DECORATIVE CONCRETE
DECORATIVE CONCRETE
-Pratik Shah (T.E. Civil)
-Sunny Surlaker (T.E. Civil)
V.J.T.I
CONTENTS AT A GLANCE
TOPICS
PAGE NO.
1. INTRODUCTION
2. PATTERN IMPRINTED CONCRETE
(PIC)
2.1
2.2
2.3
2.4
Introduction
Markets
Patterns and Colours
Pros and Cons
3. STENCILCRETE
3.1
3.2
3.3
3.4
3.5
Introduction
Why Use Stencilcrete?
Various Stencil Patterns
Various Applications
Construction Of a Stenciled
Surface
3.6 Benefits To Customers
3.7 Benefits To Contractors
4. SPRAYCRETE
4.1
4.2
4.3
4.4
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Introduction
Spraycrete Process at a Glance
Spraycrete for Walls
Spraycrete Advantages
5. TEXTURED OVERLAYS
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6. CONCLUSION
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Decorative Concrete
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Decorative Concrete
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1. INTRODUCTION
For many years, concrete has been used as a simple, effective and low cost
surface for all sorts of areas ranging from car parks to driveways to commercial freight
yards. However, the one factor you rarely hear being praised is its looks.
Techniques to improve the aesthetic appeal of monolithic concrete pavements have
been around since the fifties, notably in North America where concrete is possibly the
most popular surfacing for patios, drives and 'yards', and in the southern hemisphere,
particularly Australia. However, it is only since the mid 1980s that many of these
techniques found their way to the North-west European paving market.
Decorative concretes have been used to dramatic effect in new structural
developments such as the Trafford Centre in Birmingham, UK, the Basilica of
Yamoussoukro on the Ivory Coast and the new European Parliament building. Dramatic
effects are not only achieved in large structures though. Coloured concrete is just as
effectively used in architectural pavements, paving stones and internal flooring
Undoubtedly, the most popular prettifying technique we see in the UK and Ireland
and
other
western
countries
are
Pattern
Imprint,
sometimes
known
as
Stamped?Imprinted' or 'Textured' concrete. From a sluggish start at the back end of
the 1980s this technique has slowly but surely grown in popularity and now attracts a
reasonable level of interest, in both the residential and the commercial markets.
In recent years, refinements and
developments of this technique have
emerged and we now have stencilling
techniques,
high-strength
textured
overlays. These techniques are described
in the following pages.
Stenciled Concrete-'Stencilcrete'
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2. PATTERN IMPRINTED CONCRETE (PIC)
2.1 INTRODUCTION:Pattern Imprinted Concrete (PIC) is the most popular Decorative Concrete
technique currently used in the UK. This section looks at some of the choices available
with PIC, as well as the markets where it sells best, the pros and cons. Construction of
a PIC pavement is dealt later on.
2.2 MARKETS:The use of PIC can be divided into two main markets: the residential customers
wanting their driveways, patios, paths, pool sides etc surfaced, and the commercial
sector, where clients look for a low-maintenance, attractive and decorative or
customizable surface. It is rarely, if ever, used on medium-to-high speed vehicular traffic
applications, such as roadways, as the finished surface is too uneven, and the same
criterion seems to rule out its use in shopping malls and town centers, where smallwheeled trolleys would struggle to cope with the textured surface.
2.3 PATTERNS AND COLOURS1:-
Ashlar Stone Random Stone Cobbles
riven or hewn stone
effect in rectangles and
squares
stone
effect
'crazy'
paving
Brickwork
replicating
coursed
settwork and cobbles or
European fan effects
imitating herringbone,
basketweave .
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Tiled mimicking Textures
square,
rectangular
and/or octagonal tiles
Decking
seamless stone or slate
textured effect
Safety
simulating 'boardwalks'
or planking
barred
patterns for increased
traction
on
ramps;
blister paving etc.
The Ashlar stone and Herringbone brick would seem to be the most pouplar patterns
in the UK market.
Colours tend to be somewhere in the black-brown-buff-red part of the spectrum,
although there are greens and blues. Like the paint market, some of the colour names
are not to be taken too literally. Often a lighter and darker shade are combined to give
the impression of extra 'depth' to the surfacing. For example, an Ashlar stone effect
surface might feature a darker brown base colour with 'highlights' done in a buff.
2.4 PROS AND CONS:When done properly, and not aggravated by adverse weather conditions, PIC
paving can look very attractive, and will require almost no maintenance. Unfortunately,
good contractors in this particular discipline are few and far between, so it is essential
that references are taken, previous jobs visited, and clients chatted to, to ensure you
have chosen a reliable and competent firm.
