A Hot Combo: Radiant Heat and Decorative Concrete · with modern design. by John Strieder 32 MANUFACTURER PROFILE: Davis Colors Davis Colors celebrates 50 years of coloring concrete

VOL. 3 NO. 1 • FEBRUARY/MARCH 2003 • $6.95

Sipping Tea with Fu-Tung Cheng

A Hot Combo:Radiant Heat and

Decorative Concrete

Ready Mix Gets Colorful!

Keep it Clean,Sealed and Beautiful

Early-entry Decorative Cuts

Brushed Finishes

A Hot Combo:Radiant Heat and

Decorative Concrete

Ready Mix Gets Colorful!

Keep it Clean,Sealed and Beautiful

Early-entry Decorative Cuts

Brushed Finishes

CIRCLE #88 ON READER SERVICE CARD


2 • www.ConcreteDecor.net • February/March 2003

February/March 2003 • Vol. 3 No. 1Issue No. 9 • $6.95

PPuubblliisshheerr:: Bent O. Mikkelsen

CCoo--ppuubblliisshheerr:: Ernst H. Mikkelsen

EEddiittoorr:: Rosemary Camozzi

AAssssiissttaanntt EEddiittoorr:: Harlan Baldridge

CCiirrccuullaattiioonn:: Sheri Mikkelsen

DDeessiiggnn aanndd PPrroodduuccttiioonn:: Stephen Stanley

GGrraapphhiicc DDeessiiggnneerr:: Michelle Hilden

AAddvveerrttiissiinngg SSaalleess:: Kathleen Goodman(314) 367-1121

WWrriitteerrss::Susan Brimo-CoxChristina CamaraStacey Klemenc

Joan StanusJohn StriederDenise Wendt

CCoonnttrriibbuuttiinngg WWrriitteerrss::Clark BranumJim Peterson

EEddiittoorriiaall::Professional Trade Publications, Inc.

1925 Bailey Hill Road, Suite IEugene, OR 97405Tel: 541-341-3390Fax: 541-341-6443

Email: [email protected]

CCiirrccuullaattiioonn aanndd AAddmmiinniissttrraattiioonn::Professional Trade Publications, Inc.

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

Email: [email protected]

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

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

additional mailing offices.ISSN 1542-1597

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

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

FFoorr SSuubbssccrriibbeerr SSeerrvviicceess::Call 866-341-3703 Toll Free

FFoorr AAddvveerrttiisseerr SSeerrvviicceess::Call 877-935-8906 Toll Free

© 2003 Professional Trade Publications, Inc.

www.concretedecor.net

ONTHE COVER: As radiant floor heating gains greater acceptance as aneconomical and logical choice for property owners,concretecontractors are warming up to its potential for new business.Photograph courtesy of Watts Radiant.

Got Passion?

Does this question have you scratchingyour head? If so, you may haveoverlooked some exhibits at this year’s

WOC show in Las Vegas.While part of the show gave contractors the

means for enforcing a stronger mix, adding produc-tivity and ensuring more durable finishes, anotherpart of the week-long event was showing the samecontractors how to turn these permanent fixturesinto lifelong works of art.

Pigments, additives, reactive stains; embossing,polishing and stenciling tools; forms and liners; epoxies and sealers; overlays; newuses for many everyday concrete tools — all had their manufacturers showingcreative new methods for carving a decorative niche for yourself in concrete.

Many of those who have decided to learn decorative applications have discovereda new passion for concrete as well as increased business and profitability. For others,the new concrete applications may be an unwelcome change from programs thathave been working just fine. Although tradesmen are often reluctant to face change,it is truly healthy, and it actually keeps us from becoming lodged in routines that aretoo comfortable or which keep us from maximizing our full potential.

Unlike other industries, the concrete construction trade has tremendousresources awaiting those who choose to tap into them. Education abounds, and it’smostly guided by people like you and me who find concrete such an appealingmaterial with unlimited potential. Many of those trainers are people whose passionfor the trade can easily rub off on you and your team in the most natural way. A passion for concrete and a commitment to change are the most important toolsfor inscribing higher quality standards into your concrete finishes.

Passion develops from within. It keeps us seeking, experimenting, discoveringand seldom content with the status quo. If today’s industry developments have notalready created that passion for exploring new applications in concrete, it is likelythat the exciting direction this trade is taking will ignite your interest very soon.

Concrete Decor is committed to helping you realize your potential in decorativeconcrete, both through informative, well-illustrated articles and by plugging yourbusiness into our Web site, where consumers can find contractors — like you —who are passionate about what they do.

Sincerely,

Bent MikkelsenPublisher

http://www.ConcreteDecor.net

mailto:[email protected]


http://www.concretedecor.net

FEATURES1122 IInntteeggrraall CCoolloorr ffoorr RReeaaddyy MMiixx

CCoommppuutteerriizzeedd ssyysstteemmss mmaakkee ccoolloorriinngg yyoouurr ccoonnccrreettee aass eeaassyy aass 11,, 22,, 33..by Stacey Klemenc

1188 MMaaiinnttaaiinniinngg DDeeccoorraattiivvee CCoonnccrreetteeYYoouu’’vvee ccrreeaatteedd ssoommeetthhiinngg bbeeaauuttiiffuull.. HHeerree’’ss hhooww ttoo kkeeeepp iitt tthhaatt wwaayy..by Christina Camara

2266 EEaarrllyy--eennttrryy CCuuttss ffoorr DDeeccoorrGGrreeeenn ccoonnccrreettee ssaawwss mmaakkee ffaasstt wwoorrkk ooff ddeeccoorraattiivvee ccuuttss..by John Strieder

3344 RRaaddiiaanntt FFlloooorr HHeeaattiinnggCChheecckk oouutt tthhiiss hhoott nneeww mmaarrkkeett ffoorr ccoonnccrreettee ccoonnttrraaccttoorrss!!by Susan Brimo-Cox

4444 BBrruusshheedd FFiinniisshheessBBrruusshheess ooffffeerr aa vvaarriieettyy ooff ssnnaazzzzyy fifinniisshheess..by Joan Stanus

DEPARTMENTS0088 CCOONNTTRRAACCTTOORR PPRROOFFIILLEE:: IIrraa GGoollddbbeerrgg

BBoommaanniittee ccoonnttrraaccttoorr IIrraa GGoollddbbeerrgg ppaavveedd tthhee wwaayy ffoorr ddeeccoorraattiivveeccoonnccrreettee iinn NNeeww JJeerrsseeyy aanndd ssuurrrroouunnddiinngg aarreeaass..by Denise Wendt

2222 PPRROOJJEECCTT FFOOCCUUSS:: CCeellaaddoonn TTeeaa SShhoopp:: AAllbbaannyy,, CCaalliiffoorrnniiaaBBeerrkkeelleeyy aarrcchhiitteecctt FFuu--TTuunngg CChheenngg ccoommbbiinneess aanncciieenntt ccuussttoommwwiitthh mmooddeerrnn ddeessiiggnn..by John Strieder

3322 MMAANNUUFFAACCTTUURREERR PPRROOFFIILLEE:: DDaavviiss CCoolloorrssDDaavviiss CCoolloorrss cceelleebbrraatteess 5500 yyeeaarrss ooff ccoolloorriinngg ccoonnccrreettee..

5500 CCllaassssiififieeddss4488 CCoonnccrreettee MMaarrkkeettppllaaccee0066 DDeeccoorraattiivvee CCoonnccrreettee TTiippss0044 IInndduussttrryy NNeewwss4422 IInndduussttrryy SSppoottlliigghhtt5522 PPrroodduucctt NNeewwss3311 PPrroodduucctt PPrroofifillee0022 PPuubblliisshheerr’’ss LLeetttteerr

www.ConcreteDecor.net • February/March 2003 • 3

Contents

8

12

18

22

32

44



Industry New

s

Multiquip CEO retiresIrv Levine, chairman of Multiquip Inc., has retirednearly 30 years after founding the constructionequipment company. “It’s been an unbelievableexperience for me and one heckof a ride,” Levine says. “I believeour success is truly due to thephilosophy of taking care of ourcustomers and our employees.”

Levine founded Multiquip inLong Beach, Calif., in 1973,establishing the company as theexclusive U.S. distributor forMikasa compaction equipment.After purchasing a number ofother companies over the years,the company is now a leading supplier of soil and asphaltcompaction equipment; concrete placing, finishing andcutting machines; portable power generation equipment;dewatering pumps; welders and light towers. Multiquiphas more than $200 million in annual sales, with offices inEngland, Mexico, Canada and Brazil.

Multiquip’s new CEO is Tom Yasuda. He has beenassociated with the company for more than 20 years,serving most recently as executive vice president.

For more information, visit www.multiquip.com orcall (800) 421-1244.

Sanders Saws celebrates 50 yearsSanders Saws Inc., one of the most respected names incutting tools and diamond blades, celebrates its 50thanniversary this year. Founded in 1953 by EugeneSanders, the Honey Brook, Penn., manufacturer servesthe professional concrete contractor and the masonry,refractory and quarry industries. Sanders Saws’ productline includes a full line of concrete and masonry saws,diamond core bits, diamond blades, and grinding heads.

Under Eugene Sanders, the company was among thefirst to develop the popular hotpressed process, whichblends powdered metals and diamonds to producesuperior diamond blades that cut faster, wear longer andare more cost-efficient. In 1983, current presidentRobert B. Priest purchased Sanders Saws. The sameyear, the company acquired Mission Diamond Productsof Mission Viejo, California, which was then renamedCPR Diamond Research Division and relocated toSanders Saws’ headquarters. In 1985, Sanders Sawsadded diamond blade manufacturer Wispurr Cut ofVancouver, Canada.

To accommodate the rapid expansion, improveproduction efficiencies, and continue its goal of highquality manufacturing, the company moved into a newmanufacturing plant in 1992. A decade later, SandersSaws was acquired by California-based Multiquip Inc.,

one of the world’s leading light- and medium-sizedconstruction equipment suppliers.

Today, Sanders Saws Inc., a Multiquip company,continues to thrive as one of the premier manufacturersand marketers of concrete saws, diamond blades andcutting tools. The company has more than 40 employeesand is a member of numerous industry associations,including the American Concrete PavementAssociation, International Grooving & GrindingAssociation, Concrete Sawing & Drilling Association,Associated Equipment Distributors, and the AmericanRental Association.

For more information, call 800/486-0207 or visitwww.sanderssaws.com.

Concrete technology training offeredA five-day course offering concrete technology trainingand certification will be held in Denver, Colo., March3-7. The short course, offered by the NRMCA, is acomprehensive curriculum on concrete and aggregatetechnology designed to provide the fundamentalknowledge needed to perform job functions successfullyand efficiently. The course covers the specifications,testing, properties and uses of concrete as well as itsingredients, materials, mixture proportioning, qualitycontrol procedures and more. Laboratory sessions onproper testing of fresh concrete and aggregates will beheld. The course culminates with examinations offeringthree levels of industry-wide recognized certification.For registration forms or more information, visitwww.nrmca.org or call (888)-84NRMCA.

Education facility opensA state-of-the-art education facility that will serve theready-mixed concrete and related construction industriesrecently opened adjacent to the headquarters of theNational Ready Mixed Concrete Association, in SilverSpring, Maryland. The facility, called the RMC ResearchFoundation Education Center, will host a wide variety ofcourses and seminars aimed at improving the performanceof concrete industry personnel, including dispatchers,drivers, sales persons and technical employees. “In today’scompetitive environment, well-trained employees are acritical element for a successful concrete business,” saysNRMCA member Tom Chandler, chairman of ChandlerConcrete Co. of Burlington, North Carolina. Informationabout the education and training courses offered by theNRMCA can be found at www.NRMCA.org.

New director of marketingMarshalltown has promoted Dan Kester, formerly productdevelopment manager, to director of marketing. “Danbrings an excellent combination of experience and talentto this position,” says Jim Stormont, vice president of


http://www.multiquip.com

http://www.sanderssaws.com

http://www.nrmca.org

http://www.NRMCA.org



marketing for thecompany. His provenabilities will certainlybring great corporatesuccess in promotingMarshalltown’s name andproducts.” Marshalltown,founded in 1890, is

America’s largest manufacturer andmarketer of masonry and related hand-tools. The company recently acquired thecomplete product line of Embee Corp.,thus uniting two of America’s oldest toolcompanies under one roof.

