vol. 3 iss. 3 june/july, 2003 - concrete decor · 4• • june/july 2003 decorative concrete tips...

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VOL. 3 NO. 3 • JUNE/JULY 2003 • $6.95

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June/July 2003 • Vol. 3 No. 3Issue No. 11 • $6.95

Publisher: Bent O. Mikkelsen

Co-publisher: Ernst H. Mikkelsen

Editor: Rosemary Camozzi

Assistant Editor: Harlan Baldridge

Circulation: Sheri Mikkelsen

Design and Production: Stephen Stanley

Advertising Sales: Kathleen Goodman(314) 367-1121

Writers:Susan Brimo-Cox

Gail ElberStacy KlemencJohn Strieder

Contributing Writer:Bart Sacco

Editorial:Professional Trade Publications, Inc.

3410 West 11th AvenueEugene, OR 97405Tel: 541-341-3390Fax: 541-341-6443

Email: [email protected]

Circulation and Administration:Professional Trade Publications, Inc.

P.O. Box 25210Eugene, OR 97402Tel: 541-341-3390Fax: 541-341-6443

Email: [email protected]

Concrete Decor The Journal of DecorativeConcrete is published six times a year by

Professional Trade Publications, Inc. Bulk ratepostage paid at Lebanon Junction, KY and

additional mailing offices.ISSN 1542-1597

Subscriptions:One year: USA $19.95; Canada $32.00;

Other countries $60. All funds in U.S. dollars.

For Subscriber Services:Call 866-341-3703 Toll Free

For Advertiser Services:Call 877-935-8906 Toll Free

© 2003 Professional Trade Publications, Inc.

www.concretedecor.netONTHE COVER: “Colloquy One,” a concrete sculpture by Carole Vincent.Photograph by Clive Boursnell.

We’re Moving and Grooving …… a new path to education and training in decorativeconcrete.

On July 1, Professional Trade Publications will bemoving to larger facilities here in Eugene,Oregon. The new facility will accommodate not

only two growing magazines, but an exciting neweducation and training center as well.

The center, named the Institute for AmericanCraftsmanship (IAC), will offer educational programs designed for basic andadvanced contractor training as well as product-oriented training seminars hostedby manufacturers. The Institute includes 3,500 square feet of indoor trainingfacilities and over 8,000 square feet of outdoor area. Many of the nation’s topprofessionals will be teaching seminars at the IAC.

As a publishing company, our primary objective has been to continuallydevelop and identify new ways to support the trade. The development of the IACwill support overall improvements to the magazines’ editorials and stimulategrowing interest for educational programs throughout the country. The magazine’sconnection with IAC will also help improve Concrete Decor’s coverage of industrydevelopments.

As always, we would like to express our gratitude to the companies who supportConcrete Decor through their advertising. Without their support these excitingnew developments would not be possible.

Please watch the pages of Concrete Decor closely as we will soon be publishingthe Institute’s events for the balance of 2003.

Sincerely,

Bent MikkelsenPublisher

P.S. Visit our newly updated Concrete Decor Web site (www.concretedecor.net)and follow the development of the Institute for American Craftsmanship. Thecalendar of “Events and Training” identifies many exciting learning opportunities,including training events at the IAC. Also, in the near future, you will have“Subscribers Only” access to an archive of all previous articles in Concrete Decor.

http://www.concretedecor.net

http://www.ConcreteDecor.net

mailto:[email protected]



FEATURES14 Keep Your Concrete Pliable with the Right Aggregate

Experts offer some rock-solid advice.by Gail Elber

18 Concrete Hardscapes Check out what these folks have done with “boring oldconcrete.”by Rosemary Camozzi

26 Color HardenersDry shake hardeners are increasingly popular as coloring agents. by John Strieder

34 Concrete SealersMatch the sealer to the job, and let your work shine!by Susan Brimo-Cox

DEPARTMENTS10 CONTRACTOR PROFILE: Lakeland Company, Rathdrum, Idaho

From mountains to mine shafts, Lakeland makes it all.by Susan Brimo-Cox

30 MANUFACTURER PROFILE: Stencil Systems Inc.Great products and top-notch technical support define thishardworking company.By Stacey Klemenc

44 Classifieds40 Concrete Marketplace04 Decorative Concrete Tips06 Industry News08 Industry Spotlight — Association News46 Product News42 Product Profiles02 Publisher’s Letter

www.ConcreteDecor.net • June/July 2003 • 3

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DECORATIVECONCRETE TIPS

Decorative Concrete Tips is a forum for readers to exchangeinformation about methods,tools,and tricks they’ve devised.

We’ll pay for any we publish.Send details to CD Tips,Concrete Decor,P.O.Box 25210,Eugene,OR 97402.

We look forward to hearing from you!

Cleaning your sprayer

Sprayers can be a real pain in the neck when they don’twork right, so I’d like to share a procedure that hasworked well for us through the years. This was developed

after throwing away a mountain of spent sprayer cans!We always use separate sprayers for solvents and water-

base materials. I guess you can use the same one for both, butit seems to work better to keep them separate. Also, that wayyou’ll usually have an extra unit if you’re out in the middle ofnowhere and your sprayer quits working.

We always clean the sprayer with xylene after using high-gloss sealers. Another quick tip: While you’re refilling yoursprayer tank, park or rest your sprayer wand in the gallon ofxylene. This will melt off excess buildup on the tip and youwill be ready to go when you’re filled. Many times I have filledup the tank, got ready to spray, and — nothing. Now you’re ata standstill — cleaning the tip. You get the idea.

Okay, back to the cleaning. When you are done with thehigh-gloss sealer, empty out the unused sealer and then dumpthe gallon of xylene (or your favorite cleaning solution) inthe tank (1), shake around a bit (2), pump up and dischargeback into the original xylene container (3). You can reusethe xylene again and again. The spent waste residue of thesealer will settle in the bottom in the xylene can and you can

discard the waste the next time you use the cleaning material.We usually run a little through the fan tip and then remove

the tip to discharge mass volume into the xylene container.Next we hold the sprayer wand vertically and open the valveto drain the tube (5). Dump any remaining cleaning materialout of the sprayer tank. Wipe down plunger, seals and thesprayer tank at the seal contact area.

Now the most important part:Leave the plunger out of the tank overnight to allow the

vapors to escape (6). The next morning put the plunger backin the tank to keep the dirt out. If you allow the xylene or thevapors to stay in the sprayer tank without allowing the vaporsto evaporate, you will ruin the seals. They will swell and notperform as well.

Note: Follow the same procedure for water-base material,but clean immediately after use with warm water instead ofsolvent.

Good luck on all your decorative projects!

— Bart Sacco is the owner of Concrete Texturing Tool & Supply,located in Throop, Pa.

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Industry New

s

Ahal Contracting winsglobal award (and more)Ahal Contracting Co. Inc., locatedin St. Louis, Mo., recently receivedthe Outstanding Bomanite ProjectWorldwide, Gold Award 2002 fromthe Bomanite International Societyfor the paving installation at theAmeristar Casino, St. Charles, Mo.The casino paving included a40,000-square-foot streetscape, a4,000-square-foot sports bar floorand an 8,000-square-foot buffetfloor. The streetscape is Bomaniteimprinted concrete. The sports barand buffet floors each received areactive stain finish.The casino also won first place inthe Concrete Pavement AwardsSpecialty/Indoor Category, Cast-in-Place Concrete, 2002 Decorativeand Durable Designs.

Ahal also received the BestBomanite Project over 12,000 SFGold Award 2002 for the floorinstallation at Watson’s Inc., a retailstore in St. Charles that sells

outdoor andindoorrecreationalequipment andfurniture.

AhalContractingCo. performsconcreteflatwork, tilt-upand pumpingfor commercial,institutionaland industrialprojects, andarchitecturalconcrete instal-lations forcommercial andresidentialclients.

DecoCrete acquired byWeaver GroupDecoCrete Stamped ConcreteSpecialties, of Mt. Joy, Pa., has beenacquired by The Weaver Group,parent company of Weaver PrecastInc., and Weaver Masonry Inc. Anew division, DecoCrete byWeaver Concrete Specialties Inc.,has been formed within the WeaverGroup of companies.

The new division is a partnershipbetween Weaver Group presidentGary Weaver, who will serve aspresident, and his son Jared Weaver,who will serve as vice president ofoperations. Sales and administrationfor the new division will functionout of the Weaver Group corporateoffices in Ephrata, Pa., and will covermarkets in Pennsylvania, Maryland,Delaware and New Jersey.

Weaver will retain DecoCrete’s12 employees. “These guys knowwhat they’re doing,” says JaredWeaver. “They’re talented andprofessional. I don’t foresee manychanges in products, services orprice.”

DecoCrete, established in 1999,serves a specialized, niche marketthat Weaver believes will be a goodfit with its other divisions. Weaverplans to expand DecoCrete’scurrent customer base fromresidential homeowners to includenew residential builders andcommercial builders, utilizing TheWeaver Group’s relationships togrow the division. For moreinformation, call Jared Weaver at(877) 877-0084.

New location for SuperStoneSuper Stone Inc. has opened a newlocation in South Miami, Fla. SuperStone South, located at 4900 SW75th Ave., offers quality productsfor decorative concrete contractors.Super Stone also has locations inRiviera Beach and Opa Locka, Fla.,and in Las Vegas. Training seminarsare held at the Opa Locka location.

For more information, call (800)456-3561.

USG redesigns industrial products Web siteThe Industrial Products Division ofUnited StatesGypsum Co.has updated itsWeb site(www.gypsum-solutions.com)to provide moretimely andcomprehensivecontent, as wellas enhancedinteractiveassistance to its customers andprospects. The site now includesdetailed information aboutselecting and specifying thecompany’s many industrial gypsumbrands. New products andapplications will be featured on thehome page, and the MarketUpdates section will include casestudies, technical articles and newsreleases that highlight applicationsand advances of USG’s industrialproduct brands. For moreinformation, visit the Web site atwww.gypsumsolutions.com.

Slag-to-cement facilitymarks first anniversaryLafarge North America’s SouthChicago grinding facility hassuccessfully completed its first yearof operations, producing a three-way win for Lafarge, steelmanufacturer Ispat Inland Inc. andthe environment. The innovativesite uses an environmentallyfriendly process that converts slag— a byproduct of steel manufac-turing — into a premium productthat significantly enhances cementperformance when added toordinary cement.

