Explanation of Overlays
What is a concrete overlay, and how does it work?
A concrete overlay is a hybrid polymer resin
based cement, which is water compatible and non-toxic. These systems
have been successfully developed, time-tested and used for many
permanent applications by contractors, engineers, architects and
public works agencies for internal and external applications, above
and below grade.
These systems resist chemical attack and
weather degradation considerably better than conventional cement or
other modified cements; and due to its chemical structure, repairs
or imperfections in concrete are easily corrected. It adheres
tenaciously to most surfaces and is considerably more flexible,
thereby resulting in less or no cracking, with a warranted
resistance from de-lamination due to hydrostatic pressure.
These permanent overlays offer longer life,
durability, reliability, flexibility, water and chemical resistance,
and optional safety (non-slip) textures that are not only cost
effective and time saving, but can also be aesthetically appealing.
How many years have polymer cement
overlays been installed?
Contractors have been installing Overlay's
since the early 1980’s. There are millions of square feet installed
interior and exterior at some of the largest casinos, retail space
at some of the nations largest shopping malls, countless
restaurants, clothing stores, residential/commercial pool decks,
driveways and many other locations.
Polymer cement overlay is a combination of cement, various
aggregates and proprietary hybrid polymer resins.
The purpose of
adding polymer resins to the cement and aggregate is to greatly
increase the performance characteristics and versatility of
conventional cement and concrete materials.
Unlike conventional
cement and concrete mixes, polymer cement overlays can be applied as
thin as a single grain of sand or up to several inches thick without
fear of delamination or typical product failure.
In addition,
polymer cement overlays are much more resistant to damage from salt,
petrochemicals, UV, harsh weather conditions and traffic wearing.
Polymer cement
overlays were introduced over twenty years ago, intended for use as
a thin surface restoration material for concrete substrates.
With years of
successful and permanent applications, polymer cement overlays were
introduced into to architectural concrete and commercial flooring
industry in the early 80’s where it’s use has become an industry
norm.
Overview
Overlays are used to resurface on top of old worn
concrete surfaces to provide a new stamped concrete finish.
A two
component product, Overlay Plus products consists of a Proprietary Liquid
Polymer, which is mixed by the applicator on the job-site with our
prepackaged blend or the applicators own blend of sand and cement.
Overlay Plus allows the end user to use sand and cement purchased in
their local area, saving money on shipping costs.
Overlay Plus can be
stamped 1/4 to1/2-inch thick and it will accept most conventional
stamping tools. You can also use Overlay Plus to achieve thinner
knockdown finishes.
Concrete Overlays:
Custom Interior Flooring:
These applications may include extremely smooth or
moderately textured finishes in virtually limitless color and design
combination. Commercial grade sealer systems may be required to ensure
high traffic wear ability. These applications are widely used in
shopping malls, offices, hotel lobbies, retail stores, residential
floors and anywhere in place of conventional flooring such as tile,
quarry, etc..
Splatter Textures and Knockdown Finishes:
These applications are the traditional decorative
resurfacing application. Splatter textures are typically applied with a
air powered hopper gun and more are commonly applied to pool decks,
driveways, patios, etc. giving the property added beauty, added slip
resistance and added durability. Although stone, slate and tile finishes
can be easily installed like thin stamped overlays, the actual texture
is slightly less authentic looking but more textured to provide a
non-slip texture.
Trowel Down Finishes:
These applications are more authentic looking than
the traditional splatter texture but an alternatives to thin stamped
overlays. The texture of trowel down finishes create a textured
decorative finish that rivals the look of conventional slate, stone or
quarry tile at a fraction of the cost of the real thing.
Thin
Stamped Overlays:
This application is one of the most popular uses of
our polymer cement products. Until now, to obtain the look and feel of
stone, slate and various tile in a concrete surface, you needed to pour
a new concrete slab and then stamp the freshly poured concrete with
embossing tools. Although this may be the ideal application for new
concrete pours, but what about concrete surfaces that are already
existing?
Thin stamped overlays are the answer. Imagine being
able to apply a 1/4" to 3/8" layer of polymer cement over an existing
concrete surface (new pour or old deteriorated slab) then stamping the
thin layered polymer cement material to give the permanent and realistic
look of stone, slate and tile just like conventional stamped
concrete but with increased versatility and design..
