Concrete Overlay

• Cost Effective upgrade for old countertops—requires minimal demolition of existing unit
• Resurface or repair old, damaged and soiled concrete patios, driveways and walkways
• Apply borders to disguise carpet tack strip holes or unsightly flooring scars
• Enhance the look of indoor/outdoor concrete with Stamping, Stenciling & Artistic Finishes
• Color with Acid Stain or Concrete Pigment – Choose from Over 100 Color Possibilities
• Overlay also makes an ideal surface for Décors, such as spray-on stenciling and Vertical Acid Stain

• 1/4 inch = 20 to 25 sq. ft.
• 1/8th inch skim coat = 50 to 60 sq. ft.
• 1/16th inch skim coat = 100 to 120 sq. ft.

• Skim coat of 1/16th to 1/8th inch = minimum of 12 hours
• Add 4 hours for each additional ¼ inch of depth to a maximum of 1"
• Add 25% more time for high humidity conditions

• Pour one gallon of water into a five gallon pail first
• Slowly pour the contents of a 50 lb. box of overlay into the bucket while mixing continuously with a drill mixer
• For best results, use a birdcage, high-shear paddle for bucket mixing
• Thoroughly combine the water and overlay to insure the dry polymer is saturated and properly dispersed
• For a thicker consistency, use less water
• To thin the overlay during application, add water as needed up to a maximum of one additional gallon
• If using colored concrete pigment, water should be kept uniform for every box of overlay to avoid color discrepancies
• Pot life for the overlay is approximately 45 minutes and can be extended by 15 minutes by using ice cold rather than room temperature water
• Ambient temperature will also affect pot life length with cooler temperatures marginally extending and hotter shortening the expected pot life

To spray the overlay, add up to one gallon of additional water per box of smooth texture overlay until the mixture resembles a thin pancake batter suitable for spraying at 25 psi.

Complete texture overlay should be sprayed as a base-coat only.

RESURFACING CONCRETE FLOORS 

How to Avoid Concrete Overlay Cracks and Problems

1. Repair any slightly damaged areas such as carpet tack holes or similar imperfections with Concrete Patching Compound and sand flush with the floor before overlaying.
2. Allow concrete overlay to cure for minimum six hours and sand using a 100-grit pad.
3. Make sure expansion joints are thoroughly cleaned and free of all debris before overlaying.
4. Lay a piece of string in the expansion joint before applying the concrete overlay and pull the string immediately to reveal the expansion and allow cement overlay to dry for 12 hours.
5. Saw cut with a skill saw and a diamond blade if needed.
6. Ground out structural cracks using a tuck point diamond wheel, thoroughly cleaned and the crack blown out with a leaf blower until dry and completely free of debris.
7. Fill with a two-component epoxy concrete filler and allow to dry according to the manufacturer's instructions.
8. Proceed with the overlay application.

How to Resurface Concrete Floors

1. For floors with more widespread hairline cracks, chips or divets, apply a skim coat of no more 1/8 in.
2. Slabs that have significant damage such as spalling can be overlaid but the existing concrete must be structurally sound with no foundational cracks and all loose concrete material entirely removed before proceeding.
3. Use a wet/dry vacuum or leaf blower to remove dirt, organic material and debris.
4. Wash with a concrete degreaser and water solution and rinse thoroughly.
5. Machine-troweled or tiled floors should be profiled with a sander using a 60-80 grit pad to "scuff" the surface. Profiling allows the overlay to adhere more securely to the floor.
6. Floors can be chemically-profiled using a full-strength application of Hard Troweled Floor Pre-Treatment
7. Apply desired concrete overlay texture

Smooth Concrete Overlay Trowel Finish

1. For a smooth concrete finish appearance on a coat depth over 1/8", finish the overlay with a gauge rake and a magic trowel.
2. For a 1/16th to 1/8th inch skim coat, apply the overlay with either a pool trowel or a squeegee trowel.
3. The squeegee trowel will allow a less-experienced person to achieve a more uniformly smooth surface.
4. Use a gauge rake set to the desired depth on floors with up to a ¼ inch overlay.
5. Follow with a squeegee trowel to smooth out any rake marks or other imperfections.

Approximate working time for overlay once applied to the substrate:

• Skim Coat: 3-5 minutes
• 1/8th inch coat: 5-7 minutes
• ¼" inch coat: 10-12 minutes

Ambient and surface temperature will affect working time with cooler temperatures marginally extending and hotter shortening the expected working time.

Do not attempt to apply Concrete Overlay to surfaces below 40F or above 85F. Hot temperatures can be controlled by moistening the surface with water prior to application

Applying Textured Concrete Overlay

For a textured finish, spray the trowel with Concrete Liquid Release Agent and handwork the overlay with a pool trowel.

Approximate working time for overlay once applied to the substrate:

• Skim Coat: 3-5 minutes
• 1/8th inch coat: 5-7 minutes
• ¼" inch coat: 10-12 minutes

Ambient and surface temperature will affect working time with cooler temperatures marginally extending and hotter shortening the expected working time. Do not attempt to apply Concrete Overlay to surfaces below 40F or above 85F. Hot temperatures can be controlled by moistening the surface with water prior to application.

Concrete Spray Texture Finish

1. Select Smooth Concrete Overlay and mix according to the instructions above for spraying overlay.
2. Spray a single coverage coat from a flat-work texture gun at 25 psi.
3. Hold the sprayer at least 6 inches from the surface during application to minimize rebound.
4. Mix one box at a time as needed.
5. For a more coarse texture, spray down without further finishing.
6. For a smoother texture, use a pool or magic trowel immediately after spraying.
7. Spray trowels with Concrete Liquid Release Agent before use.
8. Allow drying time of 6-8 hours.

