Comprehensive SWMS for Surface Preparation and Polished Concrete Installation

Concrete Grinding and Polishing Safe Work Method Statement

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Concrete grinding and polishing transforms raw concrete surfaces into durable, attractive flooring through mechanical abrasion using progressively finer diamond grinding tools. This specialized trade encompasses surface preparation, grinding to expose aggregate, densifier application, and multi-stage polishing to achieve specified gloss levels. The work generates significant respirable crystalline silica dust requiring stringent engineering controls and monitoring. This SWMS addresses the critical safety requirements for concrete grinding and polishing operations in accordance with Australian WHS legislation, providing detailed silica dust control measures, equipment specifications, and step-by-step procedures to protect workers from serious health hazards.

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Overview

What this SWMS covers

Concrete grinding and polishing is a specialized flooring technique that mechanically refines concrete surfaces to create highly durable, aesthetically pleasing floors suitable for commercial, industrial, and residential applications. The process involves using industrial grinding equipment fitted with diamond-impregnated abrasive segments to remove surface laitance, expose aggregate, flatten high spots, and progressively refine the concrete surface to specified gloss levels ranging from matte finishes to high-gloss mirror-like surfaces. Polished concrete has become increasingly popular in Australian construction due to its exceptional durability, low maintenance requirements, sustainable credentials using existing concrete slabs, and aesthetic versatility. Retail spaces, warehouses, showrooms, office buildings, educational facilities, and modern residential developments commonly specify polished concrete flooring. The process can be applied to newly placed concrete after adequate curing or to existing concrete slabs during renovation projects, often revealing decorative exposed aggregate that provides unique visual character. The grinding and polishing process typically progresses through multiple stages beginning with coarse grinding using 30-50 grit diamond segments to remove surface coatings, adhesive residues, and concrete laitance while levelling uneven surfaces. Successive grinding passes use progressively finer grits (80, 120, 200 grit) to refine the surface and begin developing surface clarity. After mechanical grinding, liquid chemical densifiers are applied to harden the concrete surface through chemical reaction with free lime, filling microscopic pores and increasing surface density. Final polishing stages use very fine diamond abrasives (400, 800, 1500, 3000 grit) to achieve specified gloss levels, with higher grit numbers producing increasingly reflective surfaces. Equipment used in concrete grinding ranges from small hand-held angle grinders for edges and detail work, through mid-size planetary grinders with 250-450mm grinding paths for residential and small commercial projects, to large industrial planetary grinders exceeding 800mm grinding width for warehouse and large commercial applications. Modern equipment increasingly incorporates integrated dust extraction systems essential for controlling respirable silica dust generated during grinding operations. Professional concrete grinders and polishers must understand concrete characteristics, diamond tooling selection, equipment operation, surface preparation requirements, and the critical importance of dust control to protect themselves and others from serious health hazards.

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Why this SWMS matters

Concrete grinding and polishing generates respirable crystalline silica dust, a Group 1 carcinogen classified by the International Agency for Research on Cancer. Crystalline silica particles smaller than 10 micrometers penetrate deep into lung tissue when inhaled, causing silicosis, an irreversible and potentially fatal lung disease, as well as increasing risks of lung cancer, chronic obstructive pulmonary disease (COPD), and kidney disease. The Australian workplace exposure standard for respirable crystalline silica is exceptionally strict at 0.05 mg/m³ over an 8-hour time-weighted average, reflecting the serious health risks. Dry grinding of concrete can generate silica dust concentrations thousands of times above this exposure limit within minutes, making engineering controls absolutely mandatory. Safe Work Australia reports that over 600,000 Australian workers are potentially exposed to respirable crystalline silica, with construction workers, particularly those performing concrete cutting, grinding, and polishing operations, representing a significant portion of exposed workers. Silicosis has no cure—once lung tissue is scarred, the damage is permanent. Workers diagnosed with acute silicosis may experience rapidly progressive lung function decline leading to respiratory failure and death within months to years. Chronic silicosis develops over longer exposure periods, typically 10-20 years, but still results in severe disability, inability to work, and substantially reduced life expectancy. Recent Australian workplace fatalities linked to silicosis exposure have resulted in coronial inquiries, regulatory reform, and prosecutions under WHS legislation. Australian WHS regulations now mandate engineering controls for all work generating respirable crystalline silica dust. For concrete grinding and polishing, this means on-tool dust extraction systems or water suppression methods must be used—respiratory protective equipment alone is insufficient and unlawful as a primary control measure. Model WHS Regulations require PCBUs to eliminate silica dust generation where reasonably practicable, or if elimination is not possible, minimize exposure through engineering controls as the highest priority control measure. Respiratory protection serves only as a secondary control measure when engineering controls alone cannot reduce exposure below the workplace exposure standard. Beyond silica dust, concrete grinding presents substantial noise hazards with equipment regularly exceeding 100 dB(A) during operation, well above the 85 dB(A) threshold requiring hearing protection. Prolonged exposure causes permanent noise-induced hearing loss that develops gradually, often unnoticed until significant damage has occurred. Hand-arm vibration from operating grinding equipment can cause hand-arm vibration syndrome (HAVS), resulting in permanent damage to blood vessels, nerves, and joints in hands and arms. Electrical hazards exist from operating powered equipment in potentially wet environments during water suppression operations, requiring residual current devices (RCDs) and regular equipment inspection. Manual handling risks arise from moving heavy grinding equipment between work areas and maintaining awkward postures during extended grinding operations. A comprehensive SWMS addressing these multiple serious hazards through the hierarchy of controls is essential for protecting workers engaged in concrete grinding and polishing operations.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Respirable Crystalline Silica Dust Exposure

