part 2: countertops - concrete decor · back then, it was almost a daily ritual to ﬁnd that ......

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Part 2:Countertops

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Working with Slump

Making Use of Leftovers

VOL. 4 NO. 5 • OCT/NOV 2004 • $6.95

Part 2:Countertops

PPlluuss:: SSeeaalleerrss ffoorr tthhee FFiinniisshhiinngg TToouucchh

Working with Slump

Making Use of Leftovers

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CIRCLE #22 ON READER SERVICE CARD

2 • www.ConcreteDecor.net • Oct/Nov 2004

October/November 2004 • Vol. 4 No. 5Issue No. 18 • $6.95

Publisher: Bent O. Mikkelsen

Co-publisher: Ernst H. Mikkelsen

Editor: Rosemary Camozzi

Circulation: Sheri Mikkelsen

Design and Production: Stephen Stanley

Web Design: Mark Dixon

National Sales Manager: Kathleen Goodman(314) 367-1121

Western Regional Sales: Troy Ahmann(702) 869-4342

Writers:John Chandler

Susan Brimo-CoxStacey Enesey Klemenc

David Thompson

Contributing Writers:Evan Lloyd

Editorial:Professional Trade Publications, Inc.

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

Email: [email protected]

Circulation and Administration: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

Subscriptions:One year: USA $21.95; Canada $29.95;

Other countries $49.95. All funds in U.S.dollars.

For Subscriber Services:Call 866-341-3703 Toll Free

For Advertiser Services:Call 877-935-8906 Toll Free

© 2004 Professional Trade Publications, Inc.

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ONTHE COVER: These gleaming countertops were created by Stone SoupConcrete,located in Florence,Massachusetts (www.stonesoupconcrete.com).

It’s a Boy...

It’s too bad we don’t have theopportunity to meet regularly at alocal coffee shop. It’s also unfortunate

that we don’t get a chance to talk aboutmore topics in these letters of mine. Soplease understand my excitement andpride in announcing the arrival of ourthird child.

His name is Kannen and he’s got everyone in the office, our neighborhood andat home wrapped around him, literally. In spite of sleep-deprived nights and therelentless demand for our affection, he’s such a wonderful addition to our family.In fact, at one month he’s already participated in his first decorative concreteworkshop at the IAC facility here in Eugene, Oregon. And, along with our otherchildren, he now hangs out at the office on occasion, getting conditioned for a jobin publishing. I’ll talk to the kids later about any stress that may come along withthe job title.

The pleasure in writing you each time a new issue of Concrete Decor ispublished is immeasurable. While it’s a challenge to consider what will bestinfluence the lives of more than 50,000 readers, a common question runs througheverything I discuss: How can each of our lives become more fulfilling, personallyand professionally? Such questions don’t normally make things easier on us.However, they do help us discover our paths to success in many areas of our lives.

To this day, I enjoy a close relationship with a fellow tradesman I met nearly 20years ago. Though we haven’t seen each other in nearly two years, we still talk onthe phone at least once a week. Back then, it was almost a daily ritual to find thatcertain coffee shop or a tailgate and discuss important work-related matters.Sometimes we would also get philosophical about the world, challenges in raisingour children or ways we needed to improve our attitudes toward all of the above.And now, as we continue to laugh at many of our frustrations, we are glad to havethe fellowship with each other. Our phone visits add meaning to our lives andhelp us push harder to accomplish the things that mean the most to us.

So, here we are. I’m sure some of you are welcoming new children into yourlives or facing the challenge of improving your relationships. Rest assured, findingways to influence those around us for the better starts with first finding ways toimprove ourselves. And, I must add, good friends are an essential ingredient.

Now, that my family has grown, I am again realizing the importance of havingpeople around me that can help me discover ways I can improve on myself. I hopeit will help me to serve you better in the pages of this magazine as well.

Thanks for your friendship and support.

Sincerely,

Bent Mikkelsen, Publisher

http://www.ConcreteDecor.net

mailto:[email protected]



http://www.stonesoupconcrete.com

FEATURES18 Precast Countertops

Part two of a two-part series covering forms, mixes, tools andfinishes.by Susan Brimo-Cox

26 Sealing Your CountertopsKeep it beautiful! An overview of sealer types including personalrecommendations from the experts.by Susan Brimo-Cox

32 Slump SolutionsTips on achieving workability without adding water.by Stacey Klemenc

42 Waste Not, Want NotWith concrete in short supply in some areas, here are some waysto make best use of what you have.by Evan Lloyd

48 Counter PointsA countertop class presented by Buddy Rhodes Studio leftparticipants eager to try out new products and techniques.by Rosemary Camozzi

DEPARTMENTS12 CONTRACTOR PROFILE: Concrete Innovations by Hallack

Artistic talent, attention to detail and a love for the material arethis concrete contractor’s ingredients for success.by David Thompson

38 MANUFACTURER PROFILE: QC Construction ProductsA focus on quality and a complete array of products have helpedthis manufacturer make the transition from regional to national.by John Chandler

58 FINAL POUR: Bridging the gap between man and nature

46 Classifieds43 Concrete Marketplace04 Decorative Concrete Tips06 Industry News10 Industry Spotlight — Association News52 Product News50 Product Profiles02 Publisher’s Letter

www.ConcreteDecor.net • Oct/Nov 2004 • 3

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Tek Gel gets rid of rust on concrete

At a recent Flattoo workshop conducted by Surface Gel Tek, Tamryn Doolan discussed many decorative uses for the company’s products. But

I also learned another surprising benefit of Tek Gel for Profiling besidesits etching and stenciling capabilities.

Tek Gel quickly removes rust from metal and concrete. In addition, it removesmolds, mildew and algae and increases slip resistance all in one step. Its gelconsistency keeps the hydrochloric acid suspended and capable of working fastand effectively on rusty surfaces so that it takes rust spots off in no time flat.Because Tek Gel is now sold in three strengths for stenciling and surface profilingapplications, the product can address rust problems on everything from theharshest to the most delicate surfaces.

Lastly, another great attribute of this product is the fact that it washes to thesewer system completely neutralized, so it is an environmentally responsibleproduct as well.

This tip was contributed by Bent Mikkelsen, publisher of Concrete Decor magazine.

DECORATIVECONCRETETIPS

Decorative Concrete Tips is a forum for readers to exchange

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

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

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



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New companyoffers decorativedesigns,patternsMelanie Royals, founderof Modello Designs, hasbeen a leader in thedecorative painting fieldfor the last 15 years.Through her initialbusiness, Royal Design

Studio, she helped set the standard for decorativeartistry in painted and textural finishes.

Now, with Modello Designs Decorative MaskingPatterns, Royals has created a system that furtherexpands the options for architectural surfacetreatments, including decorative concrete. Possibilitiesfor sophisticated concrete applications include positive,resist and etched patterns; embossed and inlaid designs;and multi-tonal and layered treatments.

Artistic Concrete Effects (ACE) is an integratedsystem of education, design aids, and coordinatedpatterns that can be easily learned and applied for high-end, custom applications. Design planning and consul-tation services are also available. For more information,visit www.modellodesigns.com.

Lafarge wins multiple awards from PCALafarge North America’s Alpena Plant has wonnational awards for its environmental efforts, energy-saving innovations and safety record.

In April, the Portland Cement Association (PCA)awarded its third annual Cement IndustryEnvironment and Energy Awards to six U.S. plants —including four Lafarge plants — with top honors goingto the Alpena Plant for Overall EnvironmentalExcellence.

Alpena is Lafarge’s largest cement plant in NorthAmerica and one of the longest continuously operatingcement plants in the United States. In operation since1908, the site has been in use since the late 1800s, yetnew investments have made Alpena one of the mostenvironmentally advanced cement plants in the world.

A major initiative cited in the PCA award was thecompany’s rehabilitation of the abandoned PaxtonQuarry on the property. Lafarge converted the old shalequarry into a lake, grading the embankments to create anatural appearance and provide access for wildlife.Working with local elementary schools and communitypartners, the company has also restored the areasurrounding the lake to create wildlife habitats andnesting sites for migrating mallard ducks. Elementaryschool children helped plant more than 700 trees onthe site, including cherry, oak, pine and spruce trees. Inaddition, the company stocked the lake with more than

30,000 fish, including fathead minnows, rainbow trout,catfish and bluegills.

The PCA also recognized the Alpena Plant formanufacturing innovations that reduce waste andconserve energy. Lafarge installed a system that reusescement kiln dust created during manufacturing,reducing byproducts that would go to landfills. Inaddition, the plant captures excess heat created duringthe manufacturing process to generate power. Usingenergy that would otherwise be wasted, this systemgenerates 95 percent of the electricity used at the plant,helping to reduce emissions of greenhouse gases.

PCA also recognized the Alpena Plant with twoawards for its outstanding safety record: the SafetyCommendation award for one year without a lost-timeaccident, and the Safety Excellence award for1,000,000 hours with no lost-time accidents.

