Decorative concrete overlays are thin coats of fine concrete for resurfacing unattractive concrete surfaces. Most applications are on floors but can be applied to vertical surfaces as well.
The process is fairly simple when you have all the proper tools, product and systems. A basic application is achieved by priming floor with a polymer that looks like milk. It's white and the consistency of milk. Then polymer is poured into a 5 gallon bucket, add color, mix quickly then slowly add concrete and mix to a pancake batter consistency. Pour on floor spread evenly and thin.
Decorative
Most systems are a 2 coat process that are sealed with concrete sealers. That's it. Not a big deal.
Here are the steps to apply and complete over the weekend. This system is the same whether it's a 3,000 square foot retail store or a 500 square foot basement.
Step 1 - Friday night, after work. make sure surface is clean. Use blue painters tape on edges, columns, stairs. You may want to use plastic to protect your walls. Use the kind that comes in a roll with a strip of blue painters tape attached. Always apply from bottom and work up. Then spray (garden style inexpensive sprayer) or pour polymer on floor and mop on surface. Takes about an hour for a 500 sf space.
Step 2 - Saturday morning, Prime floor again with polymer and let dry. If room temperature is comfortable and slab is room temperature, dry time is less than an hour. Use this time to set up a mixing station. You need a drill and mixing paddle (available at home improvement stores) 2 five gallon buckets, a 5' x 7' tarp to protect floor, knee pads and a "Magic Trowel". (magic trowel is a squeegee used for spreading your mix)
Once polymer is dry mix first bucket of mix. Most overlay manufacturers package product to cover 200 square feet per bucket. Process is pour manufacturers specified amount of polymer in 5 gallon bucket, add color, mix using drill and mixing paddle for a few seconds. Then slowly start adding concrete and mix until smooth with no lumps.
Once mix is ready pour about a 2-3 foot diameter amount on floor and spread thin and randomly on floor. A 500 square foot floor should only take about an hour. Let dry for 5 hours. If there are any drip marks or high spots they can be lightly sanded with a 100-120 grit palm sander. Then apply second coat which is typically a finer, wetter coat. This step should be faster than the first.
Step 3 - Sunday, Apply 2 coats of concrete sealer. Acrylic sealers are recommended.Sealers should be sprayed on using your garden pump sprayer with light coats. Let dry 2-3 hours between coats. Final application is finish or wax coats. The wax coats are usually too thick for a pump sprayer so pour on floor and spread using a thick microfiber mop. Using a thick microfiber mop will not create streaks. There are a few wax finish coats that are 30% solids which are a 2 coat system. 25% solids wax coats usually require 5-6 coats to achieve same result as a 30% solids product. Each step of sealer and wax application should take 20 - 30 minutes.
That's the process. When you figure total application time for a 500 square foot floor it's about 5 hours of actual work with lots of dry time. Total cost of all tools, and product is approximately .50 - .00 per square foot.
If you plan on applying concrete acid stains or dyes add a day to the project. Stains and dyes are inexpensive but cannot be rushed. Floor needs 24 hours to dry. You don't want to rush it and trap moisture in your slab.
How to Install a Decorative Concrete Overlay in 2 Days
For more information about decorative concrete floor coatings visit the web site www.concreteproductsnewyork.com