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Decorative Concrete
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Seminar Report on Decorative concrete 2015-2016
INTRODUCTION
Decorative concrete is the use of concrete as not simply a utilitarian medium for
construction but as an aesthetic enhancement to a structure, while still serving its
function as an integral part of the building itself such as floors, walls, driveways
and patios.
The transformation of concrete into decorative concrete is achieved through the use
of a variety of materials that may be applied during the pouring process or after the
concrete is cured, these materials and/or systems include but are not limited to
stamped concrete, acid staining, decorative overlays, polished concrete, concrete
countertops, vertical overlays and more.
Dept. of Civil Engg. 1 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Stamped Concrete
Stamped Concrete is the process of adding texture and color to concrete to make it
resemble stone, brick, slate, cobblestone and many other products found in nature
including wood, fossils, shells and many more. This limitless array of possibilities
combined with great durability and lower cost than natural products makes
Stamped Concrete an easy choice for new construction and renovation projects.
The installation consists of pressing molds into the concrete while the concrete is
still in its plastic state. Color is achieved by using Dry Shakes or Color Hardeners,
Powder or Liquid Releases, Integral Colors or Acid Stains. All these products may
be combined to create even more intricate designs.
Stamped Concrete may be used on driveways, patios, commercial roads and
parking lots and even interior floors. Stamped concrete is a desirable finish to
concrete areas, however with time and wear the color dyes fade and the surface
looks patchy and unpresentable. There are many re-coloring options which can
completely restore and rejuvenate the color and presentation of faded stamped
concrete.
Dept. of Civil Engg. 2 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Concrete dyes
Concrete "dyes" take many different forms and compositions and can be used on
both residential and commercial concrete applications, including sound/retaining
walls, bridges, countertops, floors,[1] etc.
Early concrete dyes consisted of generic printing inks that were dissolved in mild
solutions of alcohol and applied to concrete surfaces to add a wide array of color to
plain gray concrete. When alcohol-based dyes are exposed to sunlight, the color
either lightens or fades out completely. Therefore, alcohol-based dyes were more
prevalent in interior applications where direct sunlight or other forms of ultraviolet
(UV) lighting was not present.
Manufacturers later began dissolving the same printing inks in different carriers,
such as acetone, lacquer thinner and other solvents, hoping to achieve increased
penetration levels. In addition, UV inhibiting agents were added to new dyes to
help with the UV instability issues. However, slight fading (5-8% per year) still
occurs when the dye is exposed to direct sunlight.
Colored concrete can be obtained from many ready mix concrete companies and
many have color charts available.
Dept. of Civil Engg. 3 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Acid Staining
Acid staining is not a dyeing or pigment-base coloring systems, but a chemical
reaction. A mixture of water, mineral salts and a slight amount of muriatic acid is
applied to the concrete surface. This chemical reaction with the existing minerals
(primarily lime) in the concrete over a period of one to four hours creates new
earth tone colors on the concrete surface. The concrete surface is later scrubbed to
remove excess stain and neutralized by a basic solution of ammonia and water or
baking soda (less likely to cause whiting later) to help raise the ph level back to
normal level. Due to inconsistencies in the surface level of concrete floor, acid
staining creates a variegated or mottled appearance that is unique to each slab. The
color penetration ranges from 1/16 to 1/32 of an inch. Older exterior concrete
surfaces may not color as well as interior surfaces because the environment has
leached or percolated out the mineral content. As well, any exposed aggregate
(rocks) in worn concrete will not accept staining.
Chemicals commonly used in acid staining include Hydrochloric acid, Iron
chloride and Sodium bicarbonate.
Dept. of Civil Engg. 4 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Water Based Staining
Water Based Stains are similar to acid based stains in the sense that one can still
achieve a translucent look like acid; some stains are able to achieve an opaque
color and/or a translucent effect. The main difference is that acid stains react to the
concrete and change the physical make up of the concrete material, whereas water
based stains are more of a "coating" that bonds with the concrete. There are many
variations of water based stains that have come into the decorative concrete
industry that perform in a number of different ways. Some are polymer based,
acrylic and epoxy.
Overlaying
Concrete overlays date to the 1960s when chemical engineers from some of the
larger, well known chemical companies began to experiment with acrylic paint
resins as modifiers for cement and sand mixes. The result was a thin cementitious
topping material that would adhere to concrete surfaces and provide a newly
resurfaced coating to restore the worn surface. Concrete overlays lacked the long-
term performance [2] characteristics of acrylic resins. Acrylic resins provided good
Dept. of Civil Engg. 5 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
UV resistance, but lacked long term water resistance and adhesion characteristics
needed to provide a long term and permanent solution.