Sika Corp.continuesexpansionSika Corp has broken ground on a newwarehouse in Lyndhurst, New Jersey, toaccommodate the company’s expectedannual growth in sealant sales. The$3.7 million building, part of a masterplan for expansion, will be completed byOctober 2003. The 17,300-square-footbuilding will include 4,000 feet of officespace. Sika, a world leader with over 90years of experience in concrete materialsand restoration technology, providessolutions and products for concreteproduction, repair and protection. Formore information, call (800) 933-SIKAor visit www.sikausa.com.

Sanders appoints nationalsales managerChris Priest has been named national fieldsales manager at Sanders Saws & Blades, a

leading supplier of concretesaws and diamond blades.Priest has been with theHoney Brook, Penn., firmfor more than a decade,serving most recently asmid-Atlantic andsoutheast regional

manager. He has also been instrumentalin training new sales managers and isactive in many industry associations.

ACI meets in VancouverThe American Concrete Institute(ACI) will hold its 2003 springconvention in Vancouver, BritishColumbia, from March 30 through

April 3. More than 1500 delegates,mainly engineers and contractors fromthroughout North America and othercountries, are expected to attend thefive days of meetings, exhibits andrelated events. Sea-to-Sky Highwayconstruction in advance of the 2010Olympic Games will be a feature of“Contractor Day” on April 1, whenPeter Milburn of the B.C. Ministry ofTransportation will reviewimprovement plans for the busy

Vancouver-Whistler corridor in aluncheon address.

ACI is a technical and educationalsociety dedicated to improving the design,construction, maintenance and repair ofconcrete structures. One of the world’slargest concrete associations, it has morethan 30,000 members and 93 chapters in30 countries. For more information, callKari Yuers at (604) 324-8280 or send heran e-mail at [email protected].


http://www.sikausa.com



DECORATIVECONCRETE TIPS

Decorative Concrete Tips is a forum for readers toexchange information about methods,tools,and

tricks they’ve devised.We’ll pay for any we publish.Send details to CD Tips,Concrete Decor,

P.O.Box 25210,Eugene,OR 97402.We look forward to hearing from you!

Pigmenting Liquid Releaseby Clark Branum

Liquid release agent isquickly becoming thechoice of many

decorative concretecontractors. With theincreased demand for quickerturnarounds, cleaner job sitesand environmental concerns,using liquid release agent forstamped concrete becomes anobvious choice.

One concern forcontractors who are currentlyusing powdered release iswhether they could still createhighlights in the stamp work ifthey were using the liquid. It can be done through a simpleprocess I will explain here.

The most common way to achieve color highlights is toadd an oxide pigment directly to the liquid release before thetexturing process begins. Raw pigments may be used, but theyare very concentrated and difficult to control. Adding apowdered release agent in small amounts is a clean andsimple way to accomplish our goal. That way the liquidrelease acts as a carrier for the powdered color, which isalready formulated and easy to use. Usually I pigment anentire five-gallon container at one time in order to maintainuniformity with the job. The amount can be adjusted to thesize of the project.

I recommend starting with a small amount of pigment tobegin with. You can always add more if needed, but you willnot be able to go lighter once you begin applying thesolution. A quarter-cup per gallon should be sufficient tostart. Apply the liquid release to the stamping tools and tothe concrete surface with a low-pressure sprayer — set it to afine mist so you will not over-apply. Continue to move thestamping tools as normal.

As you move your texturing tools you will find that someof the pigment will lift with the stamps. This is normal. Tocompensate you will mist lightly over the already textured

areas to even out thehighlighting. After thetexturing process has beencompleted you may apply atouch-up coat as needed.

As the liquid puddles itshould carry the pigment intothe relief areas of the textureand the joints, where you wantthe highlighting. The liquidrelease should evaporate fromthe surface within 12-24 hoursdepending on the ambienttemperature, leaving thepigment we added on thesurface. With a little practice,

your technique will improve. You may not want to attemptthis method on a steep grade, as runs in the color process mayoccur.

Tips for success.● Make sure that you mix the dry pigment thoroughly before

adding the solution to the sprayer.● Test your sprayer off the slab to ensure proper color and

dispersion.● Continue to shake your sprayer from time to time to keep

the pigment suspended.● Always start with a light solution. Darken as necessary.● Do your detail and touch up work before you re-apply.● Prepare samples using this method whenever possible.● Use caution not to begin stamping too wet, as impacting

of the release may occur. This can also occur withpowdered releases.

Happy stamping!

Clark Branum has been a flatwork finisher for 20-plus years and adecorative concrete installer for the last 10. He now works fulltime for Brickform-Rafco Products as area manager for theNorthwest Territory.



Ira Goldberg says he was born withgifted hands. The Brooklyn nativewanted to share his gift, so he

attended Brooklyn College andgraduated with a teaching degree inindustrial arts.

But life had other plans forGoldberg, and after graduation hestarted his own contracting business.

“My partner and I did major high-end renovations and additions. Wewere number one in New Jersey,” saysGoldberg, who owned Alberg CustomContracting.

Meanwhile, Palo Alto, Calif.-based Bomanite Corporation was justgetting started, expanding its reachby establishing franchises around theUnited States. “Between 1979 and1982 I saw a lot of plans coming inthat called for Bomanite,” saysGoldberg. But the fledglingcorporation had too few franchises inthe area to respond to every requestfor its product.

Goldberg saw his opportunity. Hecontacted Bomanite about becoming afranchisee.

Contractor helpsNortheast clientswarm to decorativeconcreteIra Goldberg reflects on almost twenty years with Bomanite

by Denise Wendt

ContractorProfile

ContractorProfile



people (and as many as 60 during peakperiods or extremely large jobs) and isone of the largest Bomanite territories(per capita) in the country.

Bomanite stands the test oftimeIn 20 years, Goldberg has seen a lot ofchanges. He remembers a time when hehad no competition to speak of.

“If a customer wanted stamped,decorative or any kind of high-techconcrete, there was nobody else to call.Now there are thousands of contractorsacross the United States and hundredsin our area alone who are trying toduplicate what we do.”

“There are people out there who arenot quality-minded and make a badname for the good people out there,” hesays. He has to remind property ownersand architects alike that all stampedconcrete is not Bomanite. “We stillseparate ourselves [from other concretecontractors] by the quality of our work,the system we use and the proprietarythings that make us just a little bit betterthan the competition,” he says. “They’ll

get there eventually, and then hopefullywe’ll be a step ahead of them.”

Decorative concrete in theNortheast“When we started we had to convincearchitects that [decorative concrete]works here,” says Goldberg. Somearchitects had only seen it used inCalifornia and Florida and were notconvinced that it would hold up in theNortheast, where freeze-thaw conditionsare the norm.

But Goldberg changed their mindswhen he reminded them that theirpatios and driveways were concrete.“We just do decorative, beautifulconcrete, using mix designs that workfor our freeze-thaw climate,” he says.“They were speccing concrete on everyone of their jobs. Why not make itbeautiful?”

Today he draws potential customersthrough his proven track record indecorative concrete work. But the eye-catching results don’t hint at the trialsand tribulations that go along with manyprojects. Caesar’s hotel and casino in

“They wanted a concretecontractor,” he says. “We were generalcontractors and builders. It wasn’t aperfect match for them until theychecked us out and found out ourreputation was impeccable.”

Goldberg became a licensedBomanite franchisee in 1984. Hestarted with a small area in New Jerseythat included Monmouth, Middlesexand Ocean counties. He quicklyproved himself there and expanded histerritory to include areas from BergenCounty to Cape May, eventuallyincorporating all of New Jersey.

“By 1989 we had added all of LongIsland and the five boroughs of NewYork City to our territory,” Goldbergsays. Since then he has added easternPennsylvania. Bomanite of New Jersey,New York City, Long Island andEastern Pennsylvania now employs 36


Ira’s extensive showroom givescustomers a valuableenvironment for makingdecisions.



quality when heavy equipment wasdriven over the surface between the timeof placement and the seal. Despite allthese problems, the project received anaward from an independent panel ofarchitects for the best Bomanite projectworldwide.

Goldberg’s other major projectsinclude Six Flags Great Adventure inJackson, N.J., Madame Tussaud’s inManhattan and Bally’s in Atlantic City.On a smaller level, he lists thousands ofpatios, pool decks and driveways. He’scurrently working on a $60 millionrenovation on the Tropicana, also inAtlantic City.

Family tiesWith a degree from UCLA in computerscience engineering, Ira’s son Brian istaking his father’s business into the 21stcentury. Ira’s wife Ellen manages theoffice. Ira’s business partner of 15 yearsis Manual Cardoso, a native of Portugalwho spoke little English whenGoldberg met him. “Someone told mehe was amazingly talented,” Goldbergsays. “So I watched him work. His sontranslated for us that whole summer.”Goldberg hired him, later promotedhim to foreman and in 1987 offeredhim a partnership. “He’s been mypartner ever since.”

In 2001 Bomanite of NJ put togetherits first sublicense — North JerseyBomanite — for the residential northJersey market. Goldberg sees this as anopportunity to focus on largercommercial projects. The operation isproving to be successful in its first yearand will likely lead to the addition offuture sublicenses.

In 2002, Bomanite of NJ moved intoits new home, a 10,000-square footoffice and warehouse and one-acreinterior/exterior showroom. Here futureand repeat customers can view all typesof decorative concrete samples and geta realistic idea of what Bomanite cancreate.

Growth through sharingWhile the competition from non-Bomanite contractors has steadily

Atlantic City is a good example of aproject with a “faster-than-fast”turnaround that required more than itsshare of patience. A section of the roofhad to be removed to provide access tothe project area. Meanwhile, hundredsof other construction trades wereworking in and around the same area.Add to that the difficulty of dealingwith variations in pour thickness thatranged from 1⁄2 inch to over 8 inchesthick and the challenge of maintaining



CIRCLE 42 ON READER SERVICE CARD

increased, Goldberg is happy to saythat contractors operating under theBomanite name are encouraged toshare their knowledge. The BomaniteInternational Society (BIS) exists as avehicle for this exchange. Throughcorporate-sponsored training and anew BIS web site designed by Goldbergand his son Brian, the network ofBomanite-licensed contractors canshare questions, ideas and techniques.

Goldberg has twice served aschairman of the BIS Advisory Board,which serves as a liaison betweenBomanite contractors and homeownersand between contractors and theBomanite Corporation. He currentlyserves as treasurer of the board.

Training is everythingGoldberg’s teaching skills have proveduseful, as he is certified to lecture onconcrete technique and control ofconcrete and teaches classes thatprovide architects with continuingeducation credits. He is also a certified

ACI technician and concrete finisherand an active member of the NewJersey Concrete and AggregatesAssociation promotion committee.

“We’re constantly training,” he says.“We like everybody on our crew tolearn every aspect of what we do, so

that everybody can fall back intosomeone else’s position at any time.”

His advice to contractors: Keeptraining. “Training your people is themost important thing. And they needto know what you expect from them.You need to operate as a team, whereevery player on that team knows whathe’s doing and what’s expected of him.”

He adds: Don’t cut corners, anddon’t compromise quality.

“If you’re going to do this as a sidebusiness, you’re going to fail,” he says.“You have to make up your mind thatyou’re going to put 100 percent intodoing decorative concrete work. It maybe hard in the beginning, but it’s goingto pay off.”

Bomanite of New Jersey, New York City,Long Island and Eastern Pennsylvania islocated in Cliffwood Beach, NJ. Tocontact them, call (800) 972-0668, emailthem at [email protected] or visitthem online at www.patternconcrete.com.



http://www.patternconcrete.com

TheChameleon isequipped withpowerfulreportingfeatures thatallow readymix producersto monitortheir color useand verify jobdeliveries.

“It takes about 10 minutes to train someone howto use our system,” says Nick Paris, vice president ofmarketing for Davis Color, a subsidiary ofRockwood Pigments headquartered in Los Angeles.“Our goal was to make it as easy to use as an ATMmachine.”

The Chameleon, as Davis’ system is named,combines liquid color metering technology withthe computing power of a standard PC and theversatility of a Windows operating system.Likewise, Solomon Colors’ ColorSelect liquid

It’s finally happened: Computers and concretedo mix. And they’re mixing well, especiallywhen it comes to integrally colored concrete.

