Resurfacing vs. Replacement: Can This Concrete Slab Be Saved?

Table of Contents:

02-12-2026

Aging floors are a common challenge in older commercial buildings. Years of traffic, impact, chemicals, moisture, and cleaning cycles take a toll on even the most durable surfaces. Facility managers are often faced with a more fundamental question than simply “what flooring should we install next?”

Can the existing concrete slab be saved with a resinous overlay, or does the slab itself need to be replaced? That decision determines cost, downtime, and the long-term success of the new floor.

What is Floor Resurfacing?

Resurfacing in commercial and industrial environments typically means mechanically preparing the existing concrete slab and installing a new resinous flooring system directly over it. The old coating or failed surface is removed, but the concrete remains and becomes the foundation for a new, high-performance system.

This is possible when:

The concrete substrate is still structurally sound

Failures are limited to the previous flooring system, not the slab

The facility cannot afford extended shutdowns

There are environmental or disposal concerns

Power troweling concrete creates a smooth, dense, level surface. This ensures a flat foundation, eliminates imperfections, and enhances the durability and success of the installed flooring system.

What is Full Replacement Flooring?

Replacement means the concrete slab itself has deteriorated to the point where it can no longer support a new flooring system. This involves demolition of the slab, re-pouring concrete, curing time, and then installation of a new floor.

This becomes necessary when:

The slab is structurally compromised

There is severe cracking, heaving, or settlement

Moisture vapor transmission cannot be mitigated

Previous flooring failures were caused by slab issues, not surface issues

The floor profile must be redesigned for drainage or equipment

The Real Difference: What Is Failing — the Floor or the Concrete?

This is the most important distinction. If the flooring system has failed, resurfacing is usually the right solution. If the concrete slab has failed, replacement is often unavoidable. A professional evaluation focuses on moisture testing, crack analysis, and substrate integrity to determine which condition exists.

Comparing Timelines and Downtime

For many facilities, time is more valuable than materials. Resurfacing projects can often be completed in days because only surface preparation and installation are required. Full replacement, however, requires demolition, debris removal, slab work, and concrete curing time that can stretch into weeks before a flooring system can even be installed. For 24/7 operations, this difference can mean significant loss of production.

Resurfacing lets facilities upgrade floors quickly with minimal disruption, avoiding the extended downtime that full replacement can bring.

Environmental Impact

Resurfacing keeps thousands of pounds of concrete out of landfills and eliminates the need for new concrete production — one of the most carbon-intensive construction materials. Replacement, by contrast, involves demolition, disposal, new materials, and heavy equipment use. For facilities with sustainability goals, preserving the slab has measurable environmental benefits.

Performance Considerations

A common misconception is that resurfacing is a temporary fix. Modern resinous and epoxy systems are designed to bond permanently to properly prepared concrete and can provide:

Seamless, waterproof protection

Chemical and abrasion resistance

Safety and slip resistance upgrades

Improved cleanability and aesthetics

Extended service life of the existing slab

However, this is only viable when the concrete is stable and properly evaluated before installation. Properly applied overlays have been recognized as a reliable method to extend the life of concrete infrastructure prior to full replacement, providing long-term performance while avoiding the cost, downtime, and material waste of a full tear-out.^[1]

Modern resinous and epoxy resurfacing delivers long-term, seamless protection while extending the life of a stable concrete slab.

When Replacement Is the Right Choice

Resurfacing is not always appropriate. Replacement is the smarter investment when the slab has:

Structural failure

Deep, active cracking or movement

Uncontrollable moisture issues

Significant surface deterioration from neglect or age

In these cases, installing over the slab only delays the inevitable.

Key Questions Facility Managers Should Ask

Is the concrete slab still structurally sound?

Are past flooring failures related to the slab or the surface?

How much downtime can we afford if the slab must be replaced?

Can moisture and cracking be mitigated?

Can a resinous system restore performance without demolition?

The Bottom Line

The decision is not simply resurfacing vs. replacement. It is whether the concrete slab can be saved. When the slab is sound, resurfacing with a modern resinous flooring system delivers the fastest, most cost-effective, and most sustainable upgrade possible.

When the slab has failed, replacement becomes necessary. The smartest flooring decision starts with understanding what is actually failing.

About Stonhard

Stonhard is the unprecedented world leader in manufacturing and installing high-performance polymer floor, wall and lining systems. Stonhard maintains 300 territory managers and 200 application teams worldwide who will work with you on design specification, project management, final walk-through and service after the sale. Stonhard’s single-source warranty covers both products and installation.

About The Author

Christopher Trageser

Commercial Product Manager

Chris Trageser is the Commercial Product Manager for Stonhard and has been with the organization since 2008. He is actively involved with ensuring compliance with product sustainability initiatives and transparency. Chris holds a B.S. in Mechanical Engineering.