Concrete Resurfacing: Techniques, Materials, and Applications

What Is Concrete Resurfacing?

Concrete resurfacing is the process to provide a brand new look to damaged concrete. In the process of resurfacing of concrete, a concrete coating is applied on the surface of existing concrete. Concrete resurfacing is a time-consuming process, and it’s very much labour-intensive process so, it’s a little bit expensive also.

In this process, a special bonding agent is added to the cement mixture to get a smooth cementing surface. Types of concrete resurfacing-

1. Stamped Overlays
2. Pool Deck Resurfacing
3. Concrete Crack Repair
4. Driveway Repair
5. Resurfacing Patios
6. Resurfacing Products

How to Resurface Concrete?

There are generally four steps of resurfacing concrete, those are

Step 1. Concrete Cleaning

1. Concrete cleaning is done by a mechanical machine of high pressure of near about 3500 psi.
2. This process is done to remove dust, algae and other hazardous materials because a cleaned surface has a better power of bonding with new materials.

Step 2. Patch Spelled Areas

1. In damped concrete, resurfacer is used to fill those patches.
2. Resurfaced is made by one part of water with seven-part of resurfaced in a five-gallon bucket.
3. Then we need to fill up that place and smooth the area with a trowel.

Step 3. Spread the Resurfacer

1. Walkway joints are filled with resurfaced.
2. The resurfaced is only workable for 20 minutes.

Step 4. Trowel Operation

1. Trowel operation is done to spread the resurfacer.
2. The thickness of the resurfacer is ¼ to ⅛ inch.
3. We need a total of six hours to use it again.

Concrete Resurfacing Material

The general materials of resurfacing concrete are

1. A unique blend of Portland cement
2. Sand
3. Polymer modifiers
4. Many other additives

This is mainly used to repair shrinkage cracks, thin repairs, etc. A fair concrete resurfacing material is defined by its flexibility, sprayable, easy for trowel operation, etc.

Here are some condition of resurfacing concrete before we purchase it from the market-

1. It must be water-resistant
2. It must be non-slippery
3. It should be UV resistant
4. It should have the ability to withstand the freeze that cycle
5. It should have the ability to resistant against chemicals
6. It should have the ability to overcome the heavy foot and vehicle traffic.

Now some readymade products are available in the marketplace, those are-

1. Overlay Mix
2. MT resurfacer
3. Overlay foot mixes
4. Versa-Crete resurfacer smooth mix
5. Floor top STG
6. Top Cap resurfacer

Concrete Repair and Resurfacing

Concrete Repair

Concrete repair is a process where we fix the problem of the concrete internally. There are several types of concrete repair techniques available, they are

1. Epoxy Injection
2. Routing and Sealing of Cracks
3. Stitching
4. Grouting Method

#1. Epoxy Injection

1. Epoxy injection is a type of concrete repair process. It’s applied where the concrete cracks are not more than 0.002 inches or 0.05 mm.
2. In this process, epoxy resins are entered into the cracks and exposed on the concrete surface.
3. Epoxy injections are used in building cracks repairing, dams, bridges and other structures. Epoxy resin techniques need a high skill full labours.

#2. Routing and Sealing of Cracks

1. Routing and sealing are applied where structural repair is not applied.
2. This is applied where cracks are in the face of the concrete. Sealing is useful in a plane surface than a curved surface.
3. The materials used in sealant are epoxies, urethanes, silicone, polysulphide, asphaltic material, polymer mother, etc.

#3. Stitching

1. Stitching is another method of concrete repair technique.
2. In this process, two holes are drilled in both sides of the concrete cracks. After that, steel bars are used to maintain the crack.

#4.  Grouting Method

1. In the gravity dam, wide cracks are developed in the dam’s wall.
2. This process is by Portland cement grout. This method is very effective to prevent water leaks.

