Complete Guide to Mechanically Polished Concrete

Mechanically polished concrete (MPC) is one of the most durable, low-maintenance, and visually striking flooring options available today. Unlike coatings or topical sealers, MPC is achieved through a multi-stage mechanical process that hardens, densifies, and refines the concrete surface itself.

This guide provides a comprehensive, step-by-step process for first-time operators to achieve professional results. It accompanies the Taman training video, accessible via QR code below.

Why Choose Mechanically Polished Concrete?

Long-lasting, abrasion-resistant surface
Reflective, high-end appearance
Low maintenance and easy to clean
Environmentally friendly — no topical coatings required
Ideal for commercial, industrial, and residential use

Fundamentally, the goal of mechanically polished concrete is to achieve a floor that is flat, full, and hard. The gloss and reflectivity are by-products of refinement and consistency.
We grind the floor to make it flat, fill pinholes and voids with grout, and harden the surface with densifier. When a floor is full, flat, and hard, it naturally develops a high-gloss reflection with excellent clarity and minimal light diffusion.

Process Overview (Summary):
Preparation → Grinding → Grouting → Densifying → Polishing → Sealing

Safety & Preparation

Personal Protective Equipment (PPE)

Safety glasses or face shield
Hearing protection
Dust mask or respirator (P3 rated)
Safety boots and gloves
High-visibility clothing

Dust & Slurry Control

Always use H-Class dust extraction such as the TDE-AC or TDE3-AC vacuums.
Use wet grinding where possible to minimise airborne silica — do not use H-Class extraction during wet grinding.
Ensure vacuums and hoses are in good condition before starting.

Power & Equipment Safety

Confirm power supply is compatible with grinder specifications.
Inspect leads and plugs for damage.
Use RCD protection on all machines.

Stage 1 – Pre-Grinding

Before any grinding begins, preparation is key to achieving a flawless finish.

Surface Inspection & Cleaning

Remove debris, paint, adhesives, and contaminants.
Check for nails, bolts, or protrusions that may damage tooling.

Repairs

Use a crack-chasing blade to open cracks and remove loose material.
Fill with a compatible repair compound and allow to cure fully.

Assessing Concrete Hardness

Use a Mohs Hardness Test Kit to determine the floor hardness. Select diamond tooling accordingly:

Mohs Hardness	Recommended Bond
7–9	Super Soft
6–8	Soft
5–7	Medium
4–6	Hard
1–5	Extra Hard

Stage 2 – Grinding

Grinding removes high spots, levels the floor, and exposes the desired aggregate. The initial stages are critical in determining the final reflection and flatness.

Process Steps

30 Grit (Initial Cut): Begin with 30# metal-bond diamonds. Continue until desired exposure is achieved, high spots are removed, and the floor is flat.
Grinding Direction:
- During the first few passes, limit cross-cutting. Grind only in one direction — either north–south or east–west.
- Excessive cross-cutting too early can introduce a ripple effect, visible under high-gloss finishes.
- Once the floor is flat and consistent, reintroduce cross-hatch grinding for finer grits (60 → 120 grit).

Pro Tip: Avoid early cross-cutting to prevent ripple patterns that will appear once the surface is polished.

60/80 Grit Stage: Replace coarse tooling with 60# or 80# metal bonds to remove heavy scratches.
After each grit stage:
- Vacuum thoroughly.
- Inspect for consistency and uniformity before moving on.
- You should both see and feel a smoother surface after each stage.

Stage 3 – Grouting & Densifying

This stage fills pores, hardens the surface, and prepares the concrete for polishing.

Grouting

Apply polish grout with a low-pressure sprayer and spread evenly using a microfibre mop or broom.
For surfaces with larger pinholes, sprinkle a small amount of cement over the wet grout — this enhances filling.
While wet, grind using 60# diamonds to drive the paste into pores.
Only grout 3–4 m² at a time to prevent premature drying.
Allow approximately 1 hour to dry.

Densifying (Initial Application)

Apply potassium densifier using a low-pressure sprayer, ensuring even coverage.
Spread with a microfibre mop; do not allow pooling.
Allow to dry overnight before proceeding.

Next Day – Grout Removal & Re-Inspection

120/150 Grit Stage: Remove excess grout using 120# /150# diamonds.
- If grout is too heavy and 120# /150# diamonds are ineffective, step back to 60# diamonds, then return to 120# /150#.
Vacuum and closely inspect. The floor should now have no holes or visible scratches.
Optional Regrout: If minor pinholes remain, reapply a light grout coat and repeat grinding with 120# or 150# tooling.