Worldwide, Lafarge has been recognized as a leaderin environmental stewardship, with active landmanagement and reclamation programs in 75countries. Lafarge partners with WWF (World WildlifeFund) and the Wildlife Habitat Council on a variety ofenvironmental initiatives.

VanFleet watches over quality,customers

Grace Construction Productshas named Greg Van Fleet asworldwide quality assurancemanager for the company’sSpecialty ConstructionChemicals Operations team.Van Fleet is a customeradvocate, providing a quickresponse to customer needs,designing and implementingQA/QC programs and

continually pursuing product, manufacturing andservice improvements that directly impact Gracecustomers.

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Thompson is also a licensedarchitect in the state of Illinois, amember of the American Institute ofArchitects, and has more than sevenyears of experience in the ICF industry.

“ICF’s not only increase energyefficiency, but also minimizeconstruction waste, make use of locallyderived materials and capitalize on thegreen benefits of concrete,” he says.

For more information on Reward WallSystems, visit www.rewardwalls.com.

Hycrete used in bridgeconstructionBroadview Technologies’ “Hycrete”concrete additive was used for the firsttime by the Kansas DOT inconstructing a bridge. The pour usedover 450 cubic yards of concrete withHycrete being used at a dosage of 2gallons per cubic yard. As a result of thesuperior anti-corrosion properties andlower moisture permeability impartedby Hycrete, a combination of mild steeland epoxy coated re-bar was used.

Hycrete was chosen as a result ofextensive research by the Kansas DOTas well as multi-year studies conductedby the University of Connecticut andthe University of Massachusetts. Theresearch indicated that Hycrete’s abilityto retard corrosion of rebar and to lowerthe moisture permeability of concretewould increase both the structural andcosmetic life of the concrete. Life 365algorithms predict a 4-10 times increasein the useful life of the bridge.

All present for this pour wereextremely impressed with what theydescribed as the “better workability” ofthe concrete with Hycrete. Hycrete waschosen over silica fume and calciumnitrite combinations. For moreinformation, call (973) 465-0077.

Sara Jane joins Kover KreteSara Jane is the newest member of theKover Krete Team. Jane was hired asthe company’s plaster and pebblespecialist and is heading up KoverKrete’s endeavor into the repairing andpreparation of concrete swimmingpools, both gunite and shotcrete re-dos.


A graduate of the University ofNew Hampshire, where he earned adegree in environmental science, VanFleet came to Grace in 1999.

Quikrete teams up withValsparQuikrete, a top name in concrete, andValspar, a leading coatingsmanufacturer, have announced astrategic alliance to manufacture andmarket a complete line of premiumconcrete coatings. Debuting in early2005, the new line will bemanufactured and marketed jointly byValspar and Quikrete under the brandname Quikrete Professional ConcreteCoatings.

The line includes 14 advancedproducts, from sealers to floor coatingsto waterproofers. The flagship productof the new line is the Epoxy GarageFloor Coating Kit, an all-in-one kitfeaturing Bond-Lok technology thatdelivers a coating that is twice asstrong as concrete. The kit containsenough concentrated Quik-Prepcleaner, water-based, low-odor GarageFloor Epoxy and color flakes to do aone-car garage. Bond-Lok technologyis catalyzed by the revolutionary Quik-Prep three-in-one degreaser, cleanerand etcher. Quik-Prep’s advancedformula promotes the ultimate bondbetween the concrete and coating.

Since 1806, Minneapolis-basedValspar has been dedicated to bringingcustomers the latest innovations, finestquality and best customer service in

the industry. For more information, visitwww.valspar.com.

Founded in 1940, Atlanta-based TheQuikrete Companies has more than 75manufacturing facilities in the UnitedStates, Canada, Puerto Rico and SouthAmerica. For more information, visitwww.Quikrete.com or call (800) 282-5828.

Holdfast to distribute Fab-FormFab-Form Industries Ltd., manufacturerof fabric forms for concrete footings,columns and pads, has appointedHoldfast Technologies LLC as distributorin Ohio, Indiana and Kentucky. Holdfastis a leading regional construction supplydistributor, specializing in ICFconstruction and accessories. For moreinformation on Holdfast, call (877) 423-2562. To learn more about Fab-form, call(888) 303-3278.

Sales manager rewardedwith LEED accreditationDonn Thompson, AIA, commercialsales manager for Reward Wall Systems,was recently accredited in the U.S.Green Building Council’s Leadership inEnergy & Environmental Design(LEED) Green Building Rating System.“Having a LEED-accredited profes-sional on staff allows the company toprovide more accurate information tovendors and customers aboutsustainable design and constructionwith our insulating concrete forms,”says Reward president Ed Storm.

We heard with great sadnessof the passing of Geri Freis,vice-president and co-ownerof Rafco Products. Geri passedaway in her sleep onSeptember 4, 2004, followinga courageous battle withcancer. She is survived by herhusband, Robert Freis, thepresident and owner of RafcoProducts. We know she will begreatly missed by all.

http://www.rewardwalls.com


http://www.valspar.com

http://www.Quikrete.com


Jane started out working with one ofthe largest pool-supply distributorsserving the industry. After learning thepool business thoroughly, she decided toconcentrate solely on the interior ofswimming pools.

Jane, who spent several yearsworking with Pebble Tec, nowspearheads Kover Krete’s Pre-Kote(scratch coat) line. You can reach her at(407) 246-7797.


Monica Stamper (left),presidentand CEO of Kover Krete,chatswith Sarah Jane.



PORTLAND CEMENTASSOCIATIONGibson named senior vicepresident Thomas J. Gibson is the new senior vicepresident, government affairs, at thePortland Cement Association. He willhead PCA’s Washington office andrepresent the Association and itsmember companies before Congress, theadministration and the White House.

Gibson comes to PCA with a wealthof experience in politics and environ-mental affairs, including roles withgovernment agencies, on Capitol Hill,the armed forces, and as an advisor toand within the private sector. Mostrecently he served as chief of staff for theU.S. Environmental Protection Agency.

Gibson graduated magna cum laudefrom Georgetown University, where hereceived his J.D. He holds a M.S. inmarine affairs from the University ofRhode Island and a B.S. in navalarchitecture from the United StatesNaval Academy.

Cement industry leads insustainable iniativesPCA’s Executive Committee hasapproved a goal addressing theimplementation of environmentalmanagement systems (EMS) forcement plants in the United States.The committee set goals for at least40 percent of U.S. cement plants tohave implemented an auditable andverifiable EMS by the end of 2006,75 percent by the end of 2010, and90 percent by the end of 2020.

An EMS identifies the environ-mental aspects and impacts of a plant’sactivities and facilitates continuousimprovement of environmentalperformance.

This effort is the latest componentof the industry’s multi-year, sustainabledevelopment initiative, ConcreteThinking for a Sustainable World. Theinitiative is helping outline guidelinesfor the industry, educate architects anddesigners about the benefits of concretein sustainable development, andencourage sustainable cementmanufacturing processes.

In June, PCA unveiled the CementManufacturing Sustainability (CMS)Program, which began with reductiontargets for carbon dioxide emissionsand cement kiln dust and included thecall to implement EMS. Additionalgoals are also under consideration.

The cement industry was one of thefirst industries to tackle climate changeby developing policies and improvingmanufacturing processes that benefitthe global environment. Since 1975,the cement industry has reduced itsenergy usage in manufacturing by

Industry SpotlightAssociation News

33 percent. The Concrete Thinkinginitiative will enable PCA to serve as acentralized resource for sustainabledevelopment.

PCA also will continue its focus onproviding information to encouragethe industry to further minimizeemissions and waste and to use energyefficiently in its manufacturing processas part of the federal government’sClimate VISION program.

The association plans to conductenvironmentally focused technicaltraining seminars across the countryand to highlight building projects thatemploy state-of-the-art sustainabledevelopment practices using concrete.

NATIONAL READY MIXEDCONCRETE ASSOCIATIONLuther to head RMCfoundationThe RMC Research Foundation hasnamed Julie Luther as its executivedirector. Luther comes to thefoundation with extensive experiencewith the ready mixed concrete industryand not-for-profit organizations, mostrecently as senior vice president of theNRMCA. Her role as RMC executivedirector will include outreach to alliedorganizations, universities and otherstakeholders to educate them about theFoundation’s work and resources. Shewill also oversee the approval andadministration of Foundation projectsand continue fundraising efforts togrow the endowment in support of theindustry’s education and research goals.For more information on the RMC,call (888) 846-7622.





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AMERICAN CONCRETEINSTITUTEInfo available oncementitious productsA new publication from the ACI, titled“Report on Thin ReinforcedCementitious Products,” summarizesinformation on reinforcement,manufacturing methods, engineeringproperties, and applications of thinreinforced cementitious products.Special emphasis is placed on durabilityand fire resistance of thin reinforcedcementitious products, in addition toother properties such as strength,moisture resistance, dimensionalstability, aesthetics and ease of handlingand installation. The publication costs$35 for ACI members and $59.50 fornonmembers. For more information,call (248) 848-3800 or visitwww.concrete.org.

