Decorative Concrete Decorative Concrete PresentationPresentation

by Dennis Ahalby Dennis Ahal

Ahal Contracting Co., Inc.Ahal Contracting Co., Inc.

There are many methods and uses of There are many methods and uses of decorative concrete, for both exterior decorative concrete, for both exterior and interior applications.and interior applications.

Concrete has come a long way from Concrete has come a long way from when it was used as a pathway to when it was used as a pathway to keep you out of the dirt.keep you out of the dirt.

One of the oldest methods used was scored One of the oldest methods used was scored joints, to not only control cracks but also to joints, to not only control cracks but also to create a design.create a design.

Exposed aggregate is a method that Exposed aggregate is a method that has been around for a long time. The has been around for a long time. The best, most durable method is to use a best, most durable method is to use a high proportion of aggregate in the high proportion of aggregate in the mix rather than seeding the surface.mix rather than seeding the surface.

This mix looks extremely dry but is actually a 4” This mix looks extremely dry but is actually a 4” slump concrete that has a high aggregate slump concrete that has a high aggregate content. The concrete is struck off. Any surface content. The concrete is struck off. Any surface voids are filled in with concrete, not with paste.voids are filled in with concrete, not with paste.

The surface is bull-The surface is bull-floated and closed up floated and closed up with a hand float. with a hand float. Again, any void areas Again, any void areas are filled in with are filled in with concrete and not concrete and not paste.paste.

A surface retarder containing dye is sprayed A surface retarder containing dye is sprayed on the surface to ensure complete coverage. on the surface to ensure complete coverage. The slab is then covered with a The slab is then covered with a polyethylene sheet to prevent air contact polyethylene sheet to prevent air contact with the surface.with the surface.

Either later that day or the next day, Either later that day or the next day, depending on temperature, the surface is depending on temperature, the surface is broomed and washed to remove the surface broomed and washed to remove the surface cementitious coating and expose the cementitious coating and expose the aggregate.aggregate.

The view when The view when approaching the walk approaching the walk appears as a gravel appears as a gravel path. The smaller the path. The smaller the aggregate, the denser aggregate, the denser the amount at the the amount at the surface.surface.

One of the ways One of the ways of disguising of disguising expansion joints is expansion joints is through the use of through the use of brick borders or brick borders or imprinted imprinted concrete strips.concrete strips.

One of the ways of One of the ways of decorating decorating concrete is through concrete is through the use of integral the use of integral color. Bag color. Bag material has been material has been used for many used for many years but some years but some coloring systems coloring systems now use a liquid now use a liquid color agent.color agent.

The color always The color always appears darker while the appears darker while the concrete is wet.concrete is wet.

This integrally colored concrete is being This integrally colored concrete is being used to grout rocks in a small decorative used to grout rocks in a small decorative stream bed.stream bed.

This walkway was This walkway was designed to designed to resemble a dirt resemble a dirt pathway which pathway which would be handicap would be handicap accessible even accessible even after a rain.after a rain.

This walkway consists of traprock aggregate This walkway consists of traprock aggregate and charcoal gray integral color. It is being and charcoal gray integral color. It is being given a light acid wash to remove any film given a light acid wash to remove any film residue before being sealed with a residue before being sealed with a penetrating sealer.penetrating sealer.

Notice the high aggregate content at the Notice the high aggregate content at the surface.surface.

When dry the walkway appears much When dry the walkway appears much lighter, even though is has been sealed.lighter, even though is has been sealed.

You can use a glossy surface sealer, but You can use a glossy surface sealer, but this must be maintained since it will this must be maintained since it will deteriorate through wear and UV deteriorate through wear and UV breakdown.breakdown.

This area received a light colored integral This area received a light colored integral color to blend with the aggregate so it color to blend with the aggregate so it appears as a gravel path. The area where appears as a gravel path. The area where sprinklers have wet the walk appear darker. sprinklers have wet the walk appear darker. This is what a glossy surface sealer would This is what a glossy surface sealer would look like.look like.

This project used This project used the same the same aggregate but two aggregate but two different integral different integral colors to highlight colors to highlight the main walk the main walk area and the area and the borders.borders.

Expansion joints are used for crack control Expansion joints are used for crack control and to show a pattern. Control joints are and to show a pattern. Control joints are somewhat difficult to install in exposed somewhat difficult to install in exposed aggregate since the joint tool tends to push aggregate since the joint tool tends to push the aggregate down and leave an area of the aggregate down and leave an area of plain grout.plain grout.

