V EB AR Choosing an Overlay - Concrete Decorﬂoor to create abstract shapes. CIRCLE #86 ON READER SERVICE CARD. For more information on Metal Forms Corp., visit or call (414) 964-4550

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VOL. 5 NO. 1 • FEB/MAR 2005 • $6.95

Choosing anOverlayMix Additive:Metakaolin

Coloring with Dyes

Power Trowels

Choosing anOverlayMix Additive:Metakaolin

Coloring with Dyes

Power Trowels

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February/March 2005 • Vol. 5 No. 1Issue No. 20 • $6.95

Publisher: Bent O. MikkelsenCo-publisher: Ernst H. Mikkelsen

Editor: Rosemary CamozziNews Editor: John Strieder

Circulation: Sheri MikkelsenDesign and Production: Stephen Stanley

Web Design: Mark DixonNational Sales Manager: Kathleen Goodman

(314) 367-1121Western Regional Sales: Troy Ahmann

(702) 869-4342Writers:

Christina CamaraSusan Brimo-Cox

Stacey Enesey KlemencJohn Strieder

David ThompsonContributing Writers:

Michael ChusidPeter Wagner

Editorial:Professional Trade Publications, Inc.

3410 West 11th AvenueEugene, OR 97402Tel: 541-341-3390Fax: 541-341-6443

Email: [email protected] and Administration:

Professional Trade Publications, Inc.P.O. Box 25210

Eugene, OR 97402Tel: 541-341-3390Fax: 541-341-6443

Email: [email protected] Decor The Journal of DecorativeConcrete is published six times a year by

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

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One year: USA $21.95; Canada $29.95;Other countries $49.95. All funds in U.S.

dollars.For Subscriber Services:

Call 866-341-3703 Toll FreeFor Advertiser Services:

Call 877-935-8906 Toll Free© 2005 Professional Trade Publications, Inc. All rights

reserved. No part of this publication or its Website may bereproduced without written permission of Professional Trade

Publications, Inc.

www.concretedecor.netONTHE COVER: George Lacker of GLC3 Concrete poured and stained thisfountain and courtyard area of the Seminole Hard Rock Casino inHollywood,Fla.

Welcome to 2005!

With World of Concrete behind us, we can alltake a deep breath and focus on the year tocome.

It was great to connect with so many of our readersand advertisers at the show. Decorative concretecontinues to attract more and more attention each year,and we are proud to be at the forefront of the industry.We came home to Oregon inspired by the beautiful workwe saw and full of ideas for new editorial developments.

We were also fortunate to have the opportunity to sitin on PCA economist Ed Sullivan’s economic forecast for2005. While his facts and figures were geared toward thecement industry as a whole, there was much of interest tothe decorative concrete side.

There is no doubt that rising interest rates are slowingthe rush of home-buying, but from a historical perspective,single-family starts remain strong. Sullivan expects thetripping rate (when mortgage rates hit 6.5 percent andtrigger a noticeable decline in single-family construction)to come in June of this year. But, he adds, this is stillexpected to be the third strongest single-family year ever. And there’s more good news:Homes are getting bigger and the amount of cement used in the average home is increasing.

States with the highest dependence on residential construction will be strongly affectedby rising interest rates in 2006 and beyond, Sullivan says. In Delaware, for example, 40percent of construction is residential. California is another example of a state with a highdependence on the single-family market.

Sullivan expects substantial growth in non-residential construction, particularly in thepublic sector. Both industrial and office construction are expected to remain soft this year,although a rebound is expected in the years to follow. But as states raise taxes to fix theirdeficits, more money will be available for public projects. “When states have money, there is arelease of pent-up demand,” Sullivan says. “Projects that were put aside still need to be done.”

And that’s a fresh opportunity for the decorative concrete contractor. As Gerald Taylorof Images in Concrete and art professor Steven Ochs have discovered, almost every publicproject has funding for public art, which can include decorative concrete. Look for anarticle by Steven Ochs in an upcoming issue that will offer some ideas for profitable andfulfilling partnerships between artists and contractors.

We also plan to offer — along with a multitude of articles on the latest applications —more tips for growing your business and keeping it healthy. Here’s to a great year for us all!

Sincerely,

Bent Mikkelsen, Publisher Rosemary Camozzi, Editor

P.S. Bent is pleased to have been selected as one of three judges for the TechFab/C-GRID2005 Decor Concrete Design Competition. Read more about it on page 8, and be sure tosend in your entry by April 1!

news:Homes

news:Homes

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mailto:[email protected]


FEATURES16 Floors to Dye For

On their own or combined with acid stains, dyes offer coloroptions that allow the imagination to soar. Plus, they can be alifesaver when your acid staining job goes south.by David Thompson

22 Choosing an OverlayThings to consider when choosing from the ever-growing arrayof options.by Susan Brimo-Cox

32 Mighty MetakaolinDecorative concrete contractors are discovering the manybenefits of metakaolin, an admixture that makes concretebrighter, denser and more workable.by Michael Chusid

56 Concrete Exchange Design Awards

DEPARTMENTS12 CONTRACTOR PROFILE: GLC3 Concrete

Education, imagination, and lots of experimentation have givenGeorge Lacker the right to say he makes some Great LookingConcrete.by Stacey Enesey Klemenc

28 MANUFACTURER PROFILE: Proline Concrete ToolsClose communication with contractors has helped Prolineperfect its offerings and maintain its position as a leader in theindustry. by Christina Camara

40 TOOLING: Choosing a Power Trowel

44 PROJECT PROFILE: Versatile Building Products’ Liquid Granitechip flooring system transforms a garage floor. by John Strieder

52 POLISHED PERSPECTIVES:A new column on polished concrete floors begins with adiscussion of scratch patterns.by Peter Wagner

64 FINAL POUR: WOC 2005

50 Classifieds48 Concrete Marketplace04 Decorative Concrete Tips06 Industry News10 Industry Spotlight — Association News60 Product News54 Product Profiles

www.ConcreteDecor.net • Feb/Mar 2005 • 3

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Creating images with dyes prior to acid staining

DECORATIVECONCRETETIPS

Decorative Concrete Tips is a forum for readers to exchange

information about methods,tools,and tricks they’ve devised.

Send details to CD Tips,CCoonnccrreettee DDeeccoorr,, P.O.Box 25210,

Eugene,OR 97402.We look forward to hearing from you!


Thanks for this tip go to Victor Pachade ofColormaker Floors. (www.colormakerfloors.com).

By putting the dyes down beforethe acid stains,you can open up amuch wider range of color than if

the acids went down first.

Remove the objects andthen spray acid stain onthe whole floor,allowingall the colors to minglewith each other.

Spray water-based dyeson the whole floor.The

objects act as resists forthe dyes.

Place objects on thefloor to create abstractshapes.


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For more information on Metal Forms Corp., visitwww.metalforms.com or call (414) 964-4550.

Sika selects veteran New England salesmanagerThe New Construction division of Sika Corp. hasappointed Doug Smith as New England district salesmanager.

Smith has 20 years ofexperience in the concreteconstruction industry. Prior tojoining Sika, he served as NewEngland sales manager forSeparation Technologies LLC, aprocessed fly ash marketer. Smithcurrently serves as president ofthe New England Chapter of theAmerican Concrete Institute, and he is very active inpromotional and technical activities for MassachusettsConcrete and Aggregate Producers Association.

For more information about Sika Corp., visitwww.sikausa.com or call (201) 933-8800.

U.S.Gypsum launches certificationsystemThe Industrial Products Division of United StatesGypsum Co. has announced the establishment of theLEVELROCK brand Five-Star applicator program. Thenew system recognizes licensed applicators who followstandards set by the LEVELROCK floor underlaymentquality program. The initiative also gives them valuabletools and resources to help them expand theirbusinesses.

Initial benefits of being named a Five-Starapplicator include a warranty extension from two yearsto five years, opportunities to participate in an


Moose feet setin ’creteA decorative concretepad forms the base ofMetal Forms Corp.’s“Moose Park,” createdas part of thecompany’s efforts to beautify its surroundings andcelebrate its 95th anniversary.

The company’s flexible Poly Meta Forms were usedto mold the continuous curves of the pad. The reusablepolyethylene forms are strong, lighter than wood, easyto stake accurately, and suitable for straight or radiusapplications.

The park, an enclosed landscaped area adjacent tothe Metal Forms plant in Milwaukee, Wis., is home totwo large moose sculptures that stand more than six feethigh and weigh nearly 1,000 pounds each.

Industry New

s


Consider This“If the customer doesn’t like the final outcome of thecolor that comes with the stain, you can change it —move the color in a different direction with a dye.”Victor Pachade, Colormaker FloorsTo learn more about dyes, see “Floors to Dye For, “starting on page 16.

http://www.metalforms.com

http://www.sikausa.com



extended warranty program,recognition on product-related Websites, advertising and other marketingand lead-generation materials, and theuse of a special logo.

Qualifying companies have partic-ipated in U.S. Gypsum’s qualityinitiatives for at least six months to oneyear and have received field trainingfrom Alcorp Marketing Inc. They mustalso pass audits and submit job samples.

For more information, contact theIndustrial Products Division of UnitedStates Gypsum Co. by visitingwww.gypsumsolutions.com or calling(800) 487-4431.

New hires at PowersFastenersPowers Fasteners Inc., a leadingdomestic manufacturer of mechanical,adhesive and powder-actuated fasteningsystems, recently madeseveral significantappointments.

Robert Brito washired as branchmanager of the Atlantabranch warehouse,giving him outsidesales responsibility for Georgia and

Alabama. ScottGlasnap was namedbranch manager at thePhoenix warehouse,putting him in chargeof outside sales forArizona. John Partridgewas promoted to

branch manager of the New York Cityarea warehouse, givinghim sales responsibilityfor southern New York,plus all of Connecticutand New Jersey.

Powers FastenersInc. is based in NewRochelle, N.Y., and has26 branch locations throughout NorthAmerica. Visit their Web site atwww.powers.com or call them at (914)235-6300.


Construction trade showplanned for Las VegasCONEXPO-CON/AGG 2005 andIFPE 2005, the world’s largestexposition for the construction,construction materials and powertransmission industries, will be heldMarch 15 through March 19, 2005, inLas Vegas, Nev.

The massive gathering is expected todraw more than 100,000 industryprofessionals from 120 countries. Theevent will also attract an estimated2,100 vendors who will take more than42 acres of exhibit space. There will beseveral international exhibit pavilions,an information technology pavilion andmore than 80 educational sessions.Hundreds of additional industrymeetings will be held in conjunctionwith this big event.

CONEXPO-CON/AGG, whichtakes place every three years, is a collab-oration between the Association ofEquipment Manufacturers, theNational Ready-Mixed ConcreteAssociation and the National Stone,Sand & Gravel Association. IFPE isowned by the National Fluid PowerAssociation and CONEXPO-CON/AGG Show ManagementServices. For more details, visitwww.conexpoconagg.com or call (800)867-6060.

Techfab announces firstannual Décor ConcreteDesign CompetitionWant to show off your best work andmaybe win a prize to boot? TechFab hasannounced a Call for Entries for the firstannual TechFab/C-GRID DécorConcrete Design Competition.

