CoatingsPro Magazine Supplements

Concrete Dec 2017

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24 CONCRETE COVERED 2017 COATINGSPROMAG.COM Photos Courtesy of Elegant Concrete Polishing, Inc., ISCS, and Skudo, Inc. By Austin Morrison, Partner at Elegant Concrete Polishing Concrete Overlay: Protection, Maintenance, and Care C ement-based polishable overlays for interior appli- cations continue to grow in popularity due to their ability to create durable, beautiful walking surfaces. An overlay is a final floor finish that is poured and placed on top of existing substrate. W hen an overlay is installed properly and has been expertly refined, it can last for many years, even under heav y use. Retail markets in urban areas have particularly seen a rise in this type of topping solution where retrofits are the norm and floor traffic demands a more resilient floor than similar polymer-based flooring solutions. However, when dealing with cement-based products, it is important to remember that many of the same procedures for creating a concrete slab also need to be used in successfully creating and installing a concrete overlay. Reviews and Expectations Unlike tile, carpet, and other prefabricated flooring solutions, concrete overlays are engineered on site. is means that the team must not only think of the project as the site of their future facility but also as the factory that produces the final finished floor. Quality control, scheduling, and protection are needed to allow for proper curing and installation, and they all have a direct impact on the quality of floor that will be handed over to the owner. Again, think of your jobsite as a factory. For the overlay to have the best chance at succeeding, the floor surface that will receive the overlay must be cleaned and prepared. Cracks will need to be cleaned and filled, and the floor must be leveled sufficiently to create a final flat floor surface. is will help avoid gradual change from one area to the next and will eliminate unwanted physical features of the substrate from telegraphing to the final floor finish. Remember to add details for existing joints and cracks if they are missing from the drawings or construction documents because they will have to be honored with the new floor topping. Honoring a joint/crack means that it is cleaned and filled to be flush with the rest of the substrate to avoid telegraphing that joint/crack into the final floor finish. On your site walk with the owner's representative and the archi- tect, make sure you set the expectation for why these floor voids need to be honored and how that can affect where zinc strips are placed when honoring. Overlays are designed to go down thinly while still maintaining a resilient surface for walkability. erefore, it is important that the underlying base is structurally sound. A floor runs the risk of delamination if it's installed on top of an unsound surface. It is also crucial to treat the subbase with some type of moisture mitigation system that will control moisture/vapor movement from the existing concrete slab to the new cement overlay floor. A simple test for the presence of moisture vapor transmission can help you decide on how to treat the floor, but it is standard to use an epoxy system to stop vapor transmission and then broadcast sand to create a texture for the overlay itself to adhere to. Tips and Tricks Once it's time to install the overlay, be sure to use best practices. All manufacturers will have their specific require- ments for mixing and placing concrete. After all, no manufac- turer wants its products to fail. Follow the instructions for Concrete Covered An overlay is a floor finish that's poured and placed on top of an existing substrate. It is important to prep, prime, and clean the floor prior to pouring an overlay. Unlike tile, carpet, and other prefabricated flooring solutions, concrete overlays are engineered on site.

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