Most self-levelers can go down 1/4 inch to 1 inch, with the ability to be feathered into the existing floor to make a very gradual transition. One of the most important characteristics of self-leveling concrete is that it can provide a very dense and durable concrete floor. It can be colored with tints during the initial mixing, or colored can be applied after it is applied and cured using dyes. You should look for a concrete overlay that is stain-resistant and water-resistant.ĭifferent types of concrete overlay for floorsĮach concrete floor overlay type offers different decorative options and performance attributes, which are described below.Ī self-leveling overlay can be applied over most concrete floors and are thick enough to help correct uneven surfaces and relatively surface damage of old and worn out surfaces. Another material property that is mainly used in mechanistic-based design procedures is the coefficient of thermal expansion (CTE). The modulus of elasticity of the concrete is another material property input for most designs of overlay. The experts should verify that the design strength is achievable with the available materials. The average annual daily traffic and the percentage of trucks are the minimum traffic parameters required for floor pavement design.Ĭoncrete strength is a key design input, particularly flexural strength. The quantification of traffic over the design life of the floor is required for all thickness design procedures. In addition to the surface evaluation of the existing floor slab, the degree of support beneath the floor surface layers should also be evaluated. Curing is recommended for all overlay projects. The overlay will vary according to flooring conditions.Ī common method for floor surface evaluation is deflection testing, particularly with the falling weight deflectometer. For example, if it is for floors that are exposed to heavy foot traffic and extreme conditions you will need durable overlays that are built to withstand wear and tear. While deciding on the concrete overlay, it is important to analyse what type of conditions your flooring will face. Here are a few factors that should be kept in mind before the execution of concrete overlay. One must look for overlay blends that are strong and made out of high-quality ingredients such as polymer resins, a mix of cement and sand, and other additives. The surface on which the overlay is applied must be leveled and cleaned so cracked or surfacing up can be avoided. Comes in several different colors and texturesįactors to consider for concrete overlay of floor.These generally are 4 to 11 inches thick.Ī concrete overlay can fix underlying problems, or add creativity to an otherwise bland-looking appearance, it offers many advantages An unbonded concrete overlay consists of a concrete layer that is placed on the top of existing floor slab with an interlayer to separate new overlay and existing concrete. Bonded overlays cannot be used if the existing floor is in poor condition. They are 2 to 5 inches thick and are usually applied to strengthen an existing pavement or for preventive maintenance. They are placed on top of the existing concrete pavement and ensure a full bond between new and old concrete layers. Bonded overlays become part of the underlying existing floor slab. Concrete overlays can be applied as thin as a feather finish depending on the desired finish.Īll concrete overlay types fall into two divisions- the bonded and the unbonded. There are different blends of portland cement, different aggregates and polymer resins with polymer-modified additives in each product. Depending on the manufacturer, the overlay products vary in the mixture and proprietary blends. A well-designed and constructed concrete overlay floor provides excellent performance, in many cases extending the life of the floor surface for years. It could be colored or cementitious based. Concrete overlay is done over existing concrete floors for repair and decorative reasons.
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