TechFab is sponsoring thecompetition to showcase the best andbrightest the decorative concreteindustry has to offer. The objective is todesign and create — using C-GRIDreinforcement — an original concretecountertop, vanity, tabletop orarchitectural décor product suitable foruse in residential or commercialapplications.


http://www.gypsumsolutions.com

http://www.powers.com


http://www.conexpoconagg.com


C-GRID is a revolutionary high-strength carbon fiber epoxy gridstructure that is stronger and lighterthan steel by weight and that providesexcellent crack control in concretetreatments.

Judging will be conducted in April2005. The three judges selected for the2005 competition are Bent Mikkelsen,publisher, Concrete Decor magazine;Michael Smith, founding partner, EquusDesign Group; and Lauriel Leonard,Allied ASID, Dex Studios. Threewinners will be announced, andhonorable mentions will also be chosen.Most importantly, these designers will beshowcased to the industry andrecognition given for their creativity.

All entries must have beenproduced in 2004-2005. Submissionsmust be received no later than April 1,2005.


TechFab LLC is headquartered inAnderson, S.C. Send entries to orrequest more information from JohnCarson, director of commercialdevelopment, at (864) 260-5781 orvisit www.techfabllc.com.

New sales manager forLafargeLafarge North America, a leadingsupplier of construction materials inthe United States and Canada, hasnamed Blanche Davidson as assistantsales manager of the Cement Division’sMid America Sales District. Davidsonassumes responsibility for salesmanagement in the Cleveland andPittsburgh markets. For more aboutLafarge North America, visitwww.lafargenorthamerica.com.


http://www.techfabllc.com

http://www.lafargenorthamerica.com


AMERICAN CONCRETEINSTITUTEACI convention celebratesNew York and New JerseyThe American Concrete Institute willhold its 2005 convention April 17through April 21 in New York City. Thetheme will be “Concrete Soars, Spans &Supports New York and New Jersey.”

The convention will host 37technical sessions and more than 300meetings. Additional highlights willinclude the Edward Nawy HonoraryDinner and a site tour of the WorldTrade Center.

The convention also offerscompetitions and events for studentsfrom the United States, Canada,Mexico, Iran and other countries. Astudent luncheon featuring Dr. David P.Billington, professor of civil engineeringat Princeton University, will be heldApril 18, followed by the StudentFellowship Research Showcasehighlighting past recipients of the ACIstudent fellowship program.

The convention is co-hosted by theACI New Jersey Chapter and theConcrete Industry Board of New York.The American Concrete Institutecurrently has 16,000 members and 96chapters in 115 countries. To register,visit www.concrete.org or call (248)848-3700.

Concrete publications aim toeducate,commemorateThe American Concrete Instituteannounces the release of six newpublications.

“ACI 121R-04: QualityManagement System for ConcreteConstruction” helps with thedevelopment and implementation of“quality systems” for concreteconstruction projects. A quality systemallows user judgment with respect toowner needs, defined quality objectives,

project organization skills, and projectsize, importance and complexity.

“ACI 303R-04: Guide to Cast-in-Place Architectural Concrete Practice”presents recommendations forproducing cast-in-place architecturalconcrete. It discusses the importance ofspecified materials, forming, concreteplacement, curing, inspection andadditional treatment.

“ACI 440.4R-04: PrestressingConcrete Structures with FRPTendons” outlines the history and useof FRPs (fiber-reinforced polymers) inprestressing applications. Thedocument describes the materialproperties of FRPs and focuses on thestate of research and developmentneeded to ensure FRP performance asprestressing reinforcement.

“ACI ITG-3-04: Report on BridgeDecks Free of Steel Reinforcement”outlines procedures for designingbridge decks without steelreinforcement.

“ACI SP 223: InvestigatingConcrete — Selected Works of Bryantand Katherine Mather” honors BryantMather for his significant contributionsto concrete technology. The seven-partpublication covers concrete potential,cementitious materials, aggregates,durability, petrographic examination ofaggregates and concrete, specificationsfor use of concrete in transportationstructures, and research and emergingtechnologies.

“ACI SP 224: Thin ReinforcedCement-Based Products andConstruction Systems” explores recentadvances in material science, manufac-turing methods, and practicalapplications of thin reinforcedcementitious products.

These publications can be orderedfrom the American Concrete Instituteby visiting www.concrete.org or calling(248) 848-3700.

Industry SpotlightAssociation News

PORTLAND CEMENTASSOCIATIONPCA elects chair,vice chairThe Portland Cement Associationboard of directors elected James A.Repman as chairman during theassociation’sNovember boardmeeting. Repman,who will serve atwo-year term, ispresident and CEOof CaliforniaPortland Cement.He has chairedPCA’s education foundation and serveson the executive committee. CharlieSunderland of Ash Grove Cement waselected vice chairman.

For more about the PCA, visitwww.cement.org or call (847) 966-6200.

Learn more about perviousconcreteThe Portland Cement Association andthe National Ready Mixed ConcreteAssociation have released a referencemanual called “Pervious ConcretePavements.”

Pervious concrete is enjoying aresurgence in interest as a pavingmaterial because itallows water to flowthrough itself,recharginggroundwater andminimizing stormwater runoff. Theguidebookintroduces readersto perviousconcrete’sapplications andengineering properties, includingenvironmental benefits, structuralproperties and durability. Hydraulicand structural designs of pervious

http://www.concrete.org


http://www.concrete.org

http://www.cement.org



concrete pavements are discussed, asare construction techniques.

For more information visit the PCABookstore at www.cement.org/bookstore.Orders can also be placed by calling(800) 868-6733 or (847) 972-9040.

AMERICAN SOCIETY OFCONCRETE CONTRACTORSDon’t miss the Spring Fling!The Decorative Concrete Council, aspecialty council of the AmericanSociety of Concrete Contractors, willhold its spring event April 28 throughApril 30 at the Embassy Suites Hotel,Columbia, S.C. The event includesseminars on business topics for ownersand managers of decorative concretecontracting firms as well asdemonstrations of decorative concreteinstallations.

Seminar topics will include “How toGet Started,” “Keys to Success,” “ShowMe the Money,” and a preview of thedemonstration techniques. Speakersinclude World of Concrete presentersBob Harris of the Decorative ConcreteInstitute and Frank Lewis of TheCoatings Group. Concrete stamping,stenciling, staining, scoring, acid etching,overlay systems and countertops will bedemonstrated on Saturday at SpecialtyConcrete Products, 1327 Lake DogwoodDrive, West Columbia.

The ACI flatwork finisher class andexamination will be offered at the event.

The DCC is made up of decorativeconcrete contractors, manufacturers, andother interested parties. The mission ofthe organization is to advance the qualityand use of decorative concrete systemsfor both horizontal and verticalapplications. For more informationcontact the ASCC at (866) 788-2722 orvisit www.ascconline.org.



http://www.cement.org/bookstore

http://www.ascconline.org


GLC3 ConcreteFort Lauderdale, Fla.George Lacker moves from the ordinary tothe extraordinaryby Stacey Enesey Klemenc

ContractorProfile

ContractorProfile

George Lacker III, president ofGLC3 Concrete in FortLauderdale — a company

whose moniker coincides with theinitials of both the owner and “great-looking concrete” — has been in theconcrete business for more than 30years. Although his roots are firmlyplanted in the ordinary gray variety, hispresent and future involve extraor-dinary creations.

When he was only 16 years old,Lacker got his footing in the businessback in Ohio, pouring industrial floors forBaker Concrete and learning the ropesfrom the boss himself. “Dan Baker wasalways so positive,” he remembers. “We’dcomplain we didn’t know how we’d get

George Lacker(right) ownerof GLC3Concrete andGeoff Kemp,senior projectmanager.



something done and he’d say, ‘You guyswill figure it out.’” Then Baker would sitdown and draw a diagram of the job,including little stick figures so the crewcould see how many people were neededfor the job and who would do what.

In 1980, Lacker moved to Florida,where most of his work still involvedworking with regular concrete. On thedecorative front, he tinkered with rocksalt finishes, colored concrete and avariety of exposed rock and shells,services he still offers today. However,in 1996 his whole direction began tochange when he traveled to Oklahomato stain his father-in-law’s floor. “That’swhen I caught the bug,” Lacker recalls,referring to the fervor he felt about theacid-etch chemical staining process.

He was gung-ho about chemicalstains but the Floridians heencountered weren’t wild about thedark colors in his palette. Businessfloundered. Then in 1998, Lacker hadthe opportunity to hook up with MikeMiller, president of California-basedThe Concretist and a well-knownconsultant to the decorative concreteindustry. Lacker had poured the floorsfor the Dolphin Mall in Miami andMiller was involved with the aestheticsof finishing them.

“Mike is a concrete guru,” Lackersays about his now good friend, and helearned a lot from him during thisinitial encounter. With his confidencebolstered and some newfoundknowledge about lighter colors underhis belt, Lacker resigned from his joband went into business for himself.

“If you’re just getting started [indecorative concrete], the best advice Ican give you is to find somebody whoknows what they’re doing and becometheir friend,” says Lacker, who foundedGLC3 in 1999. Probably the best venuefor this is the World of Concrete, whichattracts experts from everywhere, headds. “It’s easier and more profitable toget people in different parts of thecountry to help you out than it is to gethelp from your competition.”

In addition to establishingrelationships with those in the know, he



says, make sure you keep abreast withthe industry by taking classes andattending seminars. This way you’ll notonly keep up with the latestdevelopments but you’ll learn the lingocustomers expect to hear. “Architectswant to hear the latest terminology,” hesays, and speaking their language mayhelp you land the job.

And if there’s one thing he’s learnedduring these past 30-something years, it’sthat samples will sell your work, too.“Whenever I give a seminar, I preach‘sample, sample, sample,’” he says.Practice around the house. Try out newcolor combinations and designs. Dosamples and set them outside to weather.“Practicing will let you see where youmay have problems.” And it’s the bestway to show clients what to expect.

“One of the biggest problems we haveis that we haven’t educated the architectsand general contractors about what canand cannot be achieved with acidstaining. I’d say about 20 percent of themstill don’t know that the colors in an acidwash are supposed to be inconsistent,” hesays. They also don’t want to spend theextra money to protect the floors duringthe construction phase, and then theycomplain about spills and unwantedstains.

If the architect or GC wantsconsistency, he continues, they’d bebetter off with a polished integrallycolored floor. “The color is a lot moreconsistent and the floor is more durablethan acid stain.” If acid staining is thechosen method, be sure to let theclients know that a good maintenanceprogram is key to keeping the floorlooking good for years to come. “Thiscan’t be stressed enough,” Lacker says.

Today and beyondLacker’s work today largely involves acidstaining and polishing concrete floors forcommercial establishments throughoutFlorida, including such big names as theHard Rock Cafe in Hollywood, the Ritz-Carlton in West Palm Beach andSloppy Joe’s in Key West.

Unusual requests are what he likesbest. “If they can think it, we can



in the future — involves floors thatused to be tiled or carpeted. “That’s whywe’re working to perfect a half-inchpour that can be stained or polished.We’re removing a half-inch of carpetand replacing it with concrete,” he says.He can even successfully pour concreteon top of a wood floor, a feat he’s proudto point out. “I can do it because I knowhow to cure the concrete.”

