Not all concrete resurfacing products are created equal. Picking the wrong material for your floor's condition, thickness needs, or usage demands can lead to cracks, delamination, poor wear resistance, or total failure. In this guide, we'll break down exactly how to choose the right resurfacing product for your concrete floor — so you get a durable, attractive finish that stands the test of time.
Start by inspecting the floor carefully. Are there cracks? Spalls? Pits? Laitance? Is the surface heavily worn or relatively intact? Minor cosmetic defects can be covered by thin overlays, but deep damage may require thicker resurfacing systems or patching before any coating. The worse the floor condition, the more robust (and often thicker) the resurfacing system must be to create a durable repair.
Thin polymer overlays are typically 2–10mm thick. Self-levelling underlayments may range from 5–25mm. Screeds or bonded toppings can be 25mm+ thick. Thickness impacts cost, drying time, and durability. Thin coats are faster and cheaper but won't correct major flatness or structural problems. Heavier duty areas or badly damaged slabs usually require thicker build-ups for strength and longevity.
Think about what the floor will be exposed to once complete. Light foot traffic? Heavy pedestrian areas? Forklift or vehicle traffic? Food processing, chemical exposure, or industrial loading? Lighter-duty decorative overlays are fine for patios and showrooms but will fail under warehouse forklifts. Pick a resurfacer with the compression strength, abrasion resistance, and toughness that matches your environment.
Different resurfacing systems give different looks. Thin polymer overlays create smooth, decorative finishes. Microcements offer seamless, modern aesthetics. Heavy bonded screeds give a more natural, industrial concrete look. Decide if you want a plain grey floor, a polished effect, a decorative coloured overlay, or a textured surface for slip resistance. Aesthetic goals influence which system is most appropriate for your project.
Moisture problems are a leading cause of overlay failures. Test the concrete slab for relative humidity (RH) or moisture vapor emissions rate (MVER) before choosing a product. Some resurfacers require very low moisture levels; others are more moisture-tolerant. If moisture levels are high, you may need moisture-mitigating primers or vapor barriers before resurfacing to prevent blistering, debonding, or discolouration.
Always use resurfacing systems where primers, overlays, sealers, and repairs are tested to work together by the manufacturer. Mixing brands or incompatible products risks bond failures and voids warranties. A single-manufacturer system usually guarantees compatibility, simplifies troubleshooting, and qualifies you for better technical support if needed down the line.
For challenging projects — like repairing factory floors, airport hangars, food-grade slabs, or historic restorations — always get professional input before picking a resurfacing material. Specialized conditions may demand high-build mortars, chemical-resistant toppings, or ultra-flexible overlays. Getting it wrong costs thousands. A professional contractor or manufacturer rep can steer you to the right product for tricky floors.
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