High

Concrete grinding generates extremely high concentrations of respirable crystalline silica dust, classified as a Group 1 carcinogen. Fine silica particles smaller than 10 micrometers penetrate deep into lung tissue causing silicosis, an irreversible and potentially fatal lung disease. Dry grinding operations without dust extraction can generate silica concentrations exceeding 50 mg/m³, which is 1,000 times the Australian workplace exposure standard of 0.05 mg/m³. Even brief exposure to these extreme concentrations contributes to cumulative silica dose increasing silicosis risk. Water suppression and on-tool dust extraction are mandatory engineering controls under Australian WHS regulations.

Consequence: Acute or chronic silicosis causing progressive lung function decline, respiratory failure, and death. Increased risk of lung cancer, COPD, kidney disease, and autoimmune disorders. No cure exists for silicosis—lung damage is permanent and irreversible.

Noise Exposure from Grinding Equipment

High

Concrete grinding equipment generates noise levels regularly exceeding 100 dB(A) during operation, well above the 85 dB(A) exposure limit requiring hearing protection. Large planetary grinders and hand-held grinders produce sustained high-intensity noise throughout extended grinding operations lasting multiple hours or days. The combination of equipment noise and hard reflective concrete and building surfaces creates severe acoustic environments. Operators working in proximity to grinding equipment experience continuous noise exposure throughout work shifts, with cumulative exposure causing permanent noise-induced hearing loss.

Consequence: Permanent noise-induced hearing loss developing progressively over months to years of exposure. Tinnitus (persistent ringing in ears), difficulty understanding speech in noisy environments, social isolation, and reduced quality of life. Hearing damage is irreversible.

Hand-Arm Vibration from Equipment Operation

Medium

Operating concrete grinding equipment, particularly hand-held angle grinders and smaller planetary grinders, exposes workers to significant hand-arm vibration. Vibration magnitude varies with equipment type, grinding pressure, and concrete hardness, but regularly exceeds the daily exposure action value of 2.5 m/s² specified in Australian guidelines. Extended grinding operations over multiple hours per day increase cumulative vibration dose. Hand-held grinders used for edge work and detail grinding produce particularly high vibration levels transmitted directly through hands and arms to operators.

Consequence: Hand-arm vibration syndrome (HAVS) causing permanent damage to blood vessels, nerves, joints, and muscles in hands, wrists, and arms. Symptoms include vibration white finger (blanching and numbness), reduced grip strength, reduced manual dexterity, and chronic pain. Damage is irreversible once established.

Electrical Hazards in Wet Grinding Operations

High

Water suppression methods used to control silica dust create wet working environments where electrically powered grinding equipment operates. Water and concrete slurry can contact electrical connections, power leads, and equipment housings, creating electrocution risk if insulation is damaged or electrical protection fails. Extension leads, power boards, and connections may be splashed with water or lying in slurry pools. Workers' hands are often wet when adjusting equipment or changing grinding segments. The combination of conductive wet conditions and high-power electrical equipment presents serious electrocution hazards requiring strict electrical safety controls.

Consequence: Electrocution causing cardiac arrest and death. Serious electrical shock causing burns, muscle damage, and neurological injury. Even non-fatal electrical shock can cause falls resulting in impact injuries particularly when operating equipment at height or on elevated surfaces.

Manual Handling of Heavy Grinding Equipment

Medium

Concrete grinding equipment ranges from hand-held grinders weighing 5-8kg used for extended periods in awkward postures, through mid-size planetary grinders weighing 80-150kg requiring team handling, to large industrial grinders exceeding 300kg. Equipment must be transported to work areas, manoeuvred around obstacles, lifted over floor transitions, and positioned precisely during operation. Operators maintain sustained awkward postures during grinding operations, applying downward pressure while guiding equipment, often for multiple hours continuously. Vacuum extraction units, water tanks, and electrical transformers add to equipment weight requiring handling.

