Architectural Concrete Finishes
 
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How is Decorative Concrete Overlay performed?

     Concrete Overlays fall into different catagories but share steps in the evolution of the final product.  The installation time runs from
3 ~ 7 days
depending on the size of the area, the selected style and complexity of the pattern.  The typical steps are as follows:
 
1.  Preparation.  This step is common to all applications.
 

     a. The surface is pressure washed or cleaned with a floor prep machine depending on if Exterior or Interior.


     b.  A mild Acid bath is done and then neutralized. This opens the pores of the concrete and prepares

          it to bond with the next application. (An Acid Bath is NOT done for staining a Concrete Slab).  For those interested

          in staining concrete slabs, please see the information on About Acid Stain and Builder Information pages; the

          following steps only apply to concrete overlays. 

 

2.  Base (skim) Coat.  This step is common to all overlay applications. 


     a.  Cracks in the surface are treated if needed.

     b.  A Skim or Scratch/Base coat is applied to the surface and allowed to dry.

 

*** The steps below are by style.  Depending on the complexity of your desired surface, modifications may be made.

 

3.  Texture Applications:  There are several styles that fit this catagory (a Knock-Down finish is in this catagory).

 

     a.  Basic Spray Texture would have an additional Base Coat added before the Top Coat is Sprayed on.  I feel the additional base

          coat is needed to give strength to the final product.  After the second Base Coat, the Top Coat is sprayed over a Stencil, Tape

          or a Seamless pattern.

     b.  Flagstone coatings also receive two Base Coats for the same reason above.  The next step is to apply a 1/2" Nylon Tape to

          the surface to mark off the "rocks/stones".

     c.  The Flagstone pattern is then coated with the Top Coat and after a dry time, misted with additional colors.

     d.  The tape is then pulled off to reveal the pattern and the surface is then sealed.

 

4.  Faux Slate/Tile Applications:

 

     a.  The Top Coat material is mixed and applied with a pool trowel to achieve a look that resembles a light Slate Texture or a

          swirl-type texture found on some tiles.

     b.  After drying overnight, the desired pattern is marked and scored.

     c.  Stain is applied to the surface in several coats to achieve the desired color, tint and tone.

     d.  After an overnight dry, the surface is sealed.

     e.  NOTE:  This texture may also be reffered to as a "Knock-Down" when it is done to resemble Cool Deck.

     f.   There are other variations of this style that can create a personalized tile unique to your home.

 

5.  Micro-Finish Overlay:

 

     a.  The most common use of Micro-Finish is to overlay a slab that would not react well to acid stain.  The final result is a surface

          that actually achieves a higher degree of mottleing and tone than concrete.

     b.  A Micro-Finish job will get a second Base Coat.

     c.  Two applications of Micro-Finish are applied with a pool trowel.  This process fills in the small voids in the surface and results

          in a smooth even surface.

     d.  The floor is machine-sanded to further smooth the surface and remove any trowel marks.

     e.  The pattern is scored and the surface is stained in the desired color.  After the stain works for about 4 hours, it is neutralized

          and rinsed.

     f.   Once the surface is dry it is sealed.

 

6.  Thin-Stamped Overlay

 

     a.  Texture Pave is the ultimate top-coat that is applied to the surface and accepts the stamp pattern.    

     b.  A "Wet Bond" coat is put down in advance of the Texture Pave.

     c.  The Texture Pave is spread out with a Guage Rake to ensure a consistant  application.

     d.  After about 2 hours the surface has set up enough to be stamped with the Texture Skin.

     e.  The Texxture Skin makes the Slate pattern in the surface.

     f.   After the Stamp, the material will dry over night.

     g.  The pattern is then scored and stained in the desired color.

     h.  Once the surface is dry it is sealed.

 

7.  Sealer Options:

 

     There are several sealers available and the choice of sealer should be determined by environment and use.  Some of the overlay

styles/staining required longer dry times than others.  Most surfaces can be sealed  the day after staining.

 

     a.  CSS.  This is the Primary sealer for Exterior applications.  CSS is a 53% solids, UV inhibiting sealer.  It penetrates the surface and

inhibits mold and mildew from getting a foot-hold on the surface.

    

     b.  AUS-G:  This is a Aliphatic Urethane sealer.  It is UV stable and offers higher abrasion resistance.

 

     c.  Clear Epoxy:  This is the best sealer for Interior use.  It cures up to over 14,000 PSI and is odorless.

                              

     d.  Colored Epoxy:     Colored Epoxy comes in 10 colors and is the best coating for areas such as loading

                              docks where high wear is the primary concern.

 

     e.  Wax:  All interior applications receive coats of a commercial quality liquid wax.  This wax is a 37.5% Solids commercial quality wax. 

It is applied with a looped-end Rayon mop.  The purpose of the wax is to provide a sacrificial coat to absorb the scuff marks and prolong the sealers life.

An Interior floor that recieves regular waxing will never have to be re-sealed.   

 

Note: An Exterior overlay surface should be re-sealed every 1 to 2 years depending on exposure and use.  Slip-Resistant additives are also available upon request.

 

     Warranty: We offer a 2-year warranty on workmanship on most Interior surfaces.  A 1-year warranty is standard on exterior surfaces.  Surfaces that were previousally coated and require a bonding agent will not be warranted more than 1-year.  Each warranty is specific to each job and will be stated or not stated in the contract.

 

     Information on how Acid Stain works can be found on the About Acid Stain page.  There is also a guide for

your builder located on the Builder Information PageYou can also find out how to maintain your

Acid Stained Floor or Decorative Concrete surface on the Care and Maintenance page.

 

 

 

         

 

 

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