CONCRETE SAWING &DRILLING ASSOCIATIONTake yourself to the Tech fairThe popular Tech Fair will return to the2005 CSDA Convention, which willbe held Feb. 16-19 in San Francisco.“The goal of the Tech Fair is to allowtechnical representatives frommanufacturers to meet with a veryselective group of cutting contractors topromote the latest developments inequipment and tool applications,” saidPatrick O’Brien, CSDA executivedirector. “This mini-show provides ahighly-charged, one-on-one setting thatis not possible at giant trade shows.” Formore information, visit www.csda.org orcall (727) 577-5004.

http://www.a


http://www.concrete.org

http://www.csda.org


ConcreteInnovationsby HallackTurlock,Californiaby David Thompson

Julio A. Hallack drives his wife crazy when hetravels, because he always seems to have hishead down. No, he’s not embarrassed to be seen with her. He’s just studying the floors.

As the owner of Concrete Innovations byHallack, a small company that specializes inrestoring concrete floors, he is a dedicated studentof what’s underfoot.

“My wife says I have a problem because I’malways staring at the floor,” says Hallack. “But thathelps me make decisions on what I think is goingto look good because I’ve already seen it done byother professionals in the industry.”

Based in the California farming community ofTurlock, Hallack was one of the first contractors inthe state’s vast Central Valley to do decorativeconcrete work. It wasn’t the easiest sell back in1991, when he got started, but Hallack loved itand stuck with it.

“I was like the Lone Ranger pushing a productthat many people had a hard time buying,” he says.“And the ones who were buying it were bringingin contractors from out of the area with bigportfolios.”

Hallack’s perseverance paid off as decorativeconcrete began to catch on through the 1990s.Now he travels throughout the Central Valley,working on jobs that have included rehabilitatingthe floors in a California supermarket chain (usingacid stains), recreating the labyrinth of ChartresCathedral (a gothic, paved stone floor that hereproduced in concrete on a private estate), andrestoring a 1934 terrazzo floor in an old art decomovie theater (part of the larger renovation of theState Theater in Modesto, California).

About 80 percent of his business is floorrestoration, though he also creates new floors andconcrete countertops. Chemical staining is one ofthe main tools in his bag of tricks, along withoverlays and stamping materials. He’s a real fan ofhis two primary product manufacturers: L.M.Scofield Co. and Miracote.

ContractorProfile

ContractorProfile



Designing the jobBefore starting a project, Hallack insists oninvolving his clients in developing a design, evenwhen they’d prefer to leave it entirely up to him.

“I think the client should always be involved,because they become more appreciative at the endof the project,” he says. “And it takes the weightoff of me.”

In developing a design, Hallack shows hisclients lots of photographs, both from his portfolioand from magazines. He also encourages them visithis warehouse, which doubles as a showroom with7,000 square feet of both indoor and outdoordecorative concrete on display.

Hallack believes that colors should be chosenwith careful regard for their surroundings.

“A big mistake of architectural concrete iswhen the outside colors don’t match the inside, orwhen the outside colors don’t match the stucco ofthe house or the eaves or the roof,” he says.

If a residence already has slate floors indoors, forinstance, Hallack might draw from the slate’spalette of blues, greens and terra cottas for thepatio’s color scheme. Lighter shades might beappropriate to reduce heat retention outdoors, butthe indoor and the outdoor surfaces will still tietogether, he says.

Likewise, if the house has a red roof, Hallackmight broadcast some red dry-shake color onto theconcrete to tie the new floor in with the roof.“Paying attention to detail like that is one of theways that I try to be different from mycompetitors,” he says.

You can see Hallack’s attention to detail in thehand-engraved designs he’s known for. “I starteddoing sandblasting in the early 90s wheneverybody was hot for sandblasting, but I thoughtit looked kind of boring and I didn’t like the mess,”he says. “So I started doing my own engraving byhand.”

He uses a Makita grinder for the bold lines, andspecialty tools for fine details such eyes, leaves andfeathers. He typically acid stains individualsections of the engraving with various colors andthen fills the borders with colored tile grout.

Hallack helped remodel the Central Valley’schain of homegrown grocery stores, Save MartSupermarkets and S-Mart Food, redoing the floorsand hand-engraving welcome messages at theentrances, with designs customized for each store.

When he restored the concrete floor in thelobby of a local beverage distributor, he capped offthe job with a hand engraving of the Anheuser-Busch eagle logo — an eight-foot by eight-foot



screaming bird set atop the letter ‘A.’ “It’s one ofmy masterpieces,” he says.

The path into concreteHallack, 50, was born and raised in Mexico. Hecame to California in 1973 as an exchange studentstudying international marketing at the Universityof the Pacific. Upon graduating, he got a job as theSouth American representative for a U.S. farmequipment firm, then took a job as a customerservice manager for a western boot manufacturerin El Paso. Along the way he got married, and in1986 he and his wife moved to the Central Valleyso she could be closer to her family.

The move left Hallack unemployed anduncertain of his next move. But that changed oneday while he was at a gas station filling his tank. Alandscaper pulled up next to him in a truck filledwith lawnmowers. Hallack asked how landscapingpaid, and the guy said he earned $4,000 a week,which got Hallack’s attention. The guy alsooffered Hallack work on a big job in a goodneighborhood. Hallack took it.

“While I was doing this job,” Hallack says,“somebody came by who was building a house andsaid, ‘Hey, I’m looking for a landscaper,’ and I said,‘I’m your man.’”

Suddenly Hallack had his own landscapingcompany, which he turned into a profitablebusiness.

He found his way to concrete indirectly.Occasionally he hired sub-contractors to buildretaining walls, walkways and whatnot, but he wasnever satisfied with their work.

“I was very unhappy with the quality and withhow sloppy they were,” he says. “They used toleave me a mess all the time, concrete debris andbeer cans all over.”

So Hallack began learning how to pourconcrete, gradually growing more and moreinterested in the medium. He went to the Worldof Concrete trade shows in Las Vegas, attendingseminars and learning about new products. Back athome, he began pouring and stamping practiceslabs on his property, until he had confidence inhis skills. Then he started experimenting withcolor.

Once his eyes were opened to the possibilities,there was no going back to plain old gray slabs.The allure of decorative concrete had him firmlyin its grip, and still does.

“I don’t think there’s another product you cando as much with as concrete,” Hallack says. “The



opportunities for using your artistic talent areendless. There are no limitations, no borderswhatsoever, except your imagination and yourcreativity and your enthusiasm.”

Gradually Hallack began to introduce concreteservices to his landscaping customers, and thejobs he took on grew bigger as his skills andconfidence grew. His first major milestone camewhen he contracted to do an outdoormultipurpose sports court (basketball, tennis,handball, etc.) at a private residence. It was achallenging project that couldn’t have anybirdbaths it whatsoever, and it had to drainperfectly. Hallack lost a lot of sleep worrying

about it, but it came out flawless in the end. And itopened the door for other opportunities.

“It was done in one of the most prestigiousneighborhoods in Modesto, and anytime you workin these kinds of neighborhoods, people are morewilling to trust you, and architects are willing totalk to you longer and so on,” Hallack says. “Afterthat referrals began popping up left and right.”

Eventually, the concrete side of his businessbegan eclipsing the landscaping end, and hediscontinued the landscaping entirely in 1997.

The importance of imageMaintaining a clean-cut company image hascarried over from his landscaping days into hisconcrete career.

“From Day One all of my vehicles are wellpainted and clean, and we have the companyname, telephone number and website on them,”he says. “All of my employees look clean and wellgroomed, and all of my staff representing me in thefield wear uniforms — very comfortable, goodquality T-shirts with the company name and logoon them.”

Even after all his years of concrete work,Hallack still gets jittery and loses sleep beforestarting big jobs. But he hasn’t lost any of hisenthusiasm for decorative concrete.

“I still get really excited about every project,” hesays. “You can take a boring piece of gray concrete,change the appearance of it with stains, saw-cutlines here and there, and suddenly you have apiece of artwork. It’s a fact that the best productthat Mother Nature has given us, and that Godhas given us, is concrete.”



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ConcreteCountertops

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ConcreteCountertops

A two-part series covering forms,mixes, tools and finishes

Part 2:Precast Countertopsby Susan Brimo-Cox



Concrete countertop productionfalls into two generalcategories: cast-in-place and

precast countertops. In the last issue ofConcrete Decor, we looked at cast-in-place methods. This time we’ll explorevarious techniques used in precastingconcrete countertops.

Precasting advantagesIf you prefer tight quality control, theprecast method of making concretecountertops is the way to go. Theenvironment in which you pour iscontrolled by you.

