vol. 3 iss. 5 october/november, 2003 - decorative concrete · next issue:your roadmap to world of...

Next Issue:Your Roadmap to World of Concrete

VOL. 3 NO. 5 • OCTOBER/NOVEMBER 2003 • $6.95

Countertops

Snow Melt Systems

Bonding Agents

Decorative Impressionsfor Concrete

VOL. 3 NO. 5 • OCTOBER/NOVEMBER 2003 • $6.95

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October/November 2003 • Vol. 3 No. 5Issue No. 13 • $6.95

Publisher: Bent O. Mikkelsen

Co-publisher: Ernst H. Mikkelsen

Editor: Rosemary Camozzi

Assistant Editor: Harlan Baldridge

Circulation: Sheri Mikkelsen

Design and Production: Stephen Stanley

Web Design: Mark Dixon

Advertising Sales: Kathleen Goodman(314) 367-1121

Writers:Susan Brimo-Cox

Gail ElberJennifer G. Prokopy

John StriederDavid Thompson

John VastyanDenise Wendt

Contributing Writers:Dave White

Editorial:Professional Trade Publications, Inc.

3410 West 11th AvenueEugene, OR 97405Tel: 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 $19.95; 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

© 2003 Professional Trade Publications, Inc.

www.concretedecor.net

ONTHE COVER: This “Nemo” pre-cast concrete countertop model of Cheng DesignProduct’s Geocrete line is a sculptural food prep island with attached birch diningtable. The island’s circular,tapered walls are also concrete,which creates acontinuous,monolithic feel. A perforated stainless steel door allows access to thewaste container,plumbing and garbage disposal. Photograph by Matthew Millman.

Take a refreshing perspective on work

Abusy season with long hours, lack of propernourishment and rest, and not enough time forfriends and family can lead to difficult and

oftentimes discouraging circumstances. Though ourdevotion to hard work may bring financial rewards, ourhealth often suffers as a result. And when we starveourselves of proper nutrition and rest, our attitude towardour relationships with others is affected. I’ve seen ithappen more than once in my life.

Work and the financial benefits we derive from it areimportant to all of us. That goes without saying. However,I’ve learned to identify various indicators that tell me thatwork is getting the best of me. One indicator is this: I can go for weeks or months where myrelationship with my wife and children is just great. Then suddenly, without notice,everything changes. It’s not suddenly bad — it’s just not as good as it was. Slowly, things getworse. I get irritable, and so does everyone else in the house. When this pattern starts, thingsat work become less cheerful and less productive as well.

When I don’t take care of myself, other symptoms become apparent too. I’m not aswilling to listen to other people’s ideas. I may even think that others don’t understand howhard I work, or worse yet, that they don’t work as hard as me. Though we may be right aboutsome of these thoughts, they never lend themselves to stronger working relationships. I won’t necessarily hear it at work, but at home, my wife will suddenly say, “You’re being ajerk.” That’s when I know things are out of whack.

I used to think that being a real man was showing everyone how hard I can work or howmuch faster or better I can perform various tasks. Today, I realize that the hardest thing a guycan do is be humble enough to recognize his shortcomings and then do something about it.Ugh! That’s hard. Why? Because it means more work on our part. It means working hard atsomething, like relationships, when we may not have that much experience. It can evenmean taking some attention away from important projects currently underway.

However young you are, believe this, success is measured by the number of friends youhave. Nothing more. And if you can agree with me on this, you can also agree that the besthelp in life comes from those who believe in your good character because you demonstrate astrong belief in them.

When I had only myself and a few others to help with the magazine, it seemed like aslow and tiresome road to failure. But when I did something about my precarious andunhealthy situation, I found ways to take control by focusing less energy on the work athand and more on the things that could create a healthier and happier me. A changedperspective helped me regain a healthy attitude. And the essential help I needed camerushing in.

When we ignore our mental and physical wellness, we have a tendency to also stopthinking in a healthy manner about work. We lose productivity and our ability to thinkcreatively. In this industry, where quality workmanship is the cornerstone to our long-termsuccess and where innovation is what others have come to expect, a healthy, happy andsuccessful life with our family, friends and coworkers is essential.