When done badly, there is no way of correcting any problems, as the concrete is
rigid and impossible to patch repair invisibly. If the contractor does not get the job right
first time, there is no remedial action other than to rip it up and redo.
Also, there is concern regarding underground services and drainage that may be
covered by the PIC. Should any remedial work ever be required on buried services, the
PIC will need to be broken out and any patching will be impossible to hide. The only
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solution is to create band courses or similar to delineate the original surface from the
patched area.
Common problems reported with PIC include
cracking of the surface at places other than control
joints and 'flaking' of the surface. Both of these
faults are directly attributable to bad workmanship.
Correct preparation of the sub-base/sub-grade and
inclusion of well-formed crack control joints should
eliminate all unwanted cracking, while flaking is
often a result of poor floating of the colour hardener
Cracking and Flaking
and/or the release agent. This spalling of the
Of PIC
surface can also be brought about by the addition of
extra water to the mix, which adversely affects the
design strength of the concrete.
And despite the claims often made by
the sales agents, algae and lichens do
colonise PIC, so it is not maintenance
free. The surface needs to be swept
regularly to keep it free of detritus which
can accumulate on the uneven surface
and in the 'joints' of certain patterns. Also,
the sealant will need to be re-applied
every 2-4 years, especially on heavily
Algae and Traffic Wear
trafficked areas, which can wear quite
quickly, exposing the plain grey concrete
beneath, if the original sealant is allowed
to deteriorate.
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3. STENCILCRETE
3.1 INTRODUCTION:This is a fairly straightforward variation of Pattern Imprinting. A concrete substrate is
prepared and a paper stencil of the chosen pattern is laid over the still-wet surface
before a colour-hardener is applied. The stencil is peeled away once the surface has
dried, leaving an imprint of the pattern with the colour on the non-masked areas.
Stencilcrete offers the alternative to plain concrete surfacing around your home or
business. The unique Stencilcrete surface provides the key advantage of a high quality
image and finish at very reasonable cost and in a relatively short period of time. The
product has the look of a paved area but eliminates the problems of structural
movement and weed growth of other paving forms. Architects, designers, engineers and
local councils all agree that Stencilcrete is fast becoming the preferred surface
alternative.
Stencilcrete can be used indoors or outdoors. It is commonly used in commercial
areas including roads, traffic islands, parking lots, pedestrian walkways, and shopping
centers.
In public areas such as footpaths, and domestic areas like driveways, paths, patios
and pools surrounds, Stencilcrete is a popular solution.
A complete range of colours, patterns and textures allows you to create your very
own customised appeal.
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Stencilcrete brings style
and appeal to commercial
settings.
Stencilcrete driveways
become a feature for the
home.
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Stencilcrete offers a full
variety of appeals - with
one to suit your home.
3.2 WHY USE STENCILCRETE?-
Fast - Get the full visual effect of conventional block
paving in a fraction of the time. The Stencilcrete laying
process is extremely quick and easy. Now you can
enjoy the end result sooner.
Cost efficient - Stencilcrete delivers the same
aesthetic appeal as conventional paving at a fraction of
the cost. The highly efficient Stencilcrete system
requires less labour in laying. Make huge savings using
Stencilcrete surfacing.
Style - Stencilcrete delivers the flexibility to create the
perfect appeal for your home. Elaborate paving
patterns, bordered edges and mixed block colouring
becomes affordable and easy. With the full effect of
expertly grouted paving blocks, you can get the exact
finish you want.
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Durable - The Stencilcrete surface is extremely hardwearing and is treated against discolouration and
fading. It's designed to handle high traffic loads and
lasts for years under the most stressful situations.
Custom - The Stencilcrete system offers full flexibility complete colour range and combinations, paving styles
and bordering finishes. Stencilcrete even allows you to
incorporate customised patterns including street
numbers or even a company logo.
Slip Reducing - Stencilcrete can be finished to provide
a slip reducing surface over the concrete slab. Enjoy
increased safety and reduced liability on those wet
days.
3.3 VARIOUS STENCIL PATTERNS2:-
www.concreteplus.co.nz
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3.4 VARIOUS APPLICATIONS:
Residential Buildings and houses.
Commercial Complexes.
Suitable for Driveways.
Patios.
Courtyards.
Corridors.
Pool Surroundings.
Roads etc.
3.5 CONSTRUCTION OF A STENCILLED SURFACE3:There two main methods of creating a stencilled surface:
Wet-cast - the stencil is applied to a freshly laid concrete substrate
Spray-on - stencil is laid over an existing surface and colour is applied
.This is also called as SPRAYCRETE.