Lafarge takes slag from the IspatInland steel mill in nearby EastChicago, which saves Ispat the costof disposing of the slag and provides


http://www.gypsum-solutions.com



http://www.gypsumsolutions.com


Lafarge with a steady source of materialthat it processes into cement (whileusing less energy than a conventionalcement kiln). In it s first year ofoperation, the facility processed about120,000 tons of slag and produced110,000 tons of high-quality NewCem-brand slag cement, which the companyhas found performs better than regularcement. For more information, call(703) 480-3600 or visitwww.lafargenorthamerica.com.

Ferguson returns toMultiquipMultiquip is pleased to announce thereturn of Mike Ferguson as director ofsales for the company’s generalconstruction equipment unit. Fergusonwill oversee all North AmericanMultiquip sales operations andactivities. He has earned numeroushonors at Multiquip, includingSalesman of the Year in 1985 andSalesman of the Month on numerousoccasions. Ferguson also served as chairof AEM’s Light EquipmentManufacturing Group in 2002.Multiquip is a leading supplier ofcompaction equipment, pumps,welders, generators, welders, concreteand masonry cutting, placing andfinishing products, dewatering pumpsand other construction equipment.

Janeway joins Fab-FormFab-Form Industries Ltd.,a manufacturer of fabricforms for concrete, ispleased to announce theappointment of David

Janeway as vice president, sales andmarketing. Since graduation fromGeorge Brown College in Toronto as aconcrete technician, Janeway hasdedicated his life to the concrete andcement industry. In 1984, he wasappointed Pacific Regional Manager ofConchem, a division of LafargeMaterials Inc., where he wasresponsible for sales and marketing.There he successfully created,developed and launched two new

products, one of which is now offeredworldwide.

In 1992, he became the BritishColumbia market manager for HolnamInc., a division of Holderbank Inc. ofSwitzerland, at the time the world’slargest cement manufacturer. There heauthored a supply allocation strategywhich became the model for thelaunch of blended bulk cementproducts across the USA and Canada.

In 1999, Janeway became senioraccount manager with PFBCorporation, Canada’s largestexpanded polystyrene (EPS)manufacturer and molder. There hewas responsible for implementing amarketing plan and establishing thedistribution channel for aninnovative concrete wall-formingproduct using EPS.


New appointments at SikaCorp.Sika Corp. has appointed BruceStrickland to the position of NewConstruction Regional Manager for thesoutheast. Strickland comes to Sika fromNGRM Concrete Company, where heserved as president of sales and marketing.He has also worked for such notablecompanies as Euclid Chemical Co. andMaster Builders Inc. in various technicaland sales positions. In his new position,Strickland will focus on introducing Sika’sadvanced admixture technology andtechnical support to the ready mixedconcrete and precast/prestressed industriesin the southeast.

In other Sika news, DannyMatthews is now district manager forthe Carolinas, and Jason Zelinski is asenior sales rep for South Carolina.Sika Corp. provides solutions andproducts for concrete production, repairand protection.


http://www.lafargenorthamerica.com


NRMCA endorses performance-basedcriteriaThe National Ready Mixed Concrete Association Board ofDirectors has endorsed the voluntary use of performance-based specifications for U.S. ready mixed concreteapplications. This effort, coined the Prescription-to-Performance (P2P) Initiative, calls for design engineers toseriously consider incorporating performance-based criteriain job specifications as an alternative to prescriptiverequirements that constrain the producer from optimizingconcrete proportions and innovation.

The P2P concept has long been a goal of influentialindustry leaders, says NRMCA president Robert Garbini.The current initiative is a collaborative group effort ofconcrete producers through NRMCA to identify anybarriers and to work with all stakeholders to make thisinitiative a success. Adopting the performance-basedconcepts will be voluntary.

NRMCA elects new directorThe National Ready MixedConcrete Association has electedJames A. Russ as chairman of itsboard of directors. Russ succeedsDavid L. Vickers, Lehigh CementCo., who completed his one-year

term at the conclusion of the annual convention in San Diego.Russ first entered the concrete and aggregates business in

1966, joining the Lone Star Industries group. Since 1969, hehas held numerous management positions in the readymixed concrete and mining industries in both private andpublic companies. He joined Aggregate Industries in 1991 aspresident of its mid-Atlantic region. Prior to that, he waspresident of Rosenfeld Concrete and New EnglandConcrete, both subsidiaries of Boston Sand and Gravel Co.Russ holds a bachelor of science degree in physics andengineering from Washington & Lee University.

He will lead a newly elected board that includes Hardy B.Johnson, Tarmac America, as first vice chairman; Hale D.Ritchie Jr., Ritchie Corp, second vice chairman; and PeterBrewin, Cemex, as treasurer.

ICRI announces new chapter in GreeceThe International Concrete Repair Institute approved thecharter of the ICRI Hellenic Chapter, based in Greece, inApril. The chapter is the first outside of North America.Anyone interested in joining the chapter or learning moreabout its activities should contact Athanasios Froussos,

chapter secretary, at [email protected]. If you are interested instarting a chapter in your area, contact Chris Jorgensen,marketing/chapter relations coordinator, at (847) 827-0830.ICRI is a nonprofit association dedicated to improving thequality of repair, restoration and protection of concrete andother structures.

ACI elects new presidentJosé M. Izquierdo-Encarnación, principalof Porticus, an engineering servicescompany in San Juan, Puerto Rico, wasrecently elected president of ACIInternational (the American ConcreteInstitute).

Izquierdo became the 80th president of ACI, a technicaland educational society dedicated to improving the design,construction, maintenance and repair of concrete structures.

Izquierdo received a bachelors and masters degree in civilengineering, majoring in structures, from the University ofPuerto Rico. He started work as a structural engineer forCapacete, Martin and Associates; founded Izquierdo, Ruedaand Associates; and was the Secretary of Transportation andPublic Works for Puerto Rico.

An internationally recognized leader in civil engineeringand construction, Izquierdo has been actively involved withACI since 1980. In addition to serving five years on the ACIBoard of Direction, he has been a member of numerouscommittees and task groups. He has also been active inPuerto Rico, where he was president of the San Juan chapterof the Institute of Engineers and Surveyors, president of theInstitute of Civil Engineers, chair of the governmentalInfrastructure Task Force for Health Facilities, chair of theCorporation for the Development of San Juan, and amember of the Boards of the Technological Institute of SanJuan and the Catholic University of Puerto Rico.

More ACI newsACI also elected James R. Cagley to atwo-year term as vice president. Cagley ispresident of Cagley & Associates, aconsulting structural engineer firm inRockville, Md. Four directors wereelected to three-year terms: Anne M.Ellis, senior program director, Earth Tech,Inc., Alexandria, Va.; Charles K. Nmai,chief engineer, Master Builders,Cleveland, Ohio; Aimee Pergalsky, consultant, Beachwood,Ohio; and Basile G. Rabbat, manager, transportation

Industry SpotlightAssociation News




structures and structural codes, Portland CementAssociation, Skokie, Ill.

PCA elects chairman Dan Harrington of Lehigh CementCompany is the new chairman of PortlandCement Association. Harrington’s officialappointment follows a period as interimchairman following the resignation of PaulYhouse on March 17.

As president of Lehigh’s northerndivision, Harrington has 19 years ofcement industry experience. He is also the

current chairman of Pennsylvania Aggregates & ConcreteAssociation (PACA) and the former president of theNortheast Cement Shippers Association. He earned hisM.B.A. from Fairleigh-Dickinson University and holds anM.A. in executive management and a Ph.D. in executivemanagement from the Claremont Graduate School.

Based in Skokie, Ill., the Portland Cement Associationrepresents cement companies in the United States andCanada. It conducts market development, engineering,research, education, and public affairs programs.



On the Nevada side of LakeTahoe, there’s a sprawlingresidence on the lakeshore

that has something its neighbors don’thave — a 24-foot tall mountain gushingnumerous waterfalls, pools, and ameandering stream winding through thegrounds. On the side of the mountainyou can see an old, abandoned mineshaftwith a rusted railcar on the siding. Livetrees and shrubs, plants and flowers of allkinds merge this environment into thelandscape. Birds fly from tree branch tostreamside as water gently splashes overrocks. It certainly looks and sounds real,but it’s not.

Under the mountain — accessible viathe mineshaft door — are the electroniccontrols that run this elaborate waterfeature, which spans several acres. Waterflow and water purification are allhandled automatically. At the push of abutton, controls for colored lights and fogmachines can turn this naturalistic haveninto a mesmerizing drama for the senses.

But building mountains forhomeowners is only a fraction of whatDavid Long and his team at LakelandCompany Inc. have accomplished.You’ll find Lakeland Co.’s creationsacross the country at upscale residences,casinos, zoos and museums, theme parks,restaurants, corporate offices, and even ahospital and airport. As word spreads, sodoes the reach of this Rathdrum, Idaho-based firm.

LakelandCompany,Rathdrum,Idahoby Susan Brimo-Cox

ContractorProfile

ContractorProfile


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Long saw his own “signs” forthe futureDavid Long, president of Lakeland Co.,grew up working in his father’s signbusiness — creating, constructing andinstalling signs and three-dimensionaldisplays. By the time he was 18 yearsold, he was a journeyman signwriter.

“We were involved with large-scalesignage and displays, entailing severaldifferent construction and concretemethods,” he says. “Being surroundedby multiple journeymen in thisenvironment enabled me to learn moreof the design and application methodswhich I rely upon today.” But at thetime, he wasn’t ready to follow in hisfather’s footsteps.

Fifteen years after his father closedthe business, Long took his family tonorthern Idaho, where he and his wifestarted Lakeland Sign & Display Co. inthe spring of 1991. “Our first projectwas estimated at $152,” he says, “andwe grew from there due to the fact thatwe maintained the attitude thatanything could be created provided youapply the right materials andapplication.”

Today, Lakeland Co. designs,manufactures and installs themedelements, artificial rock and waterfeatures, museum dioramas, simulatedenvironments, Glass Fiber ReinforcedConcrete panel systems, monumentsignage and architectural applications.Long is quick to acknowledge thecontributions of others to his success.

“The team environment has allowedus to apply the strengths of eachindividual in different areas of requireddesign, manufacturing, mobilization,shipping and construction applicationin order to create the highest quality offinish product possible,” he says.

Get things right from thestartLong reports that the bulk of Lakeland’sbusiness comes either from word-of-mouth or the company’s Web site(www.lakelandco.com).

Typically, 10 to 20 staff people workon any given project, plus Lakeland

frequently outsources work to the locallabor pool.

