Concrete Library

Masking and Stencils

Introduction

Overlays and Resurfacing

Skim coats

Spray Toppings

Stamp Overlays

Introduction

Whether you’re creating a new floor design or improving upon an existing surface, concrete Stenciling and patterns are a great way of standing out in a crowd. Stencil patterns can be used to create elegant borders, inlayed logos, stunning entranceways or simply create a grout line to mimic, tile, stone or wood. They can be used on walls, floors, or ceilings, indoors and out.

Stencils and masking is a technique of adding a pattern or design by masking off and area then applying a color or finish to the remaining surface. Once the masking is removed the original finish shows through and the colored area is added to or layered onto the surface, sometimes creating a new color and even a relief or texture to the unmasked area.

Stenciling concrete is an inexpensive way to add style to an otherwise utilitarian floor. Stencils may be used to make an outdoor patio surface look like brick or stone, or incorporate elaborate patterns onto indoor flooring; the process is essentially the same. Field forms are laid down over a newly poured concrete surface or an overlay, then the exposed concrete is dyed to the desired colors and finally sealed for a long-lasting finish.

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Overlays and Resurfacing

Decorative concrete overlays are comprised of many different chemical additives but generally use basic elements like, cement, aggregate (usually in the form of sand, silica, or calcium carbonate) and a polymer.

The polymer is the secret. Polymers can come in dry or liquid form. Dry polymers are often blended and already in the package when purchased, whereas liquid polymers must be added as an ingredient at the time of blending or mixing on site. Polymers are simply an acrylic type glue that helps these thin resurfacing systems bond to their substrate, giving them added strength, flexibility and generally improving their performance.

Additional chemical additives (sometimes as many as 12-15) are added to these thin resurfacing systems to help control the material and make it do what it is supposed to, including; leveling, quick drying, anti-foaming, slow drying(set retarder), etc.

By having access to numerous formulations, color options and finish techniques, a skilled professional can mold, color, add texture, and blend these elements to create hundreds of outcomes.

These are the basic types of decorative concrete overlays & resurfacing systems.

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Skim coats

Also referred to as: Squeegee coat, scratch coat, broom coat, micro topping.

All are similar in that they are designed to resurface using a very thin layer of cement. These skim coats are capable of resurfacing and covering floors, walls and accessories with a thin layer of polymer modified cement that can go down to 1/16th of an inch and usually no more than 1/8th inch.They are designed to resurface and add a new and refreshing canvas to the substrate they are applied to. A micro topping is also an ideal way for the addition of integral or topical colorations. Micro-toppings cover dull, drab, or damaged concrete surfaces that are otherwise poor candidates for the application of concrete stains or coloration or are used if a required color or texture cannot be achieved with a standard concrete substrate. They are often used on an overall smooth or level surface requiring only minor level adjustments or repairs due to their thin application.

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Spray Toppings

Also referred to as: spray deck, splatter coat, spray-crete, spray & knockdown finish.

Spray toppings are in the same family as skim coats or micro-toppings and often are the exact same product with a variation of their application. Following the same rules and application thickness as Skim coats. Spray toppings are mixed with water or liquid polymer and then filled into a hopper gun, the material is then shot out or sprayed onto the surface requiring decorating or covering. The material is left in small splatter points on the surface and is often ‘knocked-down’ with a trowel or finishing tool to flatten and spread it slightly. This finish is often found in exterior decks, pool surrounds, driveways and walkways.

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Stamp Overlays

Also referred to as: Stamped, imprinted or textured overlays.

These systems are designed to resurface concrete using a thin layer of cement. Stamp overlay systems are capable of resurfacing and covering floors, walls and accessories with a thin layer of polymer modified cement usually averaging between 1/4" -1/2" inch thick. The thickness is determined by the stamp or imprinting pattern that will be used. Stamp Overlays are designed to set-up or dry slowly to allow the craftsman the time necessary to "stamp or imprint" a pattern in to the setting topping system.

Hundreds of patterns are available and most often resemble rock, tile slate and other natural surfaces.

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