And if you also desire flexibility andmore creative opportunity, again, gowith precast.

There are other advantages toprecasting, as well. “The surface createdby precast vs. troweled concrete is a lotless permeable. [It’s] easier to formoverhangs and custom shapes on aninverted pour, and it’s easier to castintegral sinks and inlays in surfaces,”explains Steve Eyler, owner/operator ofEycon in Myersville, Md.

Daniel Gobillot, one of the foundingpartners of Stone Soup Concrete inFlorence, Mass., says that withprecasting “you can get any shape, anysize, any thickness, any color. I think it’sbetter in every situation, unless thepiece is so massive you can’t move it.”

And this is probably the primarydisadvantage of the precast process. Youhave to transport the countertop to thejob site without breaking or cracking it.

Another disadvantage is the need tomake templates. “It takes a lot moretime and traveling [to do this step],”reports Tom Ralston, president andchief executive officer of Tom RalstonConcrete in Santa Cruz, Calif. “We usedoor skins to get the exact angles. [And]if different people do the measuring andthe mold, some headaches can occur.”

Nonetheless, precasting allows youto work on several projects simulta-neously. Buddy Rhodes, president ofBuddy Rhodes Studio Inc. in SanFrancisco, observes, “Precast counters[are] more suited for making more than


one project at once. Also, if [thecountertop] goes ‘south’ you can makeit again and have a happy client.”

Building moldsAn important consideration — beforeyou even begin building a mold — isthat you have solid support for the moldand the concrete you will pour into it.Another is that the molding table belevel. If there is not enough support andthe floor or table flexes, the concrete inthe mold will reflect that. If the table isnot level, the thickness of thecountertop will not be consistent fromone end to the other.

Experienced contractors will also tellyou that now is when you have toconsider the size of the mold. AsRhodes says, “One thing about precastis you have to think about moving thesethings and placing seams at seven feetor so. The weight is a considerationwhen you have to move it up stairs orover hill and dale.”

Gobillot explains that makingsections to fit on standard 4-foot by 8-foot plywood sheets is common in theindustry, and that’s Stone SoupConcrete’s preference. “Anythingbeyond that becomes a special order,”he says, but he adds they have neverturned anything away as too large. “Ittakes more money, but we haven’t had aproject too large to make.” The largestproject his company has tackled to-datewas a countertop 12 feet long, 5 feetwide, with two different levels and anintegral sink, and which weighed morethan 1,400 pounds.

What you use to build your formsdepends on the casting and finishingtechnique you plan to use. Jeffrey Girard,president of The Concrete CountertopInstitute, explains, “If the concrete is tobe minimally processed (very littlegrinding), then the forms need to bemuch more meticulously prepared thanif the concrete is to be ground andgrouted. Either way, the forms must bedimensionally accurate in order to castslabs that will be the right size and shape.Therefore, sturdy materials like steel andmelamine are good.”


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According to Eyler, “Building formsis like normal carpentry, but a bit moreprecise. On an inverted cast everythingis formed as a negative.” Materials heprefers include melamine, plastic andrubber.

Not only do materials commonlyused for making molds need to be ableto handle the weight of the concrete

what we do and many materials to getto the same end.” But he cautions,“Not every lumberyard carries goodmaterials for working with concrete.”

Most contractors who make precastconcrete countertops use caulk or someother material to slightly round theedges and prevent the concrete fromleaking out of the mold. Silicone caulkis one of the preferred methods. Onceyou have your basic mold constructed,then the real fun — and creativity —begins, says Fu-Tung Cheng, principaland chief executive officer of ChengDesign in Berkeley, Calif. “The formcan be the ultimate simplicity. Whatyou do from there is what it’s all about.It’s your imagination — it’s unlimited.”

Rigid foam, rubber molds and othermaterials are used to create thenegative forms for sinks, faucetknockouts, trivets and stand offs,integral drain boards, and the like.Embedded objects are affixed to thebottom of the mold — upside down, ofcourse, so they are right side up when

and create a smooth face, they alsoneed to withstand moisture.

“You need water-resistant orwaterproof materials,” reports Gobillot.His company uses plastics andlaminated wood. For a finish that lookslike hand-troweled, they’ve used MDO(medium density overlay plywood) tobuild molds. “There’s 10 ways to do





the countertop is de-molded andinverted. And then there is theconcrete mix and what you do with it.

Reinforcement and mixdesignMost precast contractors usereinforcement. Wire mesh, fiberreinforcement and rebar are all usedwith this process, depending on thethickness of the countertop and theproject specifics.

But concrete countertops are not thesame as sidewalks poured on-grade.Countertops have differentreinforcement requirements, Girardpoints out. “The topic of reinforcing isone of the most misunderstood in theindustry today. It’s basically anengineering problem — you need

primary and secondaryreinforcement with the rightmaterials and in the rightplaces to ensure propercompressive, tensile andflexural strength.”

With precast concretecountertops, aesthetics goeshand-in-hand with structuralperformance, so any oldconcrete mix won’t do.

“Choice of ingredients ishighly dependent on thedesired workability, final

appearance and structural performance.I designed my mix to have a high earlystrength in order to speed fabricationand deliver in a timely fashion,” saysGirard, who designed his mix to be caston a Friday and stripped on a Monday.“I use Type 1 portland cement, sand asaggregate, integral powder pigmentsand superplasticizer in a very dry zero-slump mix.”

Rhodes also uses a thicker, drier,zero-slump mix when he is trying toachieve his “pressed finish.” With thistechnique, handfuls of the thickconcrete are hand-pressed into themold. The haphazard voids thus createdare intentional, and are filled later witha slurry mix.

Gobillot likes a mix that is workable,but not runny.

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Cheng prefers a 6-inch slump, anduses his fingers to push his denseoatmeal-like NeoMix into the mold’snooks and crannies.

To help ensure consistency, Gobillotsays, “We pour the whole kitchen atonce, in multiple mixes, but eachbatch we weigh out to the 100th of apound, especially with dyes.”

Frequently, special aggregates (suchas colored glass) are incorporated in amix, and are later exposed by grinding.

Casting and finishingtechniquesEach precast contractor has his ownpreference as to tools, but many usestandard concrete, woodworking orgranite tools. Gobillot says his preferenceis for gardening tools, which “seem towork better than construction tools.”

From Ralston’s perspective, “It’salmost a necessity for precasters to havea whole repertoire of tools that let youget into little nooks and crannies.”

Latex or rubber gloves are standardgear, as are respirators to protect fromthe ill effects of portland cement andsand.

Whether a concrete countertopneeds to be vibrated — or how much so— depends on whether you plan to

grout the surface with a slurry mix forcreative effect, Girard says.

Vibrating the poured concrete willhelp eliminate bug holes and voids.

Finally, you want to screed off theexcess concrete so it is level with thetop of the mold.

How soon you unmold depends onthe concrete mix you use.

“We de-form between two to fourdays after pouring,” Gobillot says. “Webegin sealing after three weeks. Oursurfaces come out like a mirror finish sowe go straight to sealing them.”

Cheng recommends placing a moistblanket over the piece after it sets up,and leaving it there for one to threedays while it hydrates and cures. Hetypically demolds four days after


Countertop Training OpportunitiesCheng Concrete Exchange www.concreteexchange.com (510) 849-3272Buddy Rhodes Studio www.buddyrhodes.com (877) 706-5303The Concrete Countertop Institute www.ConcreteCountertopInstitute.com

(888) 386-7711Counterfit Systems www.counterfitsystems.com (417) 725-0909

http://www.concreteexchange.com

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http://www.ConcreteCountertopInstitute.com

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pouring; then he waits another two tothree days before grinding.

For some concrete countertopartists, much of the creative magic is intheir finishing techniques.

If you’ve embedded decorativeobjects or aggregates into yourcountertop, you’ll need to grind thesurface to expose them. This can getrather messy, but can produce verysatisfactory results in short order.

If you have bugholes, these aretypically filled with a slurry mix thatmatches or contrasts with the color ofthe concrete, depending on the resultyou are seeking.

Rhodes uses voids to great effect bypressing a slurry into them in severalapplications, allowing it to set up, andgrinding between applications. Thisresults in a veined appearance.

Ralston also uses a slurry coat to fillvoids and bugholes. Then he grindswith finer and finer grit to a polishedfinish. “People seem to prefer a lightpolish,” he observes.

On the other hand, as Eyler pointsout, “The higher the polish the lesspermeable the surface.”

Still, regardless of individualpreferences, Ralston echoes thesentiments of many contractors whenhe says, “We’re always looking forsomething new and different [in ourfinishes]. It becomes an evolution ofdesign — texture, colors, embeddedobjects. It’s much more unique.”

Curing,transporting andfilling seamsHow long you should allow thecountertop to cure before you deliverand install it depends on your processand the specific recommendations ofthe manufacturer if you use aprepared mix.

Cheng gives his precast countertops10 to 29 days to cure.