Often there’s customer educationinvolved, as many people don’t realizehow very labor-intensive the work is,Long observes. “Time is spent educatinga lot of our customers who are notfamiliar with the costs associated inproducing these types of elements. Wehave learned through replication andtracking what our costs are and whatour minimum profit requirements are tostay in business.”

Project costs vary based on thelocation of the project. Not only arelocal material prices factored in, butalso travel, accommodations, shipping,transportation, staff per diem, andmore. Thanks to the assistance of amanagement advisory team, Lakelandhas incorporated all these variables intoits estimating process.

Ensuring that the customerunderstands what the final product isgoing to be also aids the process. “Wecombine the ability to hand draw anduse computer programs as another toolto enhance project designs with fasterservice to our clients. We also providescale models of larger projects to helpour customers envision the finalexhibit, while giving us an element todo better product estimates from.”

Lakeland uses a variety ofmaterialsMany of Lakeland’s artificialenvironments rely on Glass FiberReinforced Concrete, which Long sayshe uses for its durability and highlydetailed replication abilities. “We havedeveloped our molding capabilities tomold and recreate just about anythingimaginable,” he says.

Lakeland’s GFRC mix is an alkali-resistant matrix of portland cement,graded silica sands and alkali-resistantchopped glass fiber. The material,which contains 4 percent to 5 percentglass content, is applied in a spray-upmethod, using concentric guns, andcompacted in quarter-inch layers. Thepanels produce strength of approxi-mately 6,000 pounds per square inch at

3⁄4" of thickness and can be left hollow orfilled with concrete grout for structuralapplications. They can also be filled withtwo-part foam to discard hollow soundwhere weight is a concern.

“Most projects we grout fill to furtherthe quality of the application.” Longsays. “We have not had any structuralproblems with panel or boulders infreeze-thaw conditions as the result ofquality control during manufacturing.”

While 60 percent to 80 percent of aLakeland project may utilize GFRC,you’ll also see positive carved concrete,textured concrete overlays and real rock.To simulate eroded shorelines and cut

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banks, shotcrete is used. “Very seldomdo we do all artificial,” says Long.“That’s primarily in indoorenvironments. In exterior applicationswe strive to use real rock in and aroundthe artificial.”

Coloring methods vary witheach projectLong says his company typically doesn’tcolor dust their molds, because you’llhave grout seams anyway. Hispreference is to apply a base coat in arandom color application after thepanels are grouted together.

“Our base coats consist of a very fineconcrete color coat mixed with acrylicadmixture to promote excellentadhesive capabilities. The bulk of thecolor base coat is applied with a veryfine concrete color coating so as not tolose the detail of the panel textures.”Acid stains may be used in differentcombinations to create various effects.Painting techniques, such as creatingwashed areas with water-based acrylics,are used as accents — for example, toreplicate oxide or soil residues.Especially with large outdoor projects,the company will often work with locallandscapers to color-match local stone.

Long has also used these and othercolor and texture methods to re-createantiquities or period pieces.

Maintenance of artificialenvironments is minimal, Long says.The greatest challenge is ultravioletlight damage, but it helps to apply apenetrating sealer after the coloring iscomplete.

“We have found that our coloringprocess will hold its color about 3-to-5years…. We have had customers refreshthe coloring on their project at thattime and others who leave it due to thefact that they like the way it hasweathered and find it looks morenatural.”

Challenges createopportunity“Each project in itself is challengingfrom the standpoint of striving toconstantly better the finish look and

application methods,” reflects Long.Replicating trees and architecturalantiquities takes a special touch. Oneproject included creating a trail of firethrough a waterfall.

Of course, some projects are muchmore challenging than others. Take theLake Tahoe project for example. Thedecision to incorporate the mechanicalroom into a “mountain” forced them tokeep ahead of the tight constructionschedule by re-engineering, designing onsite, changing rock work and thepump/control systems simultaneouslywithout stopping construction, Longrecalls.

A project in Cripple Creek, Colo.,presented an interesting altitude-relatedchallenge. “The lack of air was obviousduring the project, and we were forcedto sit down and catch our breathmultiple times throughout each day.”

Then there was a project for the U.S.Bureau of Mines to replicate a mine shaftinterior for its training facilities. The jobsite was two stories underground.Lakeland had to crane concrete panelsdown through a vertical shaft, cart themto their location, and then lift and boltthem to the ceiling, which wasconstructed of 25,000-psi concrete 2 feetthick, with pipe sleeves through to thesurface. “We had to run all threadthrough those sleeves to secure the panelplacements, and that enabled us torecreate the plate bolting that occurs toanchor loose rock in real mineshafts,”Long says. “We also paneled the walls andcreated what appeared to be naturalseepage and water emitting from rockcrevasses into mineshaft drain trenches.”

Long’s advice for others interested inthis area of the industry? “Be patient. Bewilling to go into the unknown areas ofthe normal construction trades, as this isa combination of art and heavyconstruction methods. Gain as muchknowledge as possible and be willing tospend a lot of time and money onresearch and development.”

Other recommendations cover goodbusiness practices. “Be prepared to beaccountable and make right any failuresof product or application methods in

Photographs courtesy of Lakeland Company



order to keep your client, projects andreputation intact. Sometimes, no matterwhat you do, you will not make someclients happy. Therefore, do the best youcan prior to contracting — survey themlike they will do with your company tosee if you foresee any possible difficultiesduring and after construction orpayment for construction.”

When your project takes you to a newlocation, treat local suppliers the wayyou want to be treated, Long says. “If wecome into an area, we need to leave apositive reflection when we leave. Wemay return some day.”

“Challenging and rewarding,” that’show Long describes his involvement inthe industry thus far. Stimulating andencouraging might also apply. “Themore projects you have completed themore you want,” he says, “as theelements associated with each projectallow us to rise to the next level ofimagination.”



http://www.glaze-n-seal.com


Any concrete mix is an attemptto balance cost, placeabilityand setting time while

maintaining the necessary qualities ofstrength and durability. Ready-mixproducers use different ingredients fromregion to region depending on what’savailable and what kind of weather theconcrete will experience before and aftercuring.

Coarse aggregate makes up more than40 percent of a typical concrete mix.The type of aggregate that is availablevaries in different areas. In the northernparts of North America, round graveloccurs naturally, the result of glacialaction during the Ice Ages. Otheraggregates available are crushed rock,which is angular in form, and recycledconcrete.

So what is the best aggregate to usefor stamping applications? To answerthis question requires an understandingof aggregate’s role in the mix.

A tale of two mixesThere’s no such thing as “the best mix”for decorative applications. “There’s notnecessarily one right way, but there areupper and lower limits for eachingredient, and if you work within them,you’ll get better results,” says BruceChattin, executive director of theWashington Aggregate and ConcreteAssociation. Examining two mixes fromdecorative concrete contractors indifferent parts of North America showshow great regional and personaldifferences can be.

Tom Ralston, of Tom RalstonConcrete in Santa Cruz, California(www.tomralstonconcrete.com), startswith this mix for one cubic yard ofconcrete:

Cement: 564 lb (6 sacks)Sand: 1300-1500 lbAggregate: 1600-1800 lbWater: 312 lb (39 gal)Water reducer: 18 ozAir-entraining admixture to produce1 percent air (freezing weather is rarein Santa Cruz, which is on the coastsouth of San Francisco)


Keep your concrete pliablewith the right

Aggregateby Gail Elber

Keep your concrete pliablewith the right

Aggregateby Gail Elber

http://www.tomralstonconcrete.com


Ralston specifies that the mixture bepoured at a 3- to 4-inch slump. Ratherthan trying to predict the weather, heorders the truckload to arrive 30 to 45minutes before the pour, then doses iton the spot with Fritz-Pak admixtures(www.fritzpak.com) to accelerate orretard setting as needed.

In Cincinnati, Ohio, Bob Ware,president of the Decorative ConcreteStore (www.decorativeconcretestore.com), favors a different mixappropriate to his freeze-thaw climate:

Cement: 564 lbSand: 1330 lbNo. 8 gravel (pea gravel): 770 lbNo. 57 gravel (a crushed stone thatcan be as large as 11⁄2 in.): 1130 lbWater: 230 lbWater reducer: 21 ozAir-entraining admixture to produce6 percent air content

Though Ware also pours at a 4-inslump, his mix contains a lot of waterreducer to make the water contentunusually low in comparison withRalston’s.

With these general mix proportionsin mind, let’s look at how the size andshape of aggregate affect the propertiesof the wet mix and the finished product.

Aggregate and strengthFirst, the shape of the aggregate affectsthe strength of the finished concrete. Ingeneral, angular crushed particles giveconcrete greater strength because theyinterlock more than rounded pea gravelparticles do. Mixing sizes, as Ware does,enhances that interlocking action.

“In our area, we have a lot of roundaggregate because of deposits of glacialtill,” Ware explains. “To get an angulargravel, we would have to have ittrucked in.” When he does a job in thesouthern part of his territory, south ofwhere the glaciers stopped, he takesadvantage of the ready availability ofcrushed rock.

“Angular gravel is better,” he says.“Round gravel is soft. You have to push itdeeper into concrete than angular gravel,or it will break and spall the surface.”



Size also influences strength: Thebigger the aggregate, the stronger thefinished concrete will be, since thechunks of rock don’t crack as cementpaste does.

Aggregate and stampingBut if you’re going to stamp theconcrete, big chunks of rock willinterfere with the impression of the

stamps. Brickform Rafco(www.brickform.com) recommendsusing aggregate no bigger than 3⁄8 inchwith its stamps; other manufacturers letyou go as high as 3⁄4 inch. Ralston uses3⁄4-inch angular hard aggregate for jobsthat will be textured with mats. If heplans to use cookie-cutter-type stamps,which penetrate more deeply, Ralstonswitches to pea gravel or 1⁄2-inch

http://www.fritzpak.com

http://www.decorativeconcretestore.com

http://www.decorativeconcretestore.com


http://www.brickform.com


crushed stone. “The larger stone won’tallow the stamp to make animpression,” he says.

With this in mind, Dave Pettigrew,principal of Diamond D Concrete(www.diamonddcompany.com) inCapitola, California (near Santa Cruz),used to use pea gravel for stampingapplications, the size of aggregate hestill favors for concrete that is going tobe pumped. But now, for stamping, hespecifies a 1⁄2-inch angular rock forinterior floors and a 3⁄4-inch angularrock for foundations, which requiremore strength. He points out, “Withsmaller rock, you have to use morecontrol joints because it is not asstrong,” something to consider whenyou’re planning a stamp job and wantto position those control jointsinconspicuously.

