Description
Proper placing and finishing of decorative concrete requires specialized skills using decorative concrete products and techniques not required for most concrete placements. These skills are in addition to the proper placing, finishing, and curing skills needed for routine concrete placements that are covered by existing flatwork finisher resources and programs.
The decorative concrete industry is growing fast. As a result, there is a need for education and information from credible sources. The standards of quality for this growing industry must be maintained and increased. This document was produced with the intent of raising the quality of education for the decorative concrete industry. Quality of construction will progress by continually improving the level of craftsmanship.
Many of the skills associated with decorative concrete flatwork are not presently covered in existing concrete flatwork resources. This document supplements existing resources by providing knowledge of the materials, equipment, and techniques required to successfully install decorative concrete flatwork. Knowledge of traditional concrete flatwork techniques is recommended for full understanding of this document. Decorative concrete topics covered herein include:
Mixture design for decorative concrete mixtures;
The use of integral color and dry shake color hardeners;
The identification and uses of decorative finishing tools and equipment (such as stamping mats and stencils);
The use of surface retarders and set-retarding admixtures to produce exposed aggregate surfaces;
Stamping and texturing concrete;
Seeding fresh concrete surfaces with decorative aggregate;
Decorative treatments for stair treads and risers; and
Cleaning and sealing methods for decorative concrete.
This document also covers topics that are universal to concrete flatwork construction:
Jobsite and personal safety;
Ensuring the design adheres to Americans with Disabilities Act (ADA) guidelines;
Preplacement site preparation; and Identification and uses of concrete finishing tools.
Additionally, two chapters of texture samples and project examples are included. Architectural cast-in-place walls, chemical stains, decorative overlays, decorative scoring, and other topical finishes are not included in this document.
Keywords: flatwork, decorative concrete, decorative finishing, concrete flatwork, concrete surfaces, stamping, texturing, coatings, sealing, decorative
Table of Contents
Introduction
Chapter 1: Safety
Chapter 2: Layout Considerations
ADA Guidelines
Terms used in ADA
Requirements for Flatwork
Accessible Route
Curb Ramps
Ramps
Stairs
Detectable Warnings on Walking Surfaces
Summary
Chapter 3: Soils, Subgrade, and Base Requirements
Soils Report
Subgrade Preparation
Cement Type and Corrosion Protection
Other Information
Chapter 4: Forming, Reinforcement, Dowels, and Jointing
Allowance for Accessibility and Production
Reinforcement
Welded Wire Reinforcement
Reinforcing Steel Bar
Spacer Blocks
Dowels
Microfibers and Macrofibers
Jointing
Isolation Joints
Contraction Joints
Residential driveway and front entry
Commercial Project
Joints between Adjacent Concrete Placements
Contraction Joints
Tooled Joints
Saw-cut Joints
Chapter 5: Basic Decorative Concrete Components
Mixtures for Decorative Concrete
Nominal Maximum Size of Aggregate
Portland Cement and Other Cementitious Materials
Amount of Cementitious Materials
Air Content for Air-Entrained Concrete
Concrete Slump and Use of Admixtures
Type and Amount of Pigment for Integrally Colored Concrete
Types of Color
Basic Tools for Decorative Flatwork
Strikeoffs or Straightedges
Bull Floats and Darbies
Edgers
Groovers
Hand Floats
Hand Trowel
Fresno Trowel
Margin Trowels
Kneeboards
Brooms and Brushes
Saws
Tools Used Specifically for Decorative Flatwork
Stamping Mats
Stencils
Dry-Shake Spreaders
Tampico Brushes
Flex Mats
Texturing Skins
Tampers
Pattern Rollers
Hand Rollers and Chisels
Pump-Type Sprayers
Concrete Tools
Chapter 6: Surface Retarders
General Uses
Top-Surface Retarders
Guidelines for Use
Preparation
Applying the Surface Retarder
Removing the Surface Retarder
Environmental Note:
Tools Required
Curing and Sealing
Durability and Sustainability
Chapter 7: Stamped Concrete
Planning and Organization
Subgrade Preparation
Concrete Mixture Proportions and Admixtures
Formwork
Coloring Stamped Concrete
Release Agents
Stamping/Texturing Tools
Seamless Texturing Tools
Patterned Texturing Tools
Curing the Concrete
Early Carbonation
Wash Down
Sealing
Chapter 8: Seeding Special Aggregates
Chapter 9: Decorative Treatment of Stairs
Code Requirements
Color and Texture of Cast-in-Place Concrete Stairs
Required Tools (Specialty Tools Required)
Formwork
Finishing Practices
Procedure
Integral Color
Stamped Treads and Risers
Exposed Aggregate or Sand Finish
Contraction Joints
Building Stairs with a Stamped Texture
Summary of Stamped Steps
Cast-in-Place Steps with a Surface Retarder
Chapter 10: Sealing Decorative Concrete
Curing Compounds
Sealers
Cure and Seals
Coatings
VOC Regulations — How They Affect the Products You Use
Preventing Moisture Problems
The Effects of Deicing Salts on Sealer Performance
The Effects of Temperature on Sealer Reactivity
Low Temperature
High Temperature
Dealing with Condensation on Sealers
Preparing Surfaces for Sealer Application
Choosing the Best Applicator
Sealer Application Tips
Chapter 11: Color and Texture Samples
Seeded Aggregate Finishes
Integral Color with Seeded Aggregates
Sand Finishes Using Top Surface Retarder
Slate
Stamped Concrete with Color Hardener and Contrasting Release Agent
Chapter 12: Project Samples
Coastal Resort and Spa
Civic Center Library and City Hall
Decorative Concrete Parking Lot
Hospital/Medical Center
Church Plaza
Office Building Motor Court
Regional Aquatics Center
Medical Research Building
Office Building
Appendix A