Concrete resurfacing products are sensitive materials — mix them wrong or pour poorly and you'll end up with weak spots, cracks, lumps, or ugly surfaces. Getting the mix right, working within pot life, and pouring evenly is critical for a strong, smooth, and professional result. In this guide, we'll walk you through exactly how to mix and pour a concrete resurfacer the right way.
Once you start mixing, time is critical. Before you even open the resurfacer bag, have all tools ready: large mixing buckets, clean water, slow-speed drill with a paddle mixer, trowels, squeegees, floats, and finishing tools. Have backup buckets prefilled with water if possible. Lay out your work area so you can mix, pour, and finish without rushing back and forth. Clear the slab of debris, dust, and standing water before beginning.
Water ratios are crucial for resurfacing products. Adding too much water weakens strength dramatically and increases shrinkage cracking. Too little water causes dry mix problems and poor flow. Measure the water exactly using clean measuring containers — don't guess. Follow the manufacturer's water-to-bag ratio precisely (e.g., 4.0–4.2 litres per 25kg bag). If temperatures are high, use cool water to extend working time slightly.
Never pour water into powder — it traps air and creates dry pockets. Instead, add the dry resurfacer powder slowly into the premeasured water while mixing at low speed. Use a high-torque paddle mixer and a large clean bucket. Mix for 2–4 minutes until smooth and lump-free. Avoid whipping air into the mix — keep the drill at a slow consistent speed. Let the mixed slurry sit ("slake") for 2–3 minutes if specified, then remix lightly before pouring.
Resurfacers have short pot lives — often 20–30 minutes maximum after mixing. After that, the material starts setting and weakens if disturbed. Never try to "retemper" resurfacer by adding more water after it stiffens. Mix small batches you can pour and finish within working time. For large areas, use multiple mixing crews and stagger batch mixing. Watch for signs of early stiffening and discard any batch past its workable life.
Pour mixed resurfacer onto the slab immediately after remixing. Work in ribbons or strips across the floor. Spread with a gauge rake, smoothing trowel, or squeegee depending on desired thickness. Keep a wet edge moving — don't allow material to dry between pours. Blend batches smoothly together to avoid cold joints or visible seams. Work into corners and along walls carefully to avoid thin edges breaking later.
After pouring, use a finishing tool (smoother, squeegee, or trowel) to level the resurfacer evenly. Lightly back-roll or broom if required to match the product’s finish instructions. Don't overwork the surface — excessive finishing causes air entrapment or reduces surface smoothness. Keep movements fluid and steady. Minor trowel marks often disappear as resurfacer self-levels during setting if you move efficiently and correctly.
Once pouring and finishing are complete, protect the slab. Block off foot traffic, avoid early drying by controlling temperature and humidity, and use curing membranes if recommended. Most resurfacers reach light foot traffic strength within 24 hours but full curing (for heavy loads) may take 3–7 days. Avoid aggressive cleaning, grinding, or sealing too early — follow the manufacturer’s cure schedule for best results.
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