Avoiding Concrete Coating Failures

One of the most common reasons for concrete coating failure is inadequate surface preparation. The goal is to achieve a firm mechanical bond, which is possible with a clean, dry, and defect-free concrete surface. Without proper surface preparation, failure is imminent, which is a huge waste of time and money.

Important Factors

Manufacturer’s Recommendations – To avoid concrete coating failure and prevent the risk of voiding a warranty, recommendations provided by the manufacturer must be read and followed. By having work performed by a reputable company, like Concrete Coatings Unlimited, this is never an issue.

Surface Condition Requirements – Project specifications for preparing the surface, along with required roughness, need to be identified and understood. These specifications include things like dryness, strength, and uniformity, but they also specify just how rough the surface should be prior to applying the concrete coating.

Preconstruction Meeting – To avoid the failure of a concrete coating, a preconstruction meeting between the architect, project engineer, Concrete Coatings Unlimited professional, and the home or business owner takes place. Discussions cover things like surface preparation, equipment selection, coating requirements, cleaning techniques, surface profile, product selection, and schedules, thereby ensuring everyone has a clear understanding of expectations and responsibilities.

Surface Preparation – Before a protective or decorative concrete coating is applied, the surface is properly cleaned and profiled. To remove elastomeric concrete coatings, a special machine that removes flexible and thick materials is used. By eliminating all contaminants, including dirt, debris, dust, laitance, grease/oil, efflorescence, mortar splatter, sealers, curing agents, high spots, and surface irregularities, failure is avoided. Dry grinding or shotblasting offers a quick and easy solution, but for areas without alternative cleaning methods, acid etching may be highly effective.

Moisture Testing – Prior to applying any concrete coating, a test is performed to identify the presence of moisture. If moisture content in the concrete is too high, failure may occur.

Repair Surface Defects – Using a grinder, chipper, jackhammer, or other equipment, protrusions from concrete walls are eliminated. In addition, any unsound concrete is removed and surface defects, such as spalls, cracks, holes, and honeycombed areas, are patched.

Working with Metallic Concrete Coatings

With an exotic and warm aesthetic, metallic concrete coatings are used in commercial and residential properties. Because the installation process is similar to a traditional overlay or epoxy coating, the application of metallic concrete coatings is relatively easy for someone with decorative concrete experience. However, for superior results, you should leave the work to the professionals at Concrete Coatings Unlimited.

Important Information about Metallic Concrete Coatings

Application Options – With almost limitless possibilities, metallic concrete coatings are a popular choice in homes, as well as businesses. These surfaces are commonly seen in foyers, kitchens, hotel lobbies, nightclubs, restaurants, retail stores, and hair salons, among others. Being vibrant, contemporary, and unique, these coatings create a “wow” factor.

Surface Preparation – Before metallic concrete coatings are applied, the surface must be dry; clean; and void of oil, grease, dust, dirt, debris, foreign matter, and curing agents to ensure proper adhesion. To promote strong bonding, the concrete surface is mechanically abraded. To prevent a distorted look, the surface should be perfectly leveled.

Primer Application – To improve coating adhesion and provide a solid background of color, priming the concrete surface is strongly recommended. Based on the desired aesthetic, the color of the primer is varied.

Mixing and Application – By adding pigments separately, the experts with Concrete Coatings Unlimited produce unique color combinations and effects. Since epoxy coatings flow and self-level, they are spread in a random back-and-forth motion using a roller, trowel, or squeegee. For a glossier and more scuff-resistant surface, a clear topcoat is applied following curing.

Special Effects – Using different techniques and tools, all types of special effects with metallic concrete coatings are possible. For instance, to disperse pigmentation, denatured alcohol is sprayed on the surface soon after applying the coating. Using the right equipment, swirls of color can be created over select surface areas.

Interior and Exterior Surfaces – Typically, metallic concrete coatings are used indoors since being subjected to harsh UV rays may cause discoloration. However, for high-traffic areas, concrete floors with metallic pigmentation are ideal.

Choosing Concrete Coatings to Meet Various Exposure Requirements

Instead of replacing and patching concrete that has been damaged by exposure to the elements, choose a coating that will protect and increase the longevity of the concrete. Elements such as traffic volume, climate, and other various forms of exposure make concrete chip, break, and become weakened. Here are some reasons to choose concrete coatings that fit your exposure requirements.