Thanks to the technology of companies suchas Solomon Colors, Davis Colors and MasterBuilders Inc., there are systems designed toautomatically weigh out the correct amount ofliquid coloring agents into a holding tank whichthen discharges it directly into the mixer truck.The primary components consist of a controlpanel, a weigh chamber and hose pumps.

Integral coloringfor ready mixTechnology you can profit from

by Stacey Enesey Klemenc


Phot

ogra

ph c

ourt

esy

of D

avis

Col

ors


And then there are the dry color bags tocontend with. For starters, it’s no secret that youinevitably get little pieces of paper in the mix, nomatter how much they’re pulverized. And if you ripthe bags and pour, things tend to get a bit messy,the ready mix operator included. And in the courseof storing and moving the bags about, the bags get

dispensing system and Master Builders’CHROMIX CAM (Coloring AdmixtureMeasuring) System operate on a Windows-basedplatform, with the CAM featuring touch-screencontrols rather than a keyboard.

The strength of all three, proponents say, isthat the dosing and mixing is completelyautomated, thus avoiding potential mistakes,guaranteeing batch-to-batch consistency andeliminating unnecessary labor and cleanup.Because — shades of George Jetson — all youhave to do is push the button.

The color revolution“Liquid color has revolutionized the way color isadded to ready-mix concrete,” says RichSolomon, president of Solomon Colors Inc. inSpringfield, Ill. An operator simply enters howmany yards will be colored, the bag mix, the nameof the desired color and “the machine figures outthe rest. It’s easy. You don’t have to think.” Andbest of all, he adds, “You’ll get the sameuniformity batch after batch.”

In the United States, the demand for coloredconcrete is estimated at more than 4 millioncubic yards per year — approximately 1 percent oftotal production — but that figure is expected togrow three to five times higher within the nextdecade. Colored concrete is being used today oneverything from tilt-up concrete panels andresidential sidewalks to stamped concretecreations and roadway beautification.

According to Bob Nussmeier, executivedirector of Master Builders Inc., a Cleveland,Ohio-headquartered company that has analliance with the L.M. Scofield Co. to market andmanufacture the liquid CHROMIX L coloringadmixtures, “Throughout the country, 2 percentof all concrete is supplied with color from a ready-mix producer. We see that growing to 5 percentby 2006 because of improvements in product anddispensing technology that make it easier tosupply the demand in the marketplace.”

Dry vs.wetAlthough those in the know maintain that liquidand dry colors share the same physical character-istics and each can get the job done well, theyadmit that the dry colors take longer to dispersethroughout a mixture. Because of this, Solomonexplains, “There’s a potential for more streakingwhen the color is not fully developed. You won’tget that with a liquid added at the plant.”


New integral color machines are a welcome mix inthe concrete equation

Ready mix executives from coast to coast agree that the colordispensing machines on the market today are a godsend.

“I’m totally happy with my equipment,” says Tim Tolland, presidentof National Ready Mix Concrete headquartered in Encino, Calif.Tolland, whose company has 11 plants in Southern California andowns three of the Chameleon systems made by Davis Color, is in theprocess of getting two more.

Likening his operation to a paint store, he says that not only can hisplant now produce color concrete to order but the machinery is atremendous labor and injury saver. “Before [we got the Chameleons],our drivers had to climb up ladders and dump 50-pound bags ofpigment into the truck,” he says.

Not to mention, he used to get complaints ranging frominconsistent coloring to paper bits in the concrete when his companyused powdered pigments. But in the last two years, he says, “We’vevirtually received no color complaints. Our colors are a lot moreconsistent.”

Jeff Kelly, who heads the decorative concrete department for IrvingMaterials Inc. in Greenfield, Ind., says he, too, is very pleased with theColoring Admixture Measuring (CAM) dispenser his companyacquired from Master Builders last fall. He agrees the new technologycreates colors that are “very consistent,” with a method that is a lotcleaner than the old powdered route.

“We also have two portable systems that we can move from plant toplant,” Kelly says. Called CAM Jrs., these metering devices canaccurately dispense a premixed color directly into a truck. “They’reusually within two-tenths of a pound to be exact on every load,” withthe average color dispersion about 100 to 150 pounds per load. TheCAM Jr. draws the premixed color from a tote, which can hold up to3,300 pounds of liquid color.

Kelly says the devices are very handy for IMI, which has 130 plantsnationwide with eight in the Indianapolis area. Although they use themain system more, the CAM Jrs. and totes can be loaded onto flatbedand trucked to outlying plants to create colored concrete on site.

In Charlottesville, Va., Brad Cogan, vice president of AlliedConcrete Co., is just as happy with his Solomon ColorSelect, citingthe machine’s superb load-to-load consistency. Since his plantacquired the machine three years ago, it’s produced 5,000 cubic yardsof colored concrete. With the better quality of the colored product,“It’s been selling itself,” he says. “It’s even accurate in small dosagerates, as low as a half percent.”


The ColorSelect Pro LiquidDispenser gives customers peaceof mind by providing consistentcolor batch after batch.HenryEchandi,batch man for FourthStreet Rock Crusher in SanBernardino,CA.,prepares tobatch a load of color.



Phot

ogra

phs c

ourt

esy

of S

olom

on C

olor

s




wet, rip and some of the powder is lost — which translatesinto less color for the mix and inconsistent batches.

Finally, ready-mix plants have to have a pretty heftyinventory of dry color to produce the shades customers order.And if you want just a tad more of a certain color and they’reout of bags, you’re out of luck.

With liquid color, ready mix operators only need to havefour or five primary colors — typically a yellow-tone red, ablue-tone red, a yellow and a black or two — and they canproduce hundreds of different colors in quantities large andsmall.

“Contractors are reporting better color consistency withthese systems,” Paris says. “But the primary benefit is thebetter availability of color. Ready-mix producers canproduce virtually any color at a moment’s notice,” he adds,with the exception of the more expensive greens and blues.

But that could change as technology marches on. “We’rein the process of doing field verification and a limited releaseon exciting new color technologies that will dramaticallyexpand the color range,” says Nussmeier of Master Builders.

Matches and batchesBecause these new systems are much more accurate withdispensing color, many ready mix plants so equipped willguarantee color accuracy for batches as small as two yards.

Solomon says his company recommends a two-yardminimum but, “Our system is accurate enough to get goodcolor mix at one yard.”

But, interjects Paris, “Most ready-mix companies have aminimum of 3 cubic yards.”

As for the percentage of color in a mix, “You can have toomuch color,” Paris continues. “The intensity of a color risesto a certain level and gets maxed out,” somewhere around 7percent to 8 percent. “If you go past 8 percent, the colorstarts displacing the cement and it can reduce the strength ofthe concrete,” without intensifying the color. “Typically,most color dose rates are 5 percent or below.”

Solomon, who says most of his company’s formulas go ashigh as 4 percent, adds that operators would have tomanually override the software on the new coloring systemsto make the percentage go higher. “Theoretically, it’s notgoing to happen.”

The color load can go as low as .5 percent, he adds, but herecommends the percentage be 1 percent or more to achieveuniform color.

Adding color at the plant shouldn’t have any adverseeffects on the concrete, all three men agree, as long as thepercentage is around 4 percent to 5 percent and the slump 4inches or less.

The bottom lineFor the ready-mix producers, these integral coloring systemscost in the neighborhood of $40,000, depending on the



options selected. There are several ways to obtaina system, including buying it outright or over timewith a surcharge added to the color agent ormaterial purchased from the manufacturer of themachinery.

“In ready mix plants, truck time is money,”Solomon says. With these systems, “you canbatch out colored concrete just as fast as grayconcrete” with a much healthier profit margin. Asfar as installation labor, integrally coloredconcrete is less intensive than other decorativetechniques.

As contractors, you’ll enjoy anywhere from a10 percent to 50 percent markup, depending onwhom you ask and what part of the country you’rein. The colored product is no more complicatedto install than plain gray concrete but, cautionsParis, purchasers of colored concrete have higherstandards of appearance then purchasers ofuncolored concrete, so contractors need to raisetheir level of workmanship to meet increasedexpectations.

CIRCLE #86 READER SERVICE CARD

Buckets o’ color to go

Okay, so now you’re sold on this new color technology but don’tknow of any ready mix plants in your area that have the proper

equipment to produce integral colors. What’s a contractor to do?According to Bart Sacco of Concrete Texturing Tool and Supply —

a training center and supply house for decorative concrete tools,supplies and products based in Throop, Pa. — get in touch withsomeone like him. He owns a ColorSelect liquid dispensing systemfrom Solomon Colors and ships buckets of pigment nationwide tocontractors and ready mix plants alike.

“We have the ability to match any color from any majormanufacturer’s color chart,” says Sacco, who’s been operating the newequipment since last April. “We package to suit individual orders.

We can put multiple cubic yards worth of pigment into one pail forease of loading pigment into the truck or we can put the pigment intoseveral pails. However you want it.”

For instance, he says, if you’re pouring 5 cubic yards one day and 3the next, he’ll package the pigment accordingly. “But we usually don’tpackage higher than 5 gallons because the pails get too heavy,” headds. On average, a bucket of pigment with a 1 percent loading doseweighs anywhere from 8 to 12 pounds. Two percent would double thatweight and so on.

Sacco, who has white as his fifth color to offer his patrons a widerselection, says his buckets of color have an indefinite shelf life. “If theyfreeze, let them thaw, re-agitate and add to the mix. And you’re goodto go.”




Maintaining Decorative Concrete

Regular cleaning and sealing will keep your work at its bestby Christina Camara

cleaning services involve pretreatingthe surface with specially formulatedchemicals. The cleaning equipmentuses heat and pressure to remove thecontaminants and vacuums away mostof the water, leaving the surface nearlydry. Most sealants can be appliedimmediately.

“When you extraction clean, it’sincredible what happens,” Hicks says.“What you’ve done, other than make itlook pretty, is you’ve extracted the dirtout of the pores of the concrete.”

Many times, Hicks says, clients aresurprised to find colored concretebeneath the dirt and grime.“Sometimes it’s just so filthy, you haveno idea what you’re going to find whenyou clean it up.” Extraction cleaningcan reveal the color, but a sealer canmake it shine. “To get the color topop, typically you put a film-formingsealant on the surface that reallymagnifies the color — it’s like puttingwax on your car.”

A good pressure washing isacceptable in some applications, Hickssays, because it will dislodge the debrisfrom the porous concrete. The down

Concrete’s durability, strengthand low maintenance havelong been hallmarks of its

appeal. And now that the market fordecorative concrete is exploding,customers are willingly payingpremiums for colorful, eye-catchingdriveways, walkways, pool decks, patiosand more.

While maintenance of concrete isminimal — that’s the beauty of it —decorative concrete does requireregular cleaning and resealing toextend its life and eye appeal for yearsinto the future.

Unfortunately, though, regularmaintenance programs are oftenoverlooked by contractors andcustomers alike.

Ronald Borum, executive vicepresident of Crossfield Products Corp.and manager of the Miracote Division,says the industry as a whole has failedto do a good job of teaching customershow to maintain the color integrity,brightness and brilliance of decorativeconcrete. Concrete is indeed durable,but the color itself may have lessresilience.

“I think a lot of people in ourindustry — designers, architects,landscape/hardscape persons,contractors — sell that pristine lookwithout looking down the road, andthe customer ends up buyingsomething that two years or moredown the road they’re very dissatisfiedwith because they don’t understandhow to keep it pristine and close tothat original look.”

Education about the importance ofregular maintenance can result inhappier customers and more businessfor contractors.

Cleaning is the cornerstoneof maintenanceA thorough cleaning is the foundationof proper maintenance. It’s critical,because concrete is so porous.“Concrete is not a piece of Formica, it’smore like a sponge,” says Steven W.Hicks, president and CEO ofConcreteScience International Inc.

His Minnesota-based companyhandles the dirtiest of industrial jobs,where simple pressure washing just isn’tenough. ConcreteScience’s extraction


The Florida sun can be particularlypunishing to decorative concrete. AlexMetrovich, president of the Florida-based Innovative ConcreteTechnology Corp., says UV rays canbreak down the sealer, dulling theglossy finish and fading integral colors.A thorough cleaning and resealing canmake the color look fresh again, but it’simportant that the surface bemaintained properly from the start.