Aggregate and waterAggregate size also affects the amountof water needed in the mix. Ralstonexplains, “Because smaller aggregateparticles have more space betweenthem, more sand is added. To make theconcrete more workable, people want


to add more water, which increases theshrinkage potential.” Instead of addingwater, he says, a better practice is to addwater-reducing admixture to improveworkability without introducing theseproblems. Slump should not exceed4 inches.

Other admixturesWater reducers aren’t the onlyadmixture that is useful. Anotheringredient that can improveworkability without compromisingstrength is type F fly ash. Chattinsuggests using it to replace 10-15percent of cement in a mix. It willproduce some of the effects of addingmore water — increased setting timeand improved workability — withoutcompromising strength as increasedwater does. Granulated slag cements,relatively inexpensive in the steel-making regions of North America,can have the same effect and, beingmore uniform in content, are morepredictable in their air-entrainmentproperties. An important consid-eration for decorative applications isthat Type F fly ash makes concrete

that’s darker than concrete made withplain portland cement, andgranulated slag cement makes itlighter in color.

Tom Ralston uses 15-20 percent flyash to replace cement, but he doesn’tdo it to get workability benefits. In histown, many of his residential andcommercial customers have heard ofthe environmental benefits of fly ash— getting particulates out of the airwhile it reduces the carbon dioxideproduction associated with cementmanufacture — and are eager to specifyit for that reason.

An ingredient to avoid if you areplanning to use color hardener iscalcium chloride, which will interferewith the action of the colorant. Ifyou’re going to experiment with otheradmixtures, make sure to consult themanufacturers about each chemical’sinteractions with other components ofthe mix. “Crack reducing and air-entrainment admixtures ‘fight,’ and itweakens the mix, which becomesspongy,” Ralston explains. “It won’t setup properly. I’ve seen it not ready totrowel after 24 hours.”

http://www.diamonddcompany.com



Still, correct use of admixtures canshave time off a job. “They may costmore money, but you could be done anhour sooner or use fewer workers on thejob,” Chattin points out. Just consult themanufacturers and the ready-mixproducer to make sure that you don’tbrew up a batch of trouble in your mix.

An important relationshipIn fact, it’s always a good idea to keepyour ready-mix provider informed aboutwhat you’re going to do with theconcrete. Sit down with the ready-mixrep every so often to talk about themixes you need for different kinds ofwork. “Having a relationship with aready-mix producer is important,” saysChattin. You know the habits of yourcrew and the patterns of your climate,and the ready-mix rep knows thematerials that are available locally andthe quirks of the admixtures on themarket. Together you can put together amix tailored for your decorativeapplications.



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Anew stamping pattern, a really cool countertop oran unusual color effect always draws an excitedcrowd at a concrete training school or trade show.

Many decorative concrete contractors grew up in theindustry — often their dads were in the trade — and theylearned the basics of working with concrete at an early age.But as the demand for decorative work has increased,contractors have tackled new techniques with anenthusiasm fueled not just by the money to be made.Unlike plain old slab work, decorative concrete bringscreativity to the forefront.

We present to you here four people who fell in lovewith the possibilities inherent in concrete — its fluidity,endless possibilities for color and shading, and longevity.They have taken a substance usually thought of asmundane and used its natural characteristics to createenduring works of art.

Concrete HardscapesConcrete- inspired artistry

by Rosemary Camozzi

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Buddy Rhodes Studio

Based in San Francisco,Buddy Rhodes has built a

successful business around theartistic side of decorativeconcrete. He produces indoorand outdoor floor tiles, pre-cast counters for kitchen andbath, sinks and tubs,surrounds, and uniquearchitectural elementsranging from colorful spheresto outdoor benches andtables. A former potter whoswitched to concrete morethan 20 years ago, Rhodes’pieces capitalize on concrete’sstrength and versatility whilestill reflecting the earthy,

handmade quality of pottery.Rhodes uses his own concrete mix — which he also sells

to contractors — to create hollow three-dimensional pieces.The water/cement ratio is about one part water to 10 partsmix. “The mix is very plastic, very claylike,” Rhodes says. “Itcan be pushed up on the inside of a mold and it will stickthere.” The concrete is colored with integral color.

Molds are madefrom plaster,melamine orfiberglass. To createa sphere planter, forexample, Rhodesfirst makes a “plasterpositive,” startingwith an openframework withwire mesh over it, using perlited plaster for the first layer tobuild it up and then using casting plaster to finish it. Theform is mounted on an axis, and after each layer is applied itis spun around a semicircular screed. “It’s similar to making aclay pot,” Rhodes says. Once the positive form is complete, itis used to make a fiberglass two-part mold.

Then it’s time to start packing in the concrete andworking it up the walls of the mold. Someone actually getsinside the sphere to do the packing. First comes a pastry layer,1⁄2" to 3⁄4" thick, then a layer of expanded galvanized steeldiamond mesh. This is followed by a wetter, 3⁄4" layer ofcement that works itself into the holes of the mesh.

After the concrete comes out of the mold, it is troweledover to produce a varied surface color and texture.

At this point, Rhodes takes advantage of natural veins inthe concrete to add additional colors, using three to four

Buddy Rhodes Studio2130 Oakdale Ave.

San Francisco, CA 94124Telephone: (877) 706-5303

Web:www.buddyrhodes.com

“Throw away thepreconceived

notion of whatconcrete is andcreate your own

vision.”


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Carole Vincent

Carole Vincent lives inCornwall, England, in a

house overlooking the sea. Herfather was a concretecontractor and she grew uparound the trade, originallyworking with concrete as abuilding material and thenturning to more artistic uses forher favorite medium.

Now she makes concretespheres, pyramids, sculptures,columns and more, all dazzlingin their colors and textures.Some of them make use offiber-optic technology toradiate light.

Vincent has earnedrecognition in England for herinnovative work with concretehardscapes. Her work wasrecently displayed at the RoyalHorticultural Society’sChelsea Garden Show, one ofLondon’s grand spring events.

She is not inclined to sharemany of her techniques, but she was willing to give us someinsight into her work.

Like Rhodes, she starts with a mold. For sculptural pieces,she makes a clay model, then a plaster mold. For larger piecesthat need structural strength, she uses fiberglass. Like Rhodes,she uses integral color

But for the rest of the process, her approach is radicallydifferent. First of all, her pieces are solid. And second, sheuses self-compacting concrete. Until a few years ago, she says,she was using dry, compacted concrete mixes. In order to getfull-strength color, she had to use a water/concrete ratio ofabout .40. But since discovering self-compacting concrete,which has gained increasing attention in Europe, she hasn’tlooked back. Self-compacting concrete contains superplasti-cizers and has the fluidity of a wet concrete mix whilemaintaining full color strength, she says. And, it requires novibration.

As far as proportions in her admixture, Vincent weighseverything down to points of a gram. She monitors factorslike moisture content in aggregate very carefully. “Myaggregates contain less than 1⁄2 percent moisture,” she says.“You have to be very meticulous about the proportions.”

Vincent doesn’t want to reveal any details about hercoloring techniques. She lacquers her pieces using lacquersfrom Sika.

Some of her pieces actually glow from within. Vincentspins a web of fiber-optic fibers inside the mold and then pours

Carole VincentHalf AcreBoscastle

Cornwall, EnglandPL35OBJ

Telephone:011.44.1840.250263

Carole Vincent does nothave e-mail or a Web site.

She is happy to receiveletters or phone calls frompeople who are interested

in her work.

colors of cement (mixing white cement with liquid colors)and making a “cream cheese” paste which he swipes over theholes. Then he polishes the surface, bringing it down about1⁄32" to reveal a little bit of the aggregate.

For planters and other outdoor objects, he generally sealswith Glaze ‘N Seal, an acrylic sealer. Lacquer sealers are hischoice for countertops because they give the surface a wetlook and bring out the color.

Over the years, Rhodes has done an enormous amount ofexperimenting with mixes, colors and techniques. “There wasa lot of trial and error,” he says. “That was half the fun of it.”

His business has grown through word-of-mouth, magazinearticles and by sending samples of his work to architects. Henow offers his own line of products, including his proprietarycounter mix, liquid colors, extruded edge forms and sealers.


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Photographs by Clive Boursnell from the book ConcreteWorks by Carole Vincent,published by Alison Hodge andavailable online from www.alison-hodge.co.uk

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http://www.alison-hodge.co.uk


Marvin and Lilli AnnKillen Rosenberg

Lilli Ann Rosenbergdiscovered concrete more

or less by accident, when aconcrete truck dumped a pileof wet cement in a vacant lotacross the street from theHenry Street Settlement inNew York City, where shetaught art to children. Withthe children’s help, the pile ofcement turned into a sculpturethat included mosaic designsmade with pieces of potterythe children had created.

Now she has been workingwith concrete for more than 30 years. “It’s magic,” she says ofher favorite medium.

Lilli Ann and her husband Marvin make their own mix,choosing darker or lighter, rougher or smoother aggregatedepending on the effect they want to create. They often use atype of calcium aluminate cement called Fondu(manufactured by Lafarge) which is more plastic thanordinary cement as well as darker in color. It is extremelystrong and sets up in about eight hours, but remains plasticfor about an hour when creating a sculptural form. Whiteand gray portland cement are also favorite ingredients.

Their mix is rich, Lilli Ann says, comprising two partssand to one part cement. She doesn’t measure the water,adding just enough to get it to a clay-like consistency. “Theamount you need each time is different depending on theweather,” she says.

The Rosenbergs color with integrals and use whiteportland cement to create white areas in a design. Venetianglass and hand-formed mosaic tiles made by Lilli Ann areembedded into the concrete to create patterns and accentsthat bring the creations to life. Textures are often created bystamping with found objects of various kinds.

Some of their pieces are solid; others have a core ofStyrofoam that makes them lighter. Each is completelyindividual and created for the project at hand.

Marvin and Lilli AnnRosenberg

4001 Little Applegate RoadJacksonville, OR 97530

Telephone: (541) 899-7861E-mail: [email protected]

in the self-compacting concrete. When the piece is installedin its final location, a fiber-optic cable is run between a lightsource and the object. The fibers in the concrete absorb thelight, and the piece radiates a celestial glow.

