Covacrete Resurfacing Process

Concrete Resurfacing

Here I’m going to go through the nuts and bolts of a typical Decorative Concrete Resurfacing Project (Covacrete). The following articles consists of what I consider to be base standard with your application of the process when you choose Walker Concreting & Resurfacing to complete you project.

First things first. Typically, when we get to your concrete that you require to be resurfaced, lets be honest, it’s usually in pretty bad shape. It’s either a dirty old moulded surface, or has been previously sealed or painted in it’s history and all these things will hinder the bonding of our new Covacrete application.

Majority of the time we will complete either a heavy or light surface grind of your concrete to remove all these foreign properties and make sure that our new Covacrete product is bonding directly to the natural concrete surface. This is completed with a walk behind floor grinder and also a 9″ hand grinder for the tight to reach corners.

Surface Grinding

Concrete Floor Grinding

Next up is giving your concrete surface a nice, heavy bath in hydrochloric acid.

Using approximately 3-4 Liters in a 10 Liter watering can, your concrete surface is covered thoroughly with the acid and it is allowed to soak right into the concrete and all the pigments on the surface.

This helps to break up any remaining unwanted particles on the surface, but also lets us eat into the surface finding a more appealing structure to adhere our Covacrete to when applying it.

Acid Bath

Acid

After the hydrochloric acid has been applied and allowed to soak in for several minutes, we then attack the surface with a high powered gurnei to further remove anything we don’t want on that surface.

The combination of acid and pressure washing loosens up the surface particles even more so and again helps us get down to the bare bones of the concrete for a better Covacrete application.

Pressure Washing

Pressure Washing

Next we take care of the cracks. Cracks repair varies depending on what type of cracking it is, I’ve explained all this in another article, I really should link it here, but you’ll just have to do some research yourself :).

For standard hairline cracks that are non structural, then we simply go about grinding out these cracks thoroughly, then applying our “secret sauce” crack repair product to them. The idea behind this is that your concrete has already tensioned and cracked along it’s weak point and the crack is being held together by the steel. So if we expand that crack through grinding, then fill the area, then technically the crack should not pull apart any farther and not come back through.

This of course is not a fool proof system, although we do our best, and most of the time succeed, these little buggers do sometimes come back through again, but, typically only a hairline crack will show.

If you have structural cracking, then realistically your only option is to remove sections of your concrete where the problem is, and replace that section with new concrete before applying any Covacrete.

Crack Repairing

Crack Repair

Covacrete Application

Base Coating
After priming your newly cleaned surface, our next step for your sexy new concrete surface is applying our base coating. This stage of the application will allow us to level all of your surface smooth and give us a good initial coating of our products. Covacrete comes standard in “Ivory” colour, but there is the option of adding in a colour to your base coating. Your base coat will be visible as the “grout lines” if you will in your taped patterning. Colouring the base coat works really well when applying a lighter colour top coating of Covacrete and using a dark base to make those lines contrast well.

Taped Patterning
From here we apply our taped patterning to your hearts desire. You might decide you want diamond or tiled patterns, maybe borders, tile inserts or full showpiece compass’s installed. The world is your oyster here and we love getting a little creative with our patterns.

Top Coatings
After all our patterns have been completed, we then proceed with the fun stuff. Air compressor pumped up and hopper oiled, we begin spraying on your top coatings of Covacrete in the colour / colours that you have chosen. The top coatings are applied with a minimum of 2 coatings, with the initial run being more of a “covering” application and the later coatings for the even application and good looks.

Decorative Patterning
To finish up the spraying we then apply your decorative aspect to add contrast and depth to your installation. You might choose to simply apply a few different colour flecks to the surface or go all out with Sandstone Swirls and hand done patching. Obviously pricing matches the level of detailing we go into, but as always, we’re here to give our clients what they require and consider ourselves top of the game in the artistic side of things.

Finishing Up
From here, after all the spraying has been completed, we then rip off all the taping that we applied earlier, remove all the tape from your walls, blow off the surface, then proceed to apply 2 applications of high grade acrylic sealer to protect your new surface and give it a lovely shine in the process.

If you’re interested in our services for concrete resurfacing, give us a call soon about your next project. You’ll love what we have to offer and our professionalism and service is beyond reproach.

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