Polymer cement overlays
Construction of a polymer cement overlay to change asphalt pavement to brick
texture and color to create decorative crosswalk and traffic calming in high-
pedestrian area.
Polymer cement overlays, consisting of a proprietary blend of Portland cements,
various aggregates and polymer resins, were introduced over 20 years ago. The
purpose of adding a polymer resin to the cement and aggregate is to greatly
increase the performance characteristics and versatility of conventional cements,
mortars and concrete materials. Unlike conventional cement and concrete mixes,
polymer cement overlays can be applied thinly or thickly without fear of
delamination or typical product failure. In addition, polymer cement overlays are
much more resistant to damage from salt, petrochemicals, UV, harsh weather
conditions and traffic wearing.
Dept. of Civil Engg. 6 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Originally intended for use as a thin surface restoration material for concrete
substrates, polymer cement overlays were introduced into the architectural
concrete and commercial flooring industries in the early 80s. Subsequently, its use
in these industries has become standard. Polymer cement overlays are regarded as
economical in providing long term, durable renovation without the need for costly
and continuous repairs associated with deteriorating concrete surfaces.
Polymer cement overlays are used for interior and exterior applications ranging
from:
Skim coat/broom finish concrete resurfacing – Restore and protect damaged,
pitted, flaking and stained concrete back to the look of a new concrete
surface.
Concrete regrading & leveling – Repair and level concrete surfaces that have
settled.
Existing substrate redecorating and renovating – Alter the appearance of
existing concrete or wood substrates through applying "thin stamped" or
"thin stained" overlays, creating new textures, colors and designs. For use on
commercial or resident pool deck, this frequently takes the form of "splatter
textures" or "knockdowns," in which polymer cement is applied to the
existing concrete substrate in a moderately textured finish (average of 1/8”
Dept. of Civil Engg. 7 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
thickness) in various patterns. Often, the texture is knocked down with a
trowel to slightly modify the appearance and feel of the finished application.
Stamped overlays
Rubber imprinting tools (stamps) are impressed into thin pre-mixed concrete
overlay material shortly after it is placed to create natural stone or brick textures.
These rubber imprinting tools are manufactured from molds created from authentic
stone or wood. Release agents are used to help release the stamps from the
concrete without sticking. Release agents come in either a liquid or powder form
and are available in a wide range of colors.
Epoxy coating
Applied over acid stained, dyes and/or overlays to seal and protect. Some epoxies
are also colored.
Polishing
Concrete can be polished with Mechanical grinders and diamond pads of
increasing grit sizes. Diamond pads come in many grit or mesh sizes. Common
sizes start with 6 grit and can go up to 8500 grit although concrete can only
maintain a shine of about 800 grit, it can be helped by adding a concrete hardener
such as sodium silicate or lithium silicate which will allow concrete to hold a 1800
Dept. of Civil Engg. 8 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
through 3000 grit shine. The work is accomplished in multiple stages by passing
over the concrete with successive grit diamond pads until it has a hard-glassy
finish. Both acid stains and concrete dyes can be used during the polishing process.
Engraving
Existing concrete can be remodeled by cutting lines and grooves into its surface.
Geometric patterns, straight or curved lines and custom designs can be cut directly
into the surface of the concrete creating the look of tile, flagstone, cobblestone and
many other common surface patterns. This is usually achieved using tools like an
angle grinder fitted with diamond blades, but is more effectively accomplished
using specialty tools designed specifically for cutting designs into the concrete.
Form liner
Concrete can also be cast into unique and detailed designs using urethane form
liner. These projects can be seen around the United States and the world, usually
on sound/retaining walls, building exteriors, and bridges.
Generally, this process starts with the sculptor, who creates the design to be used in
the concrete using clay, polyurethane or wax. When the original art is complete, a
cast is made using synthetic liquid rubber, and from this cast, form liners are
produced in the reverse image of the original.
Dept. of Civil Engg. 9 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
The form liner then acts as a mold for the concrete to be formed against. Once the
concrete is set, the form liner is stripped from the hardened concrete surface. The
concrete is permanently textured with the pattern of the form liner.