Vincent scoffs at the suggestion that her work is technolog-ically advanced. “Hah,” she says, “fiber-optic technology is wellknown. What isn’t well known is how to make good concrete.”

“Concrete is wonderfulbecause it will take the

colors and the forms thatgranite or marble or all

these polished stones can’tpossibly take.But youcan’t take shortcuts.”


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The “love seat”To create the “love seat,” installed in a children’s garden atthe Eugene Public Library in Eugene, Ore., they first madean armature (framework) out of welded rebar. Inside theframework they put slabs of Styrofoam to make the seatlighter in weight. Then they covered the armature with wiremesh and covered that with about an inch of concrete. Thewhite areas are portland cement. Patterns are created with

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CIRCLE #86 ON READER SERVICE CARD CIRCLE #16 ON READER SERVICE CARD

hand-made tilesembedded in thefresh concrete.

The frogThe frog does nothave Styrofoam inthe middle. It beganlife as a clay model,

which was then copied to make a larger armature. Aftercovering the armature with wire mesh, Lilli Ann turned thefrog over and plastered his “innards” with concrete. Then sheturned him over again and coated the outside, so theconcrete is two to three inches thick. The texture on thefrog’s legs was created by stamping with decorative wroughtiron, which was first dipped in light cooking oil so that itdidn’t stick in the concrete. Brightly colored tiles were inlaidwhile the concrete was still workable.

The lizard benchTo make the bench, Lilli Ann created a pattern out ofcardboard. Then a welder used the shape to create a color-coated metal tray with rebar welded into it. The Rosenbergs

“You have to likeconcrete to workwith it.You have

to tune in towhere it’s at.”

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poured concrete into the tray and pressed in clay pieces,stones etc. The legs were an integral part of the welded frameand were set into a concrete footing on the site.

The dragonThe dragon, created in three sections, was first carved out inStyrofoam. Rebar (3⁄8") was bent to fit the form and wirewrapped around it. White sections were created withportland cement, brown areas were integrally colored, anddetails were created by stamping and embedding mosaics andtile into the fresh concrete.

Finishing touchesWhen the Rosenbergs complete a piece, they treat it with adilute solution of muriatic acid to expose a little of theaggregate. Then a penetrating sealer is applied. They arecareful to educate their customers on the importance of aregular maintenance program in the form of yearly cleaningand resealing.

“Just like when you plant a tree, you need to take care ofit,” Lilli Ann says.


Color HardenersA dual-purpose applicationby John Strieder

When contractor RichardSmith needs a tough,easy-to-repair coating on

a hotel or apartment walkway, he startsscattering the color hardener. “Itbecomes very, very hard,” says Smith,based in West Hills, Calif. “It becomes avery, very wearable surface. It almostbecomes like an eggshell finish.”

Like other concrete craftspeople,Smith still values hardener for itsoriginal function: making a concretesurface more durable and resistant toheavy traffic and other abuse.

But for a growing number ofcontractors, color hardeners aren’t justfor hardening anymore.

“I’d say the balance of interest hasgone from hardening to the dry-shakecolor aspect,” says Steve Johnson,marketer with Solomon Colors.

In the age of decorative concrete, theallure of “dust-on” has as much to dowith its coloring properties as its abilityto harden. Color hardener can, in fact,be purchased in just about any color acontractor can imagine, includinguncolored. “We stock 40,” says DebbieBliss of Rafco Products, maker ofBrickform color hardeners, “but we canmake any color in the rainbow.”

Hardeners have other practicalapplications in decorative work, too.When stamped, their dense surfaceholds clear, sharp impressions. They arealso used as lighteners, covering grayconcrete with a more workable shell ofa lighter color.

Color hardeners are made fromcement, sand and pigment, withfinishing agents, wetting agents orretardants added to suit manufacturers’preferences.

The most common pigments are ironoxides. Contractors pay more for cobaltoxides, used in blues, and chromiumoxides, which make greens. Titaniumadditives are used for whites and tolighten colors. “Organics” can makequirky colors such as ultramarine.

But the most important element incolor hardener isn’t the pigment, saysJoe Garceau, co-owner of ButterfieldColor Inc. It’s the sand.


Photographs courtesy of Rafco/Brickform


Quality sand should be hard andclean, he says. The grains should haveangular shapes or hard edges likecrushed quartz, not be round like silica.“Round aggregate doesn’t have goodfinishing characteristics,” he says. “Thesurface does not close as well. Theydon’t nestle into each other. They justcontinue to want to move as you trowelthem closed.”

Another big factor is gradation,Garceau says. Most manufacturers’ sandmix recipes are proprietary, he says.“That is the secret. Everybody can buycement.”

Hardener is usually scattered across asurface by hand or by brush, althoughmachines are available for bigcommercial jobs. Water in the wetconcrete bonds with the cement in thehardener after troweling.

The material is applied in twosweeps with spot follow-up, using abouttwo-thirds on the first pass. Therecommended coverage rate forBrickform is 60 pounds for every 100square feet of concrete, Bliss says. Withlight and pastel colors, contractors mayneed to use more, she says, as much as90 to 100 pounds per 100 square feet.

Distributing hardener is somethingof a skill. “How do you keep it even?You get good at it,” Garceau says.

Put it on too early, Bliss says, and itwill not allow moisture to escape fromthe curing concrete, causing the solidifiedhardener to peel away. Wait too long,and the color will not be worked inproperly, resulting in blotchy color.

Use too little, and either the graywill show through the hardener or foottraffic will wear it off. “I’ve never had athickness problem,” Smith says. “I’vehad numerous failures not havingenough. The secret to dust-on is,thicker is better than thinner.”

And if the dust-on is troweled beforeit becomes uniformly wet, lumps form,Johnson says.

Application is also affected byweather conditions and the kind ofconcrete used. Back east, for example,contractors often use air-entrainedconcrete, which cracks and crumbles






less when it freezes. In those cases, aretardant is needed to keep the surfaceopen long enough for the dust-on to set,Bliss says. “Even then there’s sometechnique involved. I’ve seencontractors stick their fingers up in theair to see if the humidity is right.”

When it comes to color, hardenerfaces some stiff competition fromintegral colors, which are mixed intothe concrete before it is poured.

Johnson of Solomon Colors, for one,is sold on integrals. “If you’re asking me,absolutely, integrals are preferable,” hesays.

Integrals require less manual labor,don’t leave airborne residue, have a

they strengthen the slab’s surface. “Foottraffic causes more abrasion thanvehicular traffic,” he says. “People scufftheir feet. They shuffle.”

Dust-on colors are long-lasting, sayscontractor Richard Smith. Whenhardeners are used, the color of a sectioncan be duplicated well after it’s beenfinished. “It’s easier to add to it becausethe color density hasn’t changed,” hesays. “I would definitely, definitely gowith a dust-on color. Most of mycompetition uses integral colors. But ifthe customer eventually wants to addsomething to it, or there’s a compli-cation or failure, I can come back to thecustomer and say, no problem.”

greater chance of achieving a solidcolor, and don’t require access to everysquare inch of a slab’s surface, Johnsonsays. “I really don’t think the use ofcolor hardeners is increasing muchacross the United States, but integralcolor use is increasing by leaps andbounds.”

Integral color is often used indoorssimply because it doesn’t flood a sitewith loose powder. And because theentire slab is saturated with color, itholds up better to scrapes and chips.

But color hardeners offer more colorsand snazzier effects, such as marbling.

They are less expensive than integralcolorants, Garceau says. And, of course,

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What’s more, he says, contractorswho work on big jobs must sometimesuse concrete from different quarrieswith varying shades of sand. Colorhardeners cover up the difference.

Contractors who opt for dust-onsalso duck the costs that come withmixing a batch of colored concrete,Johnson notes. “Contractors don’t wantto pay a cleanup fee. Ready-mixconcrete makers can charge contractors$150 a truck to clean them out.”

Garceau says his company sells morecolor hardener down south. Integralcolors are generally more popular upnorth, although Detroit and Chicagocontractors are healthy consumers ofcolor hardeners, he says. The primaryfactors are cold weather and cost, he says.“We find that when labor is cheaper theyprefer color hardener. When labor isexpensive they prefer to keep an extraman off the job and go with integral.”

Geography also influences the mix ofthe concrete. Maine concrete tends toincorporate particularly hard rock,Johnson says, while Illinois concretecontains porous limestone. “Becauseaggregates have different densities, youwill get different amounts of bleedwater,”he says. “You have to alter the mixdesign of your base concrete in colderareas to use dry-shake color hardeners.”

Contractors often mix colors on thejob. One technique, called “flashing,”involves laying down a base color, thenscattering small amounts of others. “Itkind of blends together,” says Las Vegas-based contractor Ron Garamendi. “Youget a highlighted surface, with differentshades, rather than a bland one.”

Garamendi, like many othercontractors, has some favorite recipes.“I like the off-white color to start with,”he says. “And then I flash in somecoconut, some coffee, a little bit ofterracotta and a little green.” It givesthe surface the look of “a nice naturalslate,” he says.

Smith has a technique for antiquingthe surface after applying hardener. Mix20 parts water to one part colorhardener, he says. Pour the mixturethrough a screen to take out the sand.


Garceau of Butterfield sees the issuedifferently. “I think anybody should beable to get as artistic as they want,” hesays. “I think that’s what the industry’sabout. Concrete guys are not as dumb asthey are cracked up to be. Theyunderstand if they mix two colorstogether at a job site that the result ofthose two colors is their responsibility.”


Then spray the liquid onto the cornersof selected tiles. This gives each tile anindividual, weathered look, he says.

Bliss of Rafco says her company doesnot recommend contractors mix colorsby hand. “Job problems come back tothe manufacturer,” she says. Instead, hercompany touts its own custom colorservice, which is no extra charge. “Thatway we’ve got recourse. We know whatwe did. We can track it back here.”



Creative contractors looking fornew ways to boost their profitsand differentiate their work

would be wise to check into thestencils available from Stencil SystemsInc. and its distributors.

Headquartered in Sandy, Utah,Stencil Systems is part of theDecorative Technologies Group, anAustralia-based company thatmanufactures and supplies more than60 million square feet of productsannually to more than 25 countries.

In addition to its large selection ofhigh-quality stencils — as well ascustom-cut logos and designs —Stencil Systems offers an extensiverange of color hardeners, colordispersants, modifiers, release agents,acid stains and decorative tools for usewith concrete cast-in-place projects.Most recently, the company, which hasbeen operating in this country for the

Stencil SystemsQuality stencils can up your profit bycutting down on timeby Stacey Enesey Klemenc

past seven years, added Cover-tex, adecorative overlay that is sprayed ontoexisting concrete and is formulated towork with stencils.