Broom Finish
Restoration:
This is an application most concrete contractors
would like to believe is possible, yet still have a high level of
pessimism towards the success and long term durability of the
application. The basis behind the application is to
repair/restore/resurface pitted, flaked, deteriorated or poorly finished
concrete that would otherwise need torn out and replaced.
Normal applications are applied 1/32" to 1/4" thick
with thicker applications being optional if needed. Finished
applications look as if new concrete was poured, yet offer increased
levels of performance including: resistance to chemicals, salt,
petrochemicals, UV, water resistance and more. Because of the
inexpensive cost of this application, it is becoming the standard for
surface repair.
Concrete Overlays
We are the premier provider of commercial and residential
decorative concrete. Our goal is to provide the very best in
flooring designs that can be installed indoors or outdoors. Not
only do we install concrete designs, but we also offer overlays
that can enhance the look of your current concrete floor and give
it the look of authentic stone, brick, or slate.
These systems are
engineered and proven to perform as exterior architectural coatings
as well as elegant interior commercial and residential flooring.
Our goal is to always deliver
superior customer service with a durable elegant product.
Here is a List of Our Concrete Overlay Systems:
- Knockdowns
- Acid Stain Overlays
-
Broom Finishes
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- Splattered Textures
-
Skim Coat Resurfacing
-
Thin Stamped Overlays
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The versatility of our products and systems can
often times be a bit overwhelming, if not confusing. Few other
architectural concrete overlay manufacturers have a product line
with such options and finishes. Listed below are the more popular
systems that our products create.
Thin Stamped Overlays:
This application is
one of the most popular uses of our polymer cement products. Until
now, to obtain the look and feel of stone, slate and various tile
in a concrete surface, you needed to pour a new concrete slab and
then stamp the freshly poured concrete with embossing tools.
Although this may be the ideal application for new concrete pours,
but what about concrete surfaces that are already existing?
Thin stamped
overlays are the answer. Imagine being able to apply a 1/4" to
3/8" layer of polymer cement over an existing concrete surface
(new pour or old deteriorated slab) then stamping the thin layered
material to give the permanent and realistic look of stone, slate
and tile just like conventional stamped concrete.
With decreased
costs, decreased labor, decreased required experience but
increased versatility and increased profitability, why would
anyone want to stamp conventional concrete or pay up to three
times as much for real stone and slate again?
Well, the overview is;, a thin stamped overlay is a engineered
modified polymer coating that is installed over existing concrete. The
coating is installed at only 1/4"to 3/8” thick to eliminate the cost,
hassle, and downtime of tearing out and replacing the existing concrete like
conventional full depth stamped concrete finishes. After the coating is
applied, a decorative "stamp" is impressioned into the material to give the
natural look and feel of stone, slate, brick and tile, just like
conventional full depth stamped concrete applications.
Splatter
Textures & Knockdown Finishes:
These applications are the traditional
decorative resurfacing designs and textures. Splatter textures are
typically applied with a air powered hopper gun and are commonly
applied to pool decks, driveways, patios, etc. giving the property
added beauty, added slip resistance and added durability. Although
stone, slate and tile finishes can be easily installed like thin
stamped overlays, the actual texture is slightly less authentic
looking but more textured to provide a non-slip surface.
Custom
Interior Flooring:
These applications may include extremely smooth or moderately
textured finishes in virtually limitless color and design
combinations. Commercial grade sealer systems may be required to
ensure high traffic wearability. These applications are widely
used in casinos, shopping malls, offices, hotel lobbies, retail
stores, residential floors and anywhere in place of conventional
tile, terrazzo, quarry, etc.
Concrete
Repair Resurfacing:
This is an
application most concrete contractors would like to believe is
possible, yet still have a high level of pessimism towards the
success and long term durability of the application. The basis
behind the application is to repair/restore/resurface pitted,
flaked, deteriorated or poorly finished concrete that would
otherwise need torn out and replaced.
Normal applications
are applied 1/32" to 1/8" thick with thicker applications being
optional if needed. Finished applications look as if new concrete
was poured, yet offer increased levels of performance including:
resistance to chemicals, salt, petrochemicals, UV, water
resistance and more. Because of the inexpensive cost of this
application, it is becoming the standard for surface repair.
All of our finishes are low maintenance and
permanently sealed to protect against oil, grease and dirt. These
systems are economical since they provide long term durable
renovation without the need for costly and continuous repairs
normally associated with deteriorated surfaces. They can be
installed at any time during new or old renovation processes,
which allows all other renovation or construction aspects to be
completed without fear of damaging or wearing the new surface.
