Most associate overlays and microtoppings with restoration, but they can prove useful in new construction applications as well. Decorative concrete installation may not be possible due to structural requirements, scheduling, or other complications. When this happens, it may be possible to come in a little later and use an overlay to get the same look.
In this video, John and Todd installed Brickform SC-60 Stampable Overlay in a new basement after the slab was poured and drywall hung. This way, stamping would not interfere with the other processes. Here are the steps they followed:
Clean and prepare the surface with Brickform E-Etch. The original installers did not hard trowel the concrete, probably anticipating the Stampable Overlay. This left a good profile for the overlay. Neutralize with Brickform Neutra Clean and scrub with a rotary floor scrubber until contaminants have been removed. Rinse with clean water.
Fill in control joints. This provides an even surface for more consistent curing later on. Use a high quality epoxy. Broadcast silica sand in the epoxy to ensure proper bonding. Make note of the control joint locations as you will likely want to re-cut them after the overlay has cured.
Prime the profiled and prepared surface with Brickform Triple Seven Bond Coat for optimal adhesion. View the product TIS for application instructions.
Mix the Stampable Overlay according to the instruction in the TIS. Start by mixing the Brickform Overlay Liquid Color of your choice with water. Then add the powder component and mix thoroughly. Use Brickform Turtle Set to extend pot-life in hot or dry conditions.
Apply the Stampable Overlay. Use a gauge rake to achieve a consistent, pre-determined depth. Close rake-marks with a rubber squeegee, fresno, or hand trowel. John used a rubber squeegee in this video, which is what he generally recommends. Do not overwork the product because this will cause blistering.
Let the material set, or cure, until it is spongy and does not stick to your finger when placed on the surface with moderate pressure.
Begin stamping by applying Brickform Liquid Release to your texturing tools and the Stampable Overlay just ahead of work. Place your tools and apply the appropriate amount of pressure. Avoid moving or dragging stamps after they have been placed. Always make sure you know how the stamps go together before you begin stamping. Never trowel in the liquid release.
If you must stop work for an extended amount of time, stop stamping, leave the tool in place, and scrape away excess material. Then you may remove the tool.
Allow the material to cure for 24 hours. Use a masonry rub brick, chisel, and other hand tools to detail the surface and remove minor imperfections. Vacuum and clean up any dust or debris. Use a mild detergent to remove liquid release residue. Small details like this are what separate good jobs from great jobs.
For best appearances, add secondary color using Brickform Antique-It, Blush Tone Acid Stain, ARTesian Water Based Stain, or Pro-Dye Plus. John and Todd sprayed ARTesian Stain and applied it to mimic aged wood.
Apply the best Brickform sealer for your application. In this case, John and Todd used Brickform Gem Seal 700. When possible, apply Brickform Premium Acrylic Floor Finish as a sacrificial coating for interior applications.
This article is a brief overview. Always make sure to fully read and understand product literature for EVERY product you plan on using before you begin work. When possible, create samples using the exact products and techniques you plan on using. If you are interested in learning about these processes, attend Brickform Training. Ask your local Brickform distributor or follow this link for dates and details.