Don’t be afraid to try new thingswith concrete but always read themanufacturer’s instructions, Lackeradvises, for a good basic understanding.And above all, learn from your mistakesbecause mistakes are going to happen.“You don’t get good at somethingwithout screwing something up,” hesays. And experience pays. “I may notbe the cheapest person to hire,” Lackersays, “but I’ve learned that people whodon’t have the money to hire me in thebeginning always have the money whenit comes time to fix things that didn’tturn out right.”

produce it,” he says. “We like to dothings that nobody’s done before,”adding that he creates many of hisfinishes using microtoppings withpolymer-modified cement and a largedose of imagination.

Some of his best creations, heconfesses, are developed when he’sjust “fiddling around.” For instance,for one job, he spent hours preparingsamples and then just threw onetogether for variety. “I threw somecolors down, did a real fast trowel,threw another color down and sandedit. The second color filled in the voidsleft by the colors on the first trowel. Itmade a really unusual pattern and itwas done really fast.” And that’s theone the customer picked.

“Concrete is poetry,” he says, and younever know what will appeal to whom.“We’re creating something that wasn’tthere before and we’re doing it any waywe have to, with microtoppings,poured-in place, acid stain, integral andcast-on color. Bringing all theseelements together can get complicated.But our goal is to be able to do the job assimply as possible and just have theresults look complicated.”

He says a lot of his business rightnow — and he anticipates much more




Floors to Dye For!Dyes can broaden your color palette, createsubtle effects not possible with other coloringagents, and fix problems with acid stainapplications.by David Thompson

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A skim coat carried upthe wall. All colors wereachieved with solvent-based dyes.



The only reason so few contractorsuse dyes for coloring concrete isbecause so few contractors know

you can use dyes for coloring concrete.But not only can you use them, you

can vastly expand your color palettewith them.

With dyes you can get virtually anycolor under the sun — or at least on thecolor wheel. And you can get brighter,more vibrant colors than you can getwith acid stains, which are limited to anarrow range of earth tones. If thatweren’t enough, dyes can also save yourbutt when good acid staining goes bad.

Like acid stains, dyes are translucent.But unlike acid stains, they don’tchemically react with concrete. Youdon’t get the color variegation with adye that you get with an acid stain. Infact, you don’t get any variegation at all.Instead, you get predictability.

These photographs all show skim coated floors withdyes,stains and epoxies. The blue variations and thesky on the floor to the left were all created withdyes.


By usingdifferent

dilutions ofdyes andblending

themtogether,

Brian Vicaricreated a

watercoloreffect in this

bathroom.

This floor, formerly covered bycarpet, linoleum and tile,wasresurfaced with Colormaker Floors’“Pentimento”and then acidstained.BrianVicari then useddyes to adddepth and shiftthe color of thefloor to thespecific colorthat wasrequested.


“What you see going down is thecolor it will be when all is said anddone,” says Mike Miller, managingprincipal of The Concretist Inc. “Youcan almost think about dyes likelighting in a theater, where you’ve gotlights with colored filters over them. Ifyou shift to an orange filter, everythingon stage looks orange. That’s kind ofwhat happens with a dye.”

Of course, tinting strength andpenetration will vary depending on thecharacteristics of the concrete you areworking with.

Dyes can be used in conjunctionwith acid stains or all on their own.

On their own they supply acementitious surface with the even-across-the-board color shift of stagelighting. They can be layered for avariegated effect, but the variegation isentirely in the hands of the artisan. (Forexample, Bob Harris, president of theDecorative Concrete Institute, spraysdyes along the ripped edge of paper for amarbled look). When used with acidstains, they can provide accent colors,color layering and depth, and shifts incolor extending far beyond the earthtones of acid stains.

As a butt-saving tool, dyes can setthings right when unruly acid stainsdon’t do what you want them to.Occasionally an acid stain will fail toreact on a patch of a cementitioussurface; dyes can be used to mask theimperfection. They can also beemployed to shift the entire color of anunderlying stain. “If the customerdoesn’t like the final outcome of thePh

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In order to achieve thedeepest black,the

diamonds were first acid-stained and then treated

with two dye washes.




color that comes with the stain, you canchange it — move the color in adifferent direction with a dye,” saysVictor Pachade of Colormaker Floors.

Choose your base for varyingeffectsBoth water-based and solvent-baseddyes are available, and each can befound either in solution or in powder orliquid concentrates.

Water-based dyes offer a pastel,watercolor look, which can work nicelywhen layers of color are called for.

When used at full strength, solvent-based dyes produce bold colors. Solventsquickly carry molecules of dye into theconcrete and then rapidly evaporate,leaving deeply saturated hues.

Ricardo Hernandez, owner ofConcrete Countertops in Hollywood,Florida, takes advantage of the variety ofcolors and saturation characteristics ofdyes to create faux stone effects on hiscountertops. He uses water-based dyesfor producing weathered stone, and heuses solvent-based dyes for moredramatic looks. “I can make a countertoplook like a piece of jade or a piece ofturquoise with dyes,” he says. “You can’tachieve that look with acid stain.”

Solvent-based dyes typically come inprimary and secondary colors, whichare mixed to form other colors.DecoSup’s line of solvent-based dyes,for instance, includes red, yellow, blue,brown, black, green, orange and purple.

Water-based dyes come in mix-’em-yourself basic colors, too, though somemanufacturers sell them ready-mixed.The Super Stone line of water-baseddyes, for example, includes 30 colors.“We’ve got everything from greens toyellows to grays to pinks to all sorts ofpeachy colors,” says Tony Catlett, SuperStone’s recently retired general manager.

Both water- and solvent based dyescan be diluted for less saturated color.Super Stone, for instance, recommendsdiluting its solvent-based dyes by half forpastels, and by 10:1 for light color casts.Some artisans start out with extremelyhigh dilutions, then work their way backup with layers of less diluted dye. Quick-

drying solvents lend themselves well tothis approach. “I always dilute like 90:1,and then I get a feel for it, see how it’sgoing to be reacting, and then I startapplying more color,” says Hernandez.“Once you’ve applied too much, there’sno turning back.”

Application and prepFloors have to be thoroughly cleanedand absolutely dry before applying dyes.

The more porous a floor, the better itwill accept dye. Hard-troweled or otherclosed surfaces might need to be openedup with an acid etch.

Both types of dyes can be applied inthe same ways acid stains can beapplied: with airless sprayers, brushes,rollers, sponges, etc. But dyes are a littletrickier to work with than stains. Forone thing, a knowledge of color theory(red plus yellow equals green, for



example) is required to mix colorssuccessfully. And dyes behave differentlythan stains. Water-based dyes evaporateslowly and will leave rings if allowed topool. Solvent-based dyes evaporaterapidly and require a deft touch. “You’vereally got to play with them a few timesbefore you use them,” says Art Pinto,president of DecoSup. “Especially thesolvent-based dyes — they evaporate soquickly, you’ve really got to know how

to apply them and spray them so youdon’t leave brush marks.”

But unlike stains, which leaveresidue that must be scrubbed off, dyesare applied, left to dry — and that’s it.

Dyes can be used indoors andoutdoors, but they’re not as resistant toultraviolet light as acid stains are. Andif they’re not sealed, they’re subject towashing away, since dyes don’t actuallybond to concrete like stains do. A good


UV resistant sealer can solve bothproblems at once. Bob Harrisrecommends avoiding the boldest dyecolors for outdoor use. “I would not usea very intense color outside, such as abright red, a bright yellow or a brightblue, for fear that you could get somefading,” he says. “But we’ve found thatwhen you combine primary colors — tomake a brown or a tan or something —we seem to get less fading.” He’s beentesting Colormaker’s water-basedSomeru dyes outdoors with a sealer. Inthe past two and a half years he’s foundno discernable fading in the dyes.

One caveat about applying sealerwith a roller: The roller may pick up dyeand move it to other parts of the floor. Ifthere’s a risk of spreading the dye to areaswhere you don’t want it, consider rollingeach section of the floor with a separateroller, or just spraying on the sealer.

Handle with careAnother dye caveat: Solvent-based dyescan be particularly hazardous to workwith. Stories of vapors igniting, injuringworkers and burning down job sites areall too common. Even pros like MikeMiller have horror stories. Miller wasworking with dye in a basement that thehomeowner had prepped and maskedbefore Miller got there. The pilot lighton a heater hiding behind a masked-offcloset set the floor Miller was workingon ablaze. “Fumes ignited and whateverliquid was still left on the floor burned. I was right in the middle of it,” he says.“I was burned bad enough to be in thehospital for a month. Ended up withskin grafts, and things like that.”

So be careful. Dyes can vastlyexpand your color palette and save yourbutt in a pinch - but those with solventsmust be handled with care.

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Ardex SD-Twith topicalacid staining.

self-leveling product may not be appropriate, ason stairs.

Consider the substrateThe substrate over which you are applying anoverlay is a critical component to your selectionprocess.

If you are planning to overlay an interior on-grade slab, the options are wide open. As ScottThome, director of product services for L.M.Scofield, explains, “If there is a normal amount ofmoisture, any overlays will work. That’s theirintended use.” For exterior grade slab applications,stamp-grade, stencil-grade, and trowel and sprayproducts will work, he says.

Be careful, however, when applying anoverlay over an existing overlay. LeeTizard, vice president of Floric PolytechInc., says the problem with overlaying anoverlay is that you rarely find an overlaythat hasn’t been sealed. The issue thenbecomes the recoatability over sealers.You may find you are better off removingthe base overlay and starting over.

Your choices also become morelimited when applying an overlay systemto substrates other than concrete, such aswood subflooring, terrazzo, tile, gypsum-based flooring and others.

Overlays. Have you looked at how manythere are for you to choose from thesedays?

As Ken Freestone, director of technicalengineering at Elite Crete Systems Inc., aptlyobserves: “It seems like every year there are newoverlay products released to the industry. Wheresplatter textures and plain gray restoration coatsonce dominated the concrete overlay industry,consumers now have virtually unlimited choicesof color, texture, and thickness.”

There are self-leveling products,microtoppings, trowelable mortar toppings, epoxymortar toppings, stampable products, stencil-grade products, splatter/knock-down products,and more. How do you choose?

“The primary considerations willrelate to the look the customer is tryingto achieve and the substrate that theinstaller is working with,” says BenMack, manager of national accounts atArdex Engineered Cements.

Parameters of the project will alsohelp narrow the selection. Forexample, “Over large areas, a self-leveling topping may be used becausethe installer can cover a large area aseach batch of material is poured,”Mack explains. In other situations a


The Confusing Conundrum of Choosing an Overlay

Be sure to match product attributes with the substrate and the desired outcome.

by Susan Brimo-Cox

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room floor wasfinished withArdex SD-TGray,a self-drying,self-

levelingtopping.


you have to look at impact and point load. Highcompression strength does not necessarily meanan overlay can hold up to the crushing power ofhigh density wheels.

Again, in this situation, you might turn tomicrotoppings. “Since microtoppings are very thin,you’re transferring the load through them, insteadof having them absorb into the microtopping,” saysThome.

Of course, in any overlay situation, the cardinalrule of proper substrate preparation always applies.

As Mack observes, “There is no foolproof way tostop cracking, you can only minimize it.Remember, if there is a crack in the substrate, it willtelegraph through the topping. That is why

structural saw cuts are sometimes installed.The crack will have a tendency to crackwithin the saw cut and not be unsightly.”

Indoors or outdoors?If you are familiar with overlay products,you should be aware that there areproducts that are designed to be installedindoors, outdoors or both.