Consequence: Lower back injuries from lifting and manoeuvring heavy equipment. Shoulder, arm, and wrist strain from controlling equipment during operation. Knee and hip injuries from sustained standing and walking while operating equipment. Acute injuries from dropped equipment. Chronic musculoskeletal disorders from cumulative exposure to manual handling demands.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

On-Tool Dust Extraction for All Grinding Equipment

Engineering Control

All concrete grinding equipment must be fitted with on-tool dust extraction shrouds connected to high-efficiency vacuum systems with HEPA filtration. Dust extraction shrouds must completely enclose the grinding path, capturing dust at the point of generation before it enters the breathing zone. Vacuum systems must provide adequate airflow to maintain capture velocity preventing dust escape from shrouds. HEPA filters rated to capture 99.97% of particles ≥0.3 micrometers are mandatory for silica dust. This engineering control is the primary defense against silica exposure and is legally mandated under Australian WHS regulations as the first-line control measure.

Implementation

1. Fit all planetary grinders with manufacturer-approved dust extraction shrouds creating complete seal around grinding path 2. Connect extraction shrouds to industrial HEPA-filtered vacuum units rated for Class H dust (hazardous dust) 3. Verify vacuum provides minimum 100 cubic metres per hour airflow at shroud connection point 4. Inspect shroud seals before each shift - replace damaged seals immediately to maintain extraction effectiveness 5. Monitor dust visibility during operation - any visible dust indicates inadequate extraction requiring work stoppage 6. Empty vacuum collection bags or containers when 50% full to maintain suction performance 7. Replace HEPA filters according to manufacturer schedule or when airflow drops below specified minimum 8. Maintain vacuum equipment service records documenting filter changes and performance verification

Water Suppression for Silica Dust Control

Engineering Control

Water suppression provides an alternative or supplementary engineering control for silica dust generation. Sufficient water must be applied directly to the grinding point to prevent visible dust generation. Water binds dust particles preventing them becoming airborne. Effective water suppression requires continuous water flow throughout grinding operations, adequate water volume to thoroughly wet the grinding surface, and immediate water application at the point of grinding contact. This method creates wet slurry requiring collection and disposal, and wet working conditions necessitating additional electrical safety controls.

Implementation

1. Install water feed systems delivering continuous water flow to grinding equipment throughout operation 2. Adjust water flow rate to prevent visible dust generation - typically 2-5 litres per minute depending on grinder size 3. Monitor grinding surface remains wet during all operations - dry patches indicate insufficient water application 4. Collect concrete slurry using wet vacuum systems or squeegee to designated collection area 5. Never allow slurry to dry creating secondary dust source - maintain wet collection and disposal 6. Ensure all electrical equipment operates through RCD protection when using water suppression methods 7. Inspect water delivery systems for blockages or leaks before commencing grinding each shift 8. Maintain adequate water supply throughout grinding operations - have backup water sources available

Respiratory Protective Equipment as Secondary Control

Personal Protective Equipment

Respiratory protective equipment provides essential secondary protection when engineering controls alone cannot reduce silica exposure below the workplace exposure standard. P3 particulate respirators or powered air-purifying respirators (PAPRs) must be used whenever concrete grinding occurs. Respirators must be fit-tested to individual users and workers must be clean-shaven to ensure effective face seal. RPE serves only as a secondary control—engineering controls (dust extraction or water suppression) remain mandatory as primary controls and must operate throughout all grinding work.

Implementation

1. Provide P3 particulate respirators (AS/NZS 1716) rated for protection against hazardous dusts to all grinding operators 2. Conduct individual fit testing for each worker using quantitative fit testing equipment to verify adequate seal 3. Require workers to be clean-shaven where respirator seals contact face - beards prevent effective seal 4. Replace P3 filters when breathing resistance increases or after manufacturer-specified service life 5. For extended grinding operations exceeding 4 hours, provide powered air-purifying respirators (PAPRs) reducing breathing resistance 6. Train workers in correct respirator donning, seal checking, and limitation understanding 7. Store respirators in clean sealed containers when not in use to prevent contamination 8. Maintain respirator service records including fit test dates, filter replacement, and equipment inspections

Hearing Protection Program for Noise Control

Personal Protective Equipment

Grinding operations generate noise levels exceeding 100 dB(A) requiring mandatory hearing protection to reduce exposure below 85 dB(A) daily exposure limit. Class 5 earmuffs or Class 4/5 earplugs must be worn continuously during all grinding equipment operation and when working in areas where grinding occurs. Hearing protection must be correctly fitted and worn throughout entire noise exposure period—intermittent use provides inadequate protection. Communication systems allowing verbal communication while wearing hearing protection improve safety coordination.