Densifying (Until Rejection)

Reapply potassium densifier, keeping the floor glistening wet for about 5 minutes.
Remove excess with a microfibre mop.
Apply until no more densifier is absorbed — this ensures full chemical reaction and hardness development.

Stage 4 – Polishing

The polishing stage brings out the shine and clarity of the surface. Progress through each grit in order — do not skip steps.

During polishing, apply lithium or colloidal silicate densifier again after 100# and 200# passes. These smaller-molecule products penetrate deeper, improving clarity and final gloss.

Grit	Tool Type	Purpose
50#	Resin or Ceramic	Remove metal bond scratches
100#	Resin	Smooth surface, begin gloss development
200#	Resin	Matte finish
400#	Resin	Satin finish
800#	Resin	Semi-gloss finish
1500#	Resin	Gloss finish
3000#	Resin	High-gloss mirror finish

Between each grit:
– Vacuum and inspect the surface.
– Maintain consistent machine speed and pressure.
– Replace worn pucks promptly.

Pro Tip: Apply densifier again after 100# and 200# polishing to maximise surface hardness and gloss potential.

Stage 5 – Sealing & Buffing

Sealing

Apply a solvent-based penetrating sealer using a low-pressure sprayer.
Allow 30–60 minutes to penetrate, then remove excess with a clean mop.
Apply a second coat if needed using the wet-on-wet

Buffing

Complete final polishing with 1500# or 3000# resin pads.
Buff until desired gloss and clarity are achieved.

Maintenance

Clean regularly with a pH-neutral cleaner.
Avoid harsh acids or ammonia-based products.
Re-buff periodically to maintain shine.

Recommended Tools & Products

Stage	Tool Type	Product	Notes
Coarse Grind	Razor / Diamond Shape – Single Segment	30# Full Plate	Initial cut to flatten floor. Ensure tooling bond is suitable for concrete hardness
Fine Grind	Super Puck or Coffin Shape – Double / Triple Segment	60# & 120#	Scratch removal. Soft or Medium bond.
Grouting	Polish Grout	Forti-Grout™	Use with 60–120#
Densifying	Potassium Densifier	Forti-Kal™	Early densification
Polishing (Early Stage)	Ceramic Pucks	50# / 100# Ceramic Puck	Superior scratch removal
Densifying (Mid / Late Stage)	Colloidal Densifier	Forti-Col™	High-reactivity late densifier
Polishing (Finishing)	Plastic Resin Pucks	100#–3000# Plastic Resin Puck	High clarity and gloss finish
Sealing	Solvent-Based Penetrating Sealer	Stain-Protector™	Premium protection
Grinder	Planetary Grinder	GBD-680	Recommend minimum size grinder for cost effective polishing is 7.5Kw motor and grinding head of at least 550mm.
Dust Extraction	H-Class HEPA Vacuum	TDE3-AC	Match vacuum to grinder size

Troubleshooting Guide

Problem	Likely Cause	Recommended Fix
Cloudy layer on concrete	Excess densifier or grout residue	Remove with 120# or prior grit used before grouting
Cloudy finish	Excess sealer or poor buffing	Rebuff floor
Pinholes	Insufficient grouting	Re-grout with 120# pass
Uneven gloss	Missed passes or worn tooling	Regrind and continue polishing sequence
Ripple effect	Over cross-cutting during coarse grind	Re-level and re-grind

Final Notes

Always follow the manufacturer’s data sheets for each chemical or tooling product. Environmental conditions such as humidity, temperature, and slab composition can influence results.

If unsure contact Taman Diamond Tool Solutions.

Disclaimer: The information in this guide is based on Taman’s field experience and best practice. Results may vary depending on site conditions. Liability is limited to the replacement cost of the product only.

Frequently Asked Questions (FAQ)

Can I skip steps?

No. Skipping steps will likely result in a scratchy yet shiny surface that reflects imperfections. Each grit stage is designed to remove the marks from the previous one, so skipping will compromise the final finish.

How long will this process take?

The total time depends on the desired finish and level of aggregate exposure. High-gloss, full-exposure finishes take the longest; low-gloss, nil-exposure finishes are the quickest.

Grinder size and operator experience also greatly influence productivity. If this is your first time polishing concrete, use the largest and most powerful grinder practical for the space, and allow yourself extra time.