In outdoor applications, rain, salt, dirtand other factors can all have an adverseeffect on the topping if it is not protected.Crack repair and joint sealing areimportant to prevent water intrusion. “In

Mack, of Ardex, explains, “It is difficult toinstall a product over wood without using somesort of system to help stabilize the wood frommovement.” Also, he explains, any type ofstructure that has the potential to causemovement (such as the second level of a mallstore), will cause the topping to crack.

You need to take a good look at the subfloorstructure. Is it built solid? Is there a threshold joint?If there is flex in the deck, you have to figure thatin. As Thome points out, “The thinner the overlay,the more deflection and vibration it can take, but itcan’t take sheer, side-to-side movement.”

In some cases you may be able to use fracture-resistant or fracture-isolating membranes withmicrotoppings with high polymercontent. But they are not a cure-all.

Decks and parking structures, also,have movement issues. In addition, youhave to figure in slip coefficient andabrasion requirements. That may narrowyour choices to coarser grademicrotoppings or stencil-grade toppings.

How about traffic?Most overlays can handle foot traffic.

Vehicular traffic? Stencil- and stamp-grade are generally fine for vehiculartraffic, Thome says, but not for forklifttraffic. If that is a consideration, he says,


This floor wasoverlayed withArdex SD-T,with topical

dyes andarchitectural

saw cuts.


This repair jobwas done by

Elite Crete atthe Palace ofAuburn Hills,home of the

DetroitPistons.The

application is a1⁄4" stampedoverlay donewith Texture-Pave. It wascolored withUltra-Stone

stain andsealed with

CSS Emulsionsealer.

a crack, moisture can get in and under theoverlay,” Thome says. “Then, when traffic goesover it, you get a pumping action.” Ponding andexcess water also can be problematic.

Fortunately, product manufacturers havetechnical installation guidelines on what productscan be used outdoors and how to install them.Doing a little homework up front can prevent a lotof grief in the long run.

“There are protective sealers that increase ordecrease various aspects of weather resistance,ranging from resistance to water, deicing salts, UVray, freeze/thaw, acid rain and other factors,”Freestone says, “but the composition of theoverlays themselves must be carefully looked atbefore applying just any old product.”

And technology is changing every day, so don’tbe surprised if former “rules” might be broken intime. “For years most self-leveling overlaysabsolutely could not be used outside for fear of re-emulsifying,” Freestone says. “But there aremanufacturers now that are making greatimprovements on the level of hydrophobicityamong self-leveling cements.”

The mix designIf strength is important, one might tendto believe that the thicker the overlay,the stronger it is. Freestone is quick topoint out that that just isn’t the casewith overlays. The ultimate key to thestrength of an overlay, he says, is in themix design.

“Believe it or not, the aggregate size,shape, composition, volume and mixdesign is as equally as important aspolymer-modifier content and


composition. Most manufacturers are primarilyconcerned with either modifier-to-cement ormodifier-to-water content. These ratios areimportant. However, most manufacturers willbuild in a safety percentage to make the overlaymore ‘idiot-proof.’”

With mix design, he says, the composition andperformance pitfalls of the modifier being used arecritical; as is considering what the primaryapplication the overlay system is going to be usedto create, so you can better determine abrasionresistance, adhesion, exposure to the elements andtensile strength.

Then there is the aggregate. “It still depends onthe specific application, but an ideal mix is onethat has a larger aggregate content for abrasionresistance, medium aggregates to consistently fillthe void between the large aggregate, and smalleraggregates to fill the void between the mediumaggregates. Consistency in aggregate shape iscritical and, therefore, angular or inconsistentaggregate shape simply won’t work well.”

Staining and sealing overlaysNot all overlays handle stains the same way. Forexample, most decorative concrete toppings andoverlays can take a chemical stain, but high-resin-based materials don’t stain as well as those withhigh cement content. And acrylic stains can beused, too, but compatibility to the sealer you willuse should be considered.

Compatibility between overlay and stain isessential. “That is why samples are almost alwaysrequired by an architect or designer to determinehow the look is going to turn out,” Mack says.“Some [overlay] manufacturers have done theirown testing and provide their own stains.”

In choosing a sealer, Tizard advises thatcontractors make their choice based on multiplevariables: compatibility, durability, cost-effectiveness, interior/exterior compatibility,

breathability, chemical resistance, abrasionresistance, maintenance requirements,recoatability and sheen. You weigh yourattributes and make a decision.

But Thome points out that in someareas your sealer options may be limitedby law. “What’s key is, can you usesolvent-based? That can eliminate halfyour sealers if you can’t.”

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This driveway was base-coatedand then splatter-textured withElite Crete’s Thin-Finish.


Repair and cost considerationsSome overlays are easier to repair than others.

Self-leveling products are the most difficult torepair, primarily because it is so hard to blend arepair in to the monolithic surface. Stampable andstencil-grade overlays can be patched back to ajoint. And microtoppings and splatter/knockdown overlays can be patched relatively easily.

It’s the color matching that’s the real challenge.Thome explains, “Repairing an overlay is reallythe work of an artist, especially if there weretopical color treatments.”

As for the material cost for overlays, Freestonesays he tends to view the material costs asimmaterial. “I guess that is easy since we are themanufacturer, but really, the cost for any of ouroverlays runs in the range of 25 cents a square footfor broom-finish applications, 35 cents for micro-finish applications, 40 cents for splatter texturesand knockdowns, 42 cents for skip trowel slatefinishes, and $1.25 for elaborate thin stampedoverlays. When you consider that theseapplications are being sold by the installer for $4for basic finishes and upwards of $9 for the moredetailed applications, you can see what I meanwhen I say the cost isn’t material.”


Overlay highlightsAs you look at some of the more commonly used overlay products,you can get a better sense of what might work best for your project.Lee Tizard, vice president of Floric Polytech Inc., offers this snapshotlook at some overlay options:

� Self-leveling products provide monolithic, very consistent color.� Stampable overlays have their roots in patch and repair products.

Formula modifications make them easy to use and versatile.� Microtoppings come in different formulations. Low cement/high

polymer products are softer and more flexible. Low polymer/highcement products are more brittle, but have higher compressivestrength. And there are combinations, such as applying a coarsemicrotopping for build and then a fine microtopping on top for arefined smooth finish.

� Splatter/knock-down texture finishes could be considered to fallinto the category of coarse microtoppings.

� Cementitious mortar finishes are another option for some projects.But they are very labor intensive, especially for large areas.

� Epoxy mortar toppings are primarily an industrial flooringapplication. They have more resilience than a self-levelingproduct, with high compressive strength and more impactresistance, plus they have the aesthetics of polished concrete.

� Beyond these overlays, you get into cementitious and epoxyterrazzos, which can be costly.




CIRCLE #90 ON READER SERVICE CARD CIRCLE #26 ON READER SERVICE CARD

But some overlays, such as epoxy-based overlays,can have much higher material costs. On a basicscale, including material and installation, “Terrazzois the most expensive overlay, followed by epoxymortar,” Tizard says. “Self-levelers, one-quarter-inch mortar trowel-downs and stampable overlaysare in the same ball park (in the middle). The leastexpensive are microtoppings.”

On the other hand, Mack says there may bemore to consider in the higher-material-costversus installation-cost equation. “Self-levelingproducts are more expensive because of how theyare designed to work (ease of installation, fasttrack). Trowelable products are less expensive, butthe cost of installation could be a factor since itmay take more labor to trowel down amicrotopping over a large area.”

So, which overlay product will you choose foryour next job? Much of the information you needto make the decision is available from themanufacturers of the overlay products on your“options” list. If you understand each product’slimitations, you should easily understand whichones will be compatible with the specs of yourproject.

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This interior overlay used Elite Crete’s Thin-Finish as a basecoat with a single-colored coat of Micro-Finish. Then it wascolored with Chem-Stone and Ultra-Stone stains to get thewild marbling.


http://www.concrete-texturing.com



Proline Concrete ToolsOceanside,Californiaby Christina Camara

Every decorative concrete contractor seemsto be stamping concrete these days, andthere’s always a demand for new designs in

light, easy-to-use materials that leave the bestimprint with the fewest problems.

Experienced contractors have been sharingtheir likes and dislikes with Proline ConcreteTools for 14 years. Listening to their complaintsand suggestions, combined with endless experi-mentation, has resulted in a line of products thatco-owner Jeff Irwin believes is second-to-none inboth appearance and performance.

While concrete stamps are popular now, 18years ago only a few manufacturers made them,and contractors were looking for improvements.At that time, Irwin was working in plastics andhad never seen a concrete stamp. His childhoodfriend, Paul Sowa, worked in the concrete industryand suggested combining their skills andexperience to come up with new stamps that couldsolve contractors’ problems.

“We started doing it on the side, and one thingled to another and it become a business,” Irwin says.After a few years of trial and error, they startedProline in Oceanside, Calif., in 1991. “We weretalking to contractors about what worked and didn’twork, and we were able to make products thatworked better than what was out there.”

The partners learned that contractors didn’tlike the stamps to be too soft or too hard. Theywanted stamps that could be placed on theconcrete evenly, creating a clear imprint withoutmoving around too much.

Irwin says Proline uses the highest qualityurethane around. “The materials we use are specif-ically designed for us,” Irwin says. The high-

Paul Sowa (left) and Jeff Irwin co-own ProlineConcrete Tools.



durometer rubber is light and stiff, allowing Prolineto make thinner stamps that stay together tightlybecause there are no wide edges butting together.

“Our stamps give you a more even and consistenttexture rather than a lot of high and low spots thatyou have to embed really deep,” Irwin says. “Ourstamps are designed not to do that, but they still giveyou a lot of texture and relief.”

Proline’s most successful products are itsseamless texturing skins, which gained popularityafter they were used in several Las Vegas casinos inthe early 1990s. Proline perfected the “seamlessstamping” by adding the “feathering edges” intothe seamless skins. This feathering creates asmooth transition from stamp to stamp. The skinsare also equipped with handles, which even have awarranty not to rip.

Contractors liked how easy they were to useand how quickly they could produce attractivefloors — jobs could be finished almost as fast as flatbroom-finish concrete projects.

The company’s first stamps were ashlar andrandom stone patterns. Another early stamp wasRoman slate, so named because it was used in aredesign of the Caesars Palace Pool Project. Now,Proline’s stamps come in a wide variety of patternsand designs, with over 150 patterns and styles. Thestamps include brick, wood plank, random stone,cobblestone, tile and flagstone, with variations ofeach. Irwin says Proline’s textures are all createdfrom actual stones laid out in different patterns,giving their stamps a natural look on the finishedconcrete. “None look as good as ours,” he says.

Irwin and Sowa are still talking tocontractors, and they find that the biggestproblem is not with the Proline tools they are



removes vibrations and creates a flat imprinteven if the contractor hits the tamper off-center.

Proline recently introduced a new line offlexible stamps that imprint grapevines, dolphins,ivy leaves and a “Spanish flair” design.Contractors lay feathered-edge seamless texturemats on top of the new stamps, embedding bothtextures at the same time. The stamps will curvearound any contour and can be used for borders orin many other applications.

