Types of Polishing Pads for Industrial Polished Concrete Floors

Polishing pads are essential tools in the finishing phase of concrete floor preparation, especially in industrial applications where performance, aesthetics, and durability are critical.

With advancements in diamond technology and surface refinement systems, a wide range of polishing pads has emerged—each designed for specific stages and outcomes of concrete polishing.

This article explores the main types of polishing pads used in the creation and maintenance of polished concrete industrial floors, including their composition, grit sequences, bonding materials, and application techniques.

1. Resin-Bond Polishing Pads

Overview

Resin-bond polishing pads are among the most commonly used pads in the final stages of polishing concrete surfaces.

They are made by embedding industrial-grade diamond abrasives in a resin matrix that determines flexibility and cutting performance.

These pads are designed to refine the surface after metal-bond grinding, creating a smooth, glossy finish.

Characteristics and Applications

• Grit Range: Typically available in 50 to 3000 grit, with lower grits used for honing and higher grits for gloss polishing.

• Use: Applied in the intermediate and final polishing steps after metal-bond pad preparation.

• Machines: Compatible with planetary grinders, rotary machines, and hand-held polishers.

Benefits

• Produces high-gloss, mirror-like surfaces.

• Flexible structure adapts well to slightly uneven floors.

• Reduced risk of leaving scratch patterns compared to metal pads.

2. Metal-Bond Polishing Pads

Overview

Metal-bond pads are used in the initial grinding stages where aggressive material removal is necessary.

These pads consist of diamond abrasives bonded with a metal matrix, making them ideal for surface leveling, removing coatings, and opening the concrete pores.

Characteristics and Applications

• Grit Range: Commonly available in coarse grits such as 6, 16, 30, and 70.

• Use: First phase of the polishing process—used to flatten the surface, remove laitance, and prepare for resin pads.

• Machines: Primarily used on large industrial grinding machines.

Benefits

• High durability and longevity on tough industrial floors.

• Effective at removing deep imperfections and previous coatings.

• Excellent cutting speed, minimizing grinding time on hard concrete.

3. Hybrid Polishing Pads

Overview

Hybrid polishing pads combine the characteristics of metal and resin pads.

They are designed to bridge the transition between aggressive metal grinding and smooth resin polishing.

These pads are ideal for intermediate polishing steps or when switching between grinding and honing.

Characteristics and Applications

• Grit Range: Usually between 50 and 400 grit.

• Use: Mid-stage polishing where smoothness and profile correction are needed.

• Machines: Usable on both rotary and planetary floor grinders.

Benefits

• Faster progression from coarse grinding to fine polishing.

• Reduces pad changeover time during multi-step polishing.

• Provides an even, matte surface ready for resin finishing.

4. Ceramic-Bond Polishing Pads

Overview

Ceramic-bond polishing pads are a newer innovation combining the benefits of resin and metal pads with enhanced cutting action.

They are particularly useful for dry polishing of concrete and work efficiently on high-strength concrete floors.

Characteristics and Applications

• Grit Range: Typically from 30 to 400 grit.

• Use: Intermediate polishing or aggressive refinement after metal grinding.

• Machines: High-speed planetary grinders or heavy-duty burnishers.

Benefits

• Higher heat resistance than resin pads.

• Improved abrasion and cutting efficiency on dense concrete.

• Ideal for large-scale industrial polishing with minimal downtime.

5. Transitional Polishing Pads

Overview

Transitional pads are developed to ease the step-down process between coarse metal bonds and fine resins.

These can be ceramic-hybrid or copper-hybrid pads that prevent visible scratch transfer and prepare the surface for fine resin polishing.

Characteristics and Applications

• Grit Range: 50 to 200 grit.

• Use: After metal grinding and before resin polishing to eliminate residual scratches.

• Machines: Mid-to-large planetary grinders or edge polishers.

Benefits

• Eliminates the need for multiple intermediate resin steps.

• Reduces swirl marks and visible abrasions before final glossing.

• Cost-effective option for high-speed transitions.

6. Burnishing Pads

Overview

Burnishing pads are non-abrasive or lightly abrasive pads used in the final stages of polishing, especially when polishing concrete with chemical densifiers or sealers.

These pads are made from natural fibers, synthetic blends, or diamond-infused materials to enhance shine.

Characteristics and Applications

• Grit Range: Often specified in polishing effect (e.g., gloss rating) rather than grit number.

• Use: Final buffing after resin polishing or chemical treatment.

• Machines: High-RPM burnishers (up to 3000 RPM).

Benefits

• Creates ultra-glossy, reflective surfaces.

• Can be used with polishing compounds or dry burnishing systems.

• Extends the shine and cleanliness of polished concrete floors.

7. Dry vs. Wet Polishing Pads

Wet Polishing Pads

• Require water to cool the surface and reduce dust.

• Deliver a finer polish and are preferred for decorative surfaces.

• Extend pad life due to reduced heat friction.

Dry Polishing Pads

• Ideal for large industrial spaces where water usage is impractical.

• Faster work cycle, but generate more dust and heat.

• Require high RPM and good dust extraction systems.

8. Polishing Pad Backings and Attachment Types

Polishing pads come with different backing systems for easy attachment to grinding and polishing machines:

• Velcro-Backed Pads: Easy to replace; common in both hand-held and planetary polishers.

• Magnetic Plates: Used for heavy-duty industrial machines.

• Threaded or Snail-Lock Pads: Provide secure attachment and are used for edge polishers or angle grinders.

9. Pad Selection Based on Concrete Type

Different concrete surfaces and treatment conditions influence pad selection:

• Hard Concrete: Requires softer-bond pads to ensure effective diamond exposure.

• Soft Concrete: Requires harder-bond pads to avoid over-aggressiveness.

• Densified Concrete: Performs best with resin or ceramic pads for a refined finish.

• Exposed Aggregate Floors: Often start with coarse metal-bond pads for surface leveling.

10. Maintenance and Lifespan of Polishing Pads

Proper maintenance extends the performance of polishing pads:

• Clean pads after each use to prevent clogging.

• Alternate between pads to ensure even wear.

• Store in dry conditions to prevent resin degradation.

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