Sincerely,

Bent MikkelsenPublisher

http://www.ConcreteDecor.net

mailto:[email protected]


http://www.concretedecor.net

FEATURES14 Bonding Agents

A good agent will keep you out of trouble.by Jennifer G. Prokopy

20 Countertops!Elegant, durable, colorful: Concrete earns a newplace in the home.by Susan Brimo-Cox

28 Snow Melt SystemsNo need for snow shovels here.by John Vastyan

36 Embossed and Embedded ImagesContractors get creative with “found” objects.by Gail Elber

42 Shot BlastersEssential tools for surface prep.by John Strieder

DEPARTMENTS10 CONTRACTOR PROFILE: Arcon

This Las Vegas company takes decorative concrete toa new level.

50 MANUFACTURER PROFILE: Stegmeier Corp.The pioneer in forms for cantilevered edges remainsan industry innovator.by David Thompson

52 Classifieds46 Concrete Marketplace04 Decorative Concrete Tips34 Industry Focus06 Industry News08 Industry Spotlight — Association News54 Product News48 Product Profiles02 Publisher’s Letter

www.ConcreteDecor.net • Oct/Nov 2003 • 3

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Decorative Concrete Tips is a forum for readers to exchangeinformation 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!

The “TorpedoGroover,” from SlipIndustries, is an

invaluable tool forcontractors that know itsadvantages in placingcontrol joints. But it alsohas some slick advantagesas a decorative hand tool.

As the name implies, theTorpedo Groover is longand straight. Once it isplaced into the concrete, itwill guide you straight frompoint A to point B. Itseparates the aggregate upto 11⁄2" inches deep, so it alsohelps control cracking.Where jointers have difficulty cutting a straight path, theGroover has absolutely no problem giving the jointer astraight path to follow.

Have fun cutting new lines in your flatwork with theTorpedo Groover. Now the time it takes to place joints hasjust become the least of your worries — and designpossibilities can be your greatest passion.

— Slip Industries, Livitz, PA

Cleaning and Resealing Exposed Aggregate

Exposed aggregate, common around many backyardswimming pools, is often a gorgeous accent that addsto poolside appeal. But when these surfaces are heavily

used, they begin to lose their luster. We here at Concrete Decorhave found a couple of great products that clean off hardwater/mineral deposits, algae, rust and other substances thatmake exposed aggregate look less than appealing.

Tek Gel for Profiling, from Surface Gel Tek, is anoutstanding method for cleaning these surfaces. Because TekGel (a muriatic acid in a gel form) lays on the surface of theconcrete without absorbing into the cement, it removes hardmineral deposits from the surface without deteriorating thecement. This helps keep the exposed aggregate in place. TekGel actually needs to sit on the surface for only 5 to 15minutes before it can be pressure-washed away to the sewer.That’s right, Tek Gel is also safe for the environment. After24 to 48 hours of drying time, we apply two coats of clearUltra Surface Sealcoat 1000 by Concrete Solutions. These

products offer a great solutionfor most of your customers’stained or tarnished concretesurfaces.

Note: the second coat alsoincluded a slip-resistantadditive called Shark-grip.This product is a powder thatmixes into the sealer andapplies per manufacturer’sspecifications.

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Sonneborn marks 100yearsChemRex Inc./Degussa iscelebrating the 100-yearanniversary of its Sonnebornproduct line. The company issponsoring a Hummer H2sweepstakes drawing and a year-long recognition and rewardsprogram to say thank you to itscustomers. The line began in 1903when the Sonneborn brothersbegan importing petroleum jelly tothe United States from their nativeGermany. Over the next 100 years,the family name evolved into oneof the best known brands in theconstruction industry as a providerof specialty chemical products.Today, Sonneborn is renowned forits high-quality and dependablejoint sealants, waterproofingmembranes, elastomeric wallcoatings and concrete repairproducts for both new constructionand renovation. For moreinformation on the rewardsprogram and the Hummersweepstakes, visitwww.chemrex.com or call (800)433-9517.

ISPC acquires SurfacePreparation GroupInternational Surface PreparationCorp. (ISPC), a newly formedcompany, has completed itsacquisition of United States FilterCorp.’s Surface Preparation Group.The Surface Preparation Group is aleading provider of surfacepreparation equipment, parts andconsumables.

ISPC has manufacturing anddistribution facilities in 15countries, primarily in Europe andNorth America. The company,which employs 1,900 peopleworldwide, is privately owned byan investment group led by Bard &Co. Inc. of Evergreen, Colo.