The company is growing at a fast pace, but thegoal remains the same: creating stamping toolsthat increase productivity and produce beautifulpatterns. “Decorative concrete has grownexponentially, and we didn’t have a choice but togrow,” Irwin says. “We have big ideas and we see abright future.”


using, but inexperience in facing differentsituations and failing to plan ahead. Sometimesthe concrete is too wet, leaving suction markswhen the stamps are pulled; if it’s too dry, it’shard to get a consistent-looking imprint. Failingto lay out the stamps before the concrete arrivescan also be a mistake if the contractors aren’tsure how the stamps are going to interlockahead of time. Irwin and Sowa talk contractorsthrough the issues that arise so the projectsdon’t get away from them.

Proline’s stamps are used primarily indriveways, pool decks, walkways and entries,and new border tools, designs andimprovements are a constant quest. Theirtamper, for example, was recently upgraded, andProline is working on obtaining a patent for itsdesign. The tamper’s shock-absorbing handle


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You may never have heard of metakaolin,but chances are it’s coming your way.This admixture — now being used in

everything from fashionable floors to customcountertops — makes concrete stronger, brighterand more workable while decreasing the amountof portland cement needed in the mix.

Metakaolin is a type of pozzolan, materials thatenhance the strength, density and durability ofconcrete. While decorative concrete contractorsare at the vanguard of many concreteinnovations, some have been slow to discoverthese materials. This is changing, however, sincehigh reactivity metakaolin, a relatively new typeof pozzolan, offers features unavailable from otherhighly reactive pozzolans — improved concreteappearance and workability.

Over half of the portland cement concreteused in the United States now contains pozzolans,according to the National Ready Mix ConcreteAssociation. Fly ash and silica fume, the mostcommon pozzolans, are problematic in decorativeconcrete: They are typically dark in color and,because they are industrial byproducts, are notuniform in color. Silica fume is a highly reactivepozzolan capable of producing very strong anddurable concrete, but results in “sticky” mixturesthat are difficult to place and finish and requirespecial curing techniques.

High-reactivity metakaolin (HRM), on theother hand, is a white powder that brightensconcrete. It is manufactured especially for use inconcrete and to assure consistent appearance. It ishighly reactive and meets or exceeds theperformance of silica fume. But unlike silica fume,it creates a creamy cement paste that is easier topump, trowels “like butter,” and can be cured withordinary curing techniques.

Metakaolin is produced from kaolinite, amineral found in kaolin clay (also known as chinaclay). The material is purified to removecompounds that could discolor concrete, andthen calcined under controlled heat to create anamorphous aluminosilicate that is reactive inconcrete. Generally used to replace 5 percent to20 percent of the portland cement in a mixture,metakaolin also reduces emission of greenhousegases associated with portland cement manufac-turing. A growing number of concrete producershave metakaolin on hand, and it is carried bydistributors selling plastering materials toswimming pool contractors.

MetakaolinThe Pozzolan for

Decorative Concreteby Michael Chusid

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Tom Bouknightof AzzaroneContracting

Corp.usesmetakaolin in

most of hisprojects



strength and density, metakaolin provides asafety factor to help keep your work looking itsbest.

Metakaolin-enhanced concreteOne concrete contractor who has embracedmetakaolin is Alan Bouknight, president ofAzzarone Contracting Corp. in Mineola, N.Y. Hesays, “I made samples with metakaolin and putthem out in the yard to watch how they fared.After more than three years of exposure to theelements, they show none of the pitting anddeterioration we get with typical concrete in ourharsh urban environment.”

Since then, Bouknight has used metakaolin inexposed concrete floors for a fashionable ArmaniCasa showroom, to create a sculptural concretestairway for the Museum of Modern Art, and forpool decks for a custom beachfront residence.

“Metakaolin gives the concrete more ‘butter’ andenables me to coax out the inherent beauty ofconcrete in subtle ways,” he says. “It makes concretemore consistent so we can create an ultra smoothsurface without flow lines or objectionableblemishes.” Used with white portland cement,metakaolin “can produce beautiful opalescentfinishes. Plus, the bright white metakaolin helpsintensify the color we are after.”

Tom Ralston, president of Tom RalstonConcrete in Santa Cruz, Calif., is experimentingwith metakaolin for concrete countertops, usingdosages of up to 10 percent or 15 percent of thecement weight. “Metakaolin will prove to be a veryimportant additive as we continue to improve ourcountertops,” he says. “It fills in voids and supportsthe sand particles to ease finishing. Instead of takingthree or four swipes with a trowel, you might needonly one or two to get a smooth hard finish.”

Concrete appearanceIn addition to brighter and more consistent color,metakaolin improves concrete appearance inseveral important ways:� The improved workability of metakaolin-

enriched concrete enables contractors toachieve smoother, denser finishes without overtroweling. This results in less trowel burn,reduced mottling, and fewer surface blemishes.

� Metakaolin makes concrete denser so it is lesslikely to absorb stains that could disfigure asurface.

� As a highly reactive pozzolan, metakaolinconsumes lime that might otherwise causeefflorescence. And it resists moisture penetrationthat can dissolve and transport lime and othersoluble minerals to the surface of concrete.

� Alkali silica reaction (ASR) is a chemicalreaction between the alkaline lime in concreteand the silica in some types of aggregate. If notmitigated, ASR can crack concrete. Metakaolinis one of the most effective admixtures forpreventing ASR and allows crushed recycledglass to be used in decorative concrete.

� Improved durability: Nothing ruins theappearance of decorative concrete more thancracking, corrosion, spalling, or other forms ofconcrete deterioration. By boosting concrete

How Pozzolans Affect Concrete Color

Fly Ash

Silica Fume

High-Reactivity

Metakaolin

None

Cement: White White + Gray Gray +Pigment Pigment

Metakaolin can be used in white portland cement concrete withoutcompromising its brilliance. Mixed into ordinary gray portland cement,it gives the concrete a lighter value that can create new aestheticopportunities. It can also be used in integrally colored concrete tolighten and intensify color, and its whiteness and uniformity make iteasier to match colors.

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Andrew Gosscrafts jewelry,

such as thisbracelet,with

metakaolin-enriched

concrete.



Portland cement consists primarily of calcium silicates.When mixed with water, a chemical reaction known ashydration creates calcium silicate hydrate (CSH). Needle-like crystals of CSH interlock to hold concrete together,almost like a glue.

Hydration also produces calcium hydroxide, also knownas lime. In fact, approximately 15 percent to 25 percent ofhydrated portland cement is lime. Lime does not contributeto the strength of concrete and can even be detrimental toa project. For example:� Lime migrates out of concrete to form efflorescence on

the concrete surface.� When lime leaches out of concrete, it creates voids that

increase the porosity of concrete, allowing moisturepenetration and corrosion.

� Lime is highly alkaline and contributes to alkali silicareaction (ASR) that can crack concrete.

Pozzolans are supplementary cementitious admixtures thatreact with lime to form more CSH. The additional CSHincreases the cementitious bonds in the concrete to make itstronger. This also makes concrete denser and less porous soconcrete is more resistant to penetration by water andchemicals. And because pozzolans consume lime, there isless efflorescence and ASR.

Highly reactive pozzolans like metakaolin outperformother pozzolans and can produce high-performancemixtures with higher strength and lower porosity thancould otherwise be achieved.

In this simulated microscopic viewof cement paste,hydration beginswhen portland cement particles aresurrounded by water.

The portland cement begins todissolve in the water, forming a gel.

Crystals begin to form as a result ofchemical reactions.

Calcium silicate hydrate (CSH)shown here in white,createsinterlocking crystals that giveconcrete its strength.However,asmuch as 25 percent of the products

of hydration become calcium hydroxide (lime),shown in green,and does not contribute to thestrength of concrete. Voids are formed by excesswater in a mixture.

The voids create pores that allowwater to penetrate concrete.Sincelime is soluble,it dissolves to createeven larger pores and allow moreliquid and gases to penetrate into the

concrete where they can accelerate corrosion. Thelime can also be deposited on the concrete surfacewhere it forms efflorescence and disfigures concrete.

Inside the concrete,the highlyalkaline lime can react with certaintypes of aggregate to form alkalisilica reaction (ASR). ASR expandsin the presence of water,creating

forces that can crack concrete.

As an alternative to ordinaryconcrete mixtures,high reactivitymetakaolin can be used to replace5 percent to 20 percent of theportland cement in a mixture. The

small size of the metakaolin particles fills in thegaps between cement particles to create a denserand creamier cement paste.

As a pozzolan,metakaolin reactswith lime formed during cementhydration to form additional CSH.Because there is less lime,thepotential for efflorescence and ASR

are reduced.

The additional CSH formed bymetakaolin results in a denserconcrete that is stronger and hasgreater durability due to lowerporosity.Plus,the white color of

metakaolin brightens the concrete.

A unique animation explaining how pozzolans improveconcrete is available at www.engelhard.com/metamax aspart of an online continuing education program.

A Primer on Pozzolans

Images © Engelhard Corporation.


http://www.engelhard.com/metamax



Metakaolin is an affordable alternative to using whiteportland cement to lighten the color of concrete, Ralston says.“The colors you can produce with metakaolin are in a rangeyou don’t ordinarily see; we use it if customers want concretethat is just a little more pastel.” He suggests that the higherearly strength due to metakaolin could reduce the waitingperiod before concrete is hard enough to polish, and that thedenser concrete may make countertops more stain resistant.

Metakaolin is also finding its way into the fine arts. Forexample, Andrew Goss, the author of Concrete Handbookfor Artists, uses metakaolin in concrete sculpture and jewelry.He says, “Metakaolin can double the compressive strength ofthe concrete, lowers permeability and increases density butalso has advantages over silica fume. Metakaolin makes themix creamier, less sticky, and is plain white in color.”

Guidelines for useConcrete with metakaolin can be placed, finished and curedin pretty much the same manner as concrete without HRM.It complies with ASTM C 618 — Specification for Coal FlyAsh and Raw or Calcined Natural Pozzolan for Use as a MineralAdmixture in Concrete, Class N and is accepted under ACI318 — Building Code Requirements for Structural Concrete andCommentary.


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According to Anthony Reed, market developmentmanager for Engelhard Corp.’s MetaMax high-reactivitymetakaolin, “At an HRM replacement level of 8 percent to10 percent, concrete is generally more cohesive and lesslikely to bleed. As a result, the effort required for pumpingand finishing processes is reduced. Compressive strength anddensity of hardened concrete are also increased. Optimumpozzolanic benefits of metakaolin can be obtained byreplacing 10 percent to 20 percent of the portland cement inthe mixture with HRM. These levels produce concrete withlower porosity and improved durability and resistance toimpact and abrasion.”

Reed also points out that metakaolin reduces concreteslump and generally requires the addition of a high-rangewater reducer (HRWR). “Metakaolin should generally beadded to batch after portland cement and before HRWR isadded,” he says. “Air entraining admixtures may requiresomewhat increased dosage when used with metakaolin.”

When using integrally colored concrete, metakaolinbrightens the shade of colored concrete by creating a lightercementitious base color, according to Nick Paris, marketingmanager for Davis Colors.

While metakaolin should have no impact on surface-applied coatings, special consideration must be given whenusing penetrating stains, Paris explains. “Because metakaolinincreases the density of concrete, it may reduce the ability ofstain to penetrate the surface. In addition, pozzolans


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Pool contractors use metakaolin to makeplaster more resistant to erosion and

corrosive chemicals. The white additivebrightens plaster and improves workability

to reduce trowel burn and mottling.




consume some of the lime in concrete and can reduce theability of chemically active stains to react with lime anddevelop their color.”