Girard says, “We can completelyfinish a countertop from template toinstall in 14 days. [However] we setexpectations at 4-6 weeks, since wehave multiple projects going on at thesame time, and we’re not going to be

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able to push a single project through atmaximum speed.”

Rhodes places his precast slabs on2x4 sticks to allow for even curing allaround. “If the slab is left on the table itwill warp, because the top surface willdry faster than the bottom,” he says.

Transporting precast countertops tothe installation site is a little likehandling artwork — which thesecountertops are, after all. Ship themvertically, stacked on edge. Protectthem with shipping blankets or foam,protect the corners and strap them in.

At Stone Soup Concrete, they’veinvented a lot of equipment to make thejob of moving the countertops easier.“We move everything on rolling cartsthat flip up and down,” Gobillot says.

The challenges don’t stop once youget to the job site, however.

“Sometimes when we install acounter we bring it from a nice [moist]place into a home that has the heat onand is in the direct path of thesouthern sun, [and] the counters willwarp after a couple of days,” Rhodesreports. “If the project is covered andkept moist, the warping will not occur.If they do curl they can be wet with adamp towels, and sometimes they willstraighten out.”

What to fill the seams with is amatter of preference. Colored, two-partepoxy, color-matched acrylic caulk, andsilicon are some of the materialscommonly used.

Cheng uses an innovative techniquefor seams in his precast countertops.“We key all our seams. We make amale-female tongue and groove, sowhen you push the pieces together theyself-level.”

Final thoughtsIf you are considering trying your handat either the precast or cast-in-placemethod of creating concretecountertops, know that there will be aconsiderable learning curve.

“Don’t let anyone fool you thateither technique is easy,” Ralstoncautions. “Both require practice, skilland talent.”


Girard agrees wholeheartedly.“Training and practice are essential inmaking concrete countertops. Thepioneers of the industry taughtthemselves how to make concretecountertops, but there is no need to dothat anymore.”

Fortunately, more classes arebecoming available (see list on page 23).

As Girard strongly emphasizes, “I always tell people to get the trainingthey feel they need, then make samplesand practice on their own homesbefore trying to make a concretecountertop for a client — don’t useclients as guinea pigs!”


http://www.glaze-n-seal.com


Sealers forConcreteCountertopsby Susan Brimo-Cox

Concrete countertops needprotection from everydayabuses. The acids in vinegar

and lemon juice can etch the surface,and the strong colors in tea, red wineand mustard can cause stains. Whilesealers are not a total guarantee, theycan go a long way in ensuring aconcrete countertop retains its “likenew” appearance for a good long while.

A wide range of materials can beused to seal concrete countertops. Eachhas its own performance characteristicsand maintenance requirements.Methods of application may be animportant consideration. In thekitchen, a prime issue is whether asealer is food-safe.

If you are new at creating concretecountertops, it is wise to consult withan experienced countertop contractorto learn which sealers work best forspecific countertop applications. Often,you can also acquire appropriateknowledge when you take in-depthconcrete countertop training. For thesake of our brief discussion, the expertsat the Concrete Countertop Institutedivide concrete countertop sealers intotwo main categories: penetratingsealers and film-building sealers. Thefollowing is an overview:

Penetrating sealersPenetrating sealers soak into theconcrete surface and dry to a nearlyinvisible appearance. Liquid hardenerswork by decreasing the porosity of theconcrete. Repellants, such as silanes,siloxanes and fluorocarbons, work byincreasing the surface tension to causebeading. There are also formulationsthat are a combination of both.

Concrete countertops sealed withpenetrating sealers offer some degree ofprotection, but it is still important toquickly wipe up water, acidic liquids,and substances that could stain thesurface.

Film-building sealersWax is the most basic film-buildingsealer. There are a variety of waxes thatcan be used, including plain beeswax;



however, automotive waxes should beavoided because of additives in thoseformulas. Wax produces a low- tomoderate-sheen finish. It is easy toapply and, usually needs to be reappliedregularly to remain effective. By itself,it offers minimal protection. And,because it is wax, warm temperaturescan cause it to melt and acids can stripit away.

Acrylics are a commonly used sealer.They come in solvent-based or water-based formulations (solvent-basedproducts are often preferred). Thesesealers dry water-clear and are UV-resistant. Acrylic sealers can bebrushed, sprayed or rolled on to theconcrete. Water-based products are lessdurable than solvent-based, but,overall, they offer moderate protectionand some heat resistance. Acrylicsealers can scratch, so periodic reappli-cations are required for upkeep.

Epoxies come in hundreds ofdifferent formulations, but two-component systems are typically used

for concrete. They offer a durable, hardsurface that is very resistant to staining,but they can be affected by UV light ifa UV inhibitor is not part of theformula. Epoxies create a very shinysurface and are subject to scratching.They are also sensitive to heat.

As a rule, urethanes are very stain-resistant and heat-resistant, providegood UV resistance, and are scratch-resistant. They can produce a matte orglossy finish, but also can look“plasticky” due to thick film buildup.Be aware that the application ofurethanes can be tricky and that theyrequire strict substrate preparation.Urethanes also are very expensive.

Tips from the expertsSteve Eylor, Eycon“Topical sealers are pretty muchbulletproof when it comes to acid andstain resistance, but you lose aesthetics.You get that glossy, plastic look andfeel. It scratches and is harder to repair.I use penetrating sealers mainly

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because they let the concrete breathe.This helps in the aging process to letthe concrete naturally patina.Penetrating sealers are stain-resistant,not stain-proof. The sealer I use has a15-year warranty on it. [How much usethe counter gets] determines reappli-cation need.”

Fu-Tung Cheng, Cheng Design“[The] Holy Grail of concrete sealers— by definition one that protects theconcrete from staining withoutencasing it in a layer of vulnerableplastic — has yet to be invented ordiscovered.

“Most penetrating sealers do areasonable job resisting waterpenetration, but it’s a different storywith acids such as vinegar, wines, lemonjuice and salad dressings. At best, theyresist those substances for a few minutes,just enough time to wipe them up.

“Most homeowners do not like thehigh-gloss, topical finishes likeurethane or epoxy. The look is too

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plastic and the tactical appeal of theconcrete is lost. Many fabricators whouse topical sealers (because they arevirtually stain-proof) dull the glosswith steel wool to a satin finish andthen wax and buff to get a morenatural look. We are now using ahybrid topical sealer that penetratesand leaves a thin film of protectionthat gets waxed over. It’s the best wehave found, but hardly perfect.”

Buddy Rhodes, Buddy Rhodes Studio“Most people do not like a highlypolished surface, but more of a naturallook. We use a combination ofproducts. We first brush on one to twocoats of penetrating sealer that absorbsinto the surface. Then we apply atopical sealer, either lacquer or water-base, to bring out the colors in the slabsand to put a layer of sealer between thestain and the cement. Last, we put on awax and buff it out.

“[In the kitchen], we use food-gradebeeswax for the last coat. The wax isused on a regular maintenanceschedule, say once a month or so, toprotect the surface from stains. Butwith all that, the cement will acquire apatina over time.

“We try not to tint the sealerbecause it may wear down [unevenly]over time and leave you with anuntinted area.”

Daniel Gobillot, Stone Soup Concrete“What we’re using now is an FDA-approved product that containsethylene glycol, butyl carbitol anddibutil phthalate. It works as apermeating and topical sealer, appliedover about five days in five to 10 coats.We stay away from epoxies and lacquersbecause they don’t work with theconcrete. I use butcher’s wax [for thekitchen] in my own home.”



Stumpedon How to

Fix YourSlump?JJuusstt don’t aadddd wwaatteerr!!

by Stacey Enesey Klemenc

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Testing 1-2-3For official results, slump is measuredwith a metal cone made explicitly forthat purpose. There are certainprocedures that must be followed toconduct a standard test, which areoutlined in ASTM C143, theStandard Test Method for Slump ofHydraulic Cement Concrete. Thefour-page document can be purchasedonline from ASTM International atwww.astm.org.

Bob Harris, president of theDecorative Concrete Institute inGeorgia, adds that for reliablereadings it’s key to conduct tests on alevel base made out of a nonabsorbent material such as sheet metal or Plexiglas,not wood.

Most decorative concrete contractorsdon’t conduct standardized tests whenpouring driveways, pool decks or thelike. For practical purposes, mostseasoned contractors can tell if theslump is right when they see theconcrete coming down the chute.Harris can go one better: “I can tell if it’sdry or wet just by listening to the truckturning,” he says with a laugh.


How would you define slump?According to the Tennessee Ready

Mix Concrete Association, slump is ameasurement of concrete’s workability,or fluidity.

It’s an indirect measurement ofconcrete’s quality, states Gabriel Ojeda,president of Fritz-Pak Corp. in Dallas.