The Surface Preparation Grouphas roots reaching back some 100

years with leading brand names inthe global surface preparationindustry, including Wheelabrator,Blastrac, Schmidt, Sawtec, andothers.

Robert E. Joyce, a formerexecutive vice president of USFilter who is currently serving as theSurface Preparation Group’spresident and chief operatingofficer, will be joining ISPC as itsnew president and COO. Alsojoining the Denver-based ISPCteam, as CFO, is Mark Iwan, formeraudit practice head of ArthurAndersen’s Denver offices, andMarsha Williams, formerly ofGraphic Packaging Corp. Williamswill be HR senior manager.

For more information, callRichard Bard at (303) 674-3910.

Bomanite hires new COONick Walpert has assumed the roleof chief operating officer atBomanite Corporation, a companyspecializing in architecturalconcrete flooring and paving.

Walpert is responsible for allaspects of day-to-day operations andreports directly to CEO/PresidentRuss Ingersoll. He brings more than12 years executive businessexperience and capacity inleadership, team building, businessmanagement and businessdevelopment, including his mostrecent eight-year tenure as presidentof Injection Molding America, a$150 million injection moldingcompany headquartered in SanFrancisco. Prior to that he was seniorvice president at Cal-Care MedicalGroup, where his operational andstrategic direction for the companygenerated $300 million inannualized revenues. Walpertattended Northwestern University,where he earned an MBA.

New face at Sto Corp.Sto Corp., a leader in cladding,coating and restoration systems, is

proud to announce the addition ofJames Lucas, of JKL Sales andAssociates, as the latest member ofthe Sto professional selling team.Lucas will represent Sto Corp.products in the Carolinas and beresponsible for selling concretefaçade, exterior repair, and coatingsproducts. He was most recently aterritory manager for Master Buildersin the southeast. Lucas has been theCarolina’s Chapter President of theICRI and is an active member of theACI and the ConstructionSpecifications Institute.

Grace adds researchmanagerDr. Arnon Bentur has joined GraceConstruction Products as researchmanager for its global SpecialtyConstruction Chemicals business.In this newly created position, Dr.Bentur becomes responsible for allmaterials research projects and theconcrete fabrication laboratory.

An internationally recognizedexpert on the chemical andmechanical properties of concrete,Dr. Bentur joins Grace fromTechnion, the Israel Institute ofTechnology, where he is Professor ofCivil Engineering and holder of theEdwards Chair in Engineering. Hisprimary research areas at Technionincluded composite constructionmaterials, interfaces in cementitiouscomposites, high strength concrete,supplementary building material,and durability of building materialsand structures.

Dr. Bentur also served asChairman of the board of directorsof Dimotech, Technion’stechnology transfer company. He isthe chairman of the technicalactivities committee of RILEM(Réunion Internationale desLaboratoires et Experts desMatériaux, systèmes deconstruction et ouvrages —International Union of Laboratoriesand Experts in Construction


http://www.chemrex.com

Materials, Systemsand Structures),whose mission is tostimulate progressin the research,design,manufacture,testing and use ofbuilding materialsby bringingtogether specialistsfrom research andindustry in morethan 70 countries.

Dr. Bentur has published more than100 scientific papers and co-authoredseveral important books on concretetechnology, including “FibreReinforced Cementitious Composites,”“The Science and Technology of CivilEngineering Materials,” and “SteelCorrosion in Concrete.”

Headquartered in Cambridge, Mass.,Grace Construction Products is aleading manufacturer of concreteadmixtures and fiber reinforcement. Thecompany also manufactures products forarchitectural concrete, cementprocessing additives, fire protection,firestops, and waterproofing and masonryproducts. For more information, visitwww.graceconstruction.com.

Lafarge renews focus oncustomersLafarge North America’s cementdivision has added a new marketingexecutive and promoted another aspart of an initiative to refocus itsbusiness on customers.

Manuel L. Miranda has joined thedivision as vice president of strategicmarketing. He is charged withpromoting management systems thatwill lead the company from atraditional production-orientedbusiness model to a flexible andcustomer-responsive operating modelfulfilling customer requirements.Formerly the general manager for ShellAviation in North and West Africa, hewas responsible for integrating businessfrom 15 countries into a single regional


business unit with sales in excess of$200 million.