This walk received This walk received areas of integrally areas of integrally colored concrete colored concrete along with plain along with plain gray concrete to gray concrete to create a contrast. create a contrast. Integral colors give Integral colors give the concrete a tone the concrete a tone but not an intense but not an intense color.color.

This amusement park entrance used This amusement park entrance used integrally colored concrete with diamonds of integrally colored concrete with diamonds of surface applied color hardener, which surface applied color hardener, which created interest and hid drains that occurred created interest and hid drains that occurred at some of these areas.at some of these areas.

These adjacent areas used two different These adjacent areas used two different integral colors. The bench wall that integral colors. The bench wall that separates them is also concrete.separates them is also concrete.

The second method of coloring concrete is The second method of coloring concrete is through the use of dry shake surface applied through the use of dry shake surface applied color hardener. This method gives a deeper, color hardener. This method gives a deeper, more intense color.more intense color.

The material which is broadcast onto the The material which is broadcast onto the surface adds to the durability of the surface.surface adds to the durability of the surface.

The color hardener consists of color, The color hardener consists of color, cement, and silica quartz aggregate. cement, and silica quartz aggregate.

A more durable emery aggregate can be A more durable emery aggregate can be used for high traffic areas.used for high traffic areas.

The correct The correct application for this application for this color hardener is two color hardener is two coats, usually at 90 coats, usually at 90 degree angles from degree angles from each other when each other when possible, to assure possible, to assure adequate coverage.adequate coverage.

As you can tell from As you can tell from the lack of hard hats the lack of hard hats and the model of the and the model of the truck, this photo was truck, this photo was taken a number of taken a number of years ago. However, years ago. However, the process is still the process is still pretty much the pretty much the same. The color is same. The color is worked into the worked into the surface with a bull surface with a bull float.float.

The edges are The edges are run with a tool run with a tool to create a nice to create a nice clean edge.clean edge.

In this photo, a In this photo, a stamping plastic stamping plastic is laid on the is laid on the surface and surface and imprinting tools imprinting tools are placed.are placed.

The tools are The tools are tapped into the tapped into the concrete surface to concrete surface to create a pattern.create a pattern.

The finished areas show a pattern with The finished areas show a pattern with expansion joints used to control cracking. expansion joints used to control cracking. These joints are imprinted deeper to receive These joints are imprinted deeper to receive a grout in the joints.a grout in the joints.

The grouting makes the cobblestone pattern The grouting makes the cobblestone pattern look more authentic. The advantage of look more authentic. The advantage of using concrete is that the slab is reinforced using concrete is that the slab is reinforced with rebar and stays together as one unit.with rebar and stays together as one unit.

This close-up of the grout shows the loafing This close-up of the grout shows the loafing of the cobblestone pattern, created by of the cobblestone pattern, created by stamping plastic and deeper joints. Since stamping plastic and deeper joints. Since the slab works as a unit, there is no stress the slab works as a unit, there is no stress on the individual grout joints.on the individual grout joints.

This grouted walkway is a running bond This grouted walkway is a running bond brick pattern.brick pattern.

This basket weave This basket weave patio has other patio has other colors broadcast colors broadcast onto the surface to onto the surface to create interest.create interest.

This walkway and This walkway and step project was step project was placed next to an placed next to an old stone old stone foundation. foundation. Imagine the hand Imagine the hand work that would be work that would be required to fit required to fit pavers adjacent to pavers adjacent to the stone.the stone.

This restaurant area used an 18” x 18” tile This restaurant area used an 18” x 18” tile with grouted joints.with grouted joints.

This atrium area This atrium area used surface used surface applied color applied color hardener with hardener with tooled joints, tooled joints, which were which were grouted.grouted.

This project used multiple colors and This project used multiple colors and patterns to define areas and foot traffic patterns to define areas and foot traffic patterns.patterns.

The areas of the landings were adjusted The areas of the landings were adjusted slightly to fit the steps.slightly to fit the steps.

This was a 2” topping over existing concrete This was a 2” topping over existing concrete which contained many joints. A ¼” rubber which contained many joints. A ¼” rubber mat was used to separate the topping from mat was used to separate the topping from the sub-slab.the sub-slab.

Polypropylene fibers were used in a pea Polypropylene fibers were used in a pea gravel mix, and dry shake color hardener gravel mix, and dry shake color hardener was applied. was applied.