David Kucera, president of David Kucera Inc., Gardiner,N.Y., a fabricator of precast concrete ornamentation andarchitectural cladding, points out a further tip on finishingconcrete with metakaolin. “Metakaolin makes my concretemore resistant to acid rain, but it also makes it more difficultto use an acid wash to expose the aggregate. I now have towork twice as hard to remove the cement paste.” He admitsthat this is an ironic testimony to the effectiveness ofmetakaolin in improving the density of concrete. On theother hand, he says, metakaolin simplifies sandblasting. “Theharder concrete makes it easier to keep an edge on a piece,and corners don’t get rounded off as easily.”

Contractors who have used metakaolin advise that beforedoing a project with the additive, decorative concretecraftsmen should prepare trial batches using proposedmaterials in order to refine their mix and technique. “Oncethey get used to working with it,” Bouknight says, “the guyson my crew love metakaolin, especially how it finishes. Itmakes them prouder of the work they do.”

Michael Chusid, FCSI, is an architect and serves on the ACICommittee 124 — Concrete Aesthetics. He is a technical andmarketing consultant to building product manufacturers and canbe reached at www.chusid.com.

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Tom Ralston polishes a countertop createdwith metakaolin. The additive prevents

alkali silica reaction (ASR),making itpossible to use recycled glass as aggregate.


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Power Trowels

TOOLINGPower Trowels

The type of equipment you use should reflect careful considerationof the surface you’re working on and the region you live in.by John Strieder



Picking the right power trowelfor the job is something adecorative contractor needs to

consider carefully.A power trowel will save time and

sweat, but the machine is not knownfor its delicacy. Between its weight andthe heat of its steel blades, the wrongchoice can wreak havoc on adecorative concrete floor. So do yourhomework.

Ride-on vs.walk-behindPower trowels can be divided into twocategories: walk-behind and ride-on.

The first consideration in pickingone or the other will be the size of thejob. A ride-on power trowel’s greateststrength is its productivity — itcontains more blades and pans on itsunderside. Its greatest liability is its size.It is simply too big and heavy tomaneuver into a residential basementand along the edges of walls. It alsocosts much more than a walk-behind.

The high productivity of the ride-onhelps with the fast-curing concrete usedin commercial applications. But theheavy machine would obliterate a thinoverlay system.

So a decorative contractor, who istypically working a relatively smallresidential job, will probably be using awalk-behind power trowel. “I don’t thinkI’ve ever seen a ride-on on somethingsmaller than 2,500 square feet,” says EdVarel, engineering project manager withStone Construction Equipment Inc.“And ride-ons are such large-ticket itemsthat the only way they pay for themselvesis to use them quite a bit.”

A walk-behind power trowel handleslike a waxer, Varel says. “The trowel is

constantly trying to push you over. Theyare tough to operate. You have to findsomebody willing to build up the callusesand muscles to operate that guy.”

Not all walk-behinds are createdequal, of course. Weight is an issuehere too. In some climates, even awalk-behind may be heavy enough tosink into green concrete. “In the coldNorth, you want it light, or otherwiseit will dig into the finish,” Varel says.“Northerners want as little weight aspossible, because things don’t set upreal quickly. Down in Florida, theycan’t get enough weight. They wantthe biggest.”

There are specialized powertrowels that are designed for use on

Power Trowel ManufacturersHoverTrowel Inc.: www.hovertrowel.comStone Construction Equipment Inc.: www.stone-equip.comWagman Metal Products Inc.: www.wagmanmetal.comWhite Cap Construction Supply: www.whitecapdirect.comMultiquip Inc.: www.multiquip.com

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Fagley also likes the idea. “Ipersonally think down the road there isgoing to be a lot of remote trowelingdone,” he says.

Choosing a bladeAfter picking a machine, a contractormust decide what will go underneath it.

The blade “spider” of a power trowelextends from the center like the bladesof a lawnmower. There are threecategories of blades: float, finishing andcombination.

The float blade is used first, spinningflat at a relatively low RPM rate. As itworks over the surface, high spots areleveled, water rises to the top and largerrocks sink.

Then comes the finishing blade,applied with a higher RPM and at aslight angle. The heavier pressure sealsthe concrete and increases its density.

Combination blades can be used toboth float and polish, as long as they arereset at the necessary angle between tasks.

polymer-modified systems. Forexample, the HoverTrowel is lighterthan a conventional walk-behind,which allows it to be operated on athin-coat system that won’t take aheavier machine. “The HoverTrowelis really the only lightweight trowel onthe market that can handleoverlayments,” says HoverTrowel Inc.president Drew Fagley.

The HoverTrowel is pneumatic,which makes it a good choice in jobswhere a gas-powered machine can’t beused. If a contractor wants to switch toa gas-powered engine, the HoverTrowelcan be retrofitted with one.

“It’s a power trowel that also doesthings that a man can do,” Fagley says.“It’s sort of a hand trowel standing up.”

Varel’s company, Stone ConstructionEquipment, makes power trowels withunique features of their own. An RPMadjuster and hand-disconnect clutchallow the engine to rev up to speedbefore the blades are engaged. When

the operator isn’t actively troweling, heor she simply disengages the blades. Theengine continues to hum at the sameRPM, ready to resume work at asecond’s notice.

A safety switch on Stone’s machinedisengages the blades automatically if themachine spins one full turn, safeguardingagainst the power trowel running amuck,injuring workers and ruining the pad.

Then there is the remote-controlpower trowel. White Cap ConstructionSupply exhibited a Tibroc CCF-40radio-controlled power trowel at the2005 World of Concrete conference.The 85-pound machine, which thecompany bills as the first of its kind, iscontrolled with two joysticks.

Remote-control power trowels aren’tin wide use right now, but they mightcatch on. They would reduce operatorfatigue without being as big orexpensive as a ride-on, Varel says.“They would be a little bit of bothworlds, is what I’m thinking.”

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Instead of float blades, an operatormay attach paddle-shaped float pans tothe spider. The attachments are oftenused to smooth epoxy coatings overconcrete floors. They will also leave aflatter surface than float blades, giventhe same number of passes. But becausepans don’t close up a surface aseffectively as blades, they are not usedfor finishing.

Each type of blade is progressivelynarrower, with floats being the widestand finish blades the skinniest. Smaller,stiffer finish blades will produce aharder swiping action and betterdensify molecules in the concrete, saysJeff Snyder, sales manager withWagman Metal Products Inc. “Thehardest surface is going to be achievedby a finish-style blade.”

Wagman Metal Products makesseveral series of plastic trowel bladesthat should last as long as the steelvariety. And unlike steel blades,plastic floats won’t leave burnishmarks, an important considerationwhen power-troweling color hardener.“You can get a high-polish finish withplastic blades without burnish marks,”Snyder says. “You can spin plastic on asurface until the machine runs out ofgas and not mark it.”

Other specialty attachments will gounderneath too. Grinding blocks canbe attached to rub out screed marks.Edger blades, with ends that are curvedinstead of square like traditional blades,can get right up against a wall.

The HoverTrowel takes mahoganyor magnesium floats, which wouldtear apart a conventional trowel. Thisfeature may come in handy when acontractor doesn’t want to use steeltrowels because of their tendency toclose the pores of the surface. Closedpores can lead to spalling in coldparts of the country where theconcrete is subject to freeze-thawcycles. “With mahogany, pores stayopen and the concrete can breathe,”Fagley says.



PROJECT PROFILEVersatile BuildingProducts Inc.Liquid Granite chip flooring systemby John Strieder

When a pair of specialistsfrom Versatile BuildingProducts made a January

trek from California to Oregon to coata concrete floor, their first concern wasthe cold.

The project: a 490-square-footgarage floor at a house near Eugene,Ore.

The coating: Versatile’s LiquidGranite chip flooring system.

The goal: Complete the installationin two days at temperatures below 45degrees.



minimum recommended temperaturefor application of these products istypically 50 degrees, not to mentionthat the humidity was alsoexceptionally high. These factorstogether would have delayed thecompletion of the process by morethan seven days.

So they added one accelerator tothe epoxy and another to the topcoat.“One of the reasons we did this job isbecause of the cold,” Gonzales says.“We wanted to come up here and testthe accelerators.”

The flooring system comes with theuser’s choice of epoxies and urethanes.On this floor, the specialists workedwith Vapor-Stop primer (a low-vaporepoxy tinted “Cottonwood”) andVersathane CRU 400 polyurethanetopcoat. The two coatings sandwiched a“Medium Tan” mix of vinyl paint chips.

The system is usually installed in 60-degree to 80-degree weather, abouttwice as warm as what Versatile salesmanager Simon Gonzales andtechnical director Mark Glendrangewere contending with in Oregon. The



The epoxy was applied first, thenthe chips. Versatile recommends thebroadcasting of chips to the point ofrejection, laying down enough to soakinto the epoxy and still leave anattractive surface afterward.

“This is the fun part,” Gonzales saidas he scattered chips. There is noproper technique to pitch chips, henoted, and nearly every applicator has

a unique approach. “I’m feedingchickens, just like with mygranddaddy,” he said.

The team emptied a 55-pound and27.5-pound box of chips, and used ablower to move chips into the remainingbare spots. The crew estimated that oncethe chips were scraped, swept andblown, about three-fifths of them wouldbe recollected for recycling.

Then, finally, came two coats of theVersathane CRU. With only twocoats, the floor was skid-free withoutthe use of aluminum oxide.

The accelerators worked. After thefirst coat of Versathane started curing,it had “the same integrity as if someonehad done it without an accelerator in70-degree or 80-degree heat,”Glendrange said. “The edge of thegarage was tacky, but you could walkon it.”

The hardest thing about layingepoxy is prep work, Gonzales said. Buton this job, prep was relatively easy.The slab was still only six months old,so the relatively few oil and fluid stainsrequired only roughing. The ghosts ofthe stains were still visible as theVersatile team began to prime and, asthey promised, the vinyl chips coveredeverything.

Cracks proved to be a slightly biggerproblem, but not by much. Four longcontrol joints, installed with zip strips,showed only as hairline cracks beforethe process started. They were stillslightly visible after the excess chipswere swept away, but that was easilyremedied. The team simply applied thefirst coat of Versathane, then scatteredmore chips on top of the cracks. Then,once again, they removed the loosechips. They spread the second coat ofVersathane over the works.

Gonzales said putting down a chipflooring system is one of his favoriteapplications at Versatile. “You can hidemultiple sins with this,” he said. “Thiscovers everything.”

If needed, a contractor orhomeowner can go back in a year’stime and put chips and sealer ontrouble spots, and the end result willlook identical to the first go-round.

Overall, the project went offwithout a hitch, Gonzales said.



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ConcreteMarketplaceis a paid listing of quality-related products.

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POLISHED PERSPECTIVESby Peter Wagner

This is the first of severalcolumns that I will have theopportunity to write for

Concrete Decor during this year.“Polished Perspectives” will focus onproviding simple, sound informationon how to deliver a polished concretefloor to your customer — one that bothyou and your customer will be proud of.To me there is no better place to startthan with the basics: your ability to useyour diamonds to establish properscratch patterns. All of the bells andwhistles in your bag of tricks will rarelysave you if you haven’t first performedyour grinding and polishing correctly.

