CCS Stylepave Overlays Concrete Resurfacing System is a unique system for transforming or renovating sound existing concrete surfaces into vibrant and attractive areas.

The system is applied by experienced applicators and can take on many forms depending on the property owners’ budget and the imagination and skill of the applicator.

The CCS Stylepave Overlay system can be a simple, single coloured topping or can be quite elaborate through the use of stencils, tapes, multi-colours and various concrete resurfacing techniques.

Concrete resurfacing with CCS Stylepave Overlays is relatively quick to install and can be applied to most structurally sound horizontal concrete surfaces which have been left to cure for a minimum of 28 days.

PREPARATION

The concrete surface being coated must be in a sound condition and be free from all laitance, organic matter and friable materials.

The concrete slab must be of adequate strength and appropriate design to withstand the service loadings and stresses that it may be subjected to.

Significant cracks must be routed and repaired in accordance with accepted repair techniques and by using appropriate materials. If ‘live’ cracks are repaired it is important that a crack is subsequently saw cut nearby or directly above the original crack so that the concrete can move.

Expansion joints and crack control joints must not remain filled with the resurfacing compound as it will eventually crack and delaminate around that area. Likewise it is essential that any expansion or control cracks must be used in the same method as with new concrete.

For aesthetic reasons, it is good practice to fill a chipped or widened expansion crack with CCS Resurfacing Compound and then saw cut this crack so that the edges are straight and neat.

Curing aids, paints and chemical hardeners must be removed prior to application of coatings. Delamination of the CCS Resurfacing Compound will occur if this isn’t performed.

APPLICATION

CCS Resurfacing Compound can be applied in a variety of ways to achieve different colours, textures and patterns. Use tapes, stencils, trowel and hopper gun finishes to achieve the finish you require.

Ensure the concrete is correctly cleaned and that all repairs have been completed.

Application of Primer

Mask all areas before application to prevent spillage and over spray onto surrounding areas.

Allow the concrete to completely dry prior to the application of primer coat.

Prime concrete surface by rolling or brooming a solution of CCS Super Polymer and water. The solution should be a mixture of one part Polymer to four parts water.

Allow primer coat to dry (apply base coat within 12 hours).

Application of Base Coat

The base coat acts as the ‘grout line’ colour between the ‘tiles’, ‘cobbles’ or ‘pavers’ that are subsequently created by the application of the stencil and top coat. To ensure a relatively high polymer cement ratio is achieved it is mandatory that no less than 2 litres of CCS Super Polymer should be added to each 20kg bag of CCS Resurfacing Compound.

To minimise the number of times you create the polymer dilution, the applicator may wish to mix sufficient water and CCS Super Polymer for the whole job in the correct ratio. Place dilution into a clean plastic container prior to mixing the compound.

As a guideline, 2 litres of CCS Super Polymer will be required to create 10m² of Stylepave (ie. one 20 litre drum of CCS Super Polymer is required to create every 100m² of Stylepave.

Mix the CCS Super Polymer and water to a ratio of 2 litres of CCS Super Polymer to 3.5 litres of water.

Add 5.5 litres of the above solution to a clean bucket.

Slowly empty one half of the 20kg bag of CCS Resurfacing Compound into this bucket whilst mixing with a paddle at low speed. Lumps will form if the dry mixture is added too quickly to the liquid.

Gradually add the remainder of the bagged contents and mix. Mix for approximately five minutes until homogeneous. Allow the material to settle for approximately two to three minutes to enable air bubbles to escape. Additional quantities of the diluted CCS Super Polymer solution can be added if the mix is consistently not to the applicators liking.

To ensure consistency of colours and texture it is imperative that the same proportions of polymer, water, and resurfacing compound are used for the whole job. It is also recommended that only one person is designated as the ‘mixing person’ and they should responsible for making all mixtures for the job. This assists in ensuring consistency of mixtures on the job.

At the completion of mixing each bag, place the paddle mixer into a 20 litre ‘cleansing’ bucket filled with water. Give it a quick spin to remove resurfacing compound from mixer blades.

Pour contents directly from the bucket to the surface, trowelling into corners and wall edges.

Use a long handled rubber squeegee or roller to spread the CCS Resurfacing Compound over concrete in an even manner. Approximate coverage for the base coat should be 15m2 per bag mixture. If necessary, trowel out high points. Allow the base coat to dry (approximately one to two hours with ambient temperatures at 20 degrees Celsius). Unwanted trowel and squeegee marks can be removed by rubbing with a carborundum block.

Sweep clean ready for application of stencils or tapes.

Hot Weather Tip

It is very important to keep the CCS Resurfacing Compound and CCS Super Polymer out of direct sun on hot days. If these products are allowed to become warm the applicator will find that his effective ‘pot life’ will decrease while it becomes more likely for the CCS Resurfacing Compound to become ‘lumpy’. If hot conditions do exist on the job it may be worth considering wrapping the Polymer in an ice blanket.

Cold Weather Tip

Do not apply CCS Resurfacing Compound when ambient and concrete temperature is less than 10 degrees Celsius.

Application of Stencil

The stencils or tape can be applied to the base coat once it is dry. If header courses are being used, then these should be applied to the base coat prior to applying the main stencil design.

As a general rule, cut a few ‘bricks’ from the header course and place at the top and bottom edges of the driveway. Align these so that the short end of the brick is parallel with the outside of the driveway.