Architectural & Decorative Concrete
Concrete is one of the most widely used construction materials in the world. One
special subset is called architectural and decorative concrete, which refers to a
substance that provides an aesthetic finish and structural capabilities in one. This
material is made to be seen. Whether creating broad expanses or minute details,
concrete permanently captures the chosen look. Achieving an architectural or
decorative appearance usually requires that something different be done to the
concrete. Whether that involves special forms, special finishing techniques, or
special ingredients, the variety of effects is almost unlimited.
Original art by Carolyn Braaksma, Denver, Colorado
Concrete is one of the most widely used construction materials in the world. One
special subset is called architectural and decorative concrete, which refers to a
Dept. of Civil Engg. 10 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
substance that provides an aesthetic finish and structural capabilities in one. This
material is made to be seen. Whether creating broad expanses or minute details,
concrete permanently captures the chosen look. Achieving an architectural or
decorative appearance usually requires that something different be done to the
concrete. Whether that involves special forms, special finishing techniques, or
special ingredients, the variety of effects is almost unlimited.
White Portland Cement: A Key Ingredient
White cement concrete is a brilliant architectural
material. Whether plain or pigmented, it allows for a broad spectrum of colors -
from bright whites and pastels to saturated colors. It can be textured, patterned, or
shaped to almost any form, allowing architects to be truly creative in their designs.
Imagination becomes architectural reality with white cement.
What makes white cement so architecturally appealing is its versatility. It can be
used for:
o Cast-in-place concrete
Dept. of Civil Engg. 11 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
o Precast concrete
o Tilt-up concrete
o Repair and retrofit applications
o Masonry and mortar
o Stucco finishes
Good Looks and More
From large to small items, structural to decorative members, white cement is the
key to good looking concrete and masonry construction. A versatile appearance
allows white cement concrete, which is pigment-friendly, to fit in with any
environment. Beyond aesthetics, its light color offers energy efficiency and safety.
These qualities can be used to advantage for:
o Bridge parapets and barrier medians
o Light reflective floors
o Exposed architectural concrete
o City streetscapes: curbs, gutters and planters
Dept. of Civil Engg. 12 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
o Landscaping
o Building accents
Whether inside or outside, white cement concrete provides a hard-wearing, durable
surface that stands up to heavy use.
Technical Aspects of Designing with White Cement Concrete
White portland cement has essentially the same properties as gray cement, except
for its color. An important quality control issue in the industry, the color of white
cement depends on raw materials and the manufacturing process. Metal oxides,
primarily iron and manganese, influence the whiteness and undertone of the
material. White cement is manufactured to conform to ASTM C 150, Specification
for Portland Cement. Types I and III are the most common, but Types II and V are
also produced.
Mix designs for white or colored concrete are
formulated with respect to the following ingredients, paying particular attention to
the resultant effect on color:
Dept. of Civil Engg. 13 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
o Type and color of cement
o Type and dosage of pigment
o Type and dosage of chemical admixtures
o Type, gradation, color, and cleanliness of fine and coarse aggregates
o Type and dosage of supplementary cementing materials: calcined clay, slag,
white silica fume
o Consistent proportions, especially maintaining a uniform water-cement ratio
It is always recommended to develop a mix design and build sample panels in
advance of starting a white cement concrete project. That way, mixtures can be
refined and improved and material usage can be optimized. The mockups serve as
references for color and surface appearance during the construction phase of the
project.
Materials & Applications
Architectural and Decorative Concrete
Dept. of Civil Engg. 14 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Concrete is one of the most widely used construction materials in the world. One
special subset is called architectural and decorative concrete, which refers to
cement-based products that provide an aesthetic finish and structural capabilities in
one.
These concrete materials are made to be seen. Whether creating broad expanses or
minute details, concrete permanently captures the chosen look. Achieving an
architectural or decorative appearance usually requires that something different be
done to the concrete. Whether that involves special forms, special finishing
techniques, or special ingredients, the variety of effects is almost unlimited.
For more information see PCA's Finishing Concrete with Color and Texture,
PA124.
Dept. of Civil Engg. 15 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Masonry
Masonry is one of our oldest, most established
building techniques. Evolution in materials, mix designs, and engineering allow for
the construction today of even stronger masonry buildings—structures that will last
for generations.
Concrete masonry units are available in a rainbow of colors, textures, shapes, and
sizes, offering building designers the chance to create structural walls that are also
beautiful. Architectural concrete masonry units offer a natural appearance that is
striking in urban applications, and blends in with the natural beauty of rural areas
—always complementing the building’s surrounding environment.