And Joe Daczko, group manager ofconcrete technology for DegussaAdmixtures Inc. (formerly MasterBuilders) in Cleveland, maintains it’s ameasurement for consistency, bothfrom a quality-control perspective andto determine how fluid or stiff amaterial is.

However you define it, though, thebottom line remains the same: Slump isa test for the rigidity of uncuredconcrete. Lower slump concrete is verystiff, and higher slump concrete is morefluid.

Most people in the business agreethat a typical slump for ordinarydecorative concrete applications wouldbe in the 4- to 5-inch range, but there’sno hard-and-fast rule. “The slumpshould match the application,” saysDaczko. “It could be anywhere from 1to 10 inches depending on what you’redoing. If you’re paving a road, you needa much stiffer material that can standon its own. If you’re doing a wall, the

A slump test will provideinformation regarding the

stability of your mix.Twoconsecutive shear slumps may

indicate that your mix is prone tosegregation and lacks cohesion.

An example of a true slump.

The 4- to 5-inch slump fordecorative concrete is a

relatively stiff mixture,butnot quite as stiff as the 2- to

3-inch slump seen here.Ahigher slumped concrete is

much more fluid and will flowsome distance on its own.

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Advantages ofsuperplasticizers� Increases flow, making placing

easier — even in heavilyreinforced or difficult to accessareas — which allows you to focusyour efforts on creating decorativeconcrete.

� Makes your mix more workablewithout adding more water orchanging the water-cement ratio.

� Temporarily makes concrete morefluid, allowing integral color todisperse much better.

� Reduces bleed water, resulting infewer shrinkage cracks and moreevenly colored surfaces.

� Improves cohesiveness andreduces concrete segregation.

� Allows for the option of addingless water, creating a strongerconcrete overall.

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flow needs to be much more fluid.” Andif you’re pouring a patio, it needs to besomewhere in between.

Sizing it upBob Harris, an industry leader andpresident of the Decorative ConcreteInstitute in Temple, Ga., says thatalthough most decorative concretecontractors don’t conduct formal slumptests on the job, that doesn’t makeusing the proper slump any lessimportant. “They need to understandthe correlation [of slump] and how itaffects the overall finish and structure ofconcrete,” he says.

Harris, who teaches concretetechniques across the country andbeyond, likes to explain it this way tohis students who are just getting startedin the business: If you make grape Kool-Aid and it’s too strong, you add water.


The new mixture isn’t as sweet and it’snot as deep a shade of purple. The sameholds true for integrally coloredconcrete: If you change the slump bythe addition of excess water, you changethe makeup of the entire mixture as wellas the intensity of the color.

“If you use excessive amounts ofwater, sometimes referred to as ‘water ofconvenience,’ it makes the concrete a

lot more permeable,” Harris says. “Itwon’t stand up to the test of time inaggressive environments and to thingslike de-icing salts and certain chemicalsthat could attack the concrete.”

Basically, if you add too much waterto your mix, it dilutes the cement pasteand weakens the concrete mixture. Thematerials segregate, with the heavieraggregates sinking to the bottom, the



The use of admixturesThere is a wide range of admixturesthat can be used to “fix the mix,”says Ojeda, whose company is wellknown for its handy Fritz-Paks thatcan be tossed into the ready-mix


sand staying in the middle and thecement floating to the top. “You end upwith a cement-poor bottom and acement-rich surface,” says Ojeda,adding that a weaker surface is prone tocracking due to cement’s inherentshrinking qualities.

There’s a huge difference inadjusting the slump with chemicalsrather than with water, Harriscontinues. By using water-reducingadmixtures, you can change the slumpwithout affecting the integrity of theconcrete mix.

High-range water reducers,sometimes referred to as superplasti-cizers, increase the mix’s flow, improveworkability, disperse the cement moreevenly and allow you to reduce theamount of water in your mix by acertain percentage, making for a moredurable product in the long run. It mustbe kept in mind that they work for alimited amount of time.

truck at the job site, bag and all.Fritz-Pak Corp.’s admixtures aredesigned to restore loads of concretethat might otherwise be rejected andto improve the performance ofproblem concrete by modifying its

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characteristics and enhancingworkability.

There are any number of reasonswhy you would use an admixture, allof which have to do with improvingcharacteristics of the concrete. “Toensure the best finished project,contractors should work with theirready-mix supplier to develop a mixdesign before the concrete isdelivered to the job site,” Daczkoadvises. “Besides adjusting slump,there are admixtures that can be usedto slow down the set of concrete oraccelerate it, improve the strength,control cracking, protect againstfreeze-thaw cycles and add coloring,just to name a few.” Some admixturesmake the concrete temporarily morefluid, so colors added to the mixdisperse much better.

Admixtures can often save the day,Ojeda points out, by increasing theslump without excessive water. Theycan fix concrete that is not quite whatyou ordered and they also can fill inwhen your crew is shorthanded orlimited on the number of stamps.

Using a technique called stepretardation, he says, you can dischargehalf the concrete and retard the otherhalf. You can start stamping at one endand work from soft to medium to hardbefore getting to the next section that’sjust starting to set. Again, you go fromsoft to medium to hard to get aconsistent pattern.

Mike Costello, a regional managerwith Dayton Superior, points out thatadmixtures have been around eversince they first started building concretedams, but he marvels over the varietyavailable today. “With the latestadmixtures, you can have just aboutany slump you want. You just decidewhat you want your concrete to do andyou can create a mix design to causethat to happen.”

Harris points out that not everyjob or application requires anadmixture. But more contractorsshould be aware that help is therewhen they need it.



QC ConstructionProductsMadera,Californiaby John Chandler

bandwagon. “I would say a large portionof (the sales) came from residential use— patios, driveways, walkways. Andwe’re seeing more decorative concreteuse in interiors as well. HGTV is hugeat getting people introduced at thehomeowner level. We get so many callsfrom people saying they want this orthat kind of stain that they saw onHGTV for their patio.”

When it became apparent that thedemand for color was going to be amarket force to be reckoned with, thebrain trust at QC faced a criticaldecision: quality versus quantity.

“We are not a commodity-drivenline,” Sullivan says. “I think one of thechallenges we faced on the way up waswhether or not we were going to tryand be all things to all people. Thereare companies out there that treat theseproducts like commodities, available onevery street corner. We want to dealwith the upper-end, leading distributorsin the market, and we want to havecutting-edge product quality. We aren’ttrying to sell everybody, just the peoplewho are striving to do the highestquality work.”

Sullivan and his QC compatriotsfound that they got great feedback bygetting the stains and colors into thehands of applicators doing the mostcreative work. “They’re doing thingswith our products that we neverthought of,” he says.

As for the products themselves,many have contributed to QC’s rise inpopularity. In addition to QC PatinaStain and ColorTech E, which havebeen used on high-profile jobs at the

QC CONSTRUCTION PRODUCTS foundgold at the end of the rainbow.

In other words, color meantopportunity.

Started in 1992 in Madera, Calif.,QC Construction began life as aregional supplier of decorative concreteraw materials — colors, hardeners,release powders — to contractors incentral and southern California. Thecompany blossomed in the mid-’90swhen contractors and homeownersalike discovered that there was more toconcrete than mere shades of gray.

“The growth of decorative concreteduring the mid-’90s was huge,” saysQC’s national technical director, ChrisSullivan. “QC went from being asmall, regional player servicing a few-hundred-mile radius from the plant inMadera to where we are now, anational player with five regional salesmanagers and 30 sales reps all acrossthe country.”

Sullivan attributes the phenomenalgrowth in sales to a few key factors. Firstof all, the design community vigorouslyembraced the product line beingoffered by QC. Suddenly, it seemed,everyone wanted concrete in differentcolors. A variety of integral colors andstains were clearly the way to go, partic-ularly in style-conscious California. Itwas only a matter of time before the restof the country followed suit.

“Number two, contractors andapplicators were seeing the increase inthe amount of money they couldmake,” Sullivan says.

And finally, he says, homeownersclimbed aboard this colorful



Luxor in Las Vegas and Disney Worldin Orlando, Sullivan is especially keenon another development.

“We have a product, that to myknowledge, nobody out there hasanything quite like it,” he says. “It’s apenetrating reactive stain, but it’s water-based. It’s called QC CemTint and it’s awater/lithium-based reactive stain. Itworks on different chemistries anddifferent properties than acid stains.

“Acid stains are available inbasically eight colors. CemTint isderived from a proprietary blend ofreactive, UV-stable chemicals. You cannow get any tint under the sun —purples, blues, shades of green. Thepalette is now endless. There are othercompanies that have what they callwater-based stains, but nothing that isactually a true reactive or penetratingstain like this product.”

Sullivan also proudly points to anew one-part modified epoxy calledQC Perma Seal. “It’s had great resultsin durability, both inside and outside,




and it’s a simple application. It’s goodfor people imprinting concrete outsidewho want more of a matte or satinlook. It’s also excellent for peopleworking inside with stain or overlaywho are looking for durability but whodon’t have the time to wait for a two-part urethane to cure out. You canwalk on this product in about an hour.”