Lafarge Cement’s former vicepresident of strategic marketing, AlZolla, has been named vice presidentof sales and marketing for the southeastregion, based in Alpharetta, Ga. Hejoined Lafarge in 2001 during the

integration of his former company, BlueCircle Cement.

Lafarge North America is the largestproducer of cement and concrete in theU.S. and Canada, and a top supplier ofconstruction aggregate. For moreinformation, visitwww.lafargenorthamerica.com.


http://www.graceconstruction.com


http://www.lafargenorthamerica.com


ASCC NewsPosition statements targetkey issuesThe American Society of ConcreteContractors (ASCC) has publishedthe second three in a series of 12position statements on key issues ofinterest to concrete contractors. Thepapers are written by Bruce Suprenant,vice president, engineering andtechnical services, Baker ConcreteConstruction, and reviewed by theASCC technical committee.

“Trowel Marks on Concrete Floors”(#4) defines and illustrates thedifference between trowel marks and atrowel pattern. “Specifications forCrack Repair” (#5) discusses thewidely varying specifications for crackrepair and the difficulty of contractorcompliance. “Division 3 versusDivision 9 Floor Flatness Tolerances”(#6) deals with the differences inspecifications for floor flatness betweenDivisions 3 and 9.

“The position papers deal withissues that constantly cause concern forconcrete contractors,” says D. ThomasRuttura, president of the ASCC. “Thebetter we can explain to designers andspecifiers what can and cannot beexpected from a concrete structure, themore likely we are to have a successfulproject.”

Copies of the papers may be orderedby calling (866) 788-2722 or by e-mailat [email protected].

Newsletter offers solutionsfor contractorsAnother ASCC publication,“Troubleshooting Newsletter #52,”provides solutions to problems

outing and special event hosted by theICRI Florida West Coast Chapter.

The ICRI 2004 Spring Conventionwill take place April 1-2, 2004 at theHotel Inter-Continental, Chicago, Ill.The convention theme is FacadeRepair and will feature a special eventhosted by the ICRI Chicago Tri-StatesChapter.

For more information on ICRIevents, visit www.icri.org or contactChris Jorgensen, marketing/chapterrelations coordinator, at 847-827-0830.

NRMCA NewsMore instructors to beapprovedResponding to industry feedback, theNational Ready Mixed ConcreteAssociation has expanded traininginstructor options for its CertifiedConcrete Sales Professional program.Sponsoring bodies that are holding aCCSP class will now receive streamlinedapproval from NRMCA for use of theirown qualified program instructor.

This policy change recognizes readymixed concrete producers’ expertise inthe program’s industry-specific materialas well as their interest in linkingNRMCA’s national performancestandards to specific proprietary salesapproaches and initiatives.

Certification standards remain thesame, and all new instructors mustcontact NRMCA’s EducationDepartment to review certificationguidelines before they teach their nextclass. Companies must still purchaseCCSP class materials and textbooks foreach candidate prior to the start of aclass. For more information, call theNRMCA at (301) 587-1400.

Industry SpotlightAssociation News

encountered by ASCC contractormembers on actual job sites.Contractors call the Concrete Hotline,a service exclusively for ASCCmembers, to obtain answers to theirquestions. Selected questions arepublished in the newsletter. Includedin this issue are questions about whatconstitutes a broom finish, cold-weather concrete protection andcuring lightweight concrete onelevated slabs.

The Concrete Hotline provides atoll-free number where ASCCmembers can obtain prompt answers toconcrete construction questions. Setsof troubleshooting newsletters areavailable to members and nonmembersand can be ordered with a credit card.For more information on the ASCC,visit www.ascconline.org or call (866)788-2722.

ICRI NewsFall Convention held inTampaThe International Concrete RepairInstitute (ICRI) held its 2003 FallConvention at the Marriott TampaWaterside Hotel, Tampa, Fla., Oct. 23-24. The convention theme was High-Rise Repair and consisted of a full slateof technical presentations covering allaspects of repair and restoration ofcommercial and residential concretehigh-rise structures.