Comparing stencils to stamps, “Youcan be a lot more creative with stencilsas far as the application goes,” says ClarkPaepke of Stencil Systems. “The onlylimitation is your imagination. We liketo encourage contractors to thinkoutside the box, to be creative, tomanipulate the stencils.”

A pattern on the floor can continueup a wall or onto a stair riser and over atread. With the snip of a regular pair ofscissors, you can create endless designvariations. And that’s not even countingthe colors and finishes that can beapplied over the design.

“Another advantage of using stencilswith the variety of finishes that can beapplied is that you end up with aconsistent finish,” says Chad Austin ofSalt Lake City-based Cencotech, StencilSystems’ West Coast master distributor.“The surface texture is much more even.”

With 26 field patterns, six borders,five circles and a diamond, there’s plentyto manipulate, mix or match. The fieldpatterns come in 1,076-square-foot rollsmade of a polycoated paper. They areonly good for one job, but they can berepositioned if the need arises. Paepkerecommends figuring the cost of the rollinto your job estimate.

How can stenciling increase yourprofits, you may ask?

“You can do a greater amount of squarefootage in less time,” explains ScottMaxfield, president of Cencotech. Oncethey get comfortable with stenciling,contractors are more productive, he says.“Normally, they’re in and out pretty much

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the same day. Stamping, on the otherhand, can take three times that long,and it’s more work.”

Stenciling is less labor intensivebecause you don’t have to continuouslypick something up and reposition it,says Jerri Adams, who co-ownsTexoma Decorative Concrete Supplyin Wichita Falls, Texas, with herhusband, David. The company isStencil Systems’ master distributor forthe East Coast. “You can have two tothree guys handling a fairly large jobwhile it takes twice that many to havefour or five stamps running.”

Help is yours for the askingBesides distributing all of the productsneeded to create, color, texture andseal stenciled concrete, Paepke says,“We pride ourselves big time ontechnical support, and we have anetwork of contractors and dealers allover the United States who will taketime out from their business or projectsto help others in the field.”

If you call with a problem, “We’regoing to help you right then on thephone,” he says. “You won’t get thatsalesman attitude reply: ‘Let me lookinto it and get back with you.’ We’llprovide information right then andthere or quickly find someone who can.”

You won’t find Stencil Systemsproducts in The Home Depot or othersimilar retail stores. Both masterdistributors sell directly to contractorsin their territory, as well to a selectgroup of local distributors that meetcertain criteria. To keep businessprofitable for all, local distributors don’tcompete with one another. “We don’twant to create a ‘Black & Deckereffect’ and have too many distributorsin one area,” Adams says.

For those of you wondering, thereare no franchise fees. “You don’t haveto pay to play,” Maxfield adds.

“It’s our goal to have enoughdistributors so that everyone is within atwo-day ship,” Adams says. LastMarch, for instance, Texomawelcomed Mt. Union Lumber &Supply in Pennsylvania on board to






distribute wares in a nine-state region.“It all comes down to better customerservice,” she says.

Contractors are kingAny way you slice it, Paepke says, thecontractor is the ultimate customer.The company makes it its business tolisten to what contractors have to sayabout its products, which areconstantly being fine-tuned andimproved “by the contractor, for thecontractor.”

Both master distributors offer freetraining seminars to their customers.Seminars are routinely held in Texasand Utah, as well as other locationsaround the country. Basic seminars areusually held in the spring whileadvanced seminars are offered in thefall. Both run for two days. For moreinformation on upcoming seminars,check www.stencilsystems.com fordates and locations.

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Paepke recommends that those newto stenciling start with a smaller areathan they would normally tackle.“Give yourself a little cushion areawhen you first start out. It’s a lotdifferent from a seminar setting to anactual job. Keep it basic and simple andbuild from there. Don’t bite off morethan you can chew.

“There are certain rules you have tofollow when using stencils,” Paepkecontinues. “We teach the basics butthen you take your creativity and applythat to our process. You can have yourown special technique and create yourown special look. Decorative concreteis an art. If you can stencil and stamp,you can get some gorgeous looks youcan’t get with just one or the other.”

Contractors should be concen-trating on their technique, heconcludes. “The last thing we want youto do is worry about the product.” Andwith Stencil Systems, that’s not part ofthe pattern.





ConcreteSealersKeep your work beautifulby choosing the right sealerfor the jobby Susan Brimo-Cox

Concrete sealers help protect andbeautify concrete work. Butchoosing the right one from a

bewildering assortment of products is notalways easy. Making the best selectiondepends on several factors: theapplication, desired aesthetics andmaintenance requirements. Knowingthe basics can help you make the rightchoice for each project.

Concrete sealers are sometimesgrouped either as film-formers orpenetrants, based on how they integratewith the concrete surface.

Film-forming sealers do just that —they form a protective film on thesurface of the concrete. “Film-formerscreate a surface barrier for stainprevention and ease of maintenance,”reports Jim Glessner, general managerof White Mountain Products, a divisionof Triangle Coating Inc. in SanLeandro, Calif. Film-formers typicallyhave a glossy sheen, which can enhancedecorative concrete.

Straight acrylics, urethanes andepoxies are examples of film-formers.Sometimes these are said to bepenetrating, but that can be misleading.As Jerry Churray, Pittsburgh-basedregional manager of L&MConstruction Chemicals Inc., explains,film-formers’ penetration extends onlyinto the surface pores.

Penetrating sealers migrate into thetop layer of the concrete surface andwork well to repel moisture and stains.Sometimes these sealers are described asreactive. Silanes, siloxanes andfluorinated resins are examples ofpenetrating sealers. These sealerstypically do not change the appearance

these products have been reformulatedsince the federal VOC requirementswere changed in 1999. To meet FederalVOC requirements, most products mustmeet ASTM C1315, which requires 25percent minimum solids. Products withhigh solid percentages can beproblematic, he explains. “From anapplication standpoint, 15 percent to 20percent solids is ideal for acrylicapplication.” Problems occur becausecontractors often thin [higher solidscontent] products that have met theVOC requirements. Thinning changesthe chemical makeup of the product soyou can’t expect the same longevity andwearability as the unaltered product.Two light coats at 25 percent VOCmaterial will make an ideal sealer.

As most acrylic products are non-yellowing, they allow the surface colorsto shine through. These products alsocan be tinted to enhance the color ofaggregate in exposed aggregateapplications or to enhance integrally-colored concrete. But beware. BobFininis, operations manager for SierraDesign Concrete in Sparks, Nev., sayscoloring with a tinted sealer “can betricky — a hit or miss deal.” He advisespurchasing sealer and tinting from thesame manufacturer for the best results.And, most importantly, “test it beforeyou take it to the job.”

For maintenance, surfaces sealed withacrylic products should be kept clean.These sealers are easy to apply andrepair. As a general guide, exteriorapplications should be resealed orrefreshed every 18 months to 2 years.Indoor use can last longer if a sacrificialwax is used regularly.

Urethanes and epoxies aretoughUrethanes and epoxies are good choiceswhen durability and stain resistance isimportant.

Iwaniec explains, “Epoxies are athicker product. They are an indoorapplication which has more abrasionresistance than some of the otherproducts. They can be tinted to customcolors and are ideal for industrial

of the surface, leaving the concrete witha natural look.

“Most sealer technology is availablein solvent and water systems,” saysFrank Livingston, president of OKONInc. in Denver. Which formulation yougo with also depends on the applicationand the desired appearance.

If you get confused by the wide rangeof products on the market described asconcrete sealers, you are not alone.“Sometimes sealers are confused withcaulking materials, which are at timesreferred to as sealers as well,” observesLivingston.

Sealer-hardeners, too, are consideredconcrete sealers by some. Theseproducts seal and densify the concretesurface, so, for this discussion theyexceed the parameters of “sealer.”

Boiled linseed sealers used to be useda lot, but little today, according toChurray. These “fringe products” arenot very environmentally-friendlybecause they are oil-based. However,Livingston observes that these sealersare often still specified by state DOTs asan anti-spalling agent for bridge decks.

For the most part, concretecontractors will use either film-formingor penetrating sealers. Here’s a look atthe basics:

Acrylics are a popular choiceAcrylic sealers are used frequently bydecorative concrete contractors —indoors and out — for several reasons.“They are inexpensive, they have a niceinitial shine and they provide relativelygood protection against water andchloride [salt] intrusion,” observesChurray. But you need to be careful.There are many different grades ofacrylic sealers, he says.

Max Iwaniec, owner of SilverbackSealants in Salt Lake City, says thatacrylic sealers are thin and allow theconcrete to “breathe.” However, he alsoobserves they “can break down fasterthen other coatings.”

Solvent-based acrylics enhance colorbetter than water-based technology,reports Glessner. But, he adds, it’simportant to understand that many of



Concrete sealers at-a-glanceCharacteristics of concrete sealers varydepending on the specific formulation, buttypically the following applies to these most-commonly used concrete sealers:

Acrylic sealers● Film-forming● Typically UV stable● Solvent-based formulas have a glossy, color-

enhancing sheen ● Water-based formulas not as shiny, but sheen

can be built up in layers● Can be tinted● Provide relatively good protection ● Good adhesion to concrete● Easy to apply and repair● Inexpensive and easy to obtain

Epoxy sealers● Film-forming● Aesthetically very

pleasing; available incolors

● Glossy finish● More durable than

acrylics● Excellent chemical

resistance● Aromatic versions are

not UV stable; aliphaticversions are UV stable

● Requires carefulpreparation andapplication, butgenerally good bonding

● Can be very expensive

Urethanes● Film-forming● Very glossy finish● Provides a hard, durable surface● Excellent chemical resistance● Aromatic versions are not UV stable;

aliphatic versions are UV stable● May have bonding problems● More expensive than acrylics

Silanes/Siloxanes● Penetrating (reactive)● Don’t change surface appearance; no gloss● Excellent water repellency● Easy to apply● Twice as much as acrylics

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Vollmer emphasizes that it isimportant to mop several timeswith clean, clear water. “The No.1 problem is using water that’snot clean and not cleaning yourmop regularly. Then, wait for thefloor to dry before sealing.”

“Over acid stains or over acidcleaners, you need to neutralizethe surface before sealing,” saysGlessner. “Water-based acrylicsare particularly prone to destabi-lization in contact with acid.”