Borum warns that integrally coloredconcrete has its limitations. He’s seensome projects fade in a matter of monthsbecause the materials were not carefullyformulated. In addition to keeping agood sealer on top of the project,protecting it from UV and chemicals iscritical to proper maintenance.

side is there’s water everywhere whenyou’re done, and drying can take 48hours — a window that allows moredirt to collect.

Even so, it’s a good alternative inmany situations. Manufacturers andcontractors say that decorative concretedriveways, patios and walkways can behosed down once a month or so, with agood pressure washing once or twice ayear. Interior floors need only becleaned with a bucket of soap and waterand topped with a polish or wax. Floorscrubbing equipment should use long,soft bristles that won’t scratch theconcrete and sealers.

A pressure washer and a scrub brushalso work well to clean joints and otherhard-to-reach areas, such as decorativeconcrete applied with form liners orstencil overlays. Borum recommendswarm water and low pressure, from 400to 800 psi, which is enough to dislodgethe debris but not too much to chip thesurface. He recommends light detergentsat low concentration, not acid mixtures,which can attack the concrete.

How often should decorativeconcrete surfaces be cleaned profes-sionally to lift the dirt, grease and oilaway? Experts say it depends on theconditions the concrete is subjected to,but if contractors educate theircustomers about the basics of regularcleaning, it will make the job easierwhen the professionals come in.

Sealers protect investmentOnce the surface is cleaned and dry, itmust be protected from the elementsand from wear and tear with a high-quality sealer that repels water, limitsdamage from UV sunlight and resistsabrasion.

John Maskas, technical director ofSuperStone of Florida, says a solvent-based penetrating sealer is theworkhorse for the residential market.Sealing for residential use isrecommended every two years or so, butagain that depends on the environ-mental conditions and wear and tear.“Just like there’s not one application,there’s not one answer,” he says.

Phot

ogra

phs c

ourt

esy

of C

oncr

eteS

cien

ce In

tern

atio

nal


Nick Paris, vice president formarketing of Davis Colors, says theiron oxides in Davis’ integral colorscannot fade. Integral colors can lookfaded if the concrete surface is wornaway or because of efflorescence, thewhite deposit on concrete that’s leftbehind when water moves through thematerial and evaporates, leaving salton the surface. That’s why maintaininga top quality sealer on the concretesurface is so important, he says.

Bob Ware, president of TheDecorative Concrete Store inCincinnati, Ohio, likes the effects ofworking dry-shake color hardenersonto decorative concrete. Hardenersincrease the surface strength to 7,000to 8,000 psi, and extend the life of the



Contractors mustunderstand regionalconditions,productsDecorative concrete must withstandsome pretty harsh conditions, andcontractors must be experts on theenvironmental conditions of their area: ● RRaaiinn aanndd WWiinndd —— Wind carries dirt,

and rains break it down into tinyparticles that can seep into thesurface and stain it. A strong, steadywind in desert areas can sandblastconcrete. Acid rain in polluted areascan erode it.

● SSnnooww aanndd IIccee —— Salt and chemicalsused to melt ice in northern climatescan allow moisture and chemicals tosoak into the surface. When thetemperature drops, the water freezesand expands, which can crack theconcrete. Sand and salt from people’sfeet will scratch concrete.

● SSuunn —— The sun’s UV rays candegrade sealers, fade integral colorsand bake stains into the concrete.

project. “By cleaning and resealing it,it’s going to look just like the day youdid it,” he says. “That’s the beauty withthe shake-on hardeners.”

Steve Adams, chief formulator forSeal Pro, Inc. Research Labs,manufacturer of sealers, overlays andcuring agents in Medford, Ore., says atop quality sealer makes cleanup easier,improves the looks of a project andextends its life.

It’s important to pick the right sealerfor the job, he says. For example, somesealers are specially formulated so thatgas won’t seep through and oil stains canbe wiped off with a rag. Look for a sealerthat is specially designed for UVprotection, or it may turn yellow overtime. He also says that hydrophobicsealers keep water out of hairline cracks,preventing them from expanding duringthe freeze/thaw cycle.

Moisture another problemMoisture intrusion is another enemy ofconcrete. Applied Concrete

Technology Inc. offers a product thatcan penetrate concrete to form apermanent barrier against moisture. Itwaterproofs the concrete bothinternally and externally and needs tobe applied only once.

Company co-owner David Johnsonrecalls selling Disney executives on theproduct, the Protecrete Densifier, whenthey were looking for a way to savesandstone and cement animals thatwere disintegrating in a water feature atAnimal Kingdom in Orlando. Johnsontook a crumbling turtle and sprayed onthe Densifier, which reacted with theportland cement inside the turtle andsolidified it. Since then, Protecreteproducts have been applied to all theconcrete in Disney’s theme parks andattractions.

Another product, the Mix WaterConditioner, is added at the batch plantto create a higher quality concrete that ismore durable and less prone to cracking.Johnson says using both nontoxicproducts can also prevent efflorescence.

CIRCLE #14 ON READER SERVICE CARDCIRCLE #54 ON READER SERVICE CARD



Manufacturers say contractors alsomust educate themselves on theproducts being applied to the concrete.Different products have different lifecycles and maintenance requirements,and customers should understand thatbuying high quality products directlyfrom manufacturers will cost moreinitially, but will save money over time.

Maintenance contractsMaskas, of SuperStone, says it makesgood sense for a contractor to build amaintenance program into his originalbid. “No. 1, it’s a good way to keep himclose to the people who can help himgrow his business. No. 2, it can helphim in term of growing his businesswith an existing job.” Customers aremore comfortable dealing with theoriginal contractor, so why send themto a competitor for a resealing job?

“Those are the upsides,” Maskascontinued. “The down side is that itdoes take manpower away fromperhaps a more profitable job.” If a


contractor has the employees to handleongoing maintenance, it will give hima competitive advantage, he says, but ifthe company isn’t geared to it, don’tover-commit and under-deliver.

Borum agreed. “If they’re big enoughand organized enough to make it aprofit center, then by all means move inthat direction.” But he added that it’simportant to market maintenanceprograms properly, or they can be a realdrain on expenses. In some cases,contractors would be better off creatinga relationship with another companythat can do the maintenance work.

Metrovich says getting that repeatmaintenance business can be as simpleas sending a reminder postcard to thecustomer, just as a dentist will sendcards out to patients reminding themto get their teeth cleaned every sixmonths. He also suggested contractorscould send out reminders whenwarranties are about to lapse.

Theo Hunsaker, inventor ofConcrafter tools and the principal

owner of the company, says that when ajob is complete, the customer willreceive a thank-you note with a photoattached. On the back is all the contactinformation the customer needs to keeptheir project looking as pretty as thatpicture.

He believes contractors should revisittheir project sites every few years. Thatway, they can continue building theirrelationship with their customers whilemaking specific suggestions formaintenance based on the conditions atthat particular site.

Hunsaker, who has 50 years ofconcrete experience, says contractorsshould base their reputation on quality,not quantity. Contractors who areserious about their work and want tobecome leaders in the field need to takemaintenance seriously too.


PROJECT FOCUSConcrete helps architect Fu-Tung Cheng make

A Perfect Cup of Tea

graceful curve. “I just thoughtit would be a more dynamicshape,” he says.

To help him create the teabar, he used NeoMix, aconcrete countertop kitmanufactured by Cheng Design for homeowners andcontractors. The kit includes pigments, admixtures, finishingtools and decorative aggregates. Cheng selected a greenpigment called “jade” to color the piece.

For concrete, he obtained about 25 bags of Quikrete5000, a commercial-grade blend that is commonly availableat hardware stores across the country. It costs more thanother options, he says, but it’s known for providing an evenmix of cement powder and aggregate throughout each sack,a quality essential for this job.

To build a mold for the piece, he started with a frame ofbamboo plywood from China. His choice of wood in hiswork has evolved, he says. He used to favor vertical grainDouglas fir, but switched to hemlock to avoid putting anymore demands on dwindling old-growth forests. Bamboo,he’s since discovered, is even more environmentally friendly— a mature forest grows in just five years, he says, and theplywood made from the harvested plant suits his purposenicely.

After securing the cylindrical wood frame with wire, heattached a piece of curved aluminum to an arm andmounted it on a pipe in the middle of the frame. He applieda layer of plaster on the inside of the wood frame and rotatedthe center assemblage to smooth it. Then he shortened thearm and put down another layer, then a third.

Finally, it was time for the pour. To keep the centerhollow, he replaced the pipe with a length of Sonotube, aform for molding concrete columns.

Not everything went perfectly. Cheng applied a layer ofdrywall mud onto the plaster to get an additional degree ofsmoothness on the surface of the concrete. But the mud wastoo soft, he says. When he pulled away the framework, someof it stayed behind. “It never affected the concrete,” he says,“But we had to do a little cleanup. It made it harder.”

As residential architects go, Fu-Tung Cheng gets hisname out there. He’s won a myriad of awards,written a stack of books and seen his name

published in an array of newspapers and magazines.But despite Cheng’s accolades, few people get to see his

work. A well-designed home is, after all, still somebody’shome. The only way his achievements can be enjoyed bythe general public is when they are photographed.

So Cheng came up with a genteel solution — have thepublic over for tea.

Cheng is designer and part owner of Celadon, a gourmettea shop that opened last summer in Albany, Calif., nearBerkeley. “It was a chance for me to go pretty full-out on myown design in a public place,” he says.

When Cheng wanted a centerpiece for his establishment,he turned to his specialty, concrete. The result: a cylindricaltea bar that flares at the top to provide counter space foreight patrons and a server. Customers’ legs tuck cozilyunderneath the lip.

The distinctive shape of the bar was designed by Chengto suggest traditional Chinese teaware. Molding the piecewas a challenge, he says. But as with tea from hand-pickedleaves, the extra work made for a finer finished product.

The projectCheng intended the concrete bar to be the focal point of histea shop. And as befits an anchor, it’s massive and practicallyimmobile, cast and cured on the spot. It weighs close to aton and measures about eight feet in diameter, with a 43-inch hole in the center for wait staff.

He acknowledges that it would have been cheaper to castthe bar as, say, a cone shape. “Even my guys were saying, ‘Fu-Tung, just make it straight.’”

But Cheng the shop owner gave the go-ahead to Chengthe designer. He says he’s a firm believer in splurging on acouple of central design elements and keeping the rest low-key. “I do a lot of high-end design on those things that areimportant to me.”

He was drawn to the flared top, which makes the bar looksomething like the top part of a golf tee, but with a more

by John Strieder



He would have been better off getting the same effectfrom a fourth layer of plaster spiked with retardant, he says.

The bar cured for 10 days. Next came grinding, finishing,and the application of penetrating sealer and wax. And thatwas it. “We wanted a good finish,” Cheng says.

Time for teaWith its vaguely Eastern shape, the tea bar reflects Cheng’sdesign scheme for the whole establishment. It’s concretethat makes a statement about culture. “I wanted to showthat Chinese design doesn’t necessarily mean red and goldand dragons all over,” Cheng says. “There’s an essence toEastern design that can come through in a modern context.”

The exotic flair of the concrete piece complementsCeladon’s menu, which features gourmet and whole leaf teasfrom China and Taiwan, with a few offerings from India,Korea and Japan added for flavor.

These are “connoisseur-level teas,” Cheng says. Andpreparing them is, like decorative concrete work, a scienceof variable control. Servers monitor and control thetemperature of the water, the temperature of the cups, thenumber of infusions the leaves have endured, even how thebrew is stirred.


(Top) Plywood formwork with cast plastermold;(middle) central column offormwork in place before pour;(bottomabove) Fu-Tung Cheng overseeingconcrete pour;and photographs ofcompleted counter.

Phot

ogra

phs c

ourt

esy

of C

heng

Des

ign

1

2

3

4



Other projects by Cheng are shown above.

Phot

ogra

phs c

ourt

esy

of C

heng

Des

ign


Tea’s time has come, Cheng says. “Tea is where wine wasin the 1960s. People don’t know what good tea is yet. Theyjust don’t have a clue.”

As for showcasing his design skills, the tea shop is provingto be a ripping success. Since it opened, Cheng has found heloves to just lay low and steep in customers’ oohs and ahs. “I sit at the tea bar like Norm in ‘Cheers,’ watching peoplecome in and their jaws drop,” he says.