Concrete Resurfacing

1. Concrete resurfacing is the process to provide a brand new look to damaged concrete.
2. In the process of resurfacing of concrete, a concrete coating is applied on the surface of existing concrete.
3. Concrete resurfacing is a time-consuming process, and it’s very much labour-intensive process so, it’s a little bit expensive also.
4. In this process, a special bonding agent is added to the cement mixture to get a smooth cementing surface.

Types of Concrete Resurfacing

Types of Concrete Resurfacing are as follows

1. Stamped Overlays
2. Pool Deck Resurfacing
3. Concrete Crack Repair
4. Driveway Repair
5. Resurfacing Patios
6. Resurfacing Products

#1. Stamped Overlays

Stamped overlays is a type of concrete resurfacing which gives us aesthetic beauty and texture. This is only used on existing concrete.

#2. Pool Deck Resurfacing

This is the process to repair damaged concrete. This process is a tiny layer of cement, sand, polymer and resin.

#3. Concrete Crack Repair

This is one of the most important processes where repair materials are poured into cracks.

#4. Driveway Repair

Naturally driveway doesn’t need repairs, but sometimes it requires.

#5. Resurfacing Patios

This is done by the cement-based overlay, which is durable and strong.

#6. Resurfacing Products

In this type, there are many types of readymade resurfacing products available in the marketplace.

FAQ on Concrete Resurfacing

What is concrete resurfacing?

Concrete resurfacing is a process that gives damaged concrete a brand new look by applying a concrete coating on the surface of existing concrete. It involves cleaning, patching, spreading the resurfacer, and trowel operations.

What are the steps involved in concrete resurfacing?

The general steps for concrete resurfacing are:

1. Concrete Cleaning: High-pressure cleaning to remove dust, algae, and other materials.
2. Patch Spelled Areas: Filling patches with a resurfacer mixture.
3. Spread the Resurfacer: Filling walkway joints and spreading the resurfacer.
4. Trowel Operation: Spreading the resurfacer to the desired thickness and smoothing it.

What materials are used in concrete resurfacing?

Common materials include:

1. A unique blend of Portland cement
2. Sand
3. Polymer modifiers
4. Various additives

These materials are chosen for their flexibility, ease of application, and durability.

What are the types of concrete resurfacing?

Types of concrete resurfacing include:

1. Stamped Overlays
2. Pool Deck Resurfacing
3. Concrete Crack Repair
4. Driveway Repair
5. Resurfacing Patios
6. Various resurfacing products

What should I consider when purchasing concrete resurfacing materials?

When purchasing concrete resurfacing materials, consider:

1. Water resistance
2. Non-slip properties
3. UV resistance
4. Ability to withstand freeze-thaw cycles
5. Resistance to chemicals
6. Durability under heavy foot and vehicle traffic

What are some ready-made resurfacing products available in the market?

Some ready-made resurfacing products include:

1. Overlay Mix
2. MT Resurfacer
3. Overlay Foot Mixes
4. Versa-Crete Resurfacer Smooth Mix
5. Floor Top STG
6. Top Cap Resurfacer

What is the difference between concrete repair and concrete resurfacing?

Concrete repair involves fixing internal problems within the concrete, such as cracks and structural issues, using techniques like epoxy injection, routing and sealing, stitching, and grouting. Concrete resurfacing, on the other hand, involves applying a new surface layer to improve the appearance and functionality of damaged concrete.

What are the methods of concrete repair?

Methods of concrete repair include:

1. Epoxy Injection: Used for small cracks (up to 0.05 mm).
2. Routing and Sealing of Cracks: Applied to non-structural face cracks.
3. Stitching: Involves drilling holes and inserting steel bars to maintain cracks.
4. Grouting Method: Used for wide cracks, especially in structures like gravity dams, to prevent water leaks.

How long does it take to use resurfaced concrete again?

After the resurfacer is applied and troweled, it typically takes about six hours before the surface can be used again.

Why is a bonding agent added to the cement mixture in resurfacing?

A special bonding agent is added to the cement mixture in resurfacing to ensure a smooth and strong bond between the new resurfacer layer and the existing concrete, enhancing durability and longevity.