(Neutralize by adding a basic materialsuch as baking soda or ammonia.Flushing with plain water does notneutralize an acid).

Mark Donaldson, director ofoperations for Skookum Floors USA inSeattle, cautions, “Each system requiresdifferent surface preparation, althoughyou will almost always find that thesurface must be free from all sealers, waxes,dust contaminates and other potentialbond breakers. Some systems require aminimum surface profile, while othersrequire the product to be scrubbed intothe surface. Always read the manufac-turers’ recommendations for installation.”

Iwaniec agrees. “It is very important torefer to the technical data sheets andmaterial safety data sheets for the product

environments. Urethane isdesigned to be able to last thelongest. It is thinner than anepoxy coating, but still has thehigh impact durability.”

On the down-side,urethanes and epoxies aremore expensive than acrylicproducts. Most are generallyconsidered for indoor-use-only(although Vexcon’s newBreathable Technology epoxyand urethane systems areformulated for both exterior andinterior applications) because they aresensitive to moisture, and they typicallyrequire specific surface preparation andcareful application.

If quick turn-around time isimportant, these products may not bethe way to go, reports Wes Vollmer, adecorative concrete consultant andowner of Alternative Finishes in SanAntonio, Texas. “The time requirementsfor epoxy and urethane are huge — 12 to16 hours dry time for heavy traffic —depending on the specific product.Acrylics usually dry very quickly.”

Urethanes can last five years to eightyears; epoxies can last five years to 15years. Life-expectancy can be dramat-ically increased with the use of a well-

maintained sacrificial wax. Both epoxyand urethane are reported to be difficultto repair.

Penetrating sealersBecause they actually penetrate into theconcrete surface — 1⁄8 to 3⁄16 of an inch onaverage, Churray says — these sealersare particularly effective. Glessnerreports silane and siloxane sealersprovide very good water resistance,while fluorinated resins are designed toresist oil penetration.

These sealers are expensive but easyto apply. Because they do not changethe appearance of the concrete surface,they may be a good choice when anatural appearance is desired. However,in some applications, the lack of sheencan be considered a disadvantage.

Churray points out that theseproducts are often used by statehighway departments on bridgesurfaces. “Parking garages are anothergood application.”

Jeffrey Potvin, owner of ArchitecturalConcrete Consultants Inc. of Lutz, Fla.,explains some penetrating sealers areused as a “water” blocker with a film-forming sealer applied on top.

Surface preparation andmaintenance are keys tolongevity“Surface preparation cannot beemphasized enough,” Livingston says.“Proper cleaning, surface pH, surfacetemperature, surface dryness…. Ifthere is any question about whether asurface has been cleaned properly,clean it again!”

What sealer where?The following are examples of typical concrete sealerchoices for various concrete applications:Driveways — acrylic sealers; silane/siloxane sealers;

exterior epoxies and urethanesIndoor residential decorative concrete — acrylic sealers;

urethane sealers; epoxy sealersPatios and poolside — acrylic sealers; silane/siloxane

sealersRestaurant and retail spaces — acrylic sealers; urethane

sealers; epoxy sealersIndustrial settings — urethane sealers; epoxy sealers

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to determine proper application.”Depending on the product, applicationtechniques “can vary between brushing,rolling, lambswool applicators,squeeges/trowels, low pressure pumpsprayers and electric airless sprayers.”

Improper application, over-application or applying sealers toothickly can cause problems. Dependingon the product used, two thin coats maybe better than one heavy coat. Orbackrolling or back brushing may berequired. Some products are moreforgiving than others. Other times youmay have to sacrifice ease of applicationfor durability.

“You have to be real careful aboutover-application,” says Potvin. “Therewill be a recommended film thickness youneed to follow to ensure correct curing.”

Longevity of a sealer usually dependson the wear-and-tear of the surface andthe maintenance schedule. One of thebiggest problems is maintaining thesurfaces properly. Vollmer recommends,“Use the proper chemicals to clean thefloors — watch out for ammonia andother harsh chemicals and cleaners. Usecleaners compatible with the [sealerand/or wax] used.”

Potvin says water latents (mineraldeposits) can also cause problems — anddo at a lot of theme parks — so it’simportant to remove puddles andstanding water.

Manufacturers and contractors alikerecommend routine inspection of thesealed surface. Moisture should notpenetrate the surface if it is well-maintained. Similarly, if the pores of theconcrete surface are sealed correctly,mold and mildew should not become aproblem.

Start with the application;then make your choiceThere is a sealer for just about everyconcrete application — horizontal andvertical, as well as concrete pavers,masonry, stucco, unglazed tile, naturalstone, manufactured stone and brick.

However, “there is no one sealer thatcan be used for all applications,”Livingston points out. He suggests you

ask yourself many questions beforeselecting or specifying a sealer.

For example: Are you concernedabout UV resistance? Abrasionresistance? Moisture, stains orchemicals? What are your state andlocal regulations regarding solvent-based products? Is there vegetationnearby the project that might bedamaged by solvent-based products?How long will the sealer last? Does themanufacturer provide a warranty?

Don’t be afraid to ask for help.“Sealers and coatings require aneducated experienced installer tosuccessfully select and ultimatelyinstall,” explains Donaldson. “It isimportant to have a close relationshipwith the manufacturer and have all therequired variables brought to the tablebefore selecting and installing a sealer orcoating system. As a beginner the easier-to-install systems usually consist ofacrylic-based or one-component



Film Forming/Penetrating Sealer Selection ChartChemical Classification Epoxy Acrylic Modified Silane Siloxane Aliphatic

Acrylic Urethane

Primer Required ✔ No No NA* NA* ✔

Adhesion ASTM 4541 5 4 4 NA NA 3

Application Rate sq.ft./gal 75-125 200-300 200-300 125 125 75-125

Exterior Gloss Retention 3 5 4 NA NA 5ASTM G-53

Interior Gloss Retention 5 5 5 NA NA 5ASTM G-53

Chemical Resistance 5 3 3 2 2 4ASTM D1308

Abrasion Resistance 4 2 2 NA NA 5ASTM D4060

Impact Resistance 4 3 3 NA NA 5ASTM D2794

Non Skid Properties 3 3 3 3 3 3ASTM D2047

Non Skid Applied 5 5 3 3 5ASTM D2047

Dry Time ASTM 1640 3 5 5 5 5 4

UV Stability ASTM G-53 3 5 5 5 5 5

Meets VOC Regulations ✔ ✔ ✔ ✔ ✔ ✔ASTM D3960 25% solids 25% solids

must meet must meetASTM C1315 ASTM C1315

Water Resistance 5 2 4 NA NA 3ASTM D1308

Water Repellent ✔ ✔ ✔ ✔ ✔SSW110C

Water Proofing ✔ ✔ ✔ ✔TTP1411, TTP1098

Breatheability 2 3 5 5 5 2ASTM D1653B

Rating: 1-5 5=Best

*NA: These are penetrants and do not change the concrete sur-face properties.

This chart was created by Darryl Manuel of Vexcon ChemicalsInc.For more information on ASTM Standards, visit www.astm.org.

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systems. These are a good steppingstone to eventually move into themulti-component, harder, morechemical- and wear-resistant systems.”

Doug Carlton, owner of CarltonConcrete Co. in Visalia, Calif., says thatwhile sealers can be a difficult area tograsp, it is an area that contractors shouldthoroughly explore. “I believe acontractor should only seal with productsthey learn inside and out. Sealer is theAchilles’ heel of decorative concrete.The secret is becoming comfortable withthe product you are using.”

Unfortunately, what you may needto know about concrete sealers isn’tnecessarily cut-and-dry. Some manufac-turers combine technologies for hybridproducts; such as blending acrylic andurethane or acrylic and siloxane. Inother cases, additives are introduced tohelp solve some potential problems. Forexample, fine grit or silica is sometimesincorporated to provide slip resistance.

Some sealers can be used incombination with others for enhancedresults; for example, applying urethaneover epoxy, or an acrylic sealer over apenetrating sealer. If you layer sealerproducts, though, be sure to usecompatible products.

“In most cases, stick with the samemanufacturer,” advises Potvin. “Mostcontractors aren’t chemists and arelooking at dollar signs rather thancompatibility. The [compatibility]problems often don’t show up until later.”

It’s more than a pricedecisionIn making your final decision about asealer, remember the sealer is a smallpart of the overall cost of a project. AsChurray points out, “It’s not the placeto save pennies. You rely on customersatisfaction and word of mouth that youdo quality work.”

Donaldson says, “We like to relateprice to cost. A less expensive systeminitially might add up to a costly mistakedown the road. Imagine saving 25 centsa foot initially but having to shut downoperations in a year to refinish a wornand damaged sealer system. Explain this

to the customer and always offer acouple options for their review.”

“So many people get stuck using onetype of product because they don’t knowwhat else is out there,” Iwaniec says. “It isimportant to try more than one productso you can compare your end results.”

If you can inform your customerabout various concrete sealer products,you convey the appearance of someonewho is knowledgeable and up-to-datewith technological changes in the

industry. And some customers are willingto pay more for a knowledgeablecontactor and a better product.

After all, making the right sealerchoice enhances and prolongs the life ofyour hard work. Learning about theoptions out there and getting the supportand technical assistance you need from areputable sealer manufacturer makesgood business sense.




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Texture Crete

Texture Crete, manufactured by Life Deck, is apolymer-modified cementitious coating that can be

applied to existing concrete surfaces as well as plywooddecks. The coating creates a decorative and safe texturedfinish with numerous color and texture options.

Texture Crete has been on the market since 1987. Theproduct’s bonding and weathering capabilities have beenwell tested at hundreds of apartment and commercialbuildings, top-end hotels, and residential decks andpatios. It was specified by 7-Eleven for store entrywaysbecause of its ability to withstand heavy abuse.

Life Deck uses highly concentrated acrylic polymers inTexture Crete, which gives the coating strength andflexibility as well as excellent weathering characteristics.Designed for driveways, walks, patios, garage floors andpool decks, it is easy to apply, low cost and extremelydurable. The anti-skid finish makes it an excellent optionfor areas that receive a lot of foot traffic.

Designs — including a stamped look — can be createdby putting down special “Stone Strips” and then skip-troweling over the surface with texturing material.

Texture Crete (when incorporated in the Life DeckAL system) can also be used as an overlay on plywooddecks and has received a Class A fire rating. For interiorsurfaces, the easy-to-clean overlay is used with an epoxyor urethane topcoat.