Stamped Concrete Overlay

1. Select Complete Overlay for stamping and apply at ¼ in. depth.
2. Choose stamps or texture mats intended for use with overlay.
3. Add 1 gallon of water per 50 lb. box, ice water if stamping in hotter temperatures.
4. Use a gauge rake set to the desired depth on surface.
5. Follow with a squeegee trowel to smooth out any rake marks or other imperfections.
6. Allow to dry until the surface can be depressed without sticking.
7. Apply  Concrete Liquid Release Agent to the stamps, tools and overlay to prevent sticking.
8. Depending on size of the job and the mats, use at least three stamps or texture mats along with one floppy for any project up to 100 square feet.
9. For 100-1500 sq. ft. projects, use a set of five stamps or mats and floppy.
10. Time is limited so make the choice according to crew size and ability.
11. Assuming 75F and a 100 sq. ft. project, allow for twenty minutes stamping time – slightly more time if colder, less time in hotter temperatures.
12. If stamping a larger area, one person should be mixing overlay continually while others are applying and stamping.
13. If the work cannot be completed at one time, do not stop applying in the middle of a section or floor.
14. End at logical separation, such as an expansion joint, for the best overall finished appearance.

Stenciled Concrete Overlay

1. Select Complete Overlay  as a base-coat for stenciling.
2. Follow the mixing instructions above for spraying overlay.
3. Spray from a flat-work texture gun at 25 psi.
4. Hold the sprayer at least 6 inches from the surface during application to minimize rebound.
5. Mix one box at a time as needed.
6. Allow to dry for 6 hours before applying the stencil.
7. Affix the stencil and then carefully spray the top or color smooth texture overlay coat in the same manner.
8. Pull the stencil after 10 minutes drying time.

RESURFACING COUNTERTOPS WITH CONCRETE OVERLAY

Concrete Overlay Over Plywood

1. Select ¾" plywood with a sturdy base that exhibits no flex.
2. Attach hardy backer board (or similar concrete board) to the plywood using non-corrosive screws.
3. Fill all seams with a two-part epoxy and allow for a 16 hours dry time.
4. Once epoxy has cured, sand the areas down flush using 180-grit non-loading sandpaper.
5. Thoroughly clean all dust and debris from the surface in preparation for the overlay.
6. Do not apply overlay directly to unsealed plywood.
7. Always seal wood first using a urethane or lacquer based sealant.
8. Allow to dry according to manufacturer's recommendations prior to overlaying.

Concrete Overlay On Formica Countertops

1. Ensure the existing countertop is well reinforced and exhibits no flex.
2. Scuff the surface with a 120-grit non-loading sandpaper.
3. Wipe the area down with a damp cloth to remove any dust and debris and allow to dry. Fill all seams with a two-part epoxy and allow for a 16 hour cure time.
4. Once cured, sand the areas down flush using 180-grit non-loading sandpaper.
5. Thoroughly clean all dust and debris from the surface in preparation for the overlay.
6. Overlay the vertical surfaces before the countertop face.

Covering Tile Countertops with Concrete Overlay

1. Scuff the surface with a 120-grit non-loading sandpaper.
2. Wipe the area down with a damp cloth to remove any dust and debris and allow to dry.
3. Fill all seams with a two-part epoxy and allow for a 16 hour cure time. Once cured, sand the areas down flush using 180-grit non-loading sandpaper.
4. Thoroughly clean all dust and debris from the surface in preparation for the overlay. Overlay the surface and allow to dry for 3-6 hours or until the overlay achieves a uniformly light gray color.
5. Apply a second skim coat and smooth with a magic trowel to prevent tile "ghosting" unless that is the desired finish.

Polished Concrete Overlays

One-Step Concrete Overlay may be polished only when applied at a minimum of ¼" depth or more.

WALL AND VERTICAL SURFACE CONCRETE OVERLAY

Troweled Vertical Concrete Overlay

To trowel overlay on to vertical surface, the overlay consistency needs to be stiff enough to roll into a ball and stick it to the countertop surface.

Wear vinyl gloves when using this method.

1. Spray a pool trowel with Concrete Liquid Release Agent and trowel material smooth in an upwards motion.
2. Scrape the excess overlay off the countertop face with the trowel.
3. Vacuum clean if needed.

Spray Texture Concrete Walls

1. Spray-on vertical application using a drywall texture gun.
2. Mix the overlay to apply to the edges (about a quart of wet mix per 100 square inches) to the consistency of a thin pancake batter.
3. Depending on the texture gun used, rotate the nozzle or tip to the ¼"or 6 millimeters or select the same attachment if the gun has interchangeable tips.
4. Set air pressure to 25 psi and spray material on to the surface.
5. Once applied, spray the trowel with Concrete Liquid Release Agent and trowel the overlay smooth in an upwards motion.
6. Scrape the excess overlay off the countertop face with the trowel.
7. Allow to dry for 3-6 hours or until the overlay achieves a uniformly light gray color.
8. Apply one additional coat for a more even finish and to avoid shadowing at the seams.
9. Scrape any overspray together on countertop surface and vacuum.
10. Once the vertical application is complete, mix the remaining overlay to a thin pancake batter consistency and pour it onto the surface.
11. Spray the trowel with Concrete Liquid Release Agent and trowel the mixture down smooth with a squeegee trowel.
12. If acid staining, allow for a 24 hour cure time before proceeding.