Implementation

1. Issue Class 5 earmuffs (AS/NZS 1270) providing minimum 30 dB noise reduction to all grinding operators 2. Provide Class 4 or 5 earplugs as alternative for workers preferring plug-style protection 3. Train workers in correct insertion of earplugs achieving proper seal in ear canal 4. Require hearing protection be worn before starting grinding equipment and maintained throughout operation 5. Implement communication systems using hand signals or two-way radio for critical safety communication 6. Inspect hearing protection regularly for damage, deterioration, or inadequate seal materials 7. Replace disposable earplugs daily and reusable plugs when dirty or damaged 8. Establish hearing conservation program including baseline and periodic hearing tests for regular operators

Electrical Safety Controls for Wet Operations

Engineering Control

All grinding equipment operating in wet conditions created by water suppression must be protected by residual current devices (RCDs) rated to 30 milliamps or less, tripping within 30 milliseconds to prevent electrocution. Power distribution systems must use insulated connectors rated for wet environments. Equipment must be regularly inspected for damaged insulation, exposed conductors, or water ingress into electrical components. This engineering control prevents electrocution in unavoidably wet working conditions during water-suppressed grinding operations.

Implementation

1. Connect all grinding equipment and vacuum units to 30mA RCDs before commencing operations 2. Test RCD function daily before work commences using integral test button to verify trip operation 3. Use only electrical connectors and extension leads rated IP56 or higher for wet environment use 4. Elevate power connections above floor level preventing submersion in water or slurry pools 5. Inspect equipment power leads daily for cuts, abrasion, or damaged insulation - remove defective equipment 6. Position electrical distribution boards in dry areas away from grinding operations and water spray 7. Never operate equipment if water ingress into motor or electrical components is suspected 8. Engage qualified electrician to inspect and test equipment if electrical faults occur during operations

Manual Handling Controls and Work Rotation

Administrative Control

Control manual handling risks through mechanical handling aids, team lifting protocols, and task rotation limiting sustained equipment operation. Equipment trolleys and lifting devices eliminate manual lifting of heavy grinders and vacuum units. Work rotation between grinding operations, equipment setup, and surface preparation tasks varies physical demands reducing cumulative musculoskeletal strain. Regular breaks prevent fatigue accumulation during extended grinding operations. These administrative controls complement equipment design features reducing manual handling injury risk.

Implementation

1. Provide equipment trolleys with pneumatic wheels for transporting planetary grinders between work areas 2. Use two-person lift for all grinding equipment exceeding 25kg when trolleys cannot access work area 3. Rotate operators between primary grinding, edge work, and equipment setup at 2-hour intervals 4. Schedule 10-minute breaks every 90 minutes during sustained grinding operations for operator rest 5. Adjust grinder handle height and position to maintain neutral wrist and spine postures during operation 6. Use grinders with variable speed and auto-leveling features reducing operator force requirements 7. Perform stretching exercises during breaks targeting shoulders, back, arms, and legs 8. Monitor operators for signs of fatigue or overexertion - rotate tasks or extend breaks if needed

Download complete control procedures

Personal protective equipment

Requirement: AS/NZS 1716 P3 rating for hazardous dust protection

When: Mandatory during all concrete grinding and polishing operations as secondary control measure supplementing engineering controls

Requirement: AS/NZS 1270 Class 5 earmuffs or Class 4/5 earplugs

When: Required during all grinding equipment operation and when working in areas where grinding occurs

Requirement: AS/NZS 1337 medium impact rated with side protection

When: Required during all grinding operations, equipment setup, and when working near grinding areas

Requirement: AS/NZS 2210.3 Category 1 impact protection with slip-resistant sole

When: Throughout all concrete grinding and polishing activities

Requirement: AS/NZS 2161.4 Level 3 cut resistance with good dexterity

When: When handling or changing diamond grinding segments and equipment maintenance activities

Requirement: AS/NZS 4602.1 Day/Night Class D/N garment

When: When working in active construction areas with mobile plant, vehicles, or multiple trade operations

Inspections & checks

Before work starts

✓Verify dust extraction equipment functionality including vacuum motor operation and airflow measurement
✓Inspect HEPA filters for damage and verify filter installation is secure with proper sealing to filter housing
✓Check extraction shrouds for damaged seals, cracks, or gaps compromising dust capture effectiveness
✓Test RCD protection devices using integral test button to verify trip function operates correctly
✓Inspect grinding equipment power leads for cuts, exposed conductors, or damaged insulation requiring replacement
✓Verify diamond grinding segments are correctly installed, secure, and have adequate remaining segment height
✓Check concrete surface for existing coatings, adhesives, or contamination requiring removal before grinding
✓Confirm adequate ventilation in enclosed areas - open doors and windows or provide mechanical ventilation
✓Verify respiratory protective equipment is clean, fit-tested to users, and has serviceable filter cartridges
✓Ensure water supply is adequate for water suppression operations if this dust control method is used

