The process of resurfacing a concrete floor with a decorative finish is relatively easy with proper analysis, information, products and tools. All the resources are readily available.
There are 3 components to concrete resurfacing
1. Surface preparation
2. Decorative Options
3. Floor Maintenance
The best place to start is to ask yourself why you want a decorative concrete floor, what are the options, how much does it cost, how do I maintain it.
1. Existing surface - Start by assessing the existing concrete floor. The most common issues are removal of tile adhesives, carpet glue, paint, crack repair and moisture.
2. Carpet Glue removal- This is a common issue. Fortunately there are highly effective solutions. There are a few products on the market that are non toxic and highly effective. The process is to spray on with typical garden style pump sprayer. Then scrape it off. Whatever doesn't come off is likely on for good. Once dry the floor can resurfaced with a skim coat usually 2 coats.
3. Paint Removal - Paint chips off concrete unless properly etched before application. Etching gives the surface "tooth" so paint has something to bite onto. Typically paint chips off because of salts in concrete, like painting sand. To remove the chipping paint use a high quality heavy duty paint remover. Unless grinding off the paint it's almost impossible to completely remove paint from concrete. What doesn't come off just leave.
4. Cleaning concrete - Acid etching concrete is highly effective for removing rust, dirt, grime and salts from the concrete surface. Always wear a mask, the fumes are strong. After about 15 minutes the acids can be washed off. Rinse, squeegee and wet vac off until water is clear. The easiest and most effective is a gelled acid. Gelled acid can be rolled on the floor and agitated with a stiff bristle broom. Then use a scraper to remove and wash with water. The acid releases dirt and grime, algae and the gel works as a carrier. A highl;y effectively cleaning and and etching process.
5. Cracks - There are a few advanced methods for fixing cracks. One of the best solutions is to grind out the crack with an angle grinder and vacuum out loose pieces and dust. A waterproof epoxy is a great crack filler and flexable. If you don't have a grinder, chip out and remove all the loose pieces.
6. Moisture - Concrete is porous. There is air in concrete, little holes and capillaries. Moisture pressure called "hydrostatic pressure" can push moisture through a concrete slab. There are a few basic remedies. A good roof gutter system is critical to keeping water from traveling along a foundation wall and under a slab. French drains around a foundation are highly effective. Coating a concrete floor and foundation wall with Epoxy waterproofers work extremely well. They prevent tons of moisture from coming through a slab.
7. Decorative concrete stains - Concrete acid stains and dyes are a great solution only if you have a clean concrete floor. The problem is its hard to find a concrete floor without blemishes. Especially right after construction. Like with hardwood stains bring out the beauty, but also the imperfections. The best results are from acid stains and various dyes. There are acetone based dyes that bite hard into concrete and waterbased dyes which are softer and tint the floor. Only use quality products. Pricing about 40 - 60 cents per square foot including sealers
8. Concrete Overlays(skim coats) - Concrete overlays are a highly effective function and design solution. There are a few on the market that are user friendly, strong as iron and stick to concrete without issue. They can be integrally colored, stained and dyed. You can create patterns of tile or stone. Flattooing, a stencil system can be used turning concrete into a canvas for artwork. The process of Flattooing, tattoing a floor turns a basic floor into a unique one of a kind floor. Overlays are thin, about 1/16th of an inch thick. They are thin and solve a height issue and doorways and steps. Overlays are the best flooring solution for basements. They're being applied everywhere, restaurants, retail stores, office buildings, grocery stores, casinos. Pricing is approximately $1.25 - $2.00 per square foot including tools and sealers
9. Epoxy floor coatings - Epoxy floors have been typically used in industrial buildings for years. During the past 5 years they have become a staple in residential garages. Floors need to be etched before application.There are a few basic epoxies.
Epoxy paint - Basic high quality floor paint. Many colors available.
Epoxy Urethane system - First coat is an epoxy primer or paint with a Urethane Top Coat. Great system for residential garages and light industrial use.
100% solids High Build Epoxy - This is the heaviest duty epoxy system. System starts with an epoxy primer or paint, then a high build epoxy topped with a Urethane. Colored quartz and chips can be added. Basic applications are about 50 cents per square foot to $2.00 per square foot for a colored quartz system.
10. Modular Flooring - This has become a popular product for use over concrete thanks to the visibility on TV shows like Monster Garage, Russo and Steel Car Auctions, Dream Car Garage. The beauty of a modular system is ease of installation, durability and custom design options. Pricing is about $3.50 per square foot. Installation is a few hours
11. Floor Cleaning Strategy - Cleaning concrete floors is the most overlooked aspect of the entire process. The thought process seems to be put a cleaner in a bucket with water. When you start to see soap subs it's ready. Slop on a floor with a mop, maybe use a buffer. Many floors have been ruined or worn prematurely by use of improper cleaning products and methods. Fortunately there are a few high quality products that have been designed for specific cleaning use. Residential homes, hair salons, restaurants, retail stores, schools, hospitals all have different cleaning needs and different products. How to choose cleaning products is not always an easy process. Its just as important to know how much to use and the types of tools required as choosing the correct products.
Do your research. Find the right resources and follow the steps. Concrete resurfacing is a value added solution and simple with the correct products and information.
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