Scratch patterns anddiamond selectionThere is nothing more defeating whenpolishing concrete than to complete allof your polishing steps and then findscratches that you did not remove atthe low end of your grinds.

When this occurs, I like to say thatyou are “paying tuition.” I don’t mindpaying tuition once, but I hate payingtuition twice for the same thing.Providing proper scratch patternsrequires that you have anunderstanding of the floor you will bepolishing, the expectations of yourcustomer, and the diamonds andequipment that you will use to performthe work.

Prior to mobilizing for the actualproject, it is smart business to perform atest patch, preferably with theequipment that you will actually use onthe floor. Whether you are grindingand polishing wet or dry, you still haveto deal with proper scratch patterns.

Each project is different; for thatmatter, even individual slabs within aproject may be different. Ideally youwant to know whether the floor is newor old; soft or hard; flat or wavy; sealedor not, before you even set foot on the

site. Why is this important? All ofthese variables will influence whichequipment and diamonds you will needto successfully perform the work, oreven help you decide if the floor is agood candidate tobe polished —because not allfloors are. Somebasic rules ofthumb:� Be wary of

weather-damaged orcarbonatedfloors, anddiscuss thepossible ramifi-cations with the owner.

� Always confirm that the floor doesnot have a topical sealer.

� If the floor is hard, you generally usea soft matrix diamond.

� If the floor is soft, you generally use ahard matrix diamond.

� Don’t move on until you havesuccessfully removed the previousscratch.

� Have the customer or theirrepresentative sign off on your test.When starting with a new or

existing slab, your initial evaluationwill expose how flat the slab is andwhat scratches and gouges you will berequired to remove. As you can see inGraphic 1, the floor surface is generallynot consistent, either in flatness or inbeing void of scratches. An irregularfloor deliversirregular reflectivityand clarity. Theblack arrowsrepresent incominglight, while thecolored arrowsrepresent reflected,or refracted light.Notice that due to

the floor irregularities, the light isrefracted in a random pattern, asopposed to being reflected uniformly asit would be from a properly ground andpolished floor.

It is necessary to understand theimportance of creating a proper scratchpattern. Every pass of each diamonddisk will impart a “scratch pattern” tothe concrete surface. You must alwaystake the proper amount of time foreach pass so that the diamonds grind orpolish every square inch consistently.

Once you have removed theobjectionable scratches or irregularitiesin the slab with your lowest gritdiamonds, you have performed nearly90 percent of your work. The purposeof each successive diamond is toremove the scratch pattern of theprevious diamond, to the point whereyou have produced an even scratchpattern, and the scratch pattern is sofine that the human eye will not beable to see it on the floor.



Whenever you leave a deep scratchor a “bird bath” (where the diamondshave not performed correctly), you willget refraction of the light, as opposedto a consistent reflection of the light.This creates a void, or dark area, in thereflection on the floor. Take your timewith each grind and continuallyevaluate your work as you proceed. Tofix a missed scratch after having movedon through the subsequent gritsrequires you to regrind an area fargreater than the area of the immediatescratch. Graphic 2 shows how a missedscratch (purple) will change thedirection of the light. This area willappear as a blemish or darker spot on

the floor. Graphic 3 shows thereflection from a correct scratchpattern.

Peter Wagner is the marketing director forRetroPlate and is responsible for workingwith RetroPlate’s Certified Applicatornetwork throughout North America. Mr.Wagner brings over 20 years experience inthe flooring industry to the job. Prior totaking his position last year, he was asmall-business owner involved in bothnatural stone restoration and concretepolishing in the Pacific Northwest.



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Artevia Decorative Concrete

Lafarge North America is putting some color in its catalog with its new lineof Artevia colored concrete.

Artevia concrete is integrally colored with a palette of earthy tints that canbe customized to fill special orders. The palette offers 38 colors in the UnitedStates, 18 in Canada. A greater variety of settings in the United States calledfor more color choices in the U.S. palette, says Greg Sheardown, vice presidentof Lafarge North America’s ready-mixed performance division.

The company supports the new line with a system that trains finishers in theart of decorative concrete. Lafarge markets the line with the promise of uniquedesigns and textures, and the training program helps ensure that propertyowners see those results. Finishers are taught decorative techniques such asetching, polishing and saw cuts. Artevia concrete customers are then referred tothose trained craftspeople.

The 38 U.S. colors are divided into three color groups with increasing levelsof pigment. Generally, the more pigment in the mix, the more the color costs.Nine “Subtle” colors are the least expensive, including hues such as“Sandstone” and “Light Gray.” The mid-priced “Standard” group of 21 colorsincludes such shades as “Sangria,” “Salmon,” “Harvest Gold,” “Pewter” and“Mocha.” The top-of-the-line “Premium” group consists of eight rich colors,such as “Brick Red,” “Flagstone Brown” and “Kahlua.” Prices vary within thegroups, but to give one example, all reddish “standard” colors cost about thesame.

Quality assurance and control are key elements of the Lafarge system, fromconcrete and pigment to service and installation, Sheardown says. “Anyproducer can provide you with a brick red. We have a quality-control system inplace to make sure what you order is what you get.”

Lafarge North America is a leading supplier of cement, ready-mixedconcrete and other construction materials to the United States and Canada.Artevia is the company’s first formal launch of products with integral color.

“We’ve sold integrated color before,” Sheardown says. “If somebodywanted to have it, we’d do it. But I think we’ve resisted itmore than we’ve supported doing it.”

The company plans to release morecolored decorative concrete products underthe Artevia brand name. Next will likely bea line of colored exposed aggregate, whichcould be on the market by the end of thisyear, Sheardown says.

For more information about Artevia, visitwww.lafargenorthamerica.com/artevia or call(703) 480-3600.

PRODUCT PROFILES

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Soff-Cut X-150D ProwlerDecorative Concrete Saw

Soff-Cut International’s X-150 Prowlerearly-entry concrete saw can be adapted to

make decorative V-shaped or radius cuts.Concrete contractors loved that feature. Butthey found themselves making that adaptationoften, and they got frustrated.

The manufacturer took the hint. Last year, itintroduced the Prowler X-150D, which doesonly decorative cuts.

And yes, most of the new saw’s buyersalready owned an X-150. “They found theyneeded a second saw,” says Soff-Cut marketingmanager Brenda Nabarrete. “Changing backand forth was too much hassle.”

At 100 pounds, the gas-powered X-150D isrelatively lightweight. “It is small,” Nabarretesays. “It was designed to be used in residentialprojects.”

Decorative cuts — V-shaped or roundedradius cuts that are ground into existinggrooves — are this Prowler’s specialty. Anotherconcrete saw is used to make the rough first cut,and the X-150D follows to make it look good.

The saw boasts a low-noise, low-vibration4.5-horsepower engine that will be appreciatedin residential neighborhoods. Its size makes itperfect for driveways, sidewalks, and wheneveran operator must work alongside biggermachines.

The blade block drops the blade directlyinto the existing cut. The integrated blockmaintains weight balance for a consistent cut,and an enclosure around the block controlsnoise and dust. Self-aligning guide wheels,which come in three sizes, assure properalignment with the joint, and depth of cut ispreset.

The Prowler X-150D costs about the same asan X-150 and a beveled-blade adapter. Soff-Cut markets seven ProEdge beveled blades foruse with the saw. Formore information, visitwww.soffcut.com orcall (800) 776-3328.

Color Spreader

Although Brian Bettencourt has logged 16 years as a concretecontractor, he had not tried his hand at using color hardener

until late 2003. He landed his first job while attending a color-hardener training workshop. And almost immediately, he was

disgusted. “It was a nightmare,” he says.Dispersing color hardener is a filthy job, he

declares. “You’re covered from head to toe. It’sin your clothes. It’s on your clothes. If there’s a

little bit of wind, it’s that much worse.”The cloud of loose powder can’t be healthy to

breathe, he says. And if a homeowner objects tothe leftover dust on plants and walls, a contractor

could end up doing a pressure-wash job on thehouse ... in both senses of the word.

So Bettencourt marched home and, in only afew days, invented a better way to spread color: The

Color Spreader.The tool is a tray of steel mesh with an aluminumframe. It’s 18.25 by 18.25 inches, weighs 3.35pounds and attaches to the end of any standard

screw-on or plug-in pole. The holes in the meshare big enough to let color hardener or release agent

pour through when jarred loose, but small enough tokeep clumps in the tray. Color hardener is dumped

into the Spreader while it’s held over a bucket, thencarried to the slab. When the tray is gently shaken back and forthover the concrete, the powder cascades downward in even strokes,laying a path 14 inches wide.

The tool disperses material more evenly than the hand-throwingmethod. And because even dispersal is more efficient, the job isfinished more quickly.

On the first pass, hand-scattering will cover only 30 percent to 40percent of the slab, Bettencourt says, while one pass with theSpreader will cover 85 percent to 95 percent.

The tool also doesn’t leave too much in spots, potentially savingthe contractor a lot of powder. “That’s just a bonus at the end of thejob, to be saving in product,” Bettencourt says.

And that powdery fog stays at knee-level and settles immediately,instead of covering everything from shrubbery to employees.

Bettencourt’s company, Innovative Tool Design, officiallylaunched The Color Spreader at the 2005 World of Concrete show.“People can really relate to the Color Spreader once they see it inaction,” he says.

Lee Levig, a Fairfield, Calif., contractor who purchased the tool,praises its speed and ease of use. “If you’re throwing color hardener,you have to have this tool,” he says. “It gives you a more even spreadwithout giving you lumps and bumps.”

Now, Bettencourt is researching customized versions for othermaterials, looking into a larger model on wheels for commercial jobs,and taking pitches from potential distributors. “It looks like thisthing is going to be going pretty crazy,” he says.

For more information about the Color Spreader, visit www.thecol-orspreader.com or call (209) 522-7334.

http://www.soffcut.com


http://www.thecol-orspreader.com




And theWinner is ...At a wine and cheese gala held during the

WOC tradeshow, Concrete Exchangepresented awards to the winners of its

first concrete countertop design competition.The Members’ Circle of Distinction Challenge

received 80 entries, with a total of seven categorywinners. At the reception, Concrete Exchangemembers from all over North America enjoyedsocializing with Fu-Tung Cheng and otherconcrete artisans as well as a slideshow presen-tation showcasing the winning projects.

“The amount of people that attended theDesign Awards reception really showed aphenomenal interest in concrete countertops,”said Luc Lafrance, a Concrete Exchange member.“Concrete Exchange’s booth was buzzing withpeople.”

The design contest’s submissions were evaluatedon exceptional design, technical skill, and overallappeal of the countertop surface.

For more information on the Concrete Exchange, visitwww.concreteexchange.com or call Jeff Osteen at(510) 849-3272, ext. 217.

Best DecorativeFinishesAndrew Simon and JaimieMcGuireLokahi StoneHonolulu, Hawaii

Best of ShowKaren Smith

Countercast DesignsSurrey, British Columbia

http://www.concreteexchange.com


Best Kitchen CountertopDale Blayone

Concrete CuisineHamilton, Ontario


Best Integral SinkMike MoncrieffMonartLynden, Washington

Best Functional FeatureMike MoncrieffMonartLynden, Washington

Best BathCountertopJosh FeiginSeattle, Washington


Concrete at Home

Fu-Tung Cheng’s eagerly awaited second book, Concrete at Home,is now available. A follow-up to the best-selling Concrete

Countertops, published in 2002, the new book has an expanded scopethat includes concrete floors, walls, mantelpieces, fireplace surrounds,water features and more.