Exposure to Water - Concrete absorbs moisture on the ground and in the air according to the relative humidity (RH) of the climate. Novolac epoxy or reactive acrylic would be a good choice to avoid any excess water absorption. Concrete naturally has moisture, but too much can lead to damage.

Exposure to Heat - Furan resin coatings are effective in warmer environments.

Exposure to Cold - More rigid coatings, like epoxies and vinyl esters, are more resistant to abrasive wear, such as from snow and ice.

Exposure to Chemicals - Cross-linking density and other factors are used to determine chemical resistance. Acid rain, industrial chemicals, and chemicals already present in the concrete are also factored in. In this case, novolac epoxies and bisphenol epoxy resins are more chemically resistant than other coatings. Chemical resistance declines as elongation and flexibility increase.

Exposure to Elements - Outdoor concrete coatings must also be resistant to UV (ultraviolet) light. Epoxies are not a good choice for exterior concrete, as UV light breaks them down. Instead, choose a polyurethane, polysiloxane, or acrylic coating formulation.

It is important to consider all factors of exposure when choosing the correct coating. Concrete Coatings Unlimited can help evaluate each situation and provide the best coating. Abrasion, erosion, high and/or low temperatures, and physical wear are all factors to consider. A concrete coating will protect the concrete and lead it to a longer life under whatever conditions are present. Choosing the wrong coating can lead to stress cracks, loss of adhesion, and other defects, so it is important to work with the professionals at Concrete Coatings Unlimited.

Thick vs Thin Film Systems

Choosing the correct concrete coating system is critical to the life and durability of the coating and the concrete itself. One factor to consider when choosing a coating system is thickness.

Thin-Film Coatings -

There are no industry-wide standards for measuring coating thickness, but generally, a thin-film coating is not reinforced and is applied by airless or conventional spray, or by brush or roller. One example is acrylic coatings, which are used for color and aesthetic appeal. Textured acrylic coatings, or acrylic elastomers, are efficient for outside use, while epoxies or polyurethanes are adequate for indoor use. Although not a critical defect, some pinholes may occur in thin-film coatings, which can be fixed with epoxies, polyurethanes, vinyl esters, and other linings.

Thick-Film Coatings -

A thick-film coating is generally reinforced or heavily filled and is applied by spray, trowel, specialized spray equipment, or other means. Thick-film coatings are good for industry use and heavy wear. They are primarily used for extra protection and primary and secondary containment. These concrete coating systems have a low permeability and strong chemical resistance. Silica aggregates are most common in thick-film coatings. Metallic or carbon fillers can be added to help conductivity, while fiberglass can be added to reinforce the coating. With thick-film coatings, there is a risk of shrinkage during solvent evaporation. Using multiple coats, reinforcement, and other means can help decrease shrinkage. A pigment can be added to the concrete coating in order to increase color, gloss, and texture in both thick-film coatings and thin-film coatings.

Concrete Coatings Unlimited has knowledgeable experts to ensure the most effective concrete coating system is installed. Many factors, such as traffic, exposure, and resistance, are important to consider when choosing a concrete coating. Thin-film coatings are good for indoor and aesthetics, while thick-film coatings are good for an industrial or harsh outdoor setting.

How to Properly Care for Polished Concrete

A polished concrete floor is a beautiful and durable choice of flooring. It’s also practical since it doesn’t need too much maintenance, unlike other forms of concrete. However, it needs to be properly taken care of in order to keep its glossy look. This type of flooring is a popular choice in commercial buildings due to its low-maintenance properties and its versatility when it comes to designs and patterns.

The focus of maintaining polished concrete revolves around keeping the surface from being abraded and scratched by dirt, grime, and other particles that can damage the surface of the polish. The key to this is daily dust mopping using a soft microfiber pad to take off the soil particles and dirt accumulated throughout the day.

A weekly mopping using clean water and mops is also recommended, especially when there is a lot of food traffic. When cleaning using this method, a pH-neutral cleaner works best. An acid or alkaline solution will react to the polish and may dull the appearance of the floor. Wet mopping using a solution that allows dirt to be suspended will be the best option for polished concrete, since using pure water will leave too much dirt behind. When using a cleaning solution, time should be given for it to work on the contaminants before wiping it off, but not too much time that the solution will dry out on the floor. The application of an anti-slip conditioner may be added during routine cleaning, which would be beneficial for safety purposes, especially in commercial areas with high foot traffic.

Daily accidents, like spills, should be cleaned up as soon as possible to avoid absorption, which discolors and dulls the shine of the concrete. If major damage occurs and repair to polished concrete is required, Concrete Coatings Unlimited restores old and damaged concrete, and we can add a clean polished finish.