This area received imprinted color hardener This area received imprinted color hardener as an accent, with a picture frame tooling of as an accent, with a picture frame tooling of the joints. This is actually an extra step and the joints. This is actually an extra step and needs to be defined in the specification.needs to be defined in the specification.

This is an imprinted area adjacent to an This is an imprinted area adjacent to an integrally colored salt finish area. The integrally colored salt finish area. The banded areas are cut with hand tools.banded areas are cut with hand tools.

The salt finish is achieved by broadcasting The salt finish is achieved by broadcasting rock salt and troweling it into the surface. rock salt and troweling it into the surface. The salt is washed away a day or two later, The salt is washed away a day or two later, leaving voids.leaving voids.

This area consists of an integrally colored This area consists of an integrally colored field which received a broom finish. The field which received a broom finish. The borders have color hardener and are hand borders have color hardener and are hand cut. This method, while expensive, is less cut. This method, while expensive, is less costly than pavers or bricks cut to fit this costly than pavers or bricks cut to fit this circular pattern.circular pattern.

This area was also This area was also hand cut. These hand cut. These types of areas were types of areas were used as accents so, used as accents so, although they cost although they cost more, they did not more, they did not materially affect the materially affect the entire project cost.entire project cost.

The darker borders were poured with the The darker borders were poured with the main areas in order to save labor on forming main areas in order to save labor on forming and finishing.and finishing.

This sample area shows a tooled joint being This sample area shows a tooled joint being installed in fresh concrete.installed in fresh concrete.

Strips of masonite are placed in the joint to Strips of masonite are placed in the joint to separate different colors as they are applied separate different colors as they are applied to various areas of the surface.to various areas of the surface.

Fields and borders can be placed at the Fields and borders can be placed at the same time, saving forming and placing costs same time, saving forming and placing costs while receiving different colors and finishes.while receiving different colors and finishes.

Separate colors are being applied to Separate colors are being applied to adjacent areas of the same slab.adjacent areas of the same slab.

The color hardener is floated and troweled The color hardener is floated and troweled into the surface.into the surface.

Edgers are run on Edgers are run on the separate the separate colors before colors before imprinting.imprinting.

The final product, showing multiple colors The final product, showing multiple colors and finishes:and finishes:

This area received a highlight, or flashing, of This area received a highlight, or flashing, of other colors to add an accent.other colors to add an accent.

This shows a fishscale pattern merged into a This shows a fishscale pattern merged into a running bond pattern, but the slab was running bond pattern, but the slab was placed as one piece.placed as one piece.

Notice the expansion joint separating two Notice the expansion joint separating two slabs and the herringbone pattern placed slabs and the herringbone pattern placed with the limestone border, which is a with the limestone border, which is a separate color and pattern.separate color and pattern.

Logos can be incorporated into the design.Logos can be incorporated into the design.

Another logo:Another logo:

Notice the grouted joints:Notice the grouted joints:

Another method of Another method of imprinting requires imprinting requires the use of a release the use of a release agent, which agent, which prevents imprinting prevents imprinting tools from sticking tools from sticking to the slab surface.to the slab surface.

The slab is The slab is finished as finished as previously.previously.

The release agent is broadcast onto the The release agent is broadcast onto the surface.surface.

The release agent most often is of a The release agent most often is of a contrasting color to the color hardener.contrasting color to the color hardener.

Texture mats are placed on the surface of Texture mats are placed on the surface of the slab. These mats impart not only a the slab. These mats impart not only a design or pattern, but also a texture.design or pattern, but also a texture.

This is an overhead view of dry shake color This is an overhead view of dry shake color hardener on the surface, before and after hardener on the surface, before and after being floated and troweled into the surface.being floated and troweled into the surface.

There is also a release agent on a portion of There is also a release agent on a portion of the surface (gray area), some of which has the surface (gray area), some of which has been imprinted with a texture mat.been imprinted with a texture mat.

Texture mats come in various sizes and Texture mats come in various sizes and textures.textures.

They are tapped They are tapped into the slab into the slab surface to impart surface to impart both pattern and both pattern and texture.texture.

Texture mats are flexible, to allow imprinting Texture mats are flexible, to allow imprinting next to vertical surfaces such as windows next to vertical surfaces such as windows and walls.and walls.

Sometimes they are overlapped to eliminate Sometimes they are overlapped to eliminate excess pattern lines.excess pattern lines.

