Resurfacing Brings a New Dimension to Concrete

Putting a new face on old concrete is nothing new. In fact, some of the better-known theme parks, hotels, airports and malls have walkways that have been resurfaced using several popular methods. Many of those pedestrian-traveled venues that look like cobblestone, slate, brick and marble are in fact, cement surfaces fashioned to look like more expensive materials at a fraction of the cost. Experienced contractors have been applying these textured finishes for years, adding to their profitability and reputations. If you haven’t ventured into this part of the business, it’s never too late to add another practical and colorful technique to your repertoire.

When dealing with existing concrete there are many options available that can enhance the surface appearance including texturing, scoring, stamping and staining. Determining which option is the best will depend on the condition of the concrete and the final desired appearance. When original concrete is in good condition, customers can consider any of these methods. Another option is sandblasting a design into the surface using stencils or templates. Various patterns and designs can also be achieved by scoring the surface.

In addition to providing a whole new look to existing concrete, resurfacing is also extremely economical. Resurfacing offers other benefits such as added safety and durability. “Unlike plain concrete or tile, decorative systems can be applied in a slip resistant finish,” says Rick Cox of Spray-Crete Industries.

“This feature of resurfacing is crucial in pool areas, and other areas like wheelchair access ramps, building entrances, and stairways.” Resurfacing products also provide extremely high compressive strength, UV resistance and resistance to stains, mildew, oil, and most solvents. Product composition is what gives these resurfacing materials such resilience. For example, Spray-Crete Industries uses high quality Portland cement combined with an exclusive liquid bonding additive for their Spray-Crete Base and Texture Coat. The water composition of most resurfacing products also makes them environmentally friendly to use, and easy to clean up when the job is done.

Other substrates like brick, block, tile, exposed aggregate and even wood decking are also ideal for resurfacing applications because of its durability and bonding strength. There are also many interior and exterior application possibilities such as pool decks, driveways, entryways, sidewalks, kitchens, baths and steps. Virtually any surface that is appropriate for walking or driving can be resurfaced.

Perhaps the only time resurfacing is not recommended is when the concrete is so badly damaged, it needs to be removed. In these cases, old concrete is replaced with new. If a decorative finish is desired, the contractor can work with the customer to determine the best finish for the job. Stamping, stenciling, and coloring freshly placed concrete become the sensible alternative.This option produces beautiful, realistic looking brick, paver or stone-like finishes. However, the process is more costly than resurfacing since the job involves creating a new “foundation.”

Getting Started
As with any new material or product, consulting the manufacturer on application techniques and tips is the best way to ensure success. Many manufacturers offer hands-on training in the field or organized classes for a more in-depth coverage of product uses, capabilities and trouble shooting. In addition, most resurfacing products are “systems,” that involve several components that should be used together.

Preparing for the base coat is the next step. Most products come packaged in 50 lb. bags, which are mixed with a bonding agent. Typically, the resurfacing material is used as both a base coat and texture coat. Mixing is best performed with a 450 to 600-rpm drill and mixing paddle. The ratio of dry product to bonding additive will depend on the type of texture you’re trying to achieve. Again, the manufacturer can supply the correct “recipe” for each application. Once you have the desired consistency, the product can be applied with a hopper gun, towel or squeegee, or a combination of methods. The thickness of the application can also vary from feather-edge to an eighth of an inch in depth. Some products can even be applied up to two inches thick.

Other tools and materials needed depend on the finish type. Manufacturers can supply a list of tools needed ( stencils, trowels, spray equipment, etc.) along with information on the necessary safety equipment. For example, manufacturers recommend wearing safety goggles and protective gloves during all stages of application including pressure washing. Respirators must also be worn when applying solvent-based concrete sealers due to fumes. If acid etching will be part of the job, check with the manufacturer for additional safety guidelines.