During work

✓Monitor dust visibility throughout grinding - any visible dust indicates control failure requiring work stoppage
✓Check extraction shroud seal integrity remains complete throughout operation without gaps developing
✓Verify vacuum airflow remains adequate by observing debris movement toward extraction points
✓Monitor water flow if using water suppression - ensure continuous flow prevents dust generation
✓Observe operator respiratory protection use - verify continuous wear and proper face seal maintained
✓Check hearing protection remains in place throughout grinding operations for all workers in noise area
✓Monitor equipment operation for unusual vibration, noise, or performance indicating maintenance needs
✓Verify slurry collection procedures prevent wet concrete from drying and creating secondary dust source
✓Check operators for signs of fatigue or overexertion requiring task rotation or scheduled breaks
✓Ensure electrical connections remain elevated above water and slurry pools throughout wet operations

After work

✓Clean grinding equipment thoroughly removing concrete dust and slurry before storage
✓Empty vacuum collection containers and dispose of silica-contaminated dust using wet methods or sealed containers
✓Inspect HEPA filters and replace if airflow has decreased or manufacturer service interval reached
✓Clean and inspect extraction shrouds - replace damaged seals maintaining effective dust capture
✓Test and inspect electrical equipment documenting any damage or defects requiring repair before next use
✓Clean work area using HEPA-filtered vacuum or wet cleaning methods - never dry sweep silica dust
✓Store respiratory protective equipment in clean sealed containers preventing contamination
✓Document grinding productivity, surface preparation achieved, and any equipment performance issues
✓Report any near-misses, equipment failures, or safety concerns in daily work log
✓Schedule equipment maintenance for any items showing performance degradation or damage during operation

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Surface Assessment and Preparation Planning

Conduct comprehensive surface assessment before commencing grinding operations. Identify surface hardness, aggregate exposure requirements, existing coatings or sealers requiring removal, and any surface defects including cracks, spalls, or contamination. Test representative areas to determine appropriate diamond grit sequence for achieving specified finish within efficient grinding time. Document existing surface conditions through photographs and written notes recording any areas requiring special attention. Verify concrete has achieved adequate strength before grinding—typically minimum 25 MPa for polished concrete applications, with higher strength preferred for optimal results. Confirm client expectations regarding aggregate exposure level, gloss specification, and final appearance. Plan grinding sequence to optimize productivity while maintaining dust control effectiveness and minimizing rework. Identify confined spaces or areas requiring enhanced ventilation provisions.

Safety considerations

Verify all electrical services, plumbing, and embedded conduits are identified and marked to prevent contact during grinding. Check for asbestos in buildings constructed before 1990—grinding asbestos-containing materials requires licensed removal before general grinding. Assess ventilation adequacy especially in basement areas or confined spaces. Ensure adequate lighting for safe equipment operation and hazard recognition.

Equipment Setup and Dust Extraction Verification

Set up grinding equipment ensuring all dust extraction systems are properly connected and functional before commencing grinding. Install appropriate grit diamond segments for initial grinding phase—typically 30-50 grit for coating removal and initial surface preparation. Connect extraction shrouds to HEPA-filtered vacuum units using appropriate diameter hoses without restrictions reducing airflow. Position vacuum units to prevent hose kinking or excessive length reducing extraction effectiveness. Test vacuum airflow at shroud connection point using airflow meter verifying minimum required flow rate is achieved. Inspect shroud seals ensuring complete contact with floor surface without gaps allowing dust escape. For water suppression operations, connect water supply lines and verify continuous water flow at required rate throughout grinding path. Test grinder operation briefly observing dust control effectiveness before commencing full grinding operations. Make adjustments to extraction or water suppression systems as required to eliminate any visible dust generation.

Safety considerations

Verify RCD protection is operational through test button function before connecting equipment. Inspect all power leads for damage before use. Ensure extraction shrouds are properly sealed—any gap compromises dust control effectiveness. Test respiratory protection fit before commencing grinding. Position vacuum units where exhaust does not blow toward workers or occupied areas. Confirm hearing protection is worn by all workers in grinding area before starting equipment.

Initial Coarse Grinding and Surface Leveling

Begin coarse grinding using 30-50 grit diamond segments to remove surface laitance, existing coatings or sealers, adhesive residues, and to level high spots creating flat surface profile. Operate planetary grinder in systematic overlapping passes covering entire floor area without missing sections. Maintain consistent forward speed allowing diamond segments adequate contact time for effective grinding—moving too quickly reduces grinding efficiency while moving too slowly may cause equipment overheating. Apply moderate downward pressure through grinder weight and operator guidance—excessive pressure does not increase grinding rate and may damage equipment or concrete surface. Monitor diamond segment wear—replace segments when diamond exposure is no longer adequate for effective grinding, typically when segment height reduces to approximately 3mm. Observe concrete surface regularly checking grinding progress and identifying areas requiring additional passes. Continue coarse grinding until surface laitance is completely removed, coatings are eliminated, and surface is level within specified tolerance typically ±3mm over 3 metre straightedge. Vacuum or wet-clean surface after completing coarse grinding phase before proceeding to finer grits.

