Considering Concrete Floors On Second Floor?

If you have a typical plywood second story and you are considering having concrete floors installed, there are a few things to consider.

First you want to make sure there are no extreme low spots in the plywood. If there are and if it is a older house you might need to reinforce the floor joist the plywood is sitting on. You probably should consider this with any other ceramic or stone floor also. The weight of concrete floors is about the same if not less then installing ceramic tile and hardi-board. So if second story in your house is qualified to accept ceramic tile on the second story you will be ok with having concrete floors.

The next thing is you should not use self-leveling overlay material to get your concrete floors. This material is brittle and will crack excessively when the plywood moves a little bit. If you need guidlines on how to install concrete floors on a second story follow the link http://mvlconcrete.com/blog/upstairs-concrete-overlay-acid-stained/ . If seen many people try to use self-leveling material and then they have a huge mess to clean up when it fails.

The first concrete floor we did on a second story was about 5 years ago, and so far there has not been any major cracking. There are a few hairline cracks that are not opened up; you mainly see the crack because of the color on the surface. So don’t expect the concrete floors to have minor cracking.

If you have any questions or are looking for someone to install concrete on the second story of your house please feel free to email me at mvlconcrete@yahoo.com or call 210-422-6116.

 

Modern Concrete Floors

This week we had a job that consisted of removing tile and then polishing the concrete underneath the tile to create a modern concrete floor. When we started removing the tile floor we realized the tile was sitting on a mud-base that was 2″ thick. Instead of removing the tile and the mud-base we prepped the tiles to receive a self-leveling cement topping. After we poured the new concrete floor we sealed the floor with a water base sealer.

Tile Prepped For Concrete Overlay

Tile Prepped For Concrete Overlay

Concrete Resurfacing Modern Concrete

Concrete Resurfacing Modern Concrete

 

 

 

 

 

Resurfacing Over Mud-Base For Wood Floors

This week we prepared a mud-base for wood flooring. A mud-base is a cement-sand mixture that is fairly soft and brittle. The mud-base was placed because the home builder did not build the front entrance of the house higher than the outside patio, so to bring the floor up in the house they placed a mud-base and then tile.

During the tile removal the mud-base got chipped up in some areas as well. There were a lot of gouges in the mud-base that had to be filled and also leveled. The homeowner had two options he could either remove the 2 1/2″ of mud-base and place concrete or repair the mud-base for the wood floors.

They decided to repair the mud-base. To do this we had to coat the entire surface with an epoxy to make sure the mud-base would not break apart, the epoxy also helps the special repair mortars bond properly. After applying the repair mortar to fill all of the gouges we applied a self-leveling underlayment to finish off the repair.

Take a look at the video below of the job:

Applying Resurfacing Cement On Saltillo & Then Staining

A lot of times Saltillo tile is applied on a mud base that can be 2-3 inches thick. The Saltillo tile can be removed along with the mud base and then re-poured with concrete, but this can get costly. The alternative would be to apply a resurfacing cement right on top of the Saltillo tile. This process is the most cost affective way and when done right can last a lifetime.

The first step would be to grind the Saltillo tile down to make them all even.

Grinding Saltillo Tile

Grinding Saltillo Tile

Saltillo Tile Ground Down

Saltillo Tile Ground Down

After the Saltillo tile is ground down, the next step would be to apply a epoxy primer with sand broadcasted in it.

Saltillo Primed With Epoxy

Saltillo Primed With Epoxy

Once the tiles are primed, we apply a special repair mortar to help fill low spots in the floor.

 

Saltillo Tile Grouted

Saltillo Tile Grouted

After the floor has been grouted, we apply the decorative overlay and then we can stain the concrete.

Concrete Resurfacing

Concrete Resurfacing

After Resurfaced & Stained

After Resurfaced & Stained

 

 

 

 

 

Concrete Spalling

Concrete spalling is often caused by improperly placing the rebar or wire mesh when pouring the concrete. If the rebar is to close to the top of the concrete slab, as water soaks into the concrete it will start to corrode the rebar. This will cause the rebar to expand, weakening the concrete above the piece of rebar.

Concrete Spalling

Concrete Spalling

If you look left of the blue line, you will notice there is a crack starting to form, this crack is right above a piece of rebar corroding. When we tap the concrete with a hammer we hear a hollow sound. To repair this we have to break out all the loose concrete, cut 90 degree edges, pressure wash & clean the rebar, and apply a non-shrink repair mortar.

Spalling Concrete Cause By Corroding Rebar

Spalling Concrete Cause By Corroding Rebar

Right after we start to chip out the bad concrete a piece of rebar started to stick out. This was the main cause of the damaged concrete. It is very important to place rebar and wire mesh at the proper place when pouring concrete.

Spalled Concrete Area Chiseled Out

Spalled Concrete Area Chiseled Out

Concrete Resurfaced & Stained

Concrete Resurfaced & Stained

After the concrete was chiseled out we applied Miracote RM 2 and then finished of the spalled concrete repair by resurfacing the area with Miracote MPC, and then applied a grey stain to match the bricks.