As a rough guide, a large 650mm+ grinder (11kW or higher) can polish approximately 150 m² in 5 days if operated by someone familiar with the process.

How much tooling should I put on the machine?

For the initial grind, use a full set of tooling (18 on 3-head machines, 24 on 4-head machines) to ensure a flat surface.

For 60# and 120# stages, a half set (9 / 12) is usually sufficient. For grinders 850mm+ and 15kW+, a full set is recommended.

For polishing, the same principle applies—more tooling generally produces a better finish, but on very hard concrete, too much tooling may reduce productivity due to lower surface pressure.

How fast should the grinder spin?

Speed depends on the grinder model and the hardness of the concrete. As a general guide:

30# = 900–1200 RPM
60# & 120# = 1200–1500 RPM
Grouting = 700–900 RPM
50# – 400# = 1400–1600 RPM
800# – 3000# = 1500 RPM to maximum

The machine is not removing material / scratches?

The bond of the tooling may be too hard for the concrete. Conduct scratch test to determine surface harness and use a softer bond of tooling

The tooling is wearing prematurely?

The selected tooling may be too soft for the concrete. Conduct scratch test to determine surface hardness and use a harder bond of tooling.

If I want a semi-exposed / salt & pepper exposure, where should I start?

Try 120# metal-bond diamonds first and assess the result. If not enough material is removed to reveal the desired level of exposure, drop back to 60# and repeat the pass. Starting finer avoids excessive aggregate exposure.

If I want a nil exposure, where should I start?

Begin with 100# ceramic polishing pucks. This will refine the surface without cutting deep into the concrete, maintaining the cream layer on top.

What stage should I finish at?

Finish after the grit that produces the desired level of shine. For most jobs, polishing to at least 400 grit is recommended to achieve the full benefit of the densification and sealing process.

Is this the only way to polish concrete?

Not necessarily. There are multiple ways to achieve polished concrete results. The exact combination of tooling, chemicals, and machinery can vary based on operator preference and conditions. The method outlined in this guide reflects Taman’s proven process developed through extensive field experience.

Veteran polishers may follow slightly different grit sequences or techniques refined through years of practice—but the fundamentals remain the same.

Final advice

Polished concrete is not easy to perfect. Expect to make mistakes on your first attempt. When you’ve spent hours on a floor, you’ll notice every blemish—but perfection is nearly impossible. The goal is to chase perfection while delivering a durable, consistent, high-quality finish.
Take your time during the early stages (from 30# through 120# and grouting). If you make an error, it can always be corrected by stepping back and redoing the stage properly.

Appendix A – Chemical Product Reference Table

Product	Application Stage	Description / Purpose	Application Method	Coverage Rate	Drying / Cure Time	Safety / PPE	Special Instructions
Forti-Grout™	Grouting & Crack Repair	Premium polymer grout designed to fill pinholes and cracks up to 3mm; provides strong adhesion and UV resistance.	Spray approx. 1.5m in front of grinder and grind while still damp. For edges, apply by brush.	N/A – apply to visible area only	Allow 1 hour before next grind; 2 hours for patching	Gloves, safety glasses	Lightly sprinkle cement over grout for better colour match; grind while still damp. Available through Taman Diamond Tool Solutions.
Forti-Kal™	Early Densification	Potassium silicate densifier; forms CSH hydrogel and hardens concrete early in grinding sequence.	Apply generously with pump sprayer; keep surface wet for 2–5 min, mop off excess.	6–15 m²/L	4+ hours before regrind; overnight preferred	Gloves, goggles	Ideal after 80–100 grit metal. Available through Taman.
Forti-Col™	Late Densification	Colloidal silica densifier with ultra-small particle size for deep penetration and high reactivity; enhances gloss.	Apply after 200 grit resin or later using sprayer; keep surface wet 5–10 min, avoid pooling.	6–15 m²/L	1–2 hours before next stage	Gloves, eye protection	Apply 2 coats if fully absorbed within 10 min; enhances final polish. Available through Taman.
Stain-Protector™	Final Sealing	Premium solvent-based impregnating sealer providing superior oil and water repellence.	Apply 2 coats with sprayer or mop; keep wet for 10 min between coats, polish off residue before dry.	4–20 m²/L total (2 coats)	Handle-free after 6 hrs; full cure 3–4 weeks	Gloves, mask, goggles	Ensure ventilation; polish residue before drying to avoid streaks. Available through Taman.