Pouring Concrete Over an Existing Concrete Floor

Although designed last for decades, a concrete floor will eventually start to show wear. Since this could impact the productivity, safety, and appearance of your facility, it becomes necessary to repair or replace a floor that is showing signs of wear.

Rather than laying an entirely new floor, some property owners wonder about the possibility of pouring a new layer of concrete over the existing floor. This can sometimes be a cost effective way to restore the look and functionality of a concrete floor, but you will need to know whether or not this will work for your facility and if it will provide the most effective option.

When Is It Possible to Pour New Concrete Over Existing Concrete?

When installed correctly concrete is a reliable foundation material and it can serve as a foundation for a floor as well. This is true as long as it is in the right condition. When considering this kind of repair, the following must be true about your existing concrete floor and the installation process.

In order for a new concrete floor to be laid over an existing one, the underlying concrete slab needs to be in good condition. Covering a deteriorating slab with new concrete will only temporarily hide problems and the new flooring will begin to deteriorate soon after installation, exhibiting all of the same effects that your previous floor had.

An existing floor can have a few small cracks once repaired and still be a reliable basis for a new flooring installation. Other conditions you will need to consider when installing a new concrete floor over an existing floor are:

  • Types of Existing Damage – Significant damage, like large cracks or pitting, that is the result of subbase problems, freezing, or similar issues should be repaired. Trying to cover cracks with new concrete will not fix the underlying issue, and cracks will soon reemerge in the new floor.
  • Unlevel Floor – If your concrete floor is settling or unlevel, it is important to fix whatever is causing the shifting so that it does not continue to occur with a new floor. Concrete leveling can often restore your concrete floor back to a usable quality and make it unnecessary for a new pour.
  • Initial Installation Mistakes – If there were mistakes made with the initial installation of your floor, it is unlikely that you will be able to address the problem by pouring a new concrete floor. Many existing issues will likely start to surface in the new floor.
  • Bonding Considerations – Concrete will not naturally bond to an existing surface. You can instead rely purely on an overlay or you will need a bonding element to adhere a new surface to the existing one.
  • Height Allowances – A floor has a minimum required thickness that will give it enough strength to support the weight that it will be required to hold. A concrete overlay will increase the height of your floor since you will now have 2 layers of concrete. This can be a problem in certain instances as it might block a door or create a tripping hazard. If this is a possibility in your facility, repairing or replacing the existing floor is a better option.

If you are having problems with your existing commercial floor or the time has come to replace it, it is important to consider all of the different options available to you. Colorado Concrete Repair offers several different flooring services for commercial properties in Denver. Our flooring installation and replacement, concrete leveling, and a range of other solutions to help you get the most out of an existing concrete floor.

Our team can help you determine if a new or replacement commercial floor will best serve your business. Learn more about the commercial flooring options available for Denver facilities and how our services at Colorado Concrete Repair can meet your property’s different needs. Contact us to get started.