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CHAPTER 1
CHOOSING ONE SYSTEM OVER ANOTHER
When it comes to choosing an overlay system, one size does not fit all. Each system described in this guide has unique qualities with distinct performance criteria to match. With the many options available, you'll probably find at least one system that meets your client's requirements for durability, appearance, maintenance, and cost. But how do you choose the ultimate system for the job?
In this chapter, I discuss some of the key factors to consider. Be sure to go over these issues with your clients as well, so they can participate in the decision-making process. By informing them of the advantages and the limitations of each system, you will help to ensure the selection of a product that lives up to their expectations.
Condition of the existing surface
The condition of the existing concrete slab will be one of the biggest considerations when choosing the appropriate system. Does the concrete exhibit excessive cracking or deep chips and gouges? Is the surface out of level? If so, the slab would not be a good candidate for a microtopping or skim coat designed to be applied at a thickness of 1/8 inch or less. These imperfections, if not perfectly patched or filled, could telegraph through a thin topping. After repair, a floor like this would be a better candidate for a higher-build material, such as a self-leveling or stampable overlay. (To review procedures for crack repair, read Chapter 10.)
Moisture content of the concrete
Too much moisture in the concrete substrate can be a problem for many overlay systems, especially products that restrict the ability of the concrete to "breathe," or release moisture as needed. As the moisture vapor travels up through the capillaries of the concrete and reaches the surface, it can cause the topping or overlay to delaminate.
There are several causes of excess moisture in concrete. If you suspect you have a problem, read Chapter 8 to learn about a couple of simple tests you can perform to check the moisture-vapor emission rate. If the rate is high, check to see what level is acceptable for the system you want to install. Some overlays will permit the moisture vapor to escape more readily than others.
Durability
Resurfacing systems permit you to experiment with a wide range of artistic effects, but your creative artwork is all for naught if the overlay is vulnerable to chipping, abrasion, or chemicals. Although many of the systems described in this guide stand up well to wear, chemical attack, and dirt penetration when properly installed and maintained, some systems are better suited than others for harsher exposure conditions. Often a higher build material will perform better in aggressive environments.
Be sure to ask the facility owner specific questions about the type of conditions the resurfaced concrete will be exposed to. Is the slab outdoors and subject to weather extremes and seasonal freezing and thawing? Is it a floor surface in a high-traffic area or in the line of fire for chemical, grease, and oil spills? Will heavy equipment or furniture be dragged across the floor? Make sure the topping or overlay system you choose is tough enough to withstand all the conditions it will confront. Often you can find this information in the technical data sheets for the product (see Chapter 12).
Desired look
Of course, the main reason to use a resurfacing system is to give the existing concrete a face-lift. While all of these systems will certainly make the surface look better, each type has its own distinct appearance. The processes for achieving color, pattern, and texture also differ among systems (see table comparing the attributes of the various overlay systems on page 13). I discuss these decorative possibilities in greater detail in the chapters devoted to each technique.
Cost
The main factors affecting the cost of materials are the applied thickness and type of coloring method used (such as integral coloring, broadcast pigments, stains, or dyes). The total cost of installation will also be higher if you are using stencils, stamping mats, or decorative sawcutting to pattern the surface. For a detailed breakdown of the average installed costs for each system, turn to Chapter 4.
Maintenance requirements
Clients often have great expectations about their newly resurfaced Concrete floors early On, but then neglect to .maintain them properly and are disappointed when the surface ends lip looking dull or lackluster. For any installed topping, the amount of maintenance required is a function of the amount and type of traffic the floor will receive. In most cases, routine sweeping to remove any abrasive particles and occasional wet mopping with a mild detergent or soap will prevent damage to the finish. Textured or patterned surfaces may require more aggressive scrubbing with a bristle brush or mechanical floor sweeper to remove dirt or grease that becomes trapped in the depressions in the surface. Occasional pressure washing may be needed to clean exterior surfaces.
As you can see, choosing the most appropriate resurfacing system often involves weighing performance attributes along with aesthetic value. Chances are, there's a system available that will strike the perfect balance for the job at hand.
Back Cover
If you're fortunate enough to work in the decorative concrete industry like I do, you've experienced firsthand the explosive growth in the demand for our product.
More and more people tell me they want decorative concrete, but many also admit they can't afford to replace their existing concrete with a gorgeous new pool deck, patio, driveway, or floor. Now they have an alternative, thanks to recent technological advances in overlays and toppings designed to rejuvenate concrete floors, exterior flatwork, and even wall surfaces. When existing concrete needs a face-lift, these systems can be a cost-effective solution to the dreaded remove-and-replace option.
Overlays and toppings can be applied at thicknesses of 1/4 inch or less yet result in an extremely durable, aesthetically pleasing surface. An endless array of decorative options in color, pattern, and texture permit complete design flexibility for makeovers that are totally unique.
The growing demand for these resurfacing systems, by both the residential and commercial markets, offers a huge opportunity for decorative concrete contractors who are willing to learn the techniques and have the desire to be creative. My purpose with Bob Harris' Guide to Concrete Overlays & Toppings is to share the knowledge I have gained from my experiences to provide you with a solid foundation for producing quality work and to help you avoid common mistakes and problems.
Here are some of the topics covered in depth in this guide:
-A to Z instructions for installing underlayments, microtoppings, spray-down systems, stampable and self-leveling overlays for industrial, commercial, and residential slabs (and even walls), both indoors and out.
-How to choose one application versus another.
-Budget analysis to determine how much to charge for each type of application.
-How to estimate materials.
-Surface preparation and crack repair.
-How to deal with and test for moisture-vapor transmission.
-Coloring options, including color layering and the use of stain, dyes, tints, and broadcast colors.
-Decorative finish options, including the use of stamping mats and stencils, scoring techniques, working with gelled acid, and polishing.
-How to set up a mixing station.
-Labor requirements for each technique. Curing times required prior to walking on, sealing, or stamping the work.
-Troubleshooting pointers for each type of application.
You'll also find a list of the essential tools, equipment, and supplies needed to mix and apply each type of system as well as an impressive pictorial gallery of completed projects.
Although this guide can certainly help you sharpen your skills and shorten your learning curve with overlays and toppings, it is not intended to be a substitute for on-the job experience-the only way you can truly master these methods. My goal is to give you a comprehensive understanding of the fundamentals while introducing you to the advanced techniques being used by seasoned pros. Enjoy!
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