Procedure for Ultra Surface® SPRAY-TOP System
Step 1 - Surface Preparation
Step 2 - Crack Repair
Step 3 - Patching holes, spalls and low spots
Step 4 - Resurfacing prior to applying Spray-Top
Applying Spray_Top over stamped concrete
Applying Spray_Top prior to acid staining
Applying Spray_Top in a solid color over smooth floors
Applying Spray_Top over stencils or Modellos
Applying Spray_Top over foam shapes
Step 4: Resurfacing Prior to Applying Spray-Top
Note: This step is not required for stamped concrete surfaces.
After patching (if required), it will be necessary to apply a thin coat of Ultra Surface Resurfacer over the entire surface to help smooth out the patches and hide any repairs. For indoor jobs, the Resurfacer is applied as smooth as possible using our Metal Edge Squeegee prior to applying Spray-Top.
For outdoor jobs, it is recommended to first apply a smooth coat of Resurfacer to hide any repairs. Once the Resurfacer dries, it is recommended to apply a texture coat of Ultra Surface Polymer Concrete, such as a broom finish, to provide adequate slip resistance. When the texture coat dries, Spray-Top can be applied to achieve a more uniform cement color. For the best results, mix the Resurfacer or texture coat the same color as the Spray-Top.
Ultra Surface Integral Color Paks are available in 30 colors to mix with the Resurfacer and Spray-Top. Mix two Integral Color Paks per bag of Resurfacer or pail of Spray-Top. Custom liquid colors are available for an extra charge. When using liquid colors, mix one can of liquid color per pail of Spray-Top.
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Applying Squeegee Coat or Resurfacer |
Applying Polymer Concrete Texture Coat |
Applying Spray-Top Over Stamped Concrete
Spray-Top can be applied directly over unsealed Stamped Concrete (that has been properly cleaned and etched) or a prime coat of Ultra Surface MRB Primer (Moisture Resistant Barrier) can be applied to achieve the best color uniformity and protection against possible moisture vapor transmission problems from below the surface.
If going over an existing sealer it will be necessary to apply Ultra Surface WB Epoxy clear before applying the Spray-Top. WB Epoxy should bond to most sealers, however, going over an existing sealer with WB Epoxy is at the applicators own risk. The best recommendation is to remove the sealer whenever possible.
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Applying Spray-Top over stamped concrete |
After Spray-Top |
Application Instructions Over Stamped Concrete - Spray-Top is used over stamped concrete to restore or change the existing color and should be applied as thin as possible to preserve the existing pattern and/or texture. Adjust the bottom knob on the gun to achieve a fine spray.
Watch the Spray-Top DVD for a better understanding of how to apply Spray-Top over stamped concrete applications. When the Spray-Top has cured for at least 12 hours or more it can be acid stained or antiqued using one of our antiquing methods taught at our training class.
Applying Spray-Top Prior to Acid Staining
For acid staining applications it is recommended to apply a basecoat of Ultra Surface Resurfacer before applying Spray-Top to cover up any patching or surface blemishes and for extra durability. Apply the Resurfacer as smooth and as thin as possible (less than 1/16th of an inch) over the surface using our metal edge squeegee and/or a hand trowel. When the Resurfacer dries, usually within 2-4 hours, apply Spray-Top over the Resurfacer using the Spray-Top sprayer to achieve a smooth, uniform finish.
The coverage rate should be approximately 400 sq. ft. or more per pail of Spray-Top. Allow the Spray-Top to cure for 12 hours or more before applying the acid stain.
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Applying Spray-Top over Resurfacer and Sawcuts |
Apply Acid Stain over Spray-Top |
Applying Spray-Top over an existing sealer before acid staining – Our recommendation is to remove any existing sealers to get down to the original concrete substrate before applying Spray-Top. However, if the existing sealer is not peeling or delaminating, it may be possible to go over it by sanding the surface with a floor polisher machine and #80 sandpaper (on smooth surfaces), followed by a prime coat of Ultra Surface WB Epoxy clear. When the WB Epoxy has dried for at least 4-6 hours, apply Ultra Surface Resurfacer followed by Spray-Top for the final coat.
Applying Acid Stain Over Spray-Top – When staining over Spray-Top, always do a sample and have it approved by the customer before doing the job. Acid stains can be diluted from 1 to 5 parts water to 1 part acid stain when staining over Spray-Top. More water will create a lighter stain color and less water will create a darker stain color.
For the best results, spray a thin coat of water over the Spray-Top ahead of the acid stain to avoid leaving spray spots. The water gives the acid stain a chance to disperse more evenly over the floor before it starts to react. Another way to avoid spray spots is to hold the tip of the pump-up sprayer close to the surface while spraying, within 6 to 12 inches.
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Applying Acid Stain over Spray-Top |
After Spray-Top and Acid Stain |
Rinsing The Acid Stain - If the acid stain was diluted with water up to 5 to 1, a light rinsing with a mop should be sufficient. The more concentrated the acid stain, the more rinsing will be required. Some applications may need to be mopped two or three times with clean water to completely remove the residue.
Sealing Over The Acid Stain – For interior and exterior jobs, once the acid staining is completed and the surface is rinsed and dry, the final step is to apply a sealer to protect the Spray-Top and acid stain. For a solvent-based sealer apply either Ultra Surface Stamped Concrete Sealer or Acrylic Urethane.
If an odorless water-base sealer is desired, especially for indoor jobs, Sealcoat 1000 or WB Epoxy can be used as the prime coat followed by WB Epoxy or WB Urethane as the topcoat. WB Epoxy will work directly over most stain colors but should not be applied over green, avocado or blue stains as it can change the color. For these colors use Sealcoat 1000 as the first coat followed by WB Epoxy or WB Urethane as the second coat.
Applying Spray-Top in a Solid Color over Smooth Floors
Before applying Spray-Top in a solid color over smooth interior floors, it is recommended to apply Ultra Surface Resurfacer as the first coat. Ultra Surface Resurfacer provides extra durability, and helps hide crack repairs, patching and surface imperfections before applying Spray-Top. Spray-Top then provides a more uniform color and smoother finish than the Resurfacer.
For outdoor applications it is recommended to apply Resurfacer and a Broom Finish Texture of Ultra Surface Polymer Concrete (straight or swirl texture) prior to applying Spray-Top. The Resurfacer helps hide crack repairs, patching and surface imperfections and the texture coat provides extra slip resistance. The Spray-Top helps to achieve a more uniform color over the texture coat before applying the topcoat sealer.
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Applying Spray-Top over a Texture Coat |
After Polymer Texture Coat
and Spray-top |
Applying Spray-Top over Stencils or Modellos
Another popular application for Spray-Top is over stencils, logos and Modellos to simulate the decorative sandblasted look without all the mess and clean up. Click here to view the many decorative patterns and designs available to choose from.
This system is taught at our Advanced Training Class in Las Vegas, Nevada.
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After Spray-Top, Modello and Stain
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After Spray-Top, Modello and Stain
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Laydown stencil or Modello |
Apply Spray-Top over stencil or Modello |
Apply Spray-Top over Foam Shapes
Ultra Surface Spray-Top can also be used on foam shapes, vertical walls and many other applications. Spray-Top is the easiest way to provide a perfect cement finish on any foam shape. For more information please click here to contact us.
For more information on the training class click here.
