Spray-on concrete is a technology that has revolutionised the way we look at concrete flooring. Since hitting the market, its many industrial uses and benefits have made it an ideal choice for businesses looking to upgrade their spaces. In this article, we’ll explore the various industrial uses of spray-on concrete, providing an in-depth look at its benefits, applications, and a step-by-step guide on how to apply it.
Applications of Spray-On Concrete
Resurfacing Old Flooring
Without a doubt, flooring is one of the most underappreciated aspects of any industrial space.
Often exposed to heavy machinery, constant foot traffic, and everyday wear and tear, traditional concrete surfaces tend to lose their aesthetic appeal over time, becoming worn-out, discoloured, and potentially hazardous. Here’s where the magic of spray-on concrete comes into play.
One of the most popular industrial uses of spray-on concrete is in floor resurfacing. This method involves applying a fresh layer of spray-on concrete to a pre-existing worn-out or drab concrete floor, with an aim to improve the appearance, as well as smoothing out cracks, dents or other potential hazards. The result is a rejuvenated floor with a fresh, clean look that keeps your workers safe.
Spray-applied concrete also comes in a wide range of colours, meaning that you can match it to existing surfaces, or create a decorative concrete floor for retail environments.
As you can see, the growing popularity of spray-on concrete in the industrial sector can be attributed to its ability to restore the original charm of the flooring without needing to relay the entire concrete slab. Unlike traditional resurfacing methods, which require complex procedures and extended drying times, spray-on concrete is a quick, economical, and highly effective solution.
While the industrial sector thrives on efficiency and productivity, the safety of employees should always be the highest priority. One of the common safety concerns in these settings is slippery floors, which pose a considerable accident risk, particularly when wet. Concrete floors, despite their durability and cost-effectiveness, unfortunately contribute to this problem even further. Fortunately, spray-on concrete has tackled this head on and provided an effective solution to this issue.
The unique composition of spray-on concrete allows it to add an extra layer of grip to existing floors. This textured, level, and slip-resistant surface significantly reduces the likelihood of slips and falls, creating a safer environment for workers. This is also beneficial in industries where the floor surfaces are frequently exposed to liquids, such as in food processing plants, breweries, or car wash centres.
Thanks to spray-on concrete, you can take advantage of the natural grit to create a non-slip surface and keep your existing flooring. This is achieved by applying spray-on concrete and not polishing the surface after curing. That means no more spending on sand, less concern around accidents and less worker compensation claims!
Why Choose Spray-On Concrete Over A Full Replacement?
When your business’ flooring has begun to lose its aesthetic appeal or integrity, you might be considering a full replacement. But, let’s look at why this may not be the best option.
If you plan on replacing existing flooring, you’re almost certain to expend a lot of time and money in the process. Laying new concrete is significantly more expensive than adding a coat of spray-on concrete, and if there are only minor concerns about the appearance or functionality, then a full replacement isn’t needed.
In addition, concrete needs to cure for upwards of a week before machinery or vehicles can be driven on the surface. If you operate a warehouse or other space requiring heavy machinery, this will put your business out of commission for a significant period, losing you revenue and customer trust.
What Are the Benefits of Spray-on Concrete?
One of the most compelling advantages of spray-on concrete is that it is very low maintenance. Unlike other flooring solutions, this innovative technique requires significantly less upkeep. Simply hose it down, using a brush or mild concrete cleaning chemicals for any tough stains. This will reduce the burden of constant care, and translates to considerable savings for businesses in the long run.
Because spray-on concrete is adhered directly onto the existing concrete, it is stronger than it might seem at first glance. With added polymer, the spray-on concrete layer is also super tough and able to withstand drops, heavy vehicles and foot traffic. This means less repairs, less often!
How To Apply Spray-On Concrete
Before you start the application process, gather all necessary materials. This includes the spray-on concrete mix, a suitable hopper gun, an air compressor, and a trowel or float. Preparation also includes a thorough clean of the surface, making sure it is free of any dirt, oil or loose debris, as an unclean surface can hinder proper adhesion.
Safety should always be at the forefront when handling any construction project. Always wear appropriate personal protective equipment, including safety goggles, gloves, and a dust mask, to protect against potential airborne concrete particles.
The application process begins with mixing the concrete. Here, it’s essential to stick to the manufacturer’s recommended water-to-concrete ratio. This will guarantee that you have the optimal consistency and avoid any potential integrity issues with the final product. Once your mixture is ready, load it into the hopper gun.
Spraying should be done evenly and systematically to prevent uneven build-up. The hopper gun should be held at a consistent distance from the surface, typically around 60 centimetres. Too close, and you risk an uneven application; too far, and you may end up with a weak bond.
After spraying, use a trowel or float to smooth out the concrete. This step not only improves the surface appearance, but also helps to ensure a strong bond. Keep in mind, the faster the application and smoothing process, the less likely the concrete is to prematurely dry or crack.
Trustworthy Spray-On Concrete Supplies in Melbourne
Spray-on concrete offers a host of benefits for businesses looking to upgrade their floors. Its versatility, durability, cost-effectiveness, and quick drying time make it an ideal choice for a wide range of industrial applications. By using spray-on concrete instead of fully relaying flooring, businesses can enhance the safety and aesthetic appeal of their spaces, while also saving money and reducing downtime.
If you’re interested in repairing old and worn floors with spray-on concrete, contact Australian Slate-Crete Supplies. We have the spray-on concrete supplies you need to complete the job yourself, quickly and easily. For advice, suggestions or to talk through your project, give our friendly and knowledgeable team a call on 03 9408 7722.