QC also has new sealers and overlayproducts in various stages ofproduction. Sealers in particular,Sullivan says, continue to create a lotof questions for applicators. QC’ssolution was to create an entireoperating system for its distributors.

“We target training and educationwith our products and getting the wordout to the applicators through ourdistribution network,” Sullivan says.“We have a training program calledthe QC Color Tour that travels aroundthe country to our big distributors andoffers either free or low-cost trainingwith our products. It’s a whole systemfrom nuts to bolts: service, training andbackup within a product family.

“Take acid staining for example: Wehave all the products from beginningto end. We have the prep products, thecleaners, the stains. We have theneutralizing and washing products. Wehave the base-coat sealers, the finishand maintenance sealers. We haveaccessory products and additives. Andwe’ll show you how to use them.”

Apparently, QC made all the rightmoves at crunch time. The company isenjoying considerable growth andcurrently has about 60 employees. QCalso recently opened a second plant inKnoxville, Tenn., to service theexpanding Northeast market.


“These trends tend to go from westto east,” Sullivan says. “Decorativeconcrete, while it continues to grownicely everywhere, is getting hot onthe East Coast. It’s a huge market withhuge potential. I expect substantialgrowth in the next five to 10 years.”

Sullivan says that he sees more andmore concrete contractors everywherelooking for training in decorativeapplications.

“I’ve been in this industry for about12 years,” he says. “When I first started,

there were a lot of applicators andready-mix suppliers who wantednothing to do with color. It was a pain,it was a bother, it was messy. Now,because of financial gain, sales anddemand, we’re seeing very few placeswhere that attitude prevails.

“We’re finding more and moreapplicators are becoming savvy to theproducts and actually becomingartisans.”



Waste Not,Want NotConserving concrete in times of shortage

By Evan Lloyd

diminished cement supply and expensive shippingrates. Prices have not only increased for cementproducts, but they have become unavailable inmany parts of the country. With conditions beingwhat they are, we as artisans need to do all we canto conserve this natural resource.

What can we do?There is an old saying that states, “A little goes along way.” First, only mix what you need. It seemssimple, but how many times have you completed aproject only to find an obscene amount of leftoverconcrete sitting in a bucket? As you nearcompletion of a stamp or overlay project, mixingonly half or a quarter of a bag will not onlyconserve materials, it will also save you money.Next, find creative ways to use your leftovermaterials. At Solid Solutions, we have reusablemolds that we use to make concrete countertopsamples. At the end of every pour, we fill thesemolds with the leftover material and then givethem to clients as samples.

On flooring jobs, always carry some scrapplywood or cement board to every job site. Afteryou complete a job, trowel the leftover flooringmaterial onto the wood and then use them assamples. We like to take these uncolored samplesto our clients’ homes, where they can spray stainon them and pick the color for their project. Theclients love being able to mix their own colors andwe’re using material that we would have had tothrow away.

Finally, make some stepping-stones. You canfind reusable molds for stepping-stones at any craftstore. Fill the molds with your scrap material, andallow them to cure. Once released from the mold,stain and seal the stepping-stones and give themto your clients as a “Thank-you-for-your-businessgift.” This small gesture has gotten us many clientreferrals. They are easy to make and thehomeowners love them.

For more information on the cement shortage,visit the Portland Cement Association atwww.cement.org.

Evan Lloyd is the president of Solid Solutions, adecorative concrete company located in Fresno,California.

Last week, I passed by my local supply houseand witnessed an unfamiliar sight.Encasing the building was an infinite line

of people eager to get in the store. At first Ithought, “Did *N SYNC get back together andstart selling concert tickets at hardware stores?”I approached one of the men in line and askedwhat the fuss was all about.

“We’re waiting in line for cement,” said DavidCunningham of David Jack Corp. “They ran outlast week and a new shipment arrived today.”When asked how long he had been waiting inline, he gave me a frustrated look and said, “Since4:30 A.M.”

Unfortunately, Mr. Cunningham is not alone.The concrete industry, as a whole, may soon beaffected by a cement shortage. In order tounderstand the cement shortage, we must first takea look at the factors that are responsible for thelack of this precious material. They include growthin construction activity, limited supply, andincreased shipping rates.

Supply vs.demandThis past year was a hallmark for the constructionindustry. The Commerce Department reportedthat nearly $100 billion dollars was spent onconstruction costs this year alone, and that thisspending trend is likely to continue. Even coldwinter days didn’t slow the building industry.Normally, when construction is slowed in theholiday season, cement plants will stock up oncement to prepare for the spring explosion. Withno letup in demand for cement products, manyplants did not have the resources to facilitate thebooming spring and summer seasons, whenconstruction is at its highest. However, this is onlya part of the problem.

The United States produces the majority of theconcrete products we use. However, 22.6 percentof our cement is imported. The importation ofcement from countries like China helps fill thevoids in domestic production and demand. Thisyear, freight costs and limited availability ofshipping have put a stranglehold on theimportation of cement. China’s economy is at anall-time high and their ability to export many ofthe goods they produce is limited. The result is


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CountertopIntensive

OffersValuableTraining

by Rosemary Camozzi



Countertops were the name of the game ata recent workshop sponsored by theInstitute for American Craftsmanship in

Eugene, Oregon.Taught by Beto Esquivel, a master craftsman

from Buddy Rhodes Studio, the two-day workshopoffered its participants valuable experience inmaking precast and cast-in-place countertops,decorative concrete tiles and even concrete stools.

“This class has been really informative,” said JoeGeise, a contractor from Roseburg, Oregon. “It openswindows for us, because we get to see all the tricksBuddy’s learned over 25 years that make him good.”

Attendees got hands-on experience in every stepof the process, from creating forms to blending thethick, integrally colored mix, pushing it into place byhand, reinforcing, troweling for a smooth finish, andsealing with a penetrating sealer and beeswax.

One of the most important benefits was the chanceto learn how to duplicate Buddy Rhodes’ signatureveined finish. “It’s a whole different technique fromwhat I already knew about countertops,” said KennySides, a contractor from Olga, Washington. “Thatgives it a whole different look.”

Buddy Rhodes Studio manufactures a completeline of products with everything needed to createcountertops, whether precast or cast-in-place. “Youtake the product and just add water and color,” saysJim Mason, sales and marketing director for themix product division. “This product is designed tosimplify the process.”

The company has recently launched itsreformulated countertop mix nationwide, withimprovements that make the mix accept colorbetter and that create a more vibrant, rich finish.

Buddy Rhodes has also recruited some of the topnames in decorative concrete as distributors andtrainers: Bob Harris and Bart Sacco on the EastCoast;Wes Vollmer, Dana Boyer and Tom Ralstonon the West Coast. “We’re trying to align ourselveswith the best people in the industry,” Mason says.“Education is so key to the success of our product.”

Indeed, as the class drew to a close, Geise said heplanned to ditch the countertops that he hadexperimented with at home and start from scratchusing the techniques he had just learned. “Usingthe mix would make a very consistent product,” hesaid. “With the techniques these guys showed us,you can get the same finish every time.”

He wasn’t the only student who was impressedwith the product. “This class was presented real well,”Sides said. “I’ve already been asking, ‘Where do I getthe product and how soon can I get it?’”




Top Cast Surface Retarder

Top Cast is a water-based, film-forming surfaceretarder that saves time by eliminating the need for

covering the surface even when it rains. The product,available in thirteen depths of etch, is designed forpoured-in-place flatwork and the top surface of precastpanels.

Top Cast has been used with both integrally coloredand color-hardened concrete surfaces to achieve the

popular “sand” finish without loss ofcoloration.

“Its outstanding quality is that it isnot only a chemical retarder, but it haspolymer in it,” says Dustin Ferch, acontractor from Roseburg, Oregon.“When you apply it, you don’t have tocover it with plastic because it creates itsown film.”

Ferch also likes the product because it willcome off concrete even if left on the surfacefor a couple of days in hot weather. “It’s veryuser-friendly, very forgiving,” he says.

The fact that it is available in many subtlegradations of depth — from super-fine sand, tosand, to exposed aggregate — also makes itextremely useful. “If you need to match a pre-existing job, it gives you a lot of range so you canget an exact match,” he says.

His only caution is that you need to be careful aboutoverspray. “Ammonia does clean it up but it takes a lot ofelbow grease,” he says. He recommends covering adjacentareas to avoid this problem.

The product is VOC-compliant and easy to apply. Ithas an excellent coverage rate. For more information, visitwww.graceconstruction.com.

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Haven’t heard of the Magic Trowel yet?You will.

Originally developed for finishing drywall, this magical toolsmoothes concrete surfaces without leaving any trowel

lines. “We’re getting so many calls from concrete people,” saysJoe Torres, president of TexMaster Tools, which makes theMagic Trowel. “The guys in this industry are going crazy!”

