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 allows the end user to use sand and cement purchased in their local area, saving money on shipping costs.

Overlay 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.

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 Splattered Textures Skim Coat Resurfacing Thin Stamped Overlays 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.