For more information about Cheng Design, call (510) 849-3272or visit www.chengdesign.com.

http://www.chengdesign.com


CIR

CLE

#36

ON

RE

AD

ER

SE

RV

ICE

CA

RD


Extreme-sports pioneer Tony Hawk isn’t the onlysouthern Californian to start a revolution with askateboard.

Sometime in the early 1980s, a concrete contractor namedEd Chiuminatta pulled the wheels off a board and attachedthem to a Skilsaw. The result? A saw blade that could rollacross green concrete, slicing a control joint in a fraction ofthe time it would take to carve the groove by hand.

Today, Chiuminatta’s company, Soff-Cut InternationalInc., is the leading manufacturer of green concrete saws —machines designed specifically to cut concrete before it dries.

Early-entrycuts for decorConcrete saws increase productivity and design optionsby John Strieder

Kelly Dickinson, sole proprietor of Superior Concrete &Masonry in Riverside, Calif., says that 10 years ago mostjointing was done by hand. “At last some people are startingto convert over to different things,” says. (He should know;he has helped Soff-Cut test and fine-tune saws for years.)

Crack control is a concrete contractor’s biggest headache,Dickinson says, and green concrete saws are the miraclecure. They allow a contractor to do expansion cutting beforethe concrete has set long enough to start cracking. “It’s asclose as you get to a guarantee that you’re going to controlcrackage,” he says.

Phot

ogra

phs c

ourt

esy

of S

off-C

ut



Early-entry saw cuts are faster, easier and look better,states Jim Johnson, an engineer who designed and improvedthe Robo-Kut saw, which is being marketed worldwide by N-E-D Corp. “After the concrete has set there for a day, mostcracks have already started,” he explains. “The sooner youcan start the better.”

What’s more, he says, the machine slashes labor costs.With the saw’s help, even a rookie can finish off an entirefloor the same day it was poured. That’s cost effective, hesays, especially on jobs where state regulations requirecontractors to match union wages when paying the crew.

Because of early-entry saws, Dickinson’s firm can pourmore concrete and use less labor to do it. So he’s makingmore money. In a word, he’s sold. “We’ve got tens ofthousands of dollars invested in Soff-Cut saws,” he says.

Soff-Cut dominates its niche, but these days, it’s hardlythe only brand on the market. Early-entry saws can be as bigas carpet-steamers or as small as electric brooms. They canbe powered by gas or electricity. They also vary in features.

The Soff-Cut brand is known for its skidplate, whichslides over the concrete on both sides of the blade to preventspalling or crumbling.

The Robo-Kut saw features torque control, which monitorsthe load on the motor and adjusts the speed of the blade tosuit. “If you run into a hard spot, like a bunch of rocks, it slowsand keeps a constant load on the blade,” Johnson says. “Thereason why we have torque control is so the operator cannotabuse that saw. He cannot screw up the concrete.”

Soff-Cut blades cut up, while Robo-Kut blades cut down.There are other green cut saws on the market too. A sawmanufactured by Rapidcut Industries LLC, for example, istouted as having the ability to cut right to the edge of a walland be particularly good at making straight cuts.

Contractors also have their pick of blades, ranging frombasic cutters to blades that “chase” existing cuts, carving V-grooves, rounding edges, or otherwise duplicating a hand-tooled effect. “You can accent your saw cuts that way,” notesSoff-Cut application specialist George Shields.

These options make early-entry saws especially intriguingfor decorative contractors, who could use them to offeranother cheap, good-looking option to their menus.

Cut with careBut especially when looks are important, experts warn,contractors must be careful when cutting green.

When it comes to decorative concrete, the more curedthe better, Johnson says. “You want to cut them green. Butcutting green decorative concrete is very difficult. The bestcuts ever made were on cured concrete.”

If the machine is pushed across the concrete too slowly,the saw blade can flutter, he says. If the machine stops, it canleave an ugly scar.

Decorative saw cuts onexisting concrete surfacesare greatly enhanced witha beveled edge blade.



Shields recommends getting on to the concrete “as soonas you can walk on it and not leave a wheel-print.”

That’s a crucial distinction — judge by wheel-print, notfootprint. The ball of a worker’s foot may exert less pressure(measured in pounds per square inch) than the wheel of amechanical saw. Harder, smaller tires press the entire weightof that machine onto the concrete at one point. Larger andsofter tires, on the other hand, exert less pressure against agiven square inch of concrete.

“It’s not how much something weighs, it’s how muchsurface, what spike you put it on,” Johnson says. “As long asit’s less than the weight of a man, you’re okay.”

Chris Green, partner in Rapidcut Industries, says acontractor can start cutting as soon as the concrete willtake a blade without spalling. But if the concrete doesn’tyet have the proper surface strength, the aggregate willpop out, he says — and it can do so even after the job isfinished. “On warehouse floors that’s a huge issue,” hesays. “They’ve got forklifts going over them and all of asudden the joints start spalling. It coasts a huge amount ofmoney to fix.”

A chaser blade must be used to grind away the damage.Otherwise, it degenerates like a pothole, he says.

Green concrete also requires blades with a harder bondthan those typically used with dry concrete, Green says.“Green concrete is softer and more abrasive, so you need alittle harder bond. A softer bond will cut through it likebutter, but you won’t have blade life.”

Another well-documented controversy surroundingearly-entry cutting is whether joints in green concrete needto be cut to the same depth as those in hard slabs. Many sayshallower cuts work just fine, and Johnson is one of them.

“Cracking is not going to be as big an issue,” he says. “If youcut it early enough you don’t have to cut it deep at all.”

But he quickly adds that, because of liability issues, it’s nota good idea to deviate from ACI standards for hard concrete,particularly if they are specified in the plans. “If the engineerspecs it out, the contractor doesn’t do it and it cracks, theperson who paid for the job can come back and say, ‘Youdidn’t cut it as deep as you were supposed to.’”

Decorative applicationsThese tools offer unique opportunities to concretecontractors. “A lot of guys aren’t aware yet that you can do itwith a saw and make it look decorative,” Green says.

Dickinson says decorative cutting and scoring is a bigmarket for his firm right now, and early-entry saws allow himto score and cut decorative patterns much faster than hecould by hand. Add some staining, and contractors canachieve mural-type effects, he says — circles, patterns, andemblems. “That’s a real popular thing.”

The saws give the cutter more control than hand cutting,making it easier to keep the joint straight and to put it whereit needs to go, Dickinson says. With a blade small enough tomaneuver, a saw can even be used to cut a joint down thecenter of a serpentine driveway, in a line that follows thecurve of the slab.

Rudy Tena, owner of Tennaco Concrete Inc., acommercial outfit in Eugene, Ore., notes that the saws arecheap enough to just buy and have around for when youneed one. “At $3,500, it’s a bargain, really,” he says. But inTena’s opinion, hand-tooled joints look better than machinecut, even after they are prettied up with a chaser blade. Youwould see aggregate in the machine cut, he says, and the

Phot

ogra

phs c

ourt

esy

of S

off-C

ut




sharp, angular look is not as attractive to him as a hand-tooled edge. “I would notice it,” he says.

Dickinson agrees that some jobs call for special detailing.“Having the exposed look of a traditional hand tool is prettyunique,” he says.

Phot

ogra

phs c

ourt

esy

of S

off-C

ut


But as contractors become more aware of what greenconcrete saws can accomplish, the saws are earning theirplace on more and more job sites. “When you get somebodywho’s experienced and they have a feel for it you can dosome pretty amazing things,” Dickinson says.


http://www.concrete-texturing.com

The Pebble-Flex System

The Pebble-Flex System, made by UnitedSurface Technologies, is a new system for

resurfacing concrete that not only offers adecorative look, but adds life to the substrate.

Pebble-Flex is a porous thermoplasticrubber made into unique pebble-likeshapes and designed to be applied overthe top of old or new cracked concreteas well as wood, metal or fiberglasssurfaces. It bonds to most surfacesand will resist surface movements. Itis comfortable to walk on, UV stable and willnot deteriorate or become inflexible even under harshweather conditions.

The company has tested the product for over 5,000 hours in itsXeron Weather ohmmeter machine without any fading ordiscoloring (equivalent to 20 years of exposure to UV sunlight).Pebble-Flex comes in 10 standard colors, and the company willcustom match any colors at an extra cost. Common uses includepatios, pool decks, driveways, sidewalks and steps. For moreinformation, call (800) 509-4144 or visit www.pebble-flex.com.



PRODUCT PROFILE

http://www.pebble-flex.com


After arriving in the U.S.as arefugee from World War II,FrankDavis became a partner in theRoberts-Davis Company in LosAngeles,a predecessor to theDavis Colors Company hefounded in 1952.

As decorative concrete hasbecome more widely used,contractors in all parts of thecountry have grown increasinglyskilled in the craftsmanshiprequired for high quality coloredconcrete work.


Frank and Jackie Davis fled theirnative Austria after the Nazisconfiscated their pigment

business during World War II. Aftersettling in southern California, Frankused his training as a chemist andcolorist to blend and distribute pigmentsespecially for the concrete industry. Hislove of color, heightened by the freedomhe experienced after escaping the war,was expressed in his philosophy: “Coloris light. Light is life. Color is life.”

His company, incorporated in 1952as the Frank D. Davis Company,remains a pioneer in the use of ironoxide pigments for coloring concrete.Now known as Davis Colors, thecompany has grown to become a globalleader, with more than 140 employees,manufacturing facilities on threecontinents and the largest line ofpigments and automated color-dosingsystems in the construction industry.

Since the company began, integrallycolored concrete has become part ofthe fabric of our landscape. Coloredconcrete is now used in every part ofthe country and is acknowledged as animportant design option for all forms ofconcrete construction. In the readymixed concrete industry, it is found ineverything from the most humbledriveway to the grandest ofmonuments. Precast concrete owespart of its growing popularity to thedesign versatility of colored concretefinishes. And colored products nowdominate the market for concretemasonry units.

Initially, colored concrete was usedprimarily in small projects such assidewalks. To prove the reliability ofcolor additives, Frank Davis collab-

orated with industry associations toestablish standards. As confidence in thematerial increased, colored concretebecame stylish on larger projects. FrankLloyd Wright, a pioneer in thedevelopment of architectural concrete,worked with Davis Colors on the GradyGamage Auditorium, built in 1959 atArizona State University. Integrallycolored concrete was also used in themid-1960s reconstruction of SanFrancisco’s famous Palace of Fine Arts.

Over the years, colored concrete haskept pace with changing tastes andbuilding methods. In the 1970s, forexample, Davis Colors provided theadobe tones for the CMU slump blocks

Company thrives onchemistry,colorDavis Colors celebrates 50 years of coloring concrete

Once used almost exclusively asan exterior building material,Davis Colors are now equally athome in residences andcommercial interiors.

Phot

ogra

phs c

ourt

esy

of D

avis

Col

ors



that were enjoying popularity. Today,on the other hand, color is a big part ofthe appeal of interlocking concretepaving units, a concrete masonryproduct which is rapidly gaining marketshare. Color has also found a home inpattern-stamped concrete simulatingbrick, stone and other texturedpavements.

Throughout the 1990s, coloredconcrete was increasingly used inenvironmentally sensitive projects —such as a bridge in Zion National Parkand the parking structure at the HooverDam Visitor Center — where earth-toned pigments harmonized with thenatural landscape. Other environ-mental benefits of integrally coloredconcrete have also gained inimportance. In comparison to paintinga concrete structure, for instance,integral colors are free of volatileorganic compounds and provide apermanent finish that improves life-cycle value by eliminating the need toreapply coatings.

And of course, colored concrete isnow immensely popular as an interiorfinish and is now used for flooring andcountertops in both homes andcommercial establishments.

Frank Davis’ company was renamedDavis Colors in 1976 when it became adivision of Rockwood Industries. Itcontinues today as a division ofRockwood Pigments, the globalpigment division of RockwoodSpecialties Inc. In addition to itsoriginal manufacturing facility in LosAngeles, Calif., Davis Colors now hasfacilities in Maryland, Missouri,Germany, Italy, and the UnitedKingdom, as well as a joint venture inChina. The company is verticallyintegrated, synthesizing its own ironoxide pigments as well as blending,liquefying and granulating colors tomeet a variety of customerrequirements.

