Blackburn Lancashire: Polished Concrete Floor

Here we have a CARRcrete PROtop concrete overlay installation that has gone wrong, laid and mixed by the clients contractors and as can be seen, this is not how to install any concrete overlay, let alone my beloved PROtop. Not only was the floor full of lips, overlaps and bulges but also innumerable tiny air pockets caused by insufficient mixing.

This could easily have been a splendid looking floor had the instructions have been followed, the correct tools used and the product mixed and placed as required.

The biggest challenge was removing these defects from an overlay that is only 4-6mm thick; not an easy task.

Our Concrete Polishing Process


The product has been left to skin over before applying more product
The product has been left to skin over before applying more product

How not to lay a concrete overlay
How not to lay a concrete overlay
The same floor ground and polished
The same floor ground and polished

As you can see we have managed to smooth out (not remove) the installation defects so the floor and is somewhat more flat and smoother. We achieved this by using our vacuum brazed diamonds that have a bevelled shape to ride of the worst offending areas at the same time as grinding away the high spots. Through successive passes with ever finer diamond abrasives we managed to produce a satin finish that was hardened with a nano silicate densifier and sealed with a protection guard coat.

Lots of overlapping pours in this concrete overlay
Lots of overlapping pours in this concrete overlay
The overlaps have been smoothed out as far as possible
The overlaps have been smoothed out as far as possible
Just one of many bulges within the floor
Just one of many bulges within the floor

CARRcrete PROtop is a free flowing, self levelling concrete overlay that is easy to use with pretty basic equipment such as a gauge rake and spiked roller. Like all professional products, PROtop does require you to follow the detailed instructions, prepare the substrate, mix and install like a professional for optimum results; the effort is worth it.

Polished Concrete Floor Lancashire