The Correct Way to Apply Acid Stain to Concrete

Applying an acid stain to a slab of concrete flooring is tricky. Unlike paint, which can be removed, once the stain sets, there is no way to reverse the process because the concrete material itself reacts with the acid stain. The right way to do acid stained concrete can be divided into four parts: preparing the floor, applying the stain, removing the stain residue, and sealing the concrete.

When preparing any surface for acid staining, the removal of any possible contaminants is important. Contaminants may interfere with the reaction process, leading to multiple undesirable areas on the final product. Make sure all other areas that should not be stained are masked off, because accidental staining can lead to permanent results.

Putting on the acid stain requires special equipment that is resistant to acid, like acid-resistant brushes and spray materials. Testing a small area is also recommended to make sure that the concentration of the stain is enough to produce the desired color. There are also recommendations for certain cure times to a concrete slab before applying a concrete acid stain. Rinsing off the stain residue comes next, involving several applications of water and neutral cleaner like water with baking soda to aid in acid neutralization. The removal of residue also accompanies scrubbing the area using a machine and the use of a wet vacuum to make sure that all residue is removed.

A sealer is used to protect the acid stained concrete after the floor is cleaned and all possible contaminants, dirt, and grime are removed. The sealer chosen should be compatible with the acid used in the process to avoid reactions that can damage the work. Concrete Coatings Unlimited provides services for working on acid stained concrete floors that will make the process hassle-free, giving your floor a beautiful finish.

Reasons That Stained Basement Floors Make Sense

The basements in new homes aren’t just made to become storage spaces anymore but have the potential to become something more. Having a finished basement can create the perfect atmosphere for additional living space. It can increase the return on investment of the house since the area can be used for various purposes, depending on what kind of space the homeowner wants.

A good idea for transforming your basement space is a game room or entertainment den to minimize the noise level in the higher floors. Natural insulation is provided by the earth, which makes the basement cooler in summer and warmer in winter. This makes the basement an ideal space for spending a lot of time in. Another idea is to use it as a laundry room to free up space above the basement for something else.

The earthy tones of stained basement floors give the space a natural, yet sophisticated-looking design. They can create warm-looking spaces to upgrade the room into a living space. Your floor can become a striking feature of the room, which will automatically make the room more inviting.

Covering up concrete in the basement using a carpet can be a bad idea, especially in humid areas, where moisture can accumulate under the carpet. This may not be visible, but it is enough to promote mold growth. Staining and sealing basement floors reduce the moisture content that may add to the formation of mold and other contaminants, which can become a source of allergens.

Staining concrete can hide minor cracks that are not caused by structural problems and can create a vintage feel. Small cracks can be left exposed, if desired, since they can add a texture and rustic charm.

With Concrete Coatings Unlimited’s concrete staining services, basement floors don’t have to look boring. We can turn your basement floor into a functional, durable, stained concrete masterpiece.

What Is the Process for Concrete Staining?

Stained finishes make concrete look elegant, and its rich color lasts for years. The design possibilities are only limited by your imagination, as stains can be applied to whole floors or used in intricate patterns, making the space look exceptional.

Surface Preparation

The popular methods of preparing a surface for staining include mechanical grinding or using a specially formulated cleaner. This first step needs to be done on any surface because it will have a big impact on the finished product. Unlike using opaque colors that can hide a lot of flaws in the existing concrete, staining is translucent and will still show minor discolorations and imperfections.

Masking off the Surrounding Area

When staining concrete, it is best to make sure that the application is only done on the intended area. Covering off all surrounding surfaces, like walls and frames, will prevent unsightly permanent stain reactions.

Stain Application

Stains require dilution with water, and each manufacturer may recommend specific ratios depending on the desired effect. The first coat should be applied using a sprayer, or a sponge if a detailed pattern is to be followed. The first layer should be thoroughly dry before applying additional coats. The number of layers would depend on the intensity of stain color preferred.

Neutralization and Removal of Residue

When using acid stains, neutralization is an important part of the process in order to allow the sealant to attach to the concrete. Water-based stains do not require this process, but both types of stains require a thorough wash before sealing.

Staining a color sample on-site will also determine the concrete’s reaction to the stain. It is best to do a sample stain on areas that will be covered with appliances or are hidden from sight. Concrete Coatings Unlimited’s experts can restore your concrete and finish it off with a beautiful stain, making any room or outside area look warm and inviting.