The Davis Colors product lineincludes concentrated pigmentpowders, Hydrotint liquid slurries,Granufin low-dust granulated pigments,and packaged pigments such as True

Tone mortar colors and Mix-Readydisintegrating bags for convenientdosing of mobile concrete mixers. Thecompany also produces automatic,computer-controlled concrete coloringsystems, including Granumat for usewith granulated pigments andChameleon for use with liquid slurries.

“As people continue to understandthe beauty of colored concrete and the

value it provides concrete producersand homeowners, they will find moreways to use color,” says Rockwoodpigments managing director Ronald L.Rapaport. “We are excited by andready for the challenges of the nextfifty years.”

To learn more about Davis Colors,visit www.daviscolors.com.



http://www.daviscolors.com


WWaarrmm uupp ttoo tthhee ooppppoorrttuunniittiieess

pprreesseenntteedd bbyy

Radiantfloor

heatingby Susan Brimo-Cox

Phot

ogra

phs c

ourt

esy

of W

atts

Rad

iant



When a technology has beenin use for some 2,000 yearsyou’d be right in thinking

that the originators might have had apretty good idea. Of course, thetechnology of radiant heat has improvedthrough the centuries. And, today, manypeople are giving radiant floor heatinganother look as an option in commercialand residential applications.

Radiant heat delivers warmthwithout ducts and registers; heats evenly,in an energy-efficient manner; and issilent. There are hydronic (hot water)and electric systems.

“A lot of smaller jobs [such as bathsand kitchens] and retrofits are done withelectric systems,” reports Hoyt Corbett, aconsultant and publisher of The RadiantFlooring Guide,” based in Seattle.Electric systems are growing fast,especially in conjunction with tiled floors,as the electric elements can be embeddedin the thinset layer, he adds.

Most big projects are hydronic, Corbettsays, because there is a better level ofcontrol with regard to water temperatureand circulation. “In 2002, there wasapproximately 130 million square feet of[new construction] hydronic radiantflooring installed—and about half of thatwas installed in concrete slabs.”

And Corbett reports that the instal-lation of radiant heat flooring isgrowing at about 20 percent to 25percent a year. So, it makes sense, heobserves, for concrete contractors toinvestigate and form a relationshipwith radiant heat installers in theirarea. “The fit is very good!”

It’s what you do anywayWhether or not radiant floor heatingpresents an opportunity for concretecontractors depends on the area of thecountry you’re in and the usual methodof construction there.

Radiant floor heating is a natural inon-grade concrete slabs. The heatingtubes are normally fastened with plasticties to 6-inch by 6-inch concrete mesh sothe tubing winds up in the middle of theslab. These slabs expand and contractmore frequently than slabs without



radiant heat, so all care of the normalsteps should be taken with the pouringand curing. But hydronic tubing is veryflexible, so some cracking should not beproblematic, just cosmetic. Corbettexplains that in Europe the systems aretypically done in two pours, with thetubes embedded in a topping slab.

If radiant floor heating is to beinstalled without a slab on-grade or on

the second floor — or higher — thestandard installation involves attachingthe tubing to the subfloor, and then,most frequently, a 11⁄2-inch slab ofconcrete or gypsum-based cementproduct is poured on top. (In someapplications, the tubing is attachedunder the floor, between the floor joists,but that doesn’t really apply to thisdiscussion.)

The good news for concretecontractors is that concrete floors havethe highest output of radiant heat, andthe best heat retention. The cost toinstall radiant floor heating runs fromabout $3.50 to $14 a square foot,depending on where you are in thecountry and how elaborate the system,according to Corbett. And, he says,there is a shortage of installers.


Phot

ogra

phs c

ourt

esy

of S

chlu

ter S

yste

ms




“Today, radiant heat is the fastestgrowing segment of the heatingindustry,” said Mike Chiles, presidentand general manager of Watts Radiant,a leading supplier of radiant heatproducts (www.wattsradiant.com).“We’re seeing an incredible rise ininterest among those in the concreteindustry — not just for the popular PEXtubing, but also for synthetic rubber

tubing, and electric radiant mats in, andover concrete. Commercial hydronicinstallations are rising fast, both forlarge concrete floors and large snowmeltsystems. We’re seeing a lot more ofthese with stamped concrete finishes.”

Beautiful warm floorsDave Pettigrew, owner of Diamond DCo. in Capitola, Calif., works the Bay

area and has plenty of experience withradiant heat floors. When it comes toinstalling the systems, he lets theplumber take care of laying the tubing,but Pettigrew is the concrete specialist.

“When I saw [concrete] stainingabout 12 years ago, I knew I wasinterested and I took that on to thenext step, to find the best market,which was radiant heat,” Pettigrew

Phot

ogra

phs c

ourt

esy

of H

acke

r Ind

ustr

ies


http://www.wattsradiant.com


recalls. Not only does a concrete floorconduct, hold and radiate heat well,“it’s beautiful with stain and art work.”

Pettigrew says he’ll do just about anykind of decorative surface hiscustomers want, but, generally, he usesstains and colored micro-toppings. Healso prefers pouring the slabs in twolayers: a structural slab, then a 31⁄2-inch

concrete layer with theradiant heating tubes. Inbetween the concrete layers isan insulator.

What about applications withplywood subfloors? Pettigrew hasdeveloped his own system for that, too.First, waterproofing goes down, then thetubes are attached. Pettigrew uses a pea

gravel concrete to fill up to the top of thetubes or coils — about three-quarters ofan inch thick. He lays a crack isolator ontop of that, and then pours 11⁄2-inchconcrete for the decorative concretework. “One and a half inches of concrete

CIRCLE #74 ON READER SERVICE CARD CIRCLE #94 ON READER SERVICE CARD

Phot

ogra

phs c

ourt

esy

of T

im S

latt

ery



weighs about the same as marble,”Pettigrew says. He adds saw cuts atpressure points to minimize randomcracking.

Valerie Wells, a decorative concretecontractor and owner of ArtScapes inAlbuquerque, N.M., has been applyingher hand to radiant heat floors for abouteight years. She comes in after-the-fact— after the concrete with theembedded tubing has set up. Herspecialty is decorating the floor surfaces.“Decorative finishes are more cost-effective than other floor coverings,”she reports. “It’s comparable to carpet,cost-wise.” For customers who are waryof decorative concrete by itself, she sayssome customers have had her apply adecorative finish and then they addarea rugs.

Wells favors decorative cuts andacid stains to achieve her decorativeeffects. She has also appliedoverlayments for stamped textures.Flagstone and rock textures arepopular in the southwest. As in otherconcrete work, expansion joints areimportant, says Wells, however,hairline cracks can be used todecorative advantage. For example,hairline cracks can add to the designof a faux marble finish.

Decorative concrete artisans mightlike concrete radiant heat floors foranother reason — they make it easierto work in cold weather. “Sealers aretemperature-sensitive, so radiant-heated floors are good to work on inthe winter,” Wells points out. Shetypically uses a two-part epoxy sealerwith urethane over it because it is moreenvironmentally friendly, but she alsouses solvent-based sealers andsolvenated acrylics in commercialapplications.

More about the “G” wordDepending on whom you talk to,Gypsum-based cement products such asTherma-Floor, Gyp-Span andLEVELROCK may have a coupleadvantages over cement with regard toradiant floor heating systems. Gypsum-





based cement products adhere well tovarious subfloors and adhere to and sealthe radiant heating tubes so you don’thave air bubbles to worry about. Theseproducts can be poured in a thin layer,are lighter in weight than concrete anddon’t shrink as they cure. In addition,they cure quickly and virtually any kindof finished floorcovering can be appliedon top.

On the negative side, gypsum-basedcements are not a wearable, finishedfloor surface, with one exception to-date. United States Gypsum Co. hasintroduced PROFLOW to its line ofLEVELROCK Brand FloorUnderlayments. According to themanufacturer, PROFLOW can be usedas a finished floor when it is “coatedwith an approved decorative finish fromRichard James Specialty ChemicalCorp.” Don Brandt, market manager forLEVELROCK products, reports thedecorative finish is a specially-developedacrylic-based epoxy topical coating.Brandt says PROFLOW can beintegrally colored and you also canmottle the topical coating to achieve afaux finish.

Beyond the pros and cons of usinggypsum-based cement products,concrete contractors may view them asanother way to expand their business.Sharon Goerlach, marketing assistantfor Construction Products Network Inc.in Prospect Park, Pa., says “There is a lotof crossover in concrete contractors whoalso install [gypsum-based cement]products.” A lot of the same applicationtechniques apply: raking it into placeand floating it out. But it requiresspecialized equipment and training.“Only trained, licensed applicators caninstall it,” reports Michelle Thompson,marketing communications coordinatorfor Hacker Industries Inc. in NewportBeach, Calif. Concrete contractorsinterested in learning more about theseproducts and available training opportu-nities should contact the variousmanufacturers of gypsum-based cementunderlayments.

Radiant heat floorcoverings at-a-glance

Here’s an overview of typical radiant-heat floor covering products and howthey compare to decorative concrete. Cost for all floorcoverings varies from

region to region and depends on the quality of product and installation.

DDeeccoorraattiivvee ccoonnccrreettee● No barriers to inhibit heat● Can be stained, coated, integrally colored, stamped, textured, saw cut, you

name it● Typically easy to clean and care for

TTiillee aanndd ssttoonnee● Good heat conductivity● Easy to install over radiant heat floors● Easy to care for

RRoollll pprroodduuccttss aanndd lliinnoolleeuumm● Check with manufacturer for compatibility● Floor temperature may affect adhesive time● Rare, but radiant heat may cause discoloration or a bad odor

HHaarrddwwoooodd flfloooorriinngg● Wood should be acclimated to room temperature before installation● Consideration of moisture content is very important!● Various installation techniques can be used, including floating floor, glue

down, direct nail or nail to sleepers● Moisture barrier a must between hardwood and concrete or gypsum subfloors● Wood floors require special care

CCaarrppeettiinngg● Most carpet products and pads can be installed over radiant floors, but check

with manufacturer for compatibility● Pad and carpet act as thermal insulators, so they cut down on conductivity; it’s

best to select the denser, less insulative carpet padding (thicker, plush productshave higher R-values)

● Ongoing care and cleaning can be a concern

Phot

ogra

ph c

ourt

esy

of D

iam

ond

D C

oncr

ete



Other things you might seein the fieldIf you, as a concrete contractor, decideto enter the radiant heat floor market,there are a couple of fairly recent itemsthat you might encounter or decide touse.

When pouring slabs on-grade, amoisture barrier is important. If yourslab will integrate radiant heat, youmight consider an insulating moisturebarrier.

Innovative Energy Inc. developedTUFF-STUFF, a high-strength,insulating moisture barrier, especially foruse below heated concrete floors. WarnerBuchelt, the company’s national salesmanager, says you typically don’t lose alot of heat to below the slab, but “havingan insulating barrier will increase theefficiency of heating the building.” It willensure the heat is directed upwards, notlost, either to the soil below or togroundwater, which can carry away heat.TUFF-STUFF reduces downward heatloss by more than 50 percent.

Contractors who cross over into theradiant heat flooring market or pourgypsum-based cement underlaymentsmay encounter the BEKOTECModular Screed System, which allowsfor continuous screed surfaces withoutcontrol joints or saw cuts. KimberlyRielly, public relations coordinator forSchluter Systems LP, the manufacturer,explains that the system’s lightweightstudded polystyrene panels are placedover the substrate, the radiant heattubing is looped between the studs anda screed or gypsum-based cementproduct is applied on top. Anymicrofine cracks that develop duringcuring occur between the studs, which“confines the curing stresses to eachmodule, eliminating the need forcontrol joints in the screed.”

For more information about radiant floorheating systems, visit the Radiant PanelAssociation’s Web site athttp://www.radiantpanelassociation.org.




http://www.radiantpanelassociation.org


To say there has been an explosion in demand fordecorative concrete is quite theunderstatement.Homeowners are hiring decorative

concrete specialists to color, stain, score, stamp, overlay orotherwise decorate the pool decks, entries, driveways andwalkways around their homes.

Training opportunities for decorative concreteapplications are exploding. The Stamp Store in OklahomaCity recently started offering two training classes per monthinstead of one just to meet demand. Concrete Solutions Inc.,out of San Diego, Calif., notes that their training classes arefilled with contractors adding decorative concrete to theirrepertoire or adding on new decorative techniques.