Safety considerations

Continuously monitor dust extraction effectiveness—any visible dust requires immediate work stoppage to investigate cause. Maintain firm two-handed grip on grinder controls preventing loss of control if equipment encounters sudden resistance. Watch for embedded objects or reinforcement that may damage diamond segments or cause equipment kickback. Take scheduled breaks every 90 minutes to prevent operator fatigue. Monitor hand-arm vibration exposure especially when using hand-held grinders for edge work. Ensure adequate hydration during sustained grinding operations in warm conditions.

Progressive Grit Grinding Sequence

Progress through sequential diamond grit stages refining surface smoothness and beginning to develop surface clarity. After coarse grinding, install 80 grit diamond segments and grind entire surface using same systematic overlapping pass technique. Each grit stage removes scratches from previous coarser grit while creating finer scratches preparing surface for next stage. Typical grit progression is 80 grit, 120 grit, 200 grit for mechanical grinding phases before densifier application. Observe surface carefully after each grit stage—scratches from previous grit should be completely removed before progressing to next finer grit. Missing patches or areas showing previous grit scratches require additional passes at current grit before advancing. Clean surface thoroughly between grit changes using HEPA-filtered vacuum or wet methods—residual coarse grit diamonds will contaminate finer grit tooling reducing effectiveness. Change diamond segments for each grit stage—attempting to use worn segments from previous stage compromises grinding effectiveness and surface quality. Document grinding progress through photographs showing surface condition at each grit stage completion.

Safety considerations

Maintain dust extraction effectiveness throughout all grit stages—finer grinding creates smaller more dangerous silica particles requiring equivalent control effectiveness. Ensure diamond segment changes are performed with equipment isolated from power supply. Wear cut-resistant gloves when handling diamond grinding segments. Monitor respiratory protection filter condition—replace filters showing increased breathing resistance. Continue hearing protection use throughout all grinding stages. Take regular breaks maintaining operator alertness and preventing fatigue accumulation.

Densifier Application and Cure Time

Apply liquid chemical densifier to concrete surface after completing 200 grit grinding stage. Densifiers chemically react with free lime in concrete creating calcium silicate hydrate that fills microscopic pores, hardens surface, and increases density. Pour densifier onto floor surface in manageable sections typically 20-30 square metres. Spread densifier evenly using microfiber mop, rayon mop, or mechanical scrubber ensuring complete coverage without pooling. Maintain wet surface appearance for manufacturer-specified reaction time, typically 20-45 minutes, adding additional densifier to areas that dry prematurely indicating high absorption. Observe surface for white crystalline residue forming as chemical reaction progresses—this residue must be scrubbed and agitated back into solution to prevent crusty deposits. After reaction period completes, remove excess densifier and residue using auto-scrubber with clean water or wet vacuum equipment. Rinse surface thoroughly ensuring all residue is removed—dried residue interferes with subsequent polishing stages. Allow densifier to cure for manufacturer-specified period before resuming grinding, typically 24-72 hours depending on product and environmental conditions. Higher temperatures and lower humidity reduce required cure time while cool damp conditions extend cure requirements.

Safety considerations

Review densifier Safety Data Sheet identifying chemical hazards and required controls. Many densifiers are alkaline requiring skin and eye protection during application. Ensure adequate ventilation during application especially in enclosed spaces—some densifiers release mild odours requiring air changes. Wear chemical-resistant gloves and safety glasses during densifier application and cleanup. Prevent slip hazards from wet densifier on floor surface—barricade areas and use appropriate signage. Dispose of densifier waste water according to environmental regulations—do not discharge to stormwater drains. Clean equipment thoroughly after densifier application preventing chemical residue contamination of next work area.

Final Polishing to Specified Gloss Level

Complete final polishing stages using progressively finer diamond grits to achieve specified surface gloss level. After densifier cure period, resume grinding with 400 grit diamonds followed by 800 grit, 1500 grit, and optionally 3000 grit depending on final gloss specification. Lower gloss satin finishes may stop at 400-800 grit while high-gloss mirror finishes require progression through 3000 grit. Each polishing stage increases surface clarity and light reflectivity. Operate polishing equipment at appropriate speeds recommended by manufacturer for each grit stage—higher grits typically require higher operating speeds for optimal polishing effect. Use burnishing pads for final stage on high-gloss specifications—these resin-bonded pads create mirror-like finish through mechanical burnishing rather than grinding. Evaluate gloss level achievement using gloss meter measuring light reflectivity at specified angle, typically 60 degrees, or through visual assessment comparing to approved samples. Continue polishing until specified gloss reading or visual appearance is consistently achieved across entire surface. Document final gloss readings and surface appearance through photographs providing quality assurance record and client handover documentation.