Once positioned and glued with ‘Blu Tac’, run a chalk line from the cut-offs at the bottom of the driveway to those at the top. Starting from the middle of the driveway, roll out and position the header course so it is in line with the chalk line. As with all stencils, it is extremely important that header courses are not stretched, as this will cause misalignment in the final design.

If stencils are being used for the body of the driveway, unroll the chosen stencil design so that it stretches from one side of the driveway to the other and slightly overlaps over the side.

Allow it to first rest at the centre of the driveway and then work outwards until it is all on the driveway. Cut the stencil with scissors and secure with Blu Tac.

Position the next row of stencil so that the edges of the top stencil are immediately above the stencil below it and ensure that all patterns are aligned correctly. Use Blu Tac at regular intervals to ensure the stencil adheres to the slab.

Application of Top Coat

Mix the CCS Super Polymer and the CCS Resurfacing Compound in the same proportion as the base coat. Adjust the consistency to suit the texture required. For example if you desire a sandier, non-slip texture then you could reduce the quantity of water by approximately half a litre. You can also alter the aperture of the gun to produce a more or less textured surface finish.

You can also control texture by the amount of depression you place on the hopper gun trigger. All of these techniques should be practised off-site prior to commencing the job.

The topcoat becomes the colour of the ‘paver’ ‘tile’, or ‘cobble’. To achieve a long lasting abrasive resistant surface, it is important that a total build of 2mm is achieved over the existing slab.

Under ideal circumstances the topcoat should be applied in one coating, (about a 20kg bag per 10m²), however such a coating may tend to seep under the stencil. If seepage is a problem, the topcoat should be applied in two applications.

Spraying

Fill the spray hopper to approximately 50% of its capacity. As a suggestion, if lumps are contained in the resurfacing compound from insufficient mixing, it can be solved by pouring mixture through a sieve into the hopper.

Spray on the texture finish using a pressure of 20-40 PSI. Favoured air pressures are normally around 35PSI.

Large size splatters will form when a low pressure is used while a higher pressure will create a ‘clinker’ like effect. To achieve a good level of durability it is important not to use a profile that is too fine. (Quick hydration of the particles will prevent adequate bonding).

Hold the gun at a 90 degree angle to the surface, at a distance of approximately 60 cm from the surface.

Rotate the spray gun in a circular motion of about 30cm while spraying the material onto the surface. Avoid holding the spray gun in one position while spraying, as ‘shiny patches’ will occur that may not be to the owners liking.

To ensure consistency in texture it is important that you constantly start from one side of the job and spray across to the ther. When you get to the other side of the job you should walk back to the starting side and commence spraying immediately next to where you have already sprayed. Avoid spraying in a ‘Z’ pattern as this will result in noticeable uneven textures.

Hopper Gun Settings for Various Finishes

Finish Air Setting Trigger Surface Water
Sandpaper (Melbourne) ¾ Fully Open 3/8 9.3mm Dry Mix eg, 2P + 3W
Orange Peel ¾ Fully Open 5/16 7.8mm 2P + 3.5W
Patchy Knockdown ¾ Fully Open 3/8 9.3mm 2P + 3W
Smooth Knockdown ¾ Fully Open 5/16 7.8mm 2P + 3.5
Very Smooth ¾ Fully Open ¼ 6.2 mm 2P + 4W
Tight Corner Areas/Obstacles ¾ ¼ As per above Chosen As per above chosen
Fleck – Course ½ Half Full 3/8 9.3mm 2P + 3W
Fleck – Fine ¾ ¼ – ½ Open 5/16 7.8mm 2P + 3.5W

 

Removal of Tape/Stencil

Allow the CCS Stylepave Resurfacing Compound to dry for one to three hours depending on temperature and conditions.

Remove the tape or stencil by ‘snapping it out’ lifting up directly and quickly, in order to create a grout line with a clean edge. If the edge breaks away in an uneven line the material is likely to be too thick or not sufficiently dry. Cease removal until the topping has sufficient time to dry.

Wear appropriate footwear (or socks) to avoid scuffing the resurfaced concrete while working. Remove colour chips that fall down from stencil onto the surface with an air blower within a few minutes of removing the stencils or tapes. If this isn’t done it is likely that these chips will be glued to the surface when someone inadvertently walks on them.

Clean Up

Clean trowels, squeegee and hopper gun immediately after use with clean water and a scrubbing brush. The hopper gun should be cleaned with water after application of each 20kg bag.
Oil and grease the hopper gun ready for the next application. Clean brooms and short nap rollers with CCS Solvent.

Sealing

It is very important that a coat of sealer be applied to the surface before any moisture is allowed to affect the Concrete Resurfacing System (This coat of sealer must be applied the same day the CCS Stylepave finish is applied).

Use two coats of CCS Hardseal, CCS Hi-build Enduro or CCS Hi-Build Enduro Matt to seal the resurfaced concrete finish. On warm days the first coat can be applied as early as two hours after final application. This is totally dependent on the Resurfacing Compound being dry prior to applying sealer.

The second coat of CCS Hardseal or CCS Hi-build Enduro or CCS Hi-Build Enduro Matt should be applied after 24 hours of the first coat, however ensure the surface is free of all moisture and dust prior to application.

Download pdf version of full application guidelines for the CCS Stylepave Exquisite Overlays System.

For further information consult the relevant Product Data Sheets.

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