In addition to the technical presen-tations, the convention hostedtechnical and administrativecommittee meetings, exhibits, liveproduct demonstrations, networkingluncheons, the ICRI 11th AnnualProject Awards Banquet and a golf



http://www.icri.org

http://www.ascconline.org


PCA NewsCD offers life-cycleassessments,energyanalysesThe latest CD-Rom from the PortlandCement Association, “Concrete:Sustainability and the Life Cycle,” setsthe record straight on the environ-mental characteristics of concrete andconcrete materials and providescontextual results of concrete’s impacton the environment.

First unveiled during the nationwideEnvironmental Council of ConcreteOrganizations (ECCO) SustainabilityRoad Show this summer, thisconvenient resource represents nearly adecade of research and analysis, theconcept of sustainability and themethods of life cycle assessment. TheCD contains life cycle inventories, lifecycle assessments, energy analyses, andother related analyses and comparisons.All data is searchable through the CD’sTable of Contents, Abstract, and Index.

Order online at www.cement.org/lifecycle or by phone at 1-800-868-6733. Price is $75.

CSDA NewsAnnual convention to beheld in FebruaryThe Concrete Sawing and DrillingAssociation will kick off its 32ndAnnual Convention as the World ofConcrete comes to a close. The CSDAConvention will be held Feb. 20-23 atthe Portofino Bay Hotel in Orlando.

Attendees will benefit from anextensive convention program thatfeatures meetings, workshops,roundtables and social events. BillPalmer, editor in chief of ConcreteConstruction magazine, will open thesession with an overview entitled“Concrete Industry Outlook: 2004.”Many other presentations tailored forconcrete cutting contractors will alsobe offered. For more information, call(727) 577-5004 or visit www.csda.org.




http://www.cement.org

http://www.csda.org

Arcon,Las Vegas,NevadaThese decorative concreteexperts will leave you floored.

ContractorProfile

ContractorProfile

Arcon is an innovative industry leader of new technology in cementitious, decorative, architectural flooring. Using

structural concrete and overlayment, thecompany has provided an alternate to tile, stone,asphalt, Kool Deck, terrazzo, marble and otherhard-surface flooring materials on many differentprojects. The company’s impressive portfolioincludes projects at the Bellagio, the MGMGrand, Caesars Palace and New York, New Yorkin Las Vegas, as well as projects in Seattle,Detroit, San Francisco and Tokyo.

Concrete Decor’s Denise Wendt talked withprincipal Mark Balogh about the company.



How did you get into concrete work?My father was a concrete contractor in Reno. Istarted working for him as a young man, then wentto the University of Nevada, Reno, where I got mydegree in business finance. I realized I had a knackfor business combined with a vision of usingconcrete as an architectural medium.

When and how did the company getstarted?We started off small in the Reno/Sacramento area,doing flower shops and wineries. Mostly integrallycolored and stamped concrete. Theirry Dougall ofDougall Designs saw some work we did at a winery.He thought that architectural concrete would be anexciting new medium for shopping mall flooring.Together, we developed the flooring for the ForumShops mall at Caesars Palace in Las Vegas. It wasthe first of its kind. Up to that point, concrete wasmostly used for bridges, curbs and driveways. Nowarchitectural concrete was now “out of the closet”and into shopping malls. The company moved to

Las Vegas at the onset of Caesars Palace and Arconof Nevada was born.

What types of overlayments andcoloring methods do you use?We provide textured concrete, stained, andintegrally colored concrete along with a variety oftoppings. We also provide terrazzo flooring both inepoxy-based and cementitious-based materials.Terrazzo, in a cementitious-based material, can beused for an exterior application without fading andwill pass co-efficient friction ratings.

We are currently working on the exterior plazaarea for the Fashion Show Mall expansion withWhiting-Turner contractors and the Maryland-based Rouse Development Co. Rather thanputting down the same types of plaza flooring thateveryone else has, we wanted to do something thatwould complement the innovative architecture ofthe mall itself. We poured white concrete,broadcast different colors and gradations ofaggregates, ground the surface smooth, then added



decorative graphics with sawcuts. The outcome isquite beautiful and unique and commensuratewith the Fashion Mall concept.

Who comes up with your designs?Our in-house team of designers works closely witharchitects and interior designers in the trade. Ourgoal is to obtain the designer’s original designintent using the most viable methodologies,combined with the most cost-effective options forthe project and the owner.