Safety considerations

Maintain dust extraction effectiveness throughout polishing stages—fine polishing creates very fine silica dust particles requiring continued engineering controls. Monitor equipment temperature during extended polishing—overheating indicates excessive pressure or inadequate segment cooling. Continue respiratory protection, hearing protection, and safety glasses use throughout all polishing stages. Monitor operator fatigue during extended polishing operations requiring sustained concentration and equipment control. Ensure adequate lighting for evaluating surface appearance and identifying areas requiring additional polishing. Take breaks maintaining operator alertness during detailed finish evaluation and quality assessment activities.

Final Cleaning and Surface Protection

Perform comprehensive final cleaning removing all grinding residues, dust, and contamination from polished surface. Use HEPA-filtered vacuum equipment for initial dust removal followed by neutral pH cleaner and auto-scrubber or microfiber mopping for final cleaning. Avoid acidic or alkaline cleaners that may affect polished surface appearance or damage densifier treatment. Inspect entire surface identifying any defects, scratches, or areas not achieving specified finish standard requiring remedial polishing. Address edge details and corners that main grinding equipment could not fully reach using hand-held polishing equipment. Apply stain protection or surface sealer if specified in project requirements—many polished concrete installations rely solely on densifier without additional sealer, while others specify penetrating sealers for enhanced stain resistance. Allow adequate cure time for any sealers applied before permitting floor traffic. Protect completed polished concrete from damage during remaining construction activities using appropriate floor protection materials. Provide client with maintenance recommendations including appropriate cleaning products, frequency, and procedures for maintaining polished concrete appearance long-term. Document completed installation through comprehensive photographs and gloss measurements for quality records and warranty documentation.

Safety considerations

Use wet cleaning methods only—never dry sweep polished concrete surfaces potentially contaminated with silica dust. Ensure cleaning chemical Safety Data Sheets are reviewed and appropriate controls implemented. Wear slip-resistant footwear on wet polished concrete during cleaning operations. Dispose of cleaning waste water appropriately according to environmental regulations. Clean and properly store all grinding and polishing equipment preventing concrete residue from hardening on equipment. Perform thorough equipment inspection documenting any damage or maintenance requirements before equipment storage. Complete health monitoring documentation for silica exposure if required by workplace health surveillance program.

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Frequently asked questions

Is dust extraction mandatory for concrete grinding in Australia?

Yes, engineering controls including on-tool dust extraction or water suppression are absolutely mandatory under Australian WHS regulations for all concrete grinding operations. The regulations follow the hierarchy of controls requiring elimination or minimisation of respirable crystalline silica dust generation as the primary control measure. Respiratory protective equipment alone is insufficient and unlawful as a primary control. Safe Work Australia's Code of Practice for Managing Crystalline Silica Dust explicitly requires that work generating crystalline silica must use engineering controls such as on-tool extraction or water suppression before considering respiratory protection. Penalties for non-compliance include substantial fines and prosecution, with recent enforcement actions resulting in fines exceeding $500,000 for companies failing to implement adequate silica dust controls. Beyond legal requirements, on-tool extraction provides the only effective protection against the serious and irreversible health effects of silica exposure including silicosis, lung cancer, and COPD.

What type of vacuum is required for concrete grinding dust extraction?

Concrete grinding requires industrial vacuum units specifically rated for Class H hazardous dust with HEPA filtration capable of capturing 99.97% of particles ≥0.3 micrometers. Standard workshop vacuums, shop vacs, or domestic vacuum cleaners are completely inadequate and dangerous for silica dust collection. The vacuum must provide adequate airflow to maintain capture velocity at the extraction shroud, typically requiring minimum 100 cubic metres per hour airflow depending on grinder size and shroud design. HEPA filters are mandatory because silica dust particles are extremely fine, with the most dangerous respirable fraction being particles smaller than 10 micrometers that penetrate deep into lung tissue. Regular vacuum filters cannot capture these fine particles, allowing them to pass through and be exhausted back into the work environment. Class H rated vacuums also incorporate safety features including filter condition monitoring, automatic filter cleaning systems, and sealed waste disposal preventing dust escape during filter changes and waste emptying. When purchasing or hiring vacuum equipment for concrete grinding, verify the unit is specifically rated for hazardous dust collection and fitted with genuine HEPA filtration—equipment labelled as 'dust extractors' without Class H and HEPA specifications is inadequate for silica dust control.

How often should diamond grinding segments be replaced?