FINISHED CONCRETE SURFACE (WET CAST):-
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3.5.1WET CAST- STENCILCRETE IN 4 EASY STEPS:-
3.6 BENEFITS TO
3.7 BENEFITS TO
CUSTOMERS:-
CONTRACTOR:-
Great range of patterns and colours
Eye catching, individual installations
Traditional style paving by modern
Fast installations for quick profit and
methods
Minimal disruptions, fast installation
good cash flow
Handle curves, contours and slopes
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Maximum design flexibility
Weed Free
Sealed surface minimizes staining
No sinking or spreading
with ease
Extra income with future resealing
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4. SPRAYCRETE
4.1 INTRODUCTION:Spraycrete is a high strength polymer cement coating and is designed for resurfacing old or new concrete. Used with stencilcrete paper stencils, Spraycrete can
create stunning designs quickly and economically.
This method is used to apply a stencilled finish to existing suitable substrates, such
as concrete or tarmac. As there is no excavation and casting of a new slab, this method
works outs considerably cheaper than the wet cast method described above and can be
used to completely rejuvenate old, tired surfaces, provided they are structurally sound.
Using this system over cracked or crumbling concrete is a complete waste of money; it
is a surface dressing, not a repair system.
Spraycrete transforms ordinary plain concrete into a beautiful practical surface
that looks like stone, slate, brick or tile. Spraycrete offers higher strength properties
than conventional concrete and is more flexible and durable. The finished Spraycrete
surface is finished with a coating of Superseal acrylic sealer to provide high abrasion
resistance and an easy to clean surface. Spraycrete coloured cement coatings offer an
attractive and durable finish at an affordable cost, making it the perfect choice for both
commercial and residential installations and for both interior and exterior use.
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4.2 SPRAYCRETE PROCESS AT A GLANCE:-
Apply Base Coat
Fix Stencil
Fix Stencil
Apply spraycrete
top coat
4.3 SPRAYCRETE FOR WALLS:-
Apply Base Coat
Apply Face Brick
Spraycrete Applied
Finished Wall
Stencil
4.4 SPRAYCRETE ADVANTAGES:
Spraycrete - Naturally slip resistant and hard wearing finished
surfaces. It is available in many standard colours with a choice of a
many designs.
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Spraycrete - Can be applied over existing concrete flatwork at 2mm
layer which permits all existing concrete falls and levels to remain
basically unchanged.
Spraycrete - Stencil patterns are uniform with shallow relief, so the
finished texture surface has no deep crevices to trip on.
5. TEXTURED OVERLAYS
Textured overlays consist of a thin screed of a high-strength polymeric concrete that
is coloured, laid over an existing substrate and then textured accordingly. It is similar to
the Spray-On stencil system described above, except the coating is usually applied by
trowel or float to a thickness of 6-20mm, rather than a thin, 1-3mm skin.
Again, a clean and structurally sound substrate is essential. An existing concrete
should be power-washed and acid-etched to remove all dirt, laitence or other
deleterious material. Existing access and drainage covers should be elevated to the
new level (3mm below finished surface level) prior to the work commencing, and
provision must be made for the extension of any movement joints. Any cracks or
damaged sections of the concrete substrate should be cut out and patch-repaired with
new concrete or an epoxy resin repair mortar. Any such repairs should be given ample
time to cure before covering with the overlay coating.
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BEFORE-applying Textured Overlays
AFTER-applying Textured Overlays
Once the substrate is prepared, a
primer coat is applied to ensure a sound
bond between the substrate and the
overlay. The overlay powder itself is mixed
with a measured quantity of clean water in
a mechanical mixer to achieve a smooth,
workable yet not 'sloppy' consistency, which
is applied immediately to the primed
substrate and leveled out by tamping with
screeder bars, and working with floats and
trowels to the desired level.
Once the overlay screed is in place, it can be left smooth or it may be textured by
use of texture mats (as used for PIC), stencils, textured rollers or other decorative tools.
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6. CONCLUSION
The Techniques described earlier viz., Stencilcrete, spraycrete, PIC, Textured
Overlays are currently extensively used in countries like , North America, European
countries and in the southern hemisphere, particularly Australia
where concrete is
possibly the most popular surfacing for patios, drives and 'yards' .These techniques
have not yet found a firm footing in India. In a country like India where costs as well as
aesthetic matter, these techniques are an excellent means to provide required
aesthetics in a cost effective way. We thus sincerely hope that these techniques will be
used to great benefits in the near future.
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