How much input do your clientsgenerally have in the design process?We are a relationship-oriented company. We arequite successful at building solid relationships

with architects, designers, contractors, developersand owners. Our relationships are based onmutual respect, honesty and trustworthiness. Ourclients know we do our very best to provide themwith the best product, in the most timely fashion,for a fair price, that can surpass the test of time inboth function and design.

How many employees do you have?What makes your team successful?There are about 20 people in the office, and ourfield crew can grow up to 100+. We enjoy afamily-like working environment, and I believeeveryone here at Arcon takes personal pride inwhat we do. We all work together for a commongoal.





What challenges do you come upagainst? What have been some ofyour most challenging projects?Most of our projects are destination resorts andcasinos. We usually work on a fast-trackedaccelerated schedule. Also, keep in mind: we workon the floor. When building a casino every tradehas to finish at the same time, and everyone has towalk on the floor. A casino has to be open on time,look fantastic and be ready for the public to enjoy.We are usually one of the last trades to start andhave one of the most important impacts visuallyfor the general public.

What do you enjoy most about yourjob and concrete work in general?I enjoy people. I love the relationships that havedeveloped over the years at Arcon. I like makingthings happen, the art of the deal. Takingsomeone’s concept, manipulating methodologiesand making it work for the client within theconfines of cementitious materials, is a great thrillfor me. We as a team develop beautiful, signature,unique environments that the Arcon family canall be proud of.

What changes do you expect in yourbusiness over the next 10 years?Nothing in business, or in life, for that matter, isever static. Evolution is imminent; change isinevitable. What’s the next best thing to captivatethe imagination of the public? It’s a question I askmyself constantly and a question I know my staffasks themselves. We try to develop the futuretogether.

For more information about Arcon, call (702) 798-4777 or visit www.arcon-intl.com.


http://www.arcon-intl.com


Forging a bond:An overview of bonding agents

in decorative concreteby Jennifer G.Prokopy

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Bonding agents are a widelydebated family of products.Some concrete contractors

will tell you they have a favoritebonding agent, one that they usealmost exclusively. Others say theyevaluate every job and develop aunique solution, drawing from a widerange of products. And there are somecontractors who swear by the oldestbonding agent of them all, simplyusing a mixture of portland cementand water. In fact, there are dozens ofproducts and methods that may be

used to create a bond between oldconcrete and new.

If there’s one thing that nearly allcontractors agree on, it’s this: nomatter what bonding agent is used,proper preparation of the substrate isessential for a successful, lastingbond. “Regardless of themanufacturer, polymer-modifiedtoppings are only as good as thesubstrate on which they areinstalled,” says Scott Truax, presidentof the Concrete Division of Vail,Colo.-based Gallegos Corp.

Bonding agents fall into two basiccategories, cement-based bondingagents (which include simple solutionslike a slush coat or a scrub coat as wellas a wide variety of latex-modifiedbonding agents), and epoxy bondingagents.

And new products are beingintroduced all the time. “New bondingagents today allow you to apply it andlet it get to a hard state, where you canwalk on it while it’s tacky,” says BobWare, owner of the DecorativeConcrete Store in Cincinnati. This


contractors should always follow themanufacturer’s instructions for theproduct they choose to use. This groupof bonding agents can add significantstrength to bonds between old and newconcrete. In many cases latex-modifiedbonding agents are mixed with cementto create a slurry for application, butsome contractors choose to apply thelatex emulsions directly.

Acrylic resinsAcrylic resins are non-re-emulsifiablebonding agents that act like a glue.These agents can be applied with abroom, brush, spray, or roller, and theoverlay is applied while the agent is stillwet. “Typically in decorative concrete,they won’t be used as an additive,” saysBruce Kreielsheimer, director ofoperations for Flemington, N.J.-basedmanufacturer Anti-HydroInternational Inc. Even so, these agentsare compatible with cementitiousmaterials. “If you add it, it will add alittle shine to the surface — some wantit, some don’t.” Acrylic resins generallyare used for indoor or outdoor settings,


allows the contractor to do larger areasat a time, he says, saving time and costson big jobs.

Other manufacturers are adding tintto bonding agents so contractors canensure even and complete coverage.The bottom line: contractors have tofind the methods that work for theirunique jobs to ensure a complete,lasting bond.

