Why Resurface Concrete Instead of Tearing Out & Re-Pouring

Amee Curtis
3 days ago
2 min read

You walk onto the jobsite and the client says, “We’re thinking we need to tear this all out and start over.”

Cracks, pitting, oil stains, uneven spots—it looks bad. But is it really beyond saving?

Not usually. In fact, tearing out and re-pouring concrete is one of the most expensive, time-consuming, and unnecessary moves contractors can make.

In this post, we’ll break down why resurfacing concrete is almost always the better choice—plus how to do it right and what systems to trust.

Resurfacing Concrete vs Re-Pour: Cost & Timeline

Tearing Out & Re-Pouring:

Equipment rental for demo and removal
Dumpster and disposal fees
Rebar, forms, pour, finish, and cure time (7–28 days)
Permitting delays
Potential damage to surrounding structures

Average cost: $8–15 per sq ftTimeline: 2–4 weeks (minimum)

Resurfacing:

Light to moderate grinding
Crack repair or leveling
Overlay system applied
Topcoat or polish (optional)

Average cost: $3–7 per sq ftTimeline: 1–3 days

You’re not just saving your client money—you’re winning back your own crew hours, equipment access, and jobsite flexibility.

Common Conditions That Can Be Resurfaced

Condition	Resurfacing Viable?	Notes
Surface cracks	✅ Yes	Use joint filler or flexible polyurea
Minor spalling	✅ Yes	Patch and overlay
Heavy oil contamination	✅ Usually	Degrease + vapor barrier epoxy
Pitting or uneven texture	✅ Yes	Use self-leveling or trowelable overlay
Vertical heaving or settling	❌ No	Re-pour may be required

⚠️ Rule of thumb: If the structural integrity is intact, you can almost always resurface.

When Re-Pouring Is Necessary

Structural damage (slab heaving, sunken sections, major movement)
Failed rebar or rust-jacking
Severe undermining or erosion
Slabs below modern code requirements for weight/support

In these cases, re-pouring may be safer and more future-proof—but it’s still rare.

Tools & Products We Recommend for Resurfacing

Overlays:

Duravel Trowelable – for texture blending and heavy-duty jobs
Kretus SL (Self-Leveling) – for smooth commercial installs

Surface Prep:

Shot blaster or grinder (PG 450 or PG 530)
Crack chaser and polyurea filler
Moisture vapor barrier epoxy (if slab is questionable)

How to Talk Clients Out of a Re-Pour

You’ll often need to educate the client. Use phrases like:

“We can repair and overlay this for half the cost—and faster.”
“Your floor isn’t broken. It just needs a better skin.”
“Replacing the slab might solve one problem, but it will create five more.”
“Let’s look at an overlay system that can be polished, coated, or textured based on your needs.”

Consider showing before/after images or cost comparisons—it seals the deal.

Conclusion

Tearing out and re-pouring should always be the last option. With modern overlay systems, repair materials, and grinding equipment, resurfacing is faster, cheaper, and way less disruptive.

At PNW ECS, we help contractors spec the right resurfacing system—and give you the support to pull it off confidently.

📍 Need Help Speccing an Overlay?Stop by Fife or Sandy with photos or slab info—we’ll help you build the system, recommend products, and quote the job.