Drain covers, expansion joints, and structural edges are some of the trickiest parts of resurfacing a concrete floor or slab. Sloppy work around these features can lead to trip hazards, cracking, water pooling, or ugly finish defects. Done right, careful resurfacing around covers and joints preserves performance, drainage, and a crisp, professional look. In this guide, we’ll show you how to do it properly, step-by-step.
Cover all drain grates, covers, or access ports before resurfacing. Use duct tape, plastic sheeting, or fitted plywood templates to protect metalwork and prevent overlay from bonding to moving parts. If the drain is removable, lift it out until after resurfacing. Neat masking around fixed covers ensures clean edges later and avoids concrete buildup that restricts drainage flow.
Expansion joints allow slabs to expand and contract without cracking. Never fill them in or overlay across them rigidly. Instead, resurface up to the joint edge carefully and maintain the gap. You can tape off joints before pouring to keep them clean or install flexible joint fillers afterward if desired. If you overlay across joints, you must cut matching joints back into the new surface immediately after curing.
Work carefully with edge trowels or margin trowels when resurfacing close to drains or joints. Pull material tightly up to the edge without flooding or overlapping the gap. Keep edges crisp, clean, and free of buildup. Smoothing and feathering the resurfacer neatly up to the drain collar or joint perimeter prevents weak edges that chip or crack later under load or weathering.
Always work outward from complex features like drains first. This allows you to focus on critical edges while the resurfacer is fresh and highly workable. If you leave drains or joints until last, the overlay may already be setting, making it much harder to achieve clean detailing. Good sequencing makes finishing faster, easier, and much more professional looking around these tricky areas.
Once the resurfacer has started to set but is still green (typically 30–90 minutes depending on conditions), carefully remove any masking from drain covers or joints. Doing it too early can damage the fresh surface; waiting too long makes it harder to pull tape or coverings cleanly. Use a sharp utility knife to lightly score edges if needed to lift tape cleanly without tearing.
Pay special attention to curing around drains and joints — thin edges dry out faster and are more prone to cracking. Cover or mist regularly to prevent edge shrinkage. Once cured, apply high-quality sealers into recessed joint gaps and along edges to protect against water ingress, freeze-thaw damage, and mechanical wear. Good sealing extends the lifespan of your resurfaced slab dramatically.
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