Stucco
Dept. of Civil Engg. 16 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Stucco, or portland cement plaster, is a versatile facing
material that can be applied to flat or curved surfaces either inside or outside any
building or structure. Stucco has great appeal as a surface finish because of its
utility, low first cost, and minimum need for maintenance.
In its hardened state, plaster is a desirable facing material: hard, strong, fire-
resistant, and color-retentive. Because plaster is also breathable, or able to transmit
moisture vapor, water that gets behind it does not become trapped. That makes it
resistant to rot and fungus. Plaster has proved to be a durable wall cover in all
climates, whether wet, dry, hot, or cold.
The final appearance of the finish coat can be varied by changing the size and
shape of the aggregate, using colored cement, adding pigments, changing the
consistency of the finish mix, the method or equipment used for plastering, and the
plasterer's skill in manipulating the finish coat.
Pervious Concrete
Dept. of Civil Engg. 17 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Pervious concrete, is one of the hottest topics
in land development today. As owners, architects, land developers, and concrete
professionals become familiar with its benefits, the interest in pervious concrete
continues to grow. Pervious concrete is porous and provides a solution to the EPA
regulations that call for decreasing the amount of surface water runoff and initially
treating the runoff.
Dept. of Civil Engg. 18 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Break New Ground with a Time-Tested Material
Masonry combines beautiful design possibilities
with versatility and value, durability and low maintenance, in any size, style, or
climate.
From civic and cultural facilities to institutional settings, buildings designed with
masonry stand the test of time. Masonry also is an investment in living well for
home owners. With its ability to withstand extreme temperatures, fires, and natural
disasters, masonry keeps adding value to residential properties.
Masonry is also the sensible choice for educational buildings. For school design
that innovates and is proven to perform, again and again its masonry.
Dept. of Civil Engg. 19 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Masonry Products and Properties
Masonry units are available in sizes, shapes, colors, textures, and profiles for
practically every conceivable need. Historically, units came from a variety of
sources and included materials such as rock and stone, either natural or cut. Today,
units most commonly used are concrete block or clay brick, offering standardized
sizes and mechanical properties. The units are joined together by mortars made
from a binder consisting of one or more cements for masonry, sand, and water.
Portland cement plaster, or stucco, is made from the same material as mortars, and
as such, is sometimes considered to be a masonry product as well.
Masonry is widely used to construct small and large structures because of its
attractive appearance, minimum maintenance, safety (fire resistance and
wind/earthquake resistance), and economy. Masonry provides an effective barrier
to sound and reduces internal temperature variations and peak loads on heating and
cooling systems. It provides architectural freedom and versatility with striking
aesthetic appeal. Almost any shape of structure is possible.
When high winds occur, reinforced masonry buildings resist the pressures and
flying debris that can knock down or damage less robust construction. Masonry
can offer fire resistant qualities that saves homes.
Dept. of Civil Engg. 20 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Masonry also resists weathering and vandalism. The durability and minimum
maintenance extend a building’s useful life, providing an enduring, high-quality
appearance.
Masonry Products
Modern masonry products include portland cement plaster (stucco), cements for
masonry, mortars, concrete block, and clay brick. These materials can be used on
the interior or exterior of structures in a wide range of environments. Load-bearing
walls serve a structural purpose, while veneers and claddings, frequently used as
architectural finishes, also function as weather barriers. Whichever materials are
used, modern masonry construction provides durability, safety, aesthetic appeal,
and other benefits in a cost-effective manner.
Brick
Brick is the oldest manufactured building material. The earliest brick, made from
mud (sometimes with added straw), was invented almost 10,000 years ago. Clay
brick started to appear about 5,000 years ago, when builders borrowed pottery
manufacturing techniques to improve its strength and durability. From some of the
oldest known structures to modern buildings, clay brick has a history of providing
shelter that is durable, comfortable, safe, and attractive.
Dept. of Civil Engg. 21 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Cements for Masonry
Cements for masonry include masonry cement (ASTM C 91) and mortar cement
(ASTM C 1329). They are hydraulic cements designed for use in mortar for
masonry construction. Masonry cement consists of a mixture of portland cement or
blended hydraulic cement and plasticizing materials (such as limestone or hydrated
or hydraulic lime), together with other materials introduced to enhance one or more
properties such as setting time, workability, water retention and durability. These
components are proportioned at the cement plant under controlled conditions to
assure uniformity of performance.
