Concrete Polishing Calculator

This calculator estimates the labor and diamond tooling needed to polish a concrete floor, using this tool's own four-level finish classification (Level 1 through Level 4). Finish level sets Grinding passes directly through a fixed lookup (3 passes for Level 1, 5 for Level 2, 7 for Level 3, 9 for Level 4), and because each step up adds exactly two more passes across the whole floor area, Finish level is the single biggest driver of Grinding hours -- more so than an equivalent swing in Floor area or Production rate, since every pass re-grinds the entire floor. Grinding hours itself is simply Floor area divided by Production rate, multiplied by the pass count, so a faster machine (a higher Production rate) lowers the hours needed while a bigger floor raises them. Diamond tooling splits along a fixed boundary: the first four passes always use metal-bond segments (for rough grinding), and any passes beyond four use resin-bond pads (for honing and polishing) -- so only Level 1 (3 passes) stays on metal segments exclusively, while Level 2, Level 3, and Level 4 (5, 7, and 9 passes) all cross past that four-pass boundary and add resin pads.

Resin pad count is rounded up to whole 3-pad boxes, though, so it does not grow with every step up in finish level -- at the calculator's own 2,000 sq ft default, Levels 2, 3, and 4 all round up to the same 3 resin pads. The levels only pull apart on larger floors, and not all at once: Level 4 is first to need more than 3 pads (past 2,000 sq ft), Level 3 needs more than 3 only past about 3,333 sq ft, and Level 2 stays at 3 pads all the way out to 10,000 sq ft. Densifier is applied once regardless of finish level, driven only by Floor area and Densifier coverage, so Finish level has no effect on how much densifier is needed. Guard coat assumes a fixed 2-coat, 1,500 sq ft/gal application rate and is not adjustable by finish level either.