Cheng, as always, combines his respect for antiquity with strikingmodern designs to create homes that are simple yet elegant. Alwaysat the cutting edge of decorative concrete, he never fails to find newways to use this age-old material. “My vision,” he says, “is athrowback to the era of the guild, the artisan and the craftsman —integrated with the tools of the 21st century.”

Featuring 350 color photographs, Concrete at Home begins withbasic information about concrete, including an overview of pouring aslab, what makes a good mix, etc. Subsequent sections are devoted tofloors, countertops, walls, fireplace surrounds and other features.Writing in an engaging, almost conversational style, Cheng takesreaders behind the scenes on 22 projects, offering both practicalinformation and inspiration.

While Concrete at Home contains a lot of basic information thatseems to be aimed at readers with relatively little knowledge ofconcrete, it also offers plenty of detailed advice and greatillustrations. Also of interest to our readers will be invaluable tipsCheng has discovered, such as how to fix stains on concretecountertops and even a suggestion to avoid putting a concrete sinkin the kitchen.

Concrete at Home will inspire you, and you might want to show itto your customers to inspire them as well.

The book is available at www.concreteexchange.com, or bycalling (510) 849-3272, ext. 217.


Honorable MentionBrian BrownSoul Focus StoneMendocino, California

Best 3-Dimensional ApplicationSteven PollockWoodstone DesignVancouver, Canada

HonorableMentionPat BigelowHollow Rock DesignsTwo Harbors, Minnesota

http://www.concreteexchange.com




Product New

s

Terrazzo application helps workers do astand-up jobMAPEI has introduced the Terratop system, a flowableterrazzo binder that can be poured or pumped over aspecial primer that is applied to a substrate. Aggregateis broadcast in decorative patterns over the surface tofulfill the architect’s design.

MAPEI’s technology lets installers work from astanding position instead of troweling terrazzo onto afloor while on their knees. Terratop dries quickly and itsflowability allows a lot of square footage to be coveredin a day. What’s more, Terratop is a water-based,LEEDS-compliant, low-VOC system.

Pro Terrazzo Inc. will distribute and support thesystem in the northeastern United States. In addition,it will supply the necessary aggregates, sealers andaccessories. The International Masonry Institute, thetraining arm of the Bricklayers and Allied CraftworkersUnion, will train and certify terrazzo installers in thenew process. Terratop will only be installed by IMI-certified craftspeople.

For more information from MAPEI, visitwww.mapei.com or call (800) 426-2734.

DuoScreed feasts on tough concreteworkMultiquip’s one-man DuoScreed features a unique bladeprofile that enables a lone operator to strike off concretefloors. This model uses blades that are 50 percent lighterthan those on its predecessor, allowing greater maneuver-ability, faster finishes and stronger slabs with less effort.

It is well suited to a variety of jobs such as sidewalks,driveways, pathways and decks.

The DuoScreed’s vibratory action embeds aggregateand reduces air voids, producing a dense slab whileeliminating the strenuous, time-consuming laborassociated with manual screeding. It sports an

integrated lifting bar that is part ofthe control handle. The bladereverses in seconds without tools,with one side used for standardform-to-form screeding while theother is utilized for wet screeding.The unit is powered by a four-stroke, 1.5-horsepower Honda GX-

31 gasoline engine. For more information, visitwww.multiquip.com or call (800) 421-1244.

New diamond blades offer manyimprovementsMultiquip Inc. has improved two series of diamondblades — the HSC combination blades and SideWinder wafer-style tuck points — that work with avariety of concrete and masonry cutting applications.

The upgraded HSC combinationblades boast increased corethickness, additional cooling holesand a new gullet configuration.These improvements increase theblade’s lifespan and make it lesssusceptible to damage from operatorerror.

The HSC allows contractors to use one blade onjobs that previously required multiple blades. Availablein diameters of 12 inches to 20 inches, the diamondblades cut concrete, asphalt, brick, block, pavers, softstone, and roof tile. They can be used on high-speedcut-off saws, low-horsepower walk-behind saws andstationary masonry saws.

The new Side Winder wafer-style tuck point seriesalso improves on the originals. The blades eliminatesegment loss from undercutting, boast superior grindingspeeds and let users easily grind away damaged mortar.

Side Winders are offered intwo-blade and three-bladedesigns with 1⁄4-inch and 3⁄8-inchthicknesses, respectively. Thereare four grades of conventionaltuck point blades in variousbond harnesses and two gradesof wafer-style tuck point blades.

For more information, visitwww.multiquip.com or call (800) 421-1244.

Fresh offerings from MarshalltownMarshalltown Co. hasadded two new epoxyfloats to its premierMarshalltown brand,both featuring thedurable and ergonomicDuraSoft handle. Thefloats offer beveled edgesand rounded front corners, as well as harder and stifferpads for handling demanding applications. The plasticbacking plate is recessed to prevent scraping. The floatscome in 10-inch by 4-inch and 12-inch by 3-inchmodels, and the larger float has an offset handle andnarrow plate for working in tight places.

Marshalltown has also introduced a new line offunctional, tough Marshalltown nylon tool bags. Theblue and black bags offer a variety of pocket configu-

rations and come in threesizes and styles.

The company hasredesigned its Mud Masher forimproved leverage andefficiency. The new masher


http://www.mapei.com




features a sturdy 23-inch hardwoodhandle with a “D” grip design.

Finally, Marshalltown has releasedfour new aluminum handle sectionsdesigned to be versatile extensions formany tools, including bull floats andfresnos. The sections come in lengths of48 inches, 96 inches, 120 inches and

144 inches, andcomplementpreviously existing60-inch and 72-

inch models. All are 13⁄4 inches indiameter and interlock with other poles.

For more information, visitwww.marshalltown.com or call (800)987-6935.

Elcometer introduces newcovermetersProtovale by Elcometer introduced theProtovale 331, a new series ofcovermeters. This model range hasbeen designed to meet all of acontractor’s needs when measuringrebar for on-site concrete inspection,from rebar location to comprehensivesite surveying.

Available in three models, theProtovale 331 can be fitted with anumber of accessories, including a largesearch head for greater depths, aborehole probe for the location of deeprebars and tendon ducts, a calibrationblock, and replaceable battery packs.

For additional information visitwww.elcometer.com or call (800) 521-0635.

Glow little GloBug,glimmer,glimmerMultiquip Inc. has released two GloBuglight towers that flood work areas with360 degrees of glare-free light. Eachlightweight tower includes a 1,000-wattmetal halide lamp that illuminatesdistances of more than 150 feet.




http://www.marshalltown.com

http://www.elcometer.com


take theguesswork out offinding embeddedstuds, rebar andother materials.They can scanthrough up to 3inches of concreteto locate rebar.

TheMultiScannerOneStep is athree-in-one toolthat locates studs,joists, metal and

rebar. Besides scanning for wood andmetal, it alerts users to the presence oflive, unshielded electrical wires,including a function that lets users scanand trace hot AC wires exclusively. Thescanner uses an LCD screen.

The TriScanner is similar to theMultiScanner, but offers an LED screenand does not include AC tracing.

Last but not least, Zircon isintroducing the ProScanner OneStep.Its floating scanner head locks into fullyarticulating arms that extend from thehandle, allowing the scanner to beplaced flat against a wall. It offers threescan modes: stud mode, metal modeand AC scan mode.

All three scanners automaticallycalibrate while in use and switch todeep scanning as needed.

For more details, visitwww.zircon.com or call (800) 245-9265.

Liquid “gloves” protecthandsGloves In A Bottle helpsprotect your hands at workby keeping moisture-robbing irritants out whilelocking natural moisture in.Unlike conventionalmoisturizers, which attemptto replace the skin’s naturalmoisture, Gloves In ABottle bonds with the skinto create a barrier much likeactual gloves.

Once dry, Gloves In ABottle is virtually undetectable. Itworks for hours and comes off naturallywith exfoliated skin cells.

It’s available at pharmaciesnationwide, on the Web atwww.glovesinabottle.com or by calling(800) 600-1881.

Power Curbers to offerhydraulic mold liftPower Curbers Inc. will introduce ahydraulic mold lift designed for the5700-SUPER-B slipform machine thatis used for barrier/parapet work as wellas curb-and-gutter and sidewalkapplications, depending on the moldattached to the machine.

The standardGlo-Bug, with acart for an optionalgenerator, has amaximum mastheight of 16 feet. Itis fitted with aparking brake,safety winch,quick-disconnectpower cable, liftinghook andpneumatic tires.

The Glo-Bug Solo, a stand-alonemodel, sports a maximum mast heightof 13 feet. It is fitted with five counter-weighted outriggers for stabilization,and its three-stage mast comes with a30-inch extension pole.

Both light towers come with aprotective canvas cover and acustomizable, water-resistant balloon.Optional drum and reflector balloonpackages are available. For moreinformation, visit www.multiquip.comor call (800) 421-1244.

One Vision,three newscannersThree scanning tools from Zircon Corp.employ the company’s newCenterVision technology that pinpointsthe center of a stud with just one pass.

The new-generation TriScannerOneStep and MultiScanner OneStep



http://www.zircon.com

http://www.glovesinabottle.com


The new lift will allow machineoperators to easily and quickly lift abarrier mold off rebar at the end of aday’s pour, making machine cleanup aneasier task. With 3 feet of lift alreadybuilt into the machine, the newhydraulic mold lift gives the machinean extra 2 feet of lift for easiermaneuverability. Walls of up to 50inches (1.3m) in height can be poured.

The mold lift will be introduced atConExpo/ConAgg March 15-19 at theLas Vegas Convention Center. PowerCurbers and its paving company, PowerPavers Inc., will display products atBooth S-8637. For more information,call (704) 647-6133.

Similar systems,differentdrivesMi-T-M Corp. has introduced two linesof cold-water aluminum pressurewashers, one with belt-drive systemsand one with direct drives.

CBA Series aluminum pressurewashers with belt-drive systems havebeen designed for commercialapplications. The lightweightaluminum frame is popular in coastalareas where salt water may cause rustand corrosion issues.

Standard features include 9.0 to 13.0horsepower Honda or Subaru engines, abelt-drive triplex piston pump withceramic plungers, a water filter withclear sleeve for screen inspection, a dualcogged belt drive system to preventslippage, 3⁄16-inch aluminum base plateswith an isolator plate to reducevibration, a 50-foot nonmarkingpressure hose with quick connects,swivel and bend restrictors, a profes-sional-grade trigger gun and quick-connect nozzles.


Mi-T-M’s aluminum pressure washerswith direct drives, called the CA Series,

are also for commercial applications.The CA Series machines come with5.5 to 13.0 horsepower Honda orSubaru engines, direct-drive triplexpiston pumps with ceramic plungers,and optional adjustable low-pressuredetergent injection, along with featurescommon to the CBA.

For more information, visitwww.mitm.com or call (800) 553-9053.



http://www.mitm.com


The Final Pour

World of Concrete 2005



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V EB AR Choosing an Overlay - Concrete Decorﬂoor to create abstract shapes. CIRCLE #86 ON READER SERVICE CARD. For more information on Metal Forms Corp., visit or call (414) 964-4550