Step 1: Preparation
Concrete:
- Cover areas at risk of over-spray with plastic drop cloth.
- Newly poured concrete must cure for 30 days before application.
- For existing concrete:
- Remove paint or previously applied sealer using Soy Gel Stripper.
- Remove carpet glue or other adhesives using Bean-E-Doo® Mastic Remover.
- Remove any oils, dirt, debris, Soy Gel Stripper, or Bean-E-Doo® Mastic Remover using scrub brush and ProClean™ Degreaser.
- Verify absorption by pouring a cup of water in various areas. If not absorbed within five minutes, etch surface with CitrusEtch™, then neutralize surface with ProClean Neutralizer™ and rinse thoroughly.
Plywood Substrate:
- Ensure there is no “flex” in the plywood substrate. Weak or flexible areas will lead to the overlay cracking.
- Once the floor is rigid and well supported, apply a moisture (vapor) barrier over plywood.
- Attach cement backer board grid-side down to plywood substrate using ceramic-head or non-corrosive screws.
Tile:
- Ensure tile is thoroughly cleaned and free of any dirt, debris, or residues – allow to dry completely.
- Sand tile with 80 grit sanding pad to provide a “scuff”, promoting a good surface for overlay to bond.
Caution: May be harmful if swallowed or ingested. Contact with skin can cause mild irritation. Avoid contact with eyes. Step 2: Application
Coverage rate is approximately 75 square feet per 50-pound box when applying a skim coat (thin coat). Coverage rates may
vary based on concrete texture, surface porosity, and application method.
NOTE: When applying on surfaces over 90 °F (32 °C), mix Concrete Overlay with ice-cold water (increases working time), then dampen surface with water.
Mixing:
- Pour 4.5 - 5 quarts (4.3 - 4.7 liters) of water into a clean five-gallon bucket
- If using concrete pigment, mix into bucket until thoroughly blended (otherwise streaking will occur).
- Pigment can settle into bottom edge of bucket; be sure mixing tool reaches this area.
- Slowly pour 50 pounds of Concrete Overlay into bucket while continuously mixing with a drill mixer.
- Use a birdcage or double box mixer attachment.
- Mix for at least three minutes to make sure water and Concrete Overlay have thoroughly combined.
- Concrete Overlay must be applied within 30 minutes (otherwise product hardens and cannot be used).
Concrete:
- Wet surface with water before applying Concrete Overlay.
- Remove pooled/puddled water from surface with a towel or squeegee.
- Wear spiked shoes so you can move around freely without affecting the fresh overlay.
- Starting on the far side, pour ¼ to ½ of the bucket into a puddle onto the surface.
- Using a 12” or 18” squeegee trowel, maintain steady pressure and pull the overlay toward you as you move backward, leaving a thin skim coat behind.
- Maintaining a wet edge, continue moving the puddle with the squeegee trowel until it is expended.
- If you must pause application, do so at a control joint and not mid-way across surface. Stopping mid-way will cause a dry line that will be difficult to blend out when you re-start application.
- Pour more Concrete Overlay onto the surface as needed and continue pulling it with the squeegee trowel until you have covered the intended surface area.
- Concrete Overlay will dry faster in higher temperatures and on windy days, requiring you to move relatively quickly.
Plywood Substrate:
- Begin by skimming overlay into grout lines, filling low grouted area to be flush with tiles.
- Allow initial skim to dry for 12-24 hours (depending on temperature and humidity).
- If grout lines are deep, a second skim may be needed to fill and bring flush with tile surface.
- Once grout lines are filled and surface is even, apply a skim coat over entire surface following the same method as described below in “First Coat”.
- Wet surface with water before applying Concrete Overlay.
- Remove pooled/puddled water from surface with a towel or squeegee.
- Wear spiked shoes so you can move around freely without affecting the fresh overlay.
- Starting on the far side, pour ¼ to ½ of the bucket into a puddle onto the surface.
- Using a 12” or 18” squeegee trowel, maintain steady pressure and pull the overlay toward you as you move backward, leaving a thin skim coat behind.
- Maintaining a wet edge, continue moving the puddle with the squeegee trowel until it is expended.
- If you must pause application, do so at a control joint and not mid-way across surface. Stopping mid-way will cause a dry line that will be difficult to blend out when you re-start application.
- Pour more Concrete Overlay onto the surface as needed and continue pulling it with the squeegee trowel until you have covered the intended surface area.
- Concrete Overlay will dry faster in higher temperatures and on windy days, requiring you to move relatively quickly.
Tile:
- Do not apply Overlay directly on plywood (wood will draw moisture, expand/contract, and Overlay will crack).
- Begin by skimming overlay into grout lines, filling low grouted area to be flush with tiles.
- Allow initial skim to dry for 12-24 hours (depending on temperature and humidity).
- If grout lines are deep, a second skim may be needed to fill and bring flush with tile surface.
- Once grout lines are filled and surface is even, apply a skim coat over entire surface following the same method as described below in “First Coat”.
- Wet surface with water before applying Concrete Overlay.
- Remove pooled/puddled water from surface with a towel or squeegee.
- Wear spiked shoes so you can move around freely without affecting the fresh overlay.
- Starting on the far side, pour ¼ to ½ of the bucket into a puddle onto the surface.
- Using a 12” or 18” squeegee trowel, maintain steady pressure and pull the overlay toward you as you move backward, leaving a thin skim coat behind.
- Maintaining a wet edge, continue moving the puddle with the squeegee trowel until it is expended.
- If you must pause application, do so at a control joint and not mid-way across surface. Stopping mid-way will cause a dry line that will be difficult to blend out when you re-start application.
- Pour more Concrete Overlay onto the surface as needed and continue pulling it with the squeegee trowel until you have covered the intended surface area.
- Concrete Overlay will dry faster in higher temperatures and on windy days, requiring you to move relatively quickly.
NOTE: You may choose to apply a second coat depending on success of initial application and/or desired thickness.
Additional Coats:
- Allow your first coat to harden and cure for 12 - 24 hours depending on temperatures.
- If there are bumps or raised edges in the finish of first coat, they can be sanded with a 100-grit sanding pad or overlayed over.
- Make sure surface is swept clean and free of dirt or debris before applying second coat.
- Apply second coat using same method as you applied first coat.
- We recommend that you do not wear spiked shoes on this application as it can lead to dents in the first coat of Concrete Overlay, depending on how well cured it is.
Pro Tips:
- If using integral pigments in your mixture, you must measure your Overlay, pigment, and water quantities to be the same every mix. Otherwise, you will have color variations across your project.
- If more than one batch of Overlay is needed for your project, have a second person on-site to mix while you apply.
Cleanup:
- Clean tools and supplies using ProClean Degreaser™ and warm water before Overlay has cured.
- Clean tools and supplies with mechanical sanding or a concrete dissolver after Overlay has cured.
Tools & Supplies:
- Pump-up sprayer
- Scrub brush, cotton mop or low-speed floor buffer with brush attachment
- Wet-dry vac or mop bucket
- Squeegee trowel or gauge rake
- Plastic drop cloth
- Drill mixer
- Bird cage or double box mixer attachment
Disclaimer: Direct Colors does not warranty or guarantee results (outcomes). Concrete variations or improper application may cause unintended results. Test product on an inconspicuous or small area and allow to fully cure to ensure compatibility and desired result.
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