Compares penetrating silane-siloxane, topical acrylic, and polyurethane guard coats by durability and sheen. Selection depends on traffic type, chemical exposure, and client maintenance capability.

Lesson 2 • Guard Coat Application Methods

Covers microfiber applicator, T-bar, and spray application with correct film thickness and overlap. Improper application causes streaking, bubbling, and premature delamination.

Lesson 3 • Sealer Types for Specific Environments

Matches epoxy, urethane, and penetrating sealers to food service, industrial, and residential environments. Chemical resistance and slip ratings drive sealer selection in regulated spaces.

Lesson 4 • Restoration and Repolishing Worn Floors

Covers assessment, guard coat stripping, and repolishing sequences for floors that have lost gloss. Restoration is more cost-effective than replacement and requires accurate diagnosis.