The Magic Trowel’s patented blade has a flexible rubberedge. The edge is cut on a 30-degree angle, which takes thepressure off so the trowel doesn’t leave trowel lines.

Another plus is the fact that the blade pushes downimperfections in the concrete instead of dragging themthrough. “It’s not like a squeegee, which has a hardedge,” Torres says.

At a recent workshop at the Institute for AmericanCraftsmanship, Colormaker Floors president GaryJones demonstrated the finish he could quicklyachieve with this trowel. Many “oohs” and “aahs”came from the crowd as he created perfectlysmooth surfaces by drawing it across cementitioustoppings applied both horizontally and vertically.

The Magic Trowel is just coming into concrete supplyhouses, but it is currently available at most Sherwin-Williams paintstores. For more information, visit www.texmaster.com or call (800) 852-8355.



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Product New

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New solution for moisture-prone areasKey Resin Company has introduced a new version ofKey Urecon that combines a urethane binder withportland cement and graded aggregates to deliversuperior qualities for a flooring application in manufac-turing and plant settings.

Key Urecon is a heavy-duty, trowel-applied,urethane-modified cementitious topping. High impact-resistance and excellent thermal shock make KeyUrecon ideal for manufacturing areas. In addition, as a“breathing” system, the product is a solution for manymoisture problems. The textured surface reducesslipping under most wet conditions.

Key Urecon may be used both indoors and outdoors.The system is ideal for rehabbing old floors because itprovides a strong and long-lasting surface. It is an idealchoice for wet areas, like dairies, food processing plantsand industrial kitchens. The product can be installedwith an integral cove base for areas requiring seamlesswall to floor coatings. It will not support the growth offungus or bacteria.

Key Urecon is available in grey, tan, red and green,in addition to a variety of custom colors subject tolaboratory approvals. Colors will not fade or wear thin.For more information, call (888) 943-4532 or visitwww.keyresin.com.

Get ready for cold weatherGround Heaters Inc. has introduced an air heater thatis ideal for temporarily heating large enclosed spacesand multistory buildings while under construction. Theunit uses a trailer-mounted hydronic heater to heat theunit’s 140 gallons of heat transfer fluid up to 180degrees Fahrenheit. A pump then circulates the warmfluid through hoses to the liquid-to-air heat exchangesplaced throughout the enclosed spaces. Each heat

exchanger’s fan draws cooler airfrom the room and blows it crossthe heated coils to produce hot, dry,clean air. The fluid then returns tothe main unit for reheating.

Hydronic air heaters are growingin popularity because they safelydeliver clean, dry heat into theworkspace while using less fuel thantraditional methods. They alsoremove excess moisture from theworkplace, which prevents moldand mildew formation and speeds

finishing work. They are also safer than traditionalheating methods because there is no open flame orcombustion byproducts. They can be powered by diesel,propane or natural gas and come with three sizes of

liquid-to-air heat exchangers. For more information,call (231) 799-9600 or visit www.groundheaters.com.

Make the cut with the Crac-VacThe Saw-Tec Crac-Vac Decorative Kit is ideal for saw-cutting artificial grout lines or decorative cuts intostained or overlay-finished decorative concrete floors.The kit includes everything needed for the contractor:a Crac-Vac saw mounted on a dolly; 6-foot hose;reusable dust collection bag; and bag shoulder strap.The saw cuts to a depthof 11⁄8 inch. It controlsdust during cutting forfaster cleanup and toallow other trades towork in the area simulta-neously. A patentedvacuum housing withinternal impeller fanroutes the dust to thereusable dust collectionbag, so no separatevacuum is required. The Crac-Vac is also used forrouting out random cracks in preparation for theapplication of repair compounds and for cleaning outexpansion or control joints on concrete floors. For moreinformation, call (800) 624-7832 or visitwww.surfacepreparation.com.

Add a scarifier to your ride-on scraperA new scarifier attachment is available for the BlastracBMS 270 scraper, which is used for high-volume, lightdemolition and concrete surface prep. The attachmentincreases the flexibility of this ride-on scraping machineto allow scarifying of concrete surfaces for planing orremoval of built-up contaminants, mastics, glues andcoatings. Scarifying can also be used to correctcommon slab problems such as curled joints, high spotsor uneven areas.


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The scarifier features a 13" workingpath and is powered via the hydraulicsystem of the BMS 270. A range ofcutter teeth is available to meetapplication needs. For moreinformation, visit www.surfaceprepa-ration.com.

New line of extended lengthtrowelsMarshalltown has released eight newExtended Length Finishing Trowels.The longer trowels vary in length from22 to 24 inches and in width from 4 to5 inches. Five of the trowels feature asmooth, natural finish hardwoodhandle and three have the patentedDurasoft handle. Six are made ofhardened carbon steel blades, while twooffer tempered blue steel blades. All areproperly shaped to deliver a smoothconsistent finish. For more information,visit www.marshalltown.com.

Backpack vibrator perfectfor remote jobsWyco Tool Company has introduced anew portable, self-contained backpackvibrator: the gas-powered Model 402.Because no electrical cords orpneumatic hoses are required, it is thebest choice for remote and hard-to-reach jobs. It is also ideal for use as an


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Concrete stain offersaffordable protectionSherwin-Williams Vertical ConcreteStain is an ideal, cost-effective way toadd distinctive color and improvedappearance to large concrete structuressuch as parking garages, stadiumsupports and tilt-up, block and stuccowalls. The penetrating coating addsextra protection from water andweather damage.

Vertical Concrete Stain can beapplied to new or aged concrete. Itoffers excellent adhesion and resistscolor fading, blistering andefflorescence. Contractors can alsocount on a fast turnaround since thestain dries quickly and is ready for asecond coat in as little as 15 minutes. Itgoes on easily with conventional sprayequipment and offers superior sagresistance and less overspray thansimilar products.

emergency or backup vibrator in caseof power failure at the job site.

The new backpack vibratormaintains constant vibration in themix, due to easy operator control of thevibration speed via the engine throttle.The powerful Robin engine suppliesconsistent, full-vibrating capacity tothe Wyco Square Head vibrator. Asingle digital tachometer/hour meteron the unit indicates precise enginespeed while the unit is operating anddisplays accumulated hours when theengine is not running, providingimportant input for preventativemaintenance. A speed increaserreduces engine speed for longer life andless noise.

The portable Model 402 is availablewith a choice of shaft lengths and headsizes. For more information, call (800)233-9926 or visit www.wycotool.com.

While some applications require theheavy-duty properties of elastomeric orhigh-build textured coatings to protectagainst harsh weather conditions andwind-driven rain, many jobs simply don’twarrant such a high level of protection.This stain offers better weatherprotection than conventional acryliccoatings without adding excessive coststo the project. It is available in a widerange of colors. For more information,visit www.sherwin-williams.com.

Bull float bracket lets yourock n’ rollBon Tool Co.’s new Rock N’ RollBracket for bull floats and fresnosprovides full-up and full-down pitchwith just half a turn on the handle.This eliminates side-to-side movementon the bull float.

The Rock N’ Roll Bracket is madeof high-strength aluminum casting with



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a heavy-duty turning mechanism andzerk grease fitting. The bracket uses 13⁄4"and 13⁄8" button-type handles and workswith two-hole and four-hole fresnos andbull floats.

Bon’s “build your own bull float”product line includes 12 bull floatoptions, more than 20 handles, sevenhandle adapters, a universal four-hole totwo-hole adapter, and additionalbrackets, including the popular Rite-Height Adjustable Bracket. For moreinformation, call (724) 443-7080 orvisit www.bontool.com.

Be kind to your kneesAlso new from Bon Tool is theContoured Kneeler Board, whichprovides comfortable, soft support forconcrete finishing. The foampolyurethane is molded to fit the shape ofthe knees in the kneeling position. Thecushion is anatomically formed to

provide even weight distribution andconsequently greater relief for knees andjoints. The exceptional absorbing charac-teristics of the foam reduce the risk ofdamage and pain to the knees, evenwhen kneeling for long periods of time.

The cushion is permanently set in aheavy-gauge, polyethylene tray thatprovides waterproofing and protectsagainst sharp objects. The overalldimension of the Contoured KneelerBoard is 24 inches by 14 inches. It ischemical resistant and washable. Formore information, visit www.bontool.comor call (724) 443-7080.

Modern colors updateScofield lineScofield has added new colors to itspremier line of Chromix Admixturesfor Color-Conditioned Concrete. The“modern” palette offers expandedchoices for integrally coloringconcrete. Morethan 400custom colorsalso areavailable byspecial order.For a copy ofColor Chart A-312.11 forCHROMIXAdmixtures for Color-ConditionedConcrete, email [email protected] orcall (800) 800-9900.

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The Final Pour

Davis Colors pigmentsmatch the colors of theearth, helping this

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part 2: countertops - concrete decor · back then, it was almost a daily ritual to ﬁnd that ......

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