Notice the Notice the clefting on this 5’ clefting on this 5’ x 5’ slate texture x 5’ slate texture mat.mat.

This is a 12” pattern This is a 12” pattern with little contrast with little contrast between the color between the color hardener and the hardener and the release agent. release agent. Some of the release Some of the release agent remains on agent remains on the slab surface, the slab surface, giving highlights giving highlights and a feeling of and a feeling of depth to the depth to the texture.texture.

This shows the This shows the use of two use of two colors and colors and three patterns. three patterns. The border The border against the wall against the wall was placed with was placed with the main gray the main gray slate area.slate area.

This curbing is not limestone. It is concrete This curbing is not limestone. It is concrete with white color hardener applied.with white color hardener applied.

This area was imprinted and textured to This area was imprinted and textured to resemble an old, used brick.resemble an old, used brick.

Chemicals were used to stain the surface Chemicals were used to stain the surface and add color variation.and add color variation.

The joints were grouted.The joints were grouted.

The use of multiple colors and textures can The use of multiple colors and textures can add interest, and visually separate areas.add interest, and visually separate areas.

Bands or strips of contracting colors can be Bands or strips of contracting colors can be used to hide expansion joints.used to hide expansion joints.

This shows the use of banding for joint This shows the use of banding for joint control.control.

This project uses a pattern to create a This project uses a pattern to create a defined drive lane. This surface is all at one defined drive lane. This surface is all at one elevation.elevation.

Another method of coloring concrete Another method of coloring concrete is through the use of stains over new is through the use of stains over new or existing concrete, or over toppings or existing concrete, or over toppings which are designed to accept stains.which are designed to accept stains.

Slab surfaces are sectioned off by tape or Slab surfaces are sectioned off by tape or saw cutting to divide stain colors if saw cutting to divide stain colors if patterning is desirable. This area is being patterning is desirable. This area is being taped and stained.taped and stained.

A stencil is being used to create a design.A stencil is being used to create a design.

This stain is being applied by brush to a new This stain is being applied by brush to a new surface.surface.

This stain was applied to an old slab. Notice This stain was applied to an old slab. Notice the variation of stain penetration. the variation of stain penetration.

Do not expect a stain color to be uniform. Do not expect a stain color to be uniform. This is part of the beauty of the product. If This is part of the beauty of the product. If you want it to be all one uniform color, you want it to be all one uniform color, paint it.paint it.

The use of chemicals, as shown on a The use of chemicals, as shown on a previous project, help give this floor a previous project, help give this floor a mottled look.mottled look.

The use of saw cuts separate the various The use of saw cuts separate the various stain colors. The use of chemicals help give stain colors. The use of chemicals help give highlights to various areas.highlights to various areas.

The backsplash The backsplash and countertop and countertop are concrete.are concrete.

Saw cuts, chemicals, and various stain Saw cuts, chemicals, and various stain colors are used to accent this area.colors are used to accent this area.

This floor was This floor was color color hardened, saw hardened, saw cut, and cut, and stained.stained.

The use of two The use of two color stains give color stains give contrast to this contrast to this floor. The saw cuts floor. The saw cuts are only ¼” deep are only ¼” deep to separate the to separate the stain areas so they stain areas so they don’t run together.don’t run together.

The same applies The same applies to this project. to this project. This floor was This floor was specified with no specified with no control joints and control joints and light reinforcing. light reinforcing. The design was The design was saw cut in later at saw cut in later at a depth of ¼”, and a depth of ¼”, and two stains were two stains were applied.applied.

This intricate logo was saw cut and stenciled This intricate logo was saw cut and stenciled on a new floor.on a new floor.

This basement craft area was one of our first This basement craft area was one of our first stain projects, performed at an employee’s stain projects, performed at an employee’s home.home.

This logo is over a topping which was poured This logo is over a topping which was poured without joints, but on which a shrinkage without joints, but on which a shrinkage control admixture was used.control admixture was used.

The stain does not take evenly everywhere. The stain does not take evenly everywhere. Saw cuts were made to separate the stains.Saw cuts were made to separate the stains.

A stencil was used to protect the lettering, A stencil was used to protect the lettering, and the background was sandblasted.and the background was sandblasted.

The overall effect is dramatic.The overall effect is dramatic.

This floor was This floor was colored with a colored with a surface applied surface applied color hardener.color hardener.

