I have a concrete porch that’s been stripped of wood, and astroturf before that. Instead of tiling it or covering it with flagstone, I would like to pour a 1-1/2″ layer of concrete over it, using some forms to make a few separate rectangles (kind of like big tiles, though not all the same size). The porch is about 6 X 8 feet, which includes one step.
My questions are: how should I prep the existing concrete, can I use a premixed concrete or is there a special mix I need to do, any tips on adding color, is there any limit on the width of my grout lines (the thickness of the forms) and what type of material should I use to fill the spaces after I remove the forms. Thanks.
Edited 5/20/2002 8:55:19 PM ET by Monkeyrunner
Replies
I'm no concrete expert, but I don't think this is gonna work. At 1.5" the new slab is probably not going to be thick enough to hold up -- it will most likely crack. And I don't think it's going to adhere very well to the old pad.
Sounds like you're trying to do this "on the cheap" to me. (??) If not, why not just lay tile, or even stone? You can get the look you want that way, and it will be structurally sound. And it won't cost that much if you DIY.
There is also a company called Concrete Technology Inc. which has franchises all over that do exactly this sort of thing with an epoxy coating, colored and stamped to look like about any kind of stone, tile, or paver you can imagine. Their web site is: http://www.cti-corp.com/
Edited 5/21/2002 9:57:13 AM ET by RUSTYCAS
Thanks, maybe I should just tile it. I was just thinking I could vary the sizes of the concrete rectangles for some interest and, as you said, do it cheap.
I had a similar project, with plans by an engineer, just a bit smaller tho. His specs called for 1/2" re-bar dowels (don't remember the spacing, something like 8 to 12 inch grid) into the existing crete, then tie welded-wire mesh to the dowels. I just used sack-crete and "Deck-o-Weld" (even Elmers glue has concrete adhesive). I'd recommend this method with a mono-pour rather than 1 1/2" wide joints, maybe you can do something decorative with a joint tool. Good luck.
Quikrete makes all sorts of stuff, and it occurred to me they might have something to address this situation, so I went to their web site. Sure 'nough they have a "Concrete Resurfacer" that sounds like just what you're looking for. Check it out at:
http://www.quikrete.com/diy/potm.html
Actually, the method explained above (rebar studs with reinforcing wire) should work fine as well. Just be sure you get the right kind of mix. Quikrete has (I think) a form for making your 'slab' look like brick pavers, and you can get tinting as well. Based on the Quikrete quantity calculator, your 1.5" slab, 6' x 8' is going to take 12 bags (60# bags) -- it doesn't really go very far. Might want to think about how you're going to mix all that. (Rent a little mixer maybe, or borrow one?) Check around for the cheapest price. Sometimes your Ace hardware store, or local yard, will be a lot cheaper than the Big Box stores.
Edited 5/21/2002 11:35:42 PM ET by RUSTYCAS
Look up "polymer overlay" in google. It'll give you another attractive option.
For the "grout lines", what about using aluminum or brass angle iron, with one leg fastened to the existing slab. The verticle leg would act as a screed guide, and after cleaning the silver or brass color wopuld show much like terazzo. If you notched the bottom leg properly, you could bend it to form arcs. The most you could probably get would be 1/4" thick material. If that;s too narrow, consider putting two angles back to back.
Edited 5/21/2002 11:39:16 PM ET by ELCID72