What is driving this huge growth in demand fordecorative concrete? What trends are emerging that those ofus with an interest in the decorative concrete industry canfill? Think vacation spot — homeowners want a resort rightin their back yard.

AMCON, located in Gaithersburg, Md., is seeing a largeincrease in pool-related projects. AMCON creates an arrayof hardscape projects — including patios, porches, walkways,and driveways — by using stamped and colored concrete

techniques that complement a variety of landscapes andprovide a touch of individuality to a homeowner’s back yard.“Many homeowners not only want a pool, but a totalpackage — a backyard retreat in which they can escape andrelax at the end of the day and on weekends,” says MaryAmaro of AMCON.

Adds Mike Boedekker of Pristine Concrete in PasoRobles, California: “Today, people want their own private

vacation spot, somewhere they can retreat to every day.”Homeowners often want an extension of their house — anexterior surface that flows with the indoor flooring materials

they have used. Boedekker is also receiving a lot of requestsfor outdoor kitchens with barbecues, sinks, burners, warmers,refrigerators and even storage areas.

Using decorative concrete as part the overall design of ahome is also happening in the Staples, Minn., area. “Wehave been doing large decorative driveways, 2,000 to 5,000square feet, lakeside patios and wrap around porches,” saysMike Verlennich of Verlennich Masonry and Concrete.“This is in keeping with the rustic and log homes found inthe lake areas.” Verlennich also noted that sometimessomeone will see one of their projects out in public and haveto find out more. One woman visiting her local Dairy Queeneagerly entered the drive-thru and asked not for an ice creambut for information — she wanted to know who created thesandblasted, red cobblestonepatio, accented in black.When the woman found outabout Verlennich, shecontacted the company andsaid she wanted her sidewalk tolook just like the Dairy Queenpatio — minus the big DairyQueen logo, of course.

Decorative contractors arealso sprucing up existingconcrete. Concrete Art,located in Carlsbad, Calif.,turns boring gray concrete intosurfaces with innovative

Industry SpotlightConcrete is Central to Home Vacation Retreats

by Jim Peterson



designs and vibrant colors. “We enhance existing surfaces sohomeowners don’t have to go through the arduous process ofreplacing concrete,” says company president Jeffrey Grieve.Concrete Art, whose clientele is equally split betweenresidential and commercial, installs 350 projects per year.“With the large amount of refinancing occurring in

Southern California due to low interest rates and soaringvalues in real estate, people are spending money enhancingtheir homes, not only as an investment vehicle, but to makeliving in them more pleasurable.”

Bill Guthro of Distinctive Concrete, located in Boston,points out that stamped concrete is also very cost effective.“Stamped concrete is usually about one-third less than theprice of installing natural materials,” according to Guthro.

As more homeowners and business owners see theoptions they have available with concrete, and with thecreativeness shown by decorative concrete contactors, thedecorative boom is sure to continue and grow out into thefuture. After all, given the chance, who doesn’t want avacation spot right in their back yard?

Jim Peterson is founder and president of The Concrete Network(www.concretenetwork.com). Founded in 1999, The ConcreteNetwork serves architects, builders, designers, consumers, andremodelers with over 1700 pages of concrete information and anationwide network of local service providers for concretecountertops, stamped concrete, acid-etch staining, concreteresurfacing, and 43 other types of concrete work.



http://www.concretenetwork.com


Brushed FinishesGrab a broom and let your imagination run wildby Joan Stanus

Applying brushed finishes onconcrete began as a practicalmatter. Contractors needed a

method to aesthetically “put a bite” onsmooth concrete so driveways, pool decksand other surfaces wouldn’t be too slippery.

But today, as contractors increasinglyseek new methods to decoratively finishconcrete, brushing or “brooming” thesurface has evolved into a fairlyuncomplicated, yet versatile, techniqueto create unique artistic applications.

“The possibilities are endless,” notesDevin Johnson, vice president ofArchitectural Concrete and Design Inc.,the Salt Lake City-based company thatserves as the Utah franchise forBomanite Corp.

“It’s more or less artistry,” he adds. “It’slike putting a brush in an artist’s handand letting him create on a canvas …except this is on concrete. You pick apattern and go with it. People just keeptaking it a step further and further.”

Contractors like Lee Levig ofConcrete Works concur.

“You can really get creative with broomfinishes,” Levig says. “A good thought tokeep in mind is to mix applications to getdifferent looks. You can mix the broomwith stamps or with stains and differentcolors. There are all kinds of things youcan do when you get creative.”

In fact, Levig adds, brushing can partof what he calls a “budget decorative”project. “For the long spans of concrete,like a driveway,” he says, “you just color itand broom it. Then you do the borderswith a stamp.”

The basics of creating brushed finishesare fairly simple — brooming concrete isnot that much different from sweepingthe floor with a broom. At its mostelementary, contractors simply push orpull a broom across the concrete whilethe pour is still soft.

The finished look can vary widely,however, depending on how soon thebrooming is done, the texture of thebristles and whether the concrete surfaceis wet or dry.

The tools for the job are simple. Thereare essentially two types of brooms —those made of horsehair and those made ofPh

otog

raph

s cou

rtes

y of

Arc

hite

ctur

al C

oncr

ete

& D

esig

n In

c.


synthetic materials such as nylon. Brushescome in either hand or push varieties.

Horsehair brooms create finer texturesthan do the synthetic varieties, althoughmanmade brushes are manufactured invarious diameters, allowing contractorsthe flexibility of fashioning dramaticallydifferent looks.

In recent years, brush manufacturerssuch as Marion Brush Co. in Iowa havedeveloped systems specifically forbrooming concrete. Marion’s handlelessfinishing system, the Chameleon Trac II,for instance, allows contractors to finishpours that are awkward and to reachfarther than traditional brushes extend.The system is equipped with color-codedbrushes of different sizes and textures, anangle adjustment device and an adaptorto convert to a twin-brush system.

“Normally, you can’t go wider thanabout 30 feet with a brush,” notes DougRouse, Marion’s general manager. “But withour handleless system, you can go as far as200 feet if you want and still get consistentand even strokes. The beauty of the systemis that you only need to take one pass to getwhat you want. That doesn’t happen intraditional brush systems.”

The moisture content of the brush isalso critical to creating various looks. Adamp, stiff- bristled broom, for instance,can produce a coarse texture, perfect forheavy traffic areas and sloping surfaces.Dry, soft-bristled brooms are best suitedfor creating medium to fine textures.

“The general rule of thumb is thestiffer the bristles, the coarser the finish,”notes Levig. “But, really, it all has to dowith timing and when you get on theconcrete.”

Therein lies the rub, say contractors.Getting on the concrete too early cancreate a weak surface; getting on it toolate can mean the strokes won’t makethe desired indentations.

Knowing when the concrete is readyto be brushed is largely a matter of“acquired touch,” contractors maintain.

“I touch it,” notes Levig, who is basedin Fairfield, Calif. “When I push hardand barely feel the movement in thecream, I know it’s ready. It’s somethingyou really learn from experience.”

Phot

ogra

phs c

ourt

esy

of L

.M. S

cofie

ld C

ompa

ny




“I do the ‘finger test,’” echoesJohnson. “I push my finger in and if it’shard enough and my finger doesn’t leavean imprint, then it’s ready. Once theconcrete is troweled, it really needs todry enough so when the brush is pulledover it, the surface doesn’t come off.”

The readiness of the concrete canalso vary from region to region and withthe technique used.

“The weather is a big factor,” notesRouse. “Contractors on the West Coast

may broom before those in Iowa.Generally, if the water bleeds off thetop, the concrete is ready.”

A critical factor to ensuring thedesired effect is keeping the brushes

clean. Whether synthetic or horsehair,the bristles should be rinsed frequently tokeep the tips clean.

Rouse recommends dipping brushesinto a 5-gallon of bucket of water, thenshaking off the excess moisture, betweeneach stroke.

“You should wash as you go,” addsLevig. “You don’t want a dirty brush.You’ll ruin the cream and remove part ofthe top.” Before he brooms, Levig alwaysmoistens the surface of the concrete toensure enough moisture exists for histechnique. That can be done by mistingthe surface of each section beforebrushing (being careful not to use toomuch water) or can be a byproduct ofdipping the broom in water to clean itbefore each stroke.

Johnson, too, cautions against addingany dirt onto the concrete.

“You don’t want any build-up,”echoes Johnson. “It can be disastrous toyour look.”

Also disastrous to the look isinconsistency in brooming differentareas of the pour. In brooming, timing iseverything, contractors like Johnson andLevig maintain.

“You have to be sincere about whatyou’re doing and pay attention,” Levigcautions. “You have to have the samepressure on the broom throughout.That might mean you may have toapply different pressure at the end ofthe job than you did in the beginningbecause you’re doing it at a differenttime of the day and the conditions aredifferent. You want the whole slab tolook the same.

“You also have to be careful from onetruck to the next,” he adds. “Where thetwo trucks meet, you may have to golighter on one side and heavier on theother. You have to use your eye and be


What to avoid when you’re brooming● To much water on the surface● Waiting too long to begin the process● A dirty broom● Getting on the concrete too early or too late

Phot

ogra

ph c

ourt

esy

of A

rchi

tect

ural

Con

cret

e &

Des

ign

Inc.




aesthetic. It’s all common sense andexperience.”

Contractors like Ray Hight withCalifornia-based Tom Ralston Concretecautions that ensuring consistency inbrooming, especially with coloredconcrete, can be tricky.

“We got away from brooming a fewyears ago because it can change theshade of the concrete and create veryuneven colors,” he says. “Even if there isno color in the concrete, you can getdifferent shades.”

Depending on the conditions of thepour, admixtures can enhance thebrooming possibilities by buying thecontractor some time and making thepour dry more evenly. In cold weather,for example, adding calcium chloride tothe pour can speed the hardeningprocess, allowing contractors to get onthe concrete faster and coordinate thetiming with the second pour.

In the end, however, it’s all about thelook. The broomed effects possible arelimited only to the contractors’imagination, say those in the field.

Some of the possibilities:● Changing the direction of strokes

with different textured brushes cansimulate the look of wood grain,similar to that of a parquet floor.

● Finishing the concrete withalternating brush strokes in jointedblocks can resemble a checkerboard.

● Swirls can be created by pulling alightly featured brush in a circularmotion.

● A “picture frame” look can beachieved by using the trowel’s hardedge to block off the broomedparameter.

● A broom can be used to create curves,waves, herringbone patterns, evencircles.

And when contractors combine theirbrooming with joint patterns, acidwashing, sandblasting and otherdecorative concrete techniques, the doorto creative possibilities opens even further.

In the hands of a true artisan, brushedconcrete can become a thing of sublimebeauty.



ConcreteMarketplaceis a paid listing of quality-related products.

If you would like more information about anyof these products, circle the appropriatenumber on the reader service card found

between pages 52 and 53 of this issue.



Acid Stains (CONCRETE STAINS)Our line of uunniiqquuee colors include: Burgundy, Blue, Green,

Blue-Green, Lemon and Brick.

Triple-S Chemical Products, Inc.Call: 1 (800) 862-5958 • Web: www.concrete-stains.com

3464 Union Pacific Avenue, Los Angeles, CA 90023

Bla

ck

Dar

k B

row

n

Ligh

t Bro

wn

Bur

gund

y

Rus

ty

Blu

e

Blu

e G

reen

Gre

en

Lim

e

Tan

Ora

nge

Bric

k

Sawtec® Crac-Vac SawThe Sawtec® Crac-Vac sawcan by dolly-mounted to cutartificial grout lines andscore cuts in stainedconcrete or overlay-finisheddecorative concrete floors.Cuts to 11⁄8" depth. Patentedvacuum housing andinternal impeller ensure thatoperation is virtuallydustless, reducing cleanuptime.Call 800-624-7832.

CIRCLE #12 ON READER SERVICE CARD CIRCLE #44 ON READER SERVICE CARD


Advanced Polymer TechnologyArchitectural Toppings and Resinous Flooring

1-(866)-4FLORIC435-6742

Polymer Modified Cementitious CoatingsStainsResinous FlooringWaterproofing Membranes


Business VentureLooking for a new business or a way to increase your existing one — weare currently looking for Artisan and Contractor Licensees. Benefits include:● Advertising Support and Marketing● Recognized National Buying Power● Tradeshow Representation● Feature Articles● Lead Referrals● On-going Training and Tech Support● Respected Industry LeadersArtflor™ offers training in our decorative architectural concrete systems;floors, walls, tiles, and counter and table tops. From project conception tocompletion and every aspect in between.