Concrete Masonry Units
Since 1882, when the first concrete block was molded, concrete masonry units
have become a standard building material. Concrete blocks create structures that
are economical, energy efficient, fire-resistant, and involve minimal maintenance.
In addition, concrete masonry allows architectural freedom and versatility.
Mortar & Grout
Masonry mortar is composed of one or more cementitious materials, clean well-
graded masonry sand, and sufficient water to produce a plastic, workable mixture.
Dept. of Civil Engg. 22 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Grout for masonry is composed of similar materials, but is generally mixed to a
much more fluid condition. It may also contain coarse aggregate.
Stucco
Stucco, the common term for portland cement plaster, is a popular exterior finish
for buildings. It provides an economical hard surface that is rot, rust, and fire
resistant, which can be colored and finished in a wide range of textures to adorn
any architectural style.
Masonry is one of our oldest, most established building techniques. Evolutions in
materials, mix designs, and engineering allow for the construction today of even
stronger masonry buildings—structures that will last for generations.
Aesthetic Variety
Concrete masonry units are available in a rainbow of colors, textures, shapes, and
sizes, offering building designers the chance to create structural walls that are also
beautiful. Architectural concrete masonry units offer a natural appearance that is
striking in urban applications, and blends in with the natural beauty of rural areas
—always complementing the building’s surrounding environment.
Dept. of Civil Engg. 23 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Safety and Durability
When it comes to fire resistance, masonry is a true performer, offering excellent
protection from fire damage. In fact, post-9/11 research performed on a building in
close proximity to the World Trade Center showed that masonry absorbed much of
the debris impact and helped save the structure from collapsing. In fact, the
building was repaired and restored to use. Masonry structures are also stand up to
high wind forces and earthquakes. More on Safety and Durability.
Sustainability
As with other concrete wall systems, masonry creates walls with high thermal
mass, minimizing temperature swings and shifting heating and cooling loads to
off-peak hours. The resulting buildings are more economical, with lower overall
heating and cooling costs, providing a consistently comfortable atmosphere for
inhabitants. Masonry also offers durability as well as sound attenuation—which
all adds up to a more quiet, comfortable atmosphere for inhabitants.
Applications
Masonry lends itself to many commercial applications. The material has been
used to create notable public buildings like churches, courthouses, and
Dept. of Civil Engg. 24 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
government offices. Educational structures, from elementary schools to Ivy
League university facilities, can balance contemporary engineering with
traditional design, offering myriad possibilities that will stand the test of time.
Technician Training
Two new masonry certification programs – one for Masonry Laboratory Testing
Technicians and the other for Masonry Field Testing Technicians – are available.
Developed by The American Concrete Institute (ACI), in cooperation with The
Masonry Society (TMS) and other industry organizations, both certification
programs aim to improve the quality of masonry testing and recognize qualified
technicians.
Both exams include a written portion and a performance portion. Technicians who
successfully complete either exam will receive a 5-year certification from ACI for
field or lab testing. It is suggested that individuals prepare for the exams through
TMS review sessions that combine classroom instruction, lab demonstrations, and
lab practice time. To learn more about the new certifications, see information at
The Masonry Society or the American Concrete Institute.
.
Dept. of Civil Engg. 25 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
Industry Resources
Detailed information on designing with masonry and masonry mortars is available
on PCA's Masonry site. There is excellent information on the safety of masonry
regarding fire resistance, high wind force resistance, and earthquakes.
Dept. of Civil Engg. 26 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
CONCLUSION
Decorative concrete is the use of concrete as not simply a utilitarian medium for
construction but as an aesthetic enhancement to a structure, while still serving its
function as an integral part of the building itself such as floors, walls, driveways
and patios.The transformation of concrete into decorative concrete is achieved
through the use of a variety of materials that may be applied during the pouring
process or after the concrete is cured, these materials and/or systems include but
are not limited to stamped concrete, acid staining, decorative overlays, polished
concrete, concrete countertops, vertical overlays and more.
Dept. of Civil Engg. 27 GPTC Muttom
Seminar Report on Decorative concrete 2015-2016
REFERENCES
Fox, Joanne (May 16, 2009). "Concrete Staining Adds Color to Flooring".
Sioux City Journal.
Downs, Stacy (April 10, 2008). "Paving the way for concrete despite freeze-
thaw cycles, driveway should last for years if properly installed".
Chicagotribune.com.
Dept. of Civil Engg. 28 GPTC Muttom