Saw cuts were Saw cuts were made and the made and the banded areas banded areas were stained.were stained.

The joints were grouted.The joints were grouted.

This slab is being textured with a texture This slab is being textured with a texture mat.mat.

The border and inset areas are stained to The border and inset areas are stained to create contrast, instead of two colors being create contrast, instead of two colors being used in the finishing process.used in the finishing process.

This patio was placed using a light beige This patio was placed using a light beige color hardener, and a textured slate pattern color hardener, and a textured slate pattern was used. The joints were deepened to was used. The joints were deepened to accept grout.accept grout.

Individual slate blocks were stained using Individual slate blocks were stained using multiple colors of stain.multiple colors of stain.

The joints were then grouted.The joints were then grouted.

The front walk and porch received the same The front walk and porch received the same treatment.treatment.

The vertical surface of the steps was The vertical surface of the steps was colored, textured and stained.colored, textured and stained.

A flowable topping is added over an existing A flowable topping is added over an existing slab.slab.

This slab receives a trowel finish.This slab receives a trowel finish.

The topping is scored, stained and sealed. The topping is scored, stained and sealed. Notice the control joint in the original Notice the control joint in the original building is honored.building is honored.

Many intricate Many intricate designs can be designs can be incorporated.incorporated.

Really bright colors:Really bright colors:

This project consists of a concrete overlay This project consists of a concrete overlay over a base slab. The slab was colored and over a base slab. The slab was colored and stained.stained.

Many designs can be incorporated into the Many designs can be incorporated into the floor surface.floor surface.

High intensity colors are available in certain High intensity colors are available in certain overlays.overlays.

An exterior retail area:An exterior retail area:

Terrazzo strips were used to divide the Terrazzo strips were used to divide the topping into separate areas to receive topping into separate areas to receive different colors of stain.different colors of stain.

The stain has a The stain has a mottled, mottled, leathery look.leathery look.

A sealer was A sealer was applied to the applied to the entire surface entire surface area.area.

A wax was applied over the sealer to take A wax was applied over the sealer to take the wear. The wax can be re-applied the wear. The wax can be re-applied periodically in the high usage areas, without periodically in the high usage areas, without stripping the entire surface.stripping the entire surface.

The terrazzo strips allow for clean, crisp The terrazzo strips allow for clean, crisp joints and corners.joints and corners.

Periodic Periodic maintenance maintenance

keeps the slab keeps the slab looking bright looking bright

and new.and new.

Since this was a topping, the terrazzo strips Since this was a topping, the terrazzo strips could have odd shapes without cracking could have odd shapes without cracking concerns.concerns.

The mottled, leathery look was the result of The mottled, leathery look was the result of the process, not necessarily the intent.the process, not necessarily the intent.

The use of The use of multiple stains multiple stains can add to the can add to the results, as long results, as long as everyone as everyone understands that understands that not every square not every square foot of the slab foot of the slab will accept the will accept the stain the same.stain the same.

The use of stencils and sand blasting The use of stencils and sand blasting created this design in an integrally colored created this design in an integrally colored slab.slab.

The use of surface The use of surface applied color applied color hardener, stencils, hardener, stencils, and sand blasting and sand blasting created the etched created the etched writing look in this writing look in this floor.floor.

A closer look at the writing:A closer look at the writing:

A closer look at the decorative border:A closer look at the decorative border:

Here a thin coat of a high intensity overlay Here a thin coat of a high intensity overlay material is being applied.material is being applied.

Use a separate section to specify Use a separate section to specify decorative concrete.decorative concrete.

Don’t let someone do your decorative Don’t let someone do your decorative concrete work just because they were low concrete work just because they were low bidder on the flatwork.bidder on the flatwork.

Don’t be afraid to negotiate your specialty Don’t be afraid to negotiate your specialty work, or at least qualify your contractors work, or at least qualify your contractors prior to bid time.prior to bid time.

This is a product that is manufactured in This is a product that is manufactured in the field, not a factory. Approved samples the field, not a factory. Approved samples are always a must before starting the are always a must before starting the actual work, so expectations are the same.actual work, so expectations are the same.

The use of decorative concrete is limited The use of decorative concrete is limited only by your imagination.only by your imagination.

Decorative Concrete Decorative Concrete PresentationPresentation

by Dennis Ahalby Dennis Ahal

Ahal Contracting Co., Inc.Ahal Contracting Co., Inc.