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Re: Pouring concrete over concrete


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Posted by Billy NY on August 05, 2009 at 14:16:47 from (74.67.3.238):

In Reply to: Pouring concrete over concrete posted by e on August 04, 2009 at 09:49:19:

I think there are 3 ways to look at this, place a new slab over the existing, thick enough say 4" so no trouble with reinforcing, fracturing and whether you want to bond the new slab to the old, hard to say how it could react, as things expand/contract. Epoxy can be used to bond new to old. Concrete has capillaries and will absorb moisture, water etc. when it freezes then thaws, things happen, so a thin layer is subject to freeze thaw, you don't want moisture in between the layers if in a cold climate, it will spall and come apart eventually.

Demo it, regrade, place good sub-base material, compact, well drained, place a new slab with 6" woven wire mesh or similar.

Thin coating products like Maxxon, mentioned below, are typically used to level out floors/decks of buildings or has been my experience with it, like for a precast concrete plank type building where you have camber in each piece of precast, center is higher than the ends. Typically, they will use a 3000 psi flowable grout to level those, but some owners want that extra layer, depending on the finish schedule, and flooring materials specified. I did an entire precast concrete plank building with this material, after it was grouted, roughly 80,000 sq. ft. worth.

I am not convinced, (and I may be wrong LOL !) that a material like this is suitable for a wear course, it is self leveling, and with correct surface prep of the existing slab, it should achieve a decent bond, but I don't recall what the actual strength is, results will vary.

The compressive strength is also something to consider, it needs to be similar or the same as what is under it, or it could fail under a heavy point load, like a wheel. Bond and compressive strength are 2 important aspects, but also abrasion resistance and the surface finish, this material is smooth once set. One would think in today's modern world there would be a material that can work as a wear course over existing concrete, some research might be in order on concrete repair materials.

Another thing to remember, if it is a quality material it will be portland cement based, Gypcrete may be gypsum based and from my years doing high rise, institutional, and many other kinds of commercial buildings, gypsum based materials often times cannot perform like a portland cement based material, because it does not have the compressive strength of portland cement. An example of this is spray applied fire proofing that is applied to structural steel to achieve an hourly fire rating, the gypsum based material has to be re-done often times during the construction phase as it does not hold up as well as the portland based does with construction activities going on that tend to disturb the material after it is applied.


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