Concrete Resurfacing

When concrete is in very bad condition cosmetically, the easiest way to repair the concrete is by resurfacing it. Concrete resurfacing involves: grinding the concrete to acheive a proper surface profile so the material will bond to the existing concrete, we then apply a base coat, and then a smooth coat or another base coat (depending if you want it rough or smooth).

The patio we worked on this week had a lot of things wrong with it. The first thing was it was very rough with a lot of pits that had to be repaired. We then ground the concrete to prepare it for the resurfacing material and to even out the construction joint where the two slabs butted up to each other. After resurfacing the concrete, we applied a stain and sealed the concrete. Once the patio was sealed we came back and re-scored the construction joint and filled with a self-leveling polyurethane.

Before Resurfacing & Staining

Before Resurfacing & Staining

Resurfacing Concrete

Resurfacing Concrete

After Resurfacing & Staining

After Resurfacing & Staining

After Staining With Mocha

After Staining With Mocha

 

 

 

Concrete Restoration

Concrete restoration is the process of restoring concrete to be functional again and pleasing to the eye. Processes used to restore concrete are:

  • Resurfacing
  • Sealing joints
  • Crack sealing
  • Concrete grinding
  • Removing unsound concrete (spalled areas)
  • Pressure washing

Concrete restoring is a cost affective way to fix concrete without tearing out and re-pouring. Concrete can be restored anywhere there are problems; whether it is a concrete driveway, sidewalk, tilt-up walls, stucco walls, concrete walls, parking garages, curbs, and parking lots.

If you have any problems with your concrete such as: cracks in the concrete, concrete spalling, concrete discoloration, and concrete joints that are un-even; give us a call at (210) 422-6116 for a free consultation.

Concrete Stairs Repaired & Resurfaced

Today we fixed some concrete stairs that had numerous areas that were spalling. We began repairing the concrete stairs by chiseling out the loose and hollow areas.

Spalled Areas on Concrete Stairs

Spalled Areas on Concrete Stairs

Chiseling Hollow Areas

Chiseling Hollow Areas in Concrete

After chiseling out all of the hollow areas we cleaned the surface with water and a brush and then applied a repair mortar to the spalled areas.

Spalled Areas Chiseled Out

Spalled Areas Chiseled Out

Applying Repair Mortar To Spalled Areas

Applying Repair Mortar To Spalled Areas

After Applying Repair Mortar

After Applying Repair Mortar

Once the repair mortar was hard, we resurfaced the whole stairs to blend it all in.

Before Concrete Stairs Repaired

Before Concrete Stairs Repaired

 

After Concrete Stairs Repaired

After Concrete Stairs Repaired

 

 

 

 

 

Resurfacing Concrete in San Antonio

Using special concrete overlay materials you can greatly enhance concrete that has been eroded away by the weather and de-icing salts. When resurfacing concrete you are just putting a very thin coat of cement that is mixed into a polymer. If the overlay goes on to thick it will actually crack and be weaker.

Below are some pictures of a job we just completed; the job consisted of a small piece of concrete that has been severely worn away, we cleaned the surface and then applied a coat of white overlay cement to help protect the concrete and enhance the look of the concrete. After resurfacing the concrete we will wait until it has cured and apply a sealer to further protect the concrete.

Eroded Concrete Before Resurfacing

Eroded Concrete Before Resurfacing

After Resurfacing The Concrete

After Resurfacing The Concrete

 

Concrete Resurfaced Stained & Sealed

This job consisted of removing glued down wood flooring, grinding Saltillo tile, grinding concrete, resurfacing an inclosed exposed aggregate patio, resurfacing the concrete and Saltillo tile to make a continuous floor, staining the concrete grey, and sealing the floor.

Before Removing Wood Floor

Before Removing Wood Floor

After Removing Glued Down Wood Flooring

After Removing Glued Down Wood Flooring

After Resurfacing Concrete

After Resurfacing Concrete

After Concrete Floor Stained & Sealed

After Concrete Floor Stained Grey & Sealed

Before Saltillo Tile Resurfaced

Before Saltillo Tile Resurfaced

After Saltillo Tile Resurfaced, Stained, & Sealed

After Saltillo Tile Resurfaced, Stained, & Sealed

Before Wood Floors Removed

Before Wood Floors Removed

Removing Glued Wood Floors

Removing Glued Wood Floors

Bedroom Resurfaced, Stained, & Sealed

Bedroom Resurfaced, Stained, & Sealed

Before Resurfacing Exposed Aggregate Concrete

Before Resurfacing Exposed Aggregate Concrete

After Exposed Aggregate Resurfaced, Stained & Sealed

After Exposed Aggregate Resurfaced, Stained & Sealed

Before Wood Floor Removed

Before Wood Floor Removed

After Living Room Resurfaced

After Living Room Resurfaced

After Living Room Stained & Sealed

After Living Room Stained & Sealed