We have the most affordable rates to offer
our clients when it comes to using state-of-the-art equipment and
products. Our quality in workmanship stands out in those
areas where other companies fall short. This enables us to
offer some of the most reasonable prices in the industry. Contact
us for any questions you have regarding our decorative concrete
surfaces or if you are ready to get started on your project.
|
Overlay Process:
Step 1: Mix Components
Step 2:
Trowel Product On
Step 3:
Use a Gauge Rake to Level
Step 4: Level As You Go
Step 5:
Allow Time to Set
Step 6:
Ready To Stamp
Step 7:
Stamping Process
Step 8:
Stamping Process
Step 9:
Seal with Premium Acrylic
In only two days, a plain concrete
patio was transformed into a beautiful slate surface that will
give years of worry free enjoyment!!!
We
categorize overlays into four types: resurfacing, textured,
stenciled and stamped.
RESURFACING: Resurfacing has many applications from
simply restoring a damaged concrete area to make it look new; as
part of a design or as a preparation for a stain application in
which a clean fresh surface is needed.
TEXTURED: A great look – it’s also called a
knockdown finish. The finish is similar to a drywall knockdown
finish. This finish looks great around a pool deck. It can be used
in conjunction with stencils to create interesting patterns.
STENCILED: One of our favorites – with the use of
stencils that are specially made for overlays, we can create the
look of brick, cobblestone, slates – which transform a driveway,
patio, pool deck into a stunning area. One of the most popular
stencil patterns is the handcrafted random or flagstone pattern in
which we create a one-of-a-kind overlay just for you!"
STAMPED: Stamped is another one of our favorites.
We can provide you with the wonderful look of stamped concrete over
your existing walkway, pool deck, etc. Many times we will integrate
the stamp process with color staining and stamp a portion of your
concrete and stain the rest to create a very unique look.
What are the advantages of a hybrid polymer overlay?
- Increased strength compared to normal concrete and
other concrete coating products.
- Highly resistant to salt, chemicals, UV, freeze/thaw, de-lamination,
hydrostatic pressure, oil, stains, mildew/fungus, and more depending on seal
coat.
- Cost effective. Since it provides a permanent, nearly maintenance free
surface that can resemble brick, stone, slate, etc. at a fraction of the
cost.
- Ability to apply from the thinness of a grain of sand up to several inches
thick with extreme durability
- Wide variety of applications. (broom finish, splatter texture, trowel
finish, stamped overlay, chemical stain), with almost unlimited and
completely customizable design options.
How long does the installation process take?
Most jobs take an average of 3-7 days depending on the
system or finish that is chosen. Larger jobs may take longer. Most surfaces
can be walked on within 24 hours. Heavy usage such as car traffic can resume
after 7 days.
What type of warranty do you offer and what does it cover?
We have a 2 year limited warranty on our overlay, epoxy,
and acid stain systems, it covers our product adhering to the concrete, i.e.
peeling, excessive fading, or delaminating from the surface.
What if my concrete is cracked or pitted?
We fix cracks as necessary
by grinding them out and re-bonding them with an epoxy crack filler. The
crack is then covered by the overlay. However, there is no guarantee that
cracks will not return, and we do not warranty cracks. It is usually best to
try to integrate cracks into the design of the overlay to minimize their
visibility should they return.
How does your products stand up against oils, stains,
salts, and discoloration?
All overlays are sealed upon completion. These sealers
all protect the overlay, giving it a nonporous finish. The majority of
stains due to oil and grease wash off with a mild detergent or plain water.
Salt, de-icers, fertilizers and such have no effect on it whatsoever.
What maintenance do your products require?
We recommend that every 3-5 years the surface be
resealed, depending on usage and traffic load. For example, a driveway with
heavy car traffic may need re-sealed every 3 years, where as a patio with
only foot traffic may only need re-sealed every 5 years.
Doesn't pressure washing revive my concrete?
Yes, pressure washing will make your concrete look
better, but pressure washing opens up the pores of the concrete and can
actually speed up the deterioration process if a proper sealer is not
applied immediately after cleaning. If your concrete is already sealed, just
a rinse with a hose should be enough to clean it.
Trust Totally Restored, to expertly upgrade your Home.
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102346