(800) 773-9363 • (702) 604-7803 • www.artflor.net






Want toknow more

aboutdecorativefinishes?

Subscribe to the best coatings journal in

the industry!

Every issue gives you:●New Product Information●Powerful Selling Ideas●Designer Insights●Technical Expertise●Great Tips Call today:

1-877-935-8906or subscribe on-line at

www.paintpro.net

http://www.paintpro.net


http://www.miracote.com


AlternativeFFIINNIISSHHEESS

• Staining concrete since 1993• References available• Acid stain floors, walls, counter tops, etc.• Decorative scoring (sawcuts)• Custom colors, color grouting• Clear coat sealers• Waxing, highspeed buffing

On the job training at your site

Wes Vollmer Concrete(210) 655-5940 Design

Specialist

www.alternativefinishes.com

Decorative Concrete Consulting and Training

Help Wanted

Classifieds

With over 16 years of experience in:Stamping Concrete, Acid Staining, Stamped

Overlays, Self-Leveling Compounds, SprayedOverlays, Troweled Overlays, Concrete

Countertops, Sealers...

On-Site — Hands-On Training:I come to the job-site, so you can learn while

making a profit from the project. Every TrainingIncludes Six Months of Free Tech Support.

Decorative Concrete Presentations:I give Decorative Concrete Power PointPresentations for group meetings with

Architects, Designers and Builders

Tech Support:I can handle your day-to-day questions andproblems or just give advice on a specific

project. I will also help with problems that mayinclude litigation.

References Available

Call Jeff Potvin(813) 909-2242

www.ac-consultants.com

FASTEST WAYS TO SUBSCRIBE!Go online to

www.concretedecor.netand fill out the on-line subscription form

or call

877-935-8906and we will take your information over the

telephone.

Decorative Concrete Supplies

Concrete Countertop Specialist$ $ $ $ $ $ $ $ $ LEARN HOW TO $ $ $ $ $ $ $ $ $

Precast Concrete CountertopsTechnical Support and Training —

Equipment and SuppliesHigh Profit — Low Overhead

Call: John Rodick (315) 725-0448 (315) 899-6247$ $ $ $ $ $ Email: [email protected] $ $ $ $ $ $ $

Concrete Countertop Supplies

The Decorative Concrete StoreColoring Agents Release AgentsStains & Sealers Stamps & Stencils

Concrete HardenerRepair and Overlay MaterialsFinishing Tools and Hardware

On-Site Training and ConsultationConcrete Countertops

Eco-Block Insulated Concrete Forms

3546 Eastern Avenue, Cincinnati, Ohio 45226Phone: (513) 533-9200 • Fax: (513) 533-3078

Toll Free: (866) 483-3330www.DecorativeConcreteStore.com




Learning Opportunities Now Await You Online At:

www.concretedecor.net

Our Decorative Concrete Training Directory isamong the finest the industry offers!

In our Calendar of Training Seminars andIndustry Events find the latest on trainingdates, locations and subject matter, with

links to the providers for more information.Also find dates and links for upcoming

industry events.

Explore Concrete Decor Online Today!

Training Materials

Easy as 1… 2… 3… for beginners and experts.Advanced hands-on decorative concrete cutting,scoring, engraving and staining techniques withexceptional equipment. Learn how to make fast,high quality, great paying installs plus how tomarket and sell your services. Discover right toolsand skills. Free information pack.

Engrave-A-Crete, Inc.1-800-884-21141-941-355-2114

Details at www.engrave-a-crete.com

Giving away Profit!

What’s NEW with• Imprinted Concrete• Concrete Stains• Self Leveling Overlayments• Texturetop™• Concrete Sealers• Specialty Tools Equipment• Application and Product Training

For more information call

1-800-938-41481-541-938-4005 (fax)

www.dcsystemssupport.com



Product New

s


Integral coloring systems for ready mixQC Construction Products has launched a new “totalsystems” approach to integral coloring for the ready mixmarket. QC ColorTech-E delivers superior concretefinishing performance from a blend of dispersements,conditioners and water-reducing agents that offset waterdemand caused by pigments. It contains engineeredcolored admixtures that do not require mix adjustmentsat the ready mixed plant. Ideal for ready-mixed concreteand all horizontaland verticalapplications, QCColorTech-E canbe utilized forconcrete flatworkapplications thatfeature salt,broom or rotaryfinishes as well as a wide range of other architecturalconcrete installations. High-strength pigments yield anexpansive palette of colors. Designed to replace QCIntegral Color, it is packaged for one cubic yard of ready-mixed concrete in disintegrating bags for exact dosing.

As an alternative, QC ColorTech provides aneconomical option for coloring ready-mixed and precastconcrete. Designed for high volume in ready mix, itdelivers high-performance color without the hiddencosts or variability found in liquid coloring systems. Theend result is a lower cost per pound of color andincreased profits for ready mix customers.QC ColorTech, available in one-, five- and 25-pounddisintegrating bags, replaces Bayferrox by QC. For moreinformation, visit www.qcconstructionproducts.com.

Adhesive anchoring adhesiveSika Corp. has entered the adhesive anchoring marketwith the introduction of four new injection cartridgesystems. Geared to the professional contractor, SikadurAnchorFix-2 is a high-performance epoxy acrylateanchoring adhesive that’s easily dispensed from a good-quality, standard caulking gun. AnchorFix-2 exhibitshigh load capabilities, can be dispensed in all types ofweather conditions, and cures in colder base-materialtemperatures than traditional epoxies. Each cartridgeincludes two static mixing nozzles, eliminating mixingerrors and reducing waste.

AnchorFix-3 is the fast set version of SikadurInjection Gel. The product’s superior bond strength andfast cure times allow for same day loading of heavy-dutyanchors. Each 22-ounce cartridge is packaged with itsown static mixing nozzle. Larger, “hi-flow” static mixingnozzles for the 55-ounce cartridges are sold separately.

AnchorFix-4 is the regular-set version of SikadurInjection Gel. Excellent long-term performance and

the same superior bond strengths provided byAnchorFix-3 meet the commercial constructionindustry’s demand for reliable attachment to concreteor masonry base materials.

For more information, call (800) 933-SIKA or visitwww.sikausa.com.

Walk-behind trowelsStow offers four walk-behind trowels with a host ofadvanced features that improve operator comfort andcontrol as well as providing “the flattest finishesanywhere.” The four-blade Honda-powered trowels areoffered in 36- or 46-inch diameter guard rings withpower options ranging from 5.5 to 11 horsepower. The36-inch ring diameter models can finish seven squarefeet of concrete per revolution. The 46-inch ringdiameter models can finish 11.5 square feet ofconcrete per revolution. All four Stow trowelscome fitted with the standard handle with a starwheel for precise adjustment. Forthose who prefersmooth and easy pitchcontrol, a quick-adjusthandle with atensioned levermechanism isavailable. Allmodels includefingertip throttle control and a durable centrifugal safetyswitch that automatically stops the trowel should theoperator lose control of the handle.

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

Diamond blades for dry cuttingThe new Side Winder II diamond blades from DiamondBack are changing the face of high-speed dry cutting.The blades, which are available in 12- and 14-inchmodels, feature a ribbed core that reduces friction andheat while providing faster cutting and applicationversatility. The blades’ T-shape diamond segmentdesign enhances fast cutting performance, making themideal for cured concrete, brick, block, asphalt and green

concrete as well as a variety ofother materials.

The unique T-shapedesign also provides

outstandingundercutting core

protection,preserving theintegrity of thesteel core while

extending blade


http://www.qcconstructionproducts.com

http://www.sikausa.com

http://www.stowmfg.com


life and providing a greater return on investment. The bladesare offered at prices comparable with competitor products.

For more information, call 800/417-0171 or visitwww.diamondbackblades.com.

Galvanize your aggregate binCustomers of Cemen Tech Inc. may now have theiraggregate bin galvanized. When the Cemen Tech aggregate

bin is completely immersed into a molten zinc bath, the steelof the aggregate bonds with the zinc, creating zinc-iron alloylayers. The zinc layer acts as a barrier against water, oxygenand atmospheric pollutants and protects the steel fromimperfections and abrasions. The galvanized bin will not onlylast longer, but because of its abrasion resistance, will also aidwith the flow of aggregates. For more information, call (800)247-2464.

Roller makes light work of compactionMultiquip’s new AR-13H tandem drum roller is a lightweightsolution to heavyweight compaction challenges. The 3,088-pound ride-on roller is built for asphalt and sub-layer granularand mixed-soil compaction jobs, making it ideal for work onparking lots, driveways, and roads. The AR-13H boasts 3,100

pounds of centrifugal force with 4,000 vibrations per minute.It has a 35.7-inch drum width and travels up to 4.8 mph. Forimproved efficiency and reduced labor cost, the AR-13Hsports a 11⁄4-inch clearance on the right side for closeoperation near walls and obstacles; a 19-inch curb clearanceensuring flush compaction to the curb; and unobstructed


To place youradvertisement

in Concrete Decor call toll-free877-935-8906

or 541-341-3390 • FAX 541-341-6443Advertising Phone Hours

8:00 A.M. – 5:00 P.M. (Pacific Time) Monday–FridayClosed Saturday/Sunday/Holidays

DeadlinesPlacement, corrections and cancellations must be made three

weeks prior to publication print date.(Please call for deadline information.)



http://www.diamondbackblades.com


driver visibility. The AR-13H’s frontdrum vibration with static rear drumprovides a smooth and even surface.For additional ballast, the rear drumcan be filled with water.

The AR-13H is powered by an 18-horsepower Honda gasoline engineand has a maintenance-free vibratoryassembly that reduces downtime. The

Glass-based cement for soilstabilizationEsportec, a French company, hasdeveloped a glass-based cement suitableas a stabilizing binder for soil. Waste fromglass containers and flat glass is ground,chemically activated and processed into abinder which can be mixed with crushedsand to stabilize soil in park pathways,bicycle lanes, footpaths, game areas,sports grounds and car parks. The newEco’Stabil® binder can be used to producereinforced stabilized soil that retains thenatural texture and color of sand. Otheradvantages include the self-repair of

micro-cracks; weather resistance; insensi-tivity to weather and flooding; load-bearing capacity and durability of at least10 years. In addition to the reinforcedstabilization of natural soils, glass-basedcements can be used in foundations forroad building, mortars, concrete andstabilized sports grounds. For moreinformation, visit www.e-esportec.com.

Face-shield/respiratorcomboThe new ClearVisor with Adflo systemcombines full eye and face protectionwith a slim, lightweight, powered, air-purifying respirator. The polycarbonateface shield has exceptional clarity and awide viewing area, while providingprotection from high-impact hazards.The respirator is used with a high-efficiency particle filter that can be“stacked” onto an optional Adflocartridge for additional protectionagainst organic vapors, sulfur dioxide,chlorine and hydrogen chloride fumes.Additional features include a brushlessmotor, automatic airflow control, and aventilated leather belt shaped for


roller also features a hydrostatic drivewith infinitely variable speed controlfor simple forward and reversemaneuvering. This allows operators tostop and start the roller smoothly whilepromoting even operation and helpingto eliminate asphalt marring.

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


http://www.e-esportec.com

http://www.multiquip.com


maximum freedom and back support. Thesystem comes with a “smart” batterycharger that controls the battery chargingprocess automatically. The blower’sbreathing tube port is parallel to theworker’s back, so it tends to stay closer tothe user’s body and is less likely to catch onsurrounding obstacles. The system can beused in a multitude of settings, includingaggregate processing, cement and stonecutting and other dusty environments. Formore information, call (800) 628-9218 orvisit www.hornell.com.





http://www.hornell.com

WORLD OF CONCRETE 2003


Phot

ogra

phs c

ourt

esy

of R

osem

ary

Cam

ozzi


CIR

CLE

#80

ON

RE

AD

ER

SE

RV

ICE

CA

RD


Documents

A Hot Combo: Radiant Heat and Decorative Concrete · with modern design. by John Strieder 32 MANUFACTURER PROFILE: Davis Colors Davis Colors celebrates 50 years of coloring concrete