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Flex-C-Ment

Having attended World of Concrete a bunch of times, Ihave never failed to find something new — a tool,

product, or technique that inspires me to go home, put onthe rubber boots and gloves and play in the mud. This year itwas Stan Yoder, Andy Yoder’s son, applying Flex-C-Mentvertically, then stamping and hand-carving the surface. Stancreated a garden wall with a walk-through archway byoverlaying wood and Styrofoam.

Flex-C-Ment Wall Mix is a cementitious dry mixdesigned specifically for deep wall textures, creating theappearance of various stone and brick patterns. It can beapplied up to 2"-3" thick without sagging. A few applicationsinclude: fireplace surrounds, interior and exterior walls,foundations, retaining walls and chimneys.

I was interested enough to fly out to North Carolina tomeet the Yoders and have a look at their product and facilityfirst hand. (My wife, being from North Carolina, had told methat I needed to experience the hospitality and the food! Iwas not disappointed!) The seminar was refreshing andinformative. Those who attended were challengedartistically as well as ethically.

The seminar was held at their facility, a modest warehouserenovated to manufacture product as well as provide spacefor hands-on training. Company executives, engineers,contractors and concrete finishers all left having learnedsomething new and convinced that the products andtraining were worth the trip.

The products used at the seminar were very easy to use, atwo-part system composed of a liquid modifier and a dry “bagmix” for the vertical wall application. (This was prefaced bya rolled-on bonding agent and a scratch coat.)

The application was incredibly easy. Overworking thematerial while applying it to a wall was the main concern. Theunderlay and overlay products were very versatile and like thewall mix, could be applied over surfaces such as plywood,sheetrock, foamboard, paint or linoleum. In the more adversesituations, reinforcement such as metal lathe and or fiberglassmesh was used. The coloring systems used seemed to be endless:color hardeners, integral colors mixed with the material,integral colors added to a water-based sealer, acid stains etc.

The encouragement and reminders to run our businesseswith honesty and integrity were priceless. I especiallyappreciated the quote from King Solomon in Proverbs 22:29.“Do you see a man who excels in his work? He will stand beforeKings; He will not stand before unknown men.”

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Super-Krete presents penetrating sealerSuper-Krete International, a manufacturer of renewal,restoration and protective surfacing systems forconcrete, introduced a new product, Pene-Krete, at theAIA National Convention and Expo in May. Pene-Krete is a penetrating sealer that waterproofs anyportland cement-based substrate and prepares surfaces

for coating. It is recommended for usewhere water is present in substrates such asretaining walls, basement walls and floors,stucco and other masonry surfaces. Theproduct increases substrate strength, whileaiding cure, and increases coating life asmuch as 300 percent. It retards dusting andpenetration of acids, oils and salts.

Super-Krete systems for coating concreteinclude stamp applications, art deco andnumerous other resurfacing systems as wellas user-friendly and environmentally safewater-based color stains. For moreinformation, call (800) 995-1716 or visitwww.super-krete.com.

New self-leveling topping from MapeiMapei has introduced a new product called Ultratop,which it calls “the perfect canvas for integral colors,stains and dyes.” Ultratop is a self-leveling concretetopping designed for fast-track resurfacing and interiorconstruction of horizontal wear surfaces in high trafficareas. Available in light gray and white, it can bestained to mimic naturalstone, marble, terrazzo orpractically any designimaginable. WhiteUltratop is engineered tomaximize the brillianceof architectural stains,integral coloring agents,unique additives, sealersand coatings. Ultratopusually hardens within three hours and can be stained,sealed or coated just 24 hours after pouring. It isabrasion-resistant and cures to compressive strengths of6,100 psi.

New brackets have added featuresFab-Form Industries, a manufacturer of fabric forms forconcrete, has released the third generation of Fast-Yokemetal bracketsused to formfooters. The newgeneration hasnew features toimprove thespeed andaccuracy of footingformwork, including wedgehanger adjustment instead of a threadedhandle; vertical positioning of the 2 x 4; nailattachment of the 2 x 4 ; thickened base plate; andextra hole in the base plate to enable attachment using3⁄4" metal stakes. “We see the Fast-Form product line as avaluable accessory for contractors working on groundconditions where staking is difficult,” says DavidJaneway, VP sales and marketing for Fab-FormIndustries.” For more information, call (888) 303-3278or visit www.fab-form.com.

Software aids project managementDexter + Chaney has released enhanced ProjectManagement software for Version 11 of its ForefrontConstruction Management Software. ProjectManagement bridges the gap between accounting staffand project managers by providing a standardizedprocess for managing workflow. “At any givenmoment,” says Dexter + Chaney president JohnChaney, “Forefront can give the status of each RFI,


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submittal, change request and change order. ProjectManagement tracks all of these project components — frominitiation to final resolution — by date and detail in an

organized, uniform, easy-to-access system.”

Among other innovations,the program’s new Inboxscreen displays items the teamneeds to address for a specificproject and allows collabo-ration between memberswithout faxing or e-mailing

documents. Viewers may view or print scanned documentsand reply to RFIs, submittals, transmittals, memos or changerequests.

For more information, call (800) 875-1400, [email protected] or visit www.dexterchaney.com.

Wet screed new fromWackerWacker has introduced a wetscreed that bridges the gap forcontractors who are looking foran economical and faster way tostrike off concrete but don’t needto invest in larger truss screeds.The Wacker wet screed ispowered by a reliable Hondaengine and is offered in a varietyof blade lengths and widths.

Additional versatility is available due to the adjustableeccentric weights. The exciter can be adjusted to sevendifferent positions, allowing the unit’s amplitude to bematched to the application. It is fully enclosed, whichprotects the operator and promotes lower maintenance. Formore information, call 800-770-0957.

Longer finishing trowels from MarshalltownMarshalltown’s newextended-lengthfinishing trowels canincrease the areafinished with every stroke.Each tool extends the trowel’s blade lengthby either 2 or 4 inches over comparable concrete finishingtrowels. The extended trowels come with different types ofhandles, including wood and DuraSoft, and either high-carbon steel or blue steel blades. For more information, call(770) 521-1010.

New tuck point blades from Diamond BackThe new Wafer Style Tuck Point Blades from Multiquip’sDiamond Back Diamond Cutting Division boast excellentgrinding speeds an inexpensive price. Eight wafer tuck blades


are offered, with double and triple stylemodels ranging in diameter from 4 to 7inches and in thickness from 1⁄4" to 3⁄8"inch. With their streamlined bladethickness, operators can easily removedamaged grout and mortar betweenbricks and in concrete blocks infoundation walls in less than half the

time of a conventional tuck blade. Fresh mortar can then bereapplied to strengthen and restore the surface to its originalfinish. The blade can be used with most right-angle grinders.

EZ cement mixerThe EZ Flipper was designed to make it easy to mix cementfor small to medium jobs. Simple to use, compact anddurable, the EZ Flipper lets two people mix a 40, 60 or 80pound bag of cement in less than a minute. Invented by aprofessional, the rectangular, tub-shaped bag with a handle ateach of its four corners costs $32.95 and mixes cement, sandand water in a short time by flipping and rolling themtogether. The concrete can be poured from the bag directlyinto the hole, formwork or mold. The manufacturerrecommends it for use in making stepping stones, custom-designed pavers, paths, personalized water features, blockwalls, concrete sculptures and moldings, garden edgings,mock dry stone walls, steps, drains and more. For moreinformation, call (407) 884-9490 or [email protected].

Waterproofing membrane is breathableSto Watertight Coat is a flexible and breathablewaterproofing membrane based on a unique combination ofacrylic emulsion, portland cement and fine fibers. WatertightCoat is both flexible and abrasion-resistant. You can use itwaterproof all types of above- or below-grade concrete andmasonry, including foundations, block walls, balconies,




http://www.dexterchaney.com


parapets, planter boxes, water tanks andfountains.

Liquid stone adds strengthand beautyThe Mr. Granite QPC Quartz PolymerCoating System — a high-buildwaterborne system consisting of threeseparate waterproof components — isboth a beautiful granite finish and adurable monolithic surface. It combinesexcellent chemical and impactresistance with non-slip characteristicsfrom its cultured quartz stone content.It is also very UV resistant.

Each component was speciallyengineered with the same cross-linkingpolymeric backbone that gives thesystem superior inter-coat adhesion.The system bonds directly to new orweathered concrete, wood, gypsumboard and a variety of other substrates.Thin and lightweight enough to beapplied vertically or horizontally, itswaterproofing properties make thesystem ideal for everything frombasements to pool decks. Designs of tile,brick and flagstone can be incorporatedinto the finish. The materials are non-hazardous and clean up with soap andwater prior to cure. For moreinformation, visit www.mrgranite.comor call (941) 758-1737.

Scraper and grinder easefloor prepStow’s new Floor Covering Scraperweighs only 130 pounds, but it canremove direct glue-down carpet,hardwoodflooring,linoleum,non-slip floorcoverings,vinyl tile andany otheradhesive,cement or

mastic. The scraper is driven by a 3⁄4-hpfan-cooled capacitor-start motor andconstructed with unitized, welded steelplates for added strength. It features aheight-adjustable handle that can beeasily folded for transportation orstorage. The scraper is only 23 incheswide, which makes it ideal for workingin narrow, space-restricted areas.

Stow’s new DFG Series FloorGrinders can remove grease, dirt, rubbercarpet backing and industrial residues onyour floors quickly, effectively and withminimal operator effort. Three dual

head floorgrinders areoffered andeach is ideal forgrinding andpolishingconcrete,asphalt,terrazzo andmarble floors.

The DFG Series is powered by Hondagasoline or electric motors and a largeselection of attachments make the floorgrinders perfect for use by concreterepair contractors, industrial buildingmaintenance specialists and surfacepreparation contractors. For moreinformation, call (800) 421-1244 or visitwww.stowmfg.com.

Newgrout saw fromMarshalltownMarshalltown has

released a new grout saw featuring thecompany’s patented, resilient DuraSofthandle, which allows for greater controland comfort and also features a fingerguard for safety. Adding to the saw’scontrol and ease of use is a thumb restatop the die-cast aluminum body, directlyover the maximum pressure point. Thesaw has a 2" abrasive blade coated withtungsten carbide. For more information,visit www.marshalltown.com.



http://www.mrgranite.com

http://www.stowmfg.com

http://www.marshalltown.com

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vol. 3 iss. 3 june/july, 2003 - concrete decor · 4• • june/july 2003 decorative concrete tips...

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