Diamond grinding segments should be replaced when diamond exposure is no longer adequate for effective grinding, which typically occurs when segment height reduces to approximately 3mm remaining above the metal bond carrier. Visual inspection reveals reduced grinding effectiveness when segments become glazed (smooth and shiny) indicating diamonds are no longer properly exposed, or when grinding rate noticeably decreases requiring multiple passes to achieve results previously obtained in single passes. Segment wear rate varies significantly depending on concrete hardness, aggregate type, diamond quality, and grinding pressure applied. Soft concrete with minimal aggregate may allow 500-1000 square metres grinding per segment set, while hard concrete with quartzite aggregate may wear segments in 100-200 square metres. Higher quality diamond segments with better diamond distribution and bond formulation provide longer service life and more consistent performance. Operating grinding equipment with worn segments is inefficient, increases grinding time and cost, and creates excessive heat potentially damaging concrete surface or equipment. Maintain records tracking segment service life on different concrete types to predict replacement timing on future projects. Purchase adequate spare segments before commencing projects to prevent work delays when segments require replacement. Properly maintained diamond tooling is essential for productivity, surface quality, and safe operation of grinding equipment.

Can I use a respirator instead of dust extraction when grinding concrete?

No, this approach is both illegal under Australian WHS regulations and provides inadequate health protection. The hierarchy of controls mandates elimination or engineering controls as the primary control measures for hazardous substances including respirable crystalline silica. Respiratory protective equipment is permitted only as a secondary control measure supplementing engineering controls, never as the sole control or replacement for dust extraction or water suppression. This requirement exists because respirators have significant limitations including requiring perfect face seal impossible to maintain with facial hair, creating breathing resistance causing worker discomfort especially during physical work, requiring individual fit testing to verify effectiveness, and providing no protection if removed even briefly during exposure period. Concrete grinding generates extremely high silica concentrations—often exceeding 50 mg/m³, which is 1,000 times the workplace exposure standard of 0.05 mg/m³. Even a P3 respirator providing 99% filtration efficiency would still allow exposure of 0.5 mg/m³, which is 10 times the exposure standard. Engineering controls using dust extraction or water suppression can reduce exposure to 0.01 mg/m³ or lower, providing far superior protection. Regulatory authorities actively prosecute companies relying on respirators as primary silica controls, with penalties including fines exceeding $500,000 and potential imprisonment for serious breaches. Workers diagnosed with silicosis resulting from inadequate dust controls have successfully pursued compensation claims, while company directors face personal liability for failing to implement mandatory engineering controls.

What is the difference between grinding and polishing concrete?

Grinding and polishing are sequential stages in creating polished concrete surfaces, with grinding referring to coarse mechanical abrasion removing surface material and polishing referring to fine mechanical refinement creating surface clarity and gloss. Grinding uses coarser diamond grit tooling (30-200 grit) to remove surface laitance, existing coatings, adhesive residues, and to flatten uneven surfaces through material removal. Grinding creates visible scratches in the concrete surface and focuses on surface preparation and leveling rather than appearance. The grinding phase may remove 1-5mm of concrete surface depending on coating thickness, surface condition, and levelness requirements. Polishing uses progressively finer diamond grits (400-3000 grit) to refine surface smoothness and develop surface clarity and light reflectivity creating the characteristic polished concrete appearance. Polishing removes minimal material, instead mechanically refining the surface through increasingly fine scratches that eventually become invisible to the naked eye creating smooth reflective surface. The polishing phase typically follows densifier application that hardens the concrete surface, fills microscopic pores, and enables higher gloss achievement. Final polishing may use resin-bonded burnishing pads rather than metal-bonded diamonds to achieve mirror-like high-gloss finishes. Both grinding and polishing generate respirable crystalline silica dust requiring identical engineering controls throughout all stages from coarsest grinding through finest polishing. The terms are often used interchangeably in industry conversation, but technically describe different phases of the overall concrete surface refinement process.

Concrete Grinding and Polishing SWMS Sample

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Risk Rating

BeforeHigh

After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Concrete Grinding and Polishing Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Respirable Crystalline Silica Dust Exposure

Noise Exposure from Grinding Equipment

Hand-Arm Vibration from Equipment Operation

Electrical Hazards in Wet Grinding Operations

Manual Handling of Heavy Grinding Equipment

Control measures

On-Tool Dust Extraction for All Grinding Equipment

Water Suppression for Silica Dust Control

Respiratory Protective Equipment as Secondary Control

Hearing Protection Program for Noise Control

Electrical Safety Controls for Wet Operations

Manual Handling Controls and Work Rotation

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Surface Assessment and Preparation Planning

Equipment Setup and Dust Extraction Verification

Initial Coarse Grinding and Surface Leveling

Progressive Grit Grinding Sequence

Densifier Application and Cure Time

Final Polishing to Specified Gloss Level

Final Cleaning and Surface Protection

Frequently asked questions

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Concrete Grinding and Polishing SWMS Sample

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