The classics:cement-basedbonding agentsSome contractors swear by the mosttraditional method of bonding newconcrete overlays to old concretesurfaces, using the materials at hand.When applied correctly, this approachcan prove adequate for manysituations, and benefits include ease ofapplication (no mixing of additionalmaterials is required), speed, and lowcost. The substrate should be preparedso that it is saturated surface dry(SSD).

One approach is to use a scrub coat,where the repair mortar or concreteoverlay material is literally scrubbedinto the prepared substrate. Expertscaution against adding any water to thescrub coat material, because excesswater will weaken the bond. To createthe most effective bond, a scrub coatmust contain enough fines and cementpaste to penetrate the pores of thesubstrate.

Another method is to use a slushcoat (or slurry coat), which iscomprised of portland cement andwater. The smooth, flowing materialensures penetration of pores in thesubstrate, creating a strong bond. Insome cases, contractors incorporatesand into the mix. A drawback to theslush coat method is that the materialdries very rapidly, so overlay materialmust be applied very quickly afterapplication of the slush coat.

In the mix: latex-modifiedbonding agentsLatex-modified bonding agents comein a wide variety of formulations, and

but are not recommended for use inareas that will experience extremechemical exposure.

The introduction of acrylicbonding agents brought increasedflexibility to the concrete overlaymarket, says Ware. “Acrylic resinswork as binding agents, and increasethe strength of the overlay and thebondability of the old to the new,” hesays. (Ware also runs RKC Increte, adecorative concrete installationcompany.) “We use it primarily for 1⁄4-inch overlays, and for self-levelingoverlays and riser faces.” Becauseacrylic resins speed up the set time ofconcrete, Ware adds a retarding agent,enabling him to cover more areabefore the material sets.

Styrene butadiene (SBR) latexLike acrylic resins, styrene butadiene(SBR) latex bonding agents are non-re-emulsifiable and are compatiblewith cementitious materials, and aresometimes used as an admixture whencreating overlays. The materials areapplied using a spray, brush, or roller.

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Applying a water-based acrylic bonding agent/primer.


A liquid polymer bondcoat is applied to theprepared substrate priorto installation of thepolymer-modified topping.Wire lathing has beeninstalled on the stair risersto increase adhesion.


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The completed stair. The antiquing of the stair wasachieved by pigmenting the solvent-based acrylicsealer with powdered release agent.

While they are used regularly for bothindoor and outdoor applications, theyare not recommended for areas thatwill receive significant water orchemical exposure.

Polyvinyl acetate (PVA)Two kinds of polyvinyl acetate (PVA)bonding agents are used in decorativeconcrete applications: re-emulsifiableand non-re-emulsifiable.

Re-emulsifiable PVAs produce a filmover the substrate that can be allowedto dry, which later becomes soft againwith the application of the overlaymaterial, offering the benefit ofsignificant advance application time.But the material is not recommendedfor outdoor use, where humidity or raincan trigger premature re-emulsifi-cation. Application can be done with aspray, brush or roller.

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Tim Blankenship, division managerof Atlanta-based Precision ConcreteConstruction, stays away from re-emulsifiable PVAs. “There is anopportunity to contaminate the agent ifyou let it set before you apply (theoverlay),” Blankenship says, notingthat the bond may be compromised as aresult. Others see the agent’s ability tore-emulsify as a benefit. “Its advantageis, you can let it totally dry,” saysKreielsheimer. On big jobs, this can bea boon to contractors, who “don’t haveto work a few feet ahead of themselves.”

Non-re-emulsifiable PVAs offer goodwater resistance and wear well. They areapplied with a spray, brush, broom orroller, and may be used in a wider varietyof applications both indoors andoutdoors.

Lay it on:epoxy bondingagentsEpoxy bonding agents contain nocement, and generally are moreexpensive than cementitious bondingagents, but offer excellent bondingstrengths. “Government agenciesspecify them constantly,” saysKreielsheimer. With their incrediblystrong bonds, epoxies generally arerecommended for jobs that requiresignificant repair work.

Epoxies must be applied to a drysubstrate. Overlays should be appliedwhile the epoxy bonding agent is stillwet. Bob Pirro, branch manager ofStructural Preservation Systems Inc.’sHawthorne, N.J. office, says a commonmistake contractors make when usingepoxy bonding agents is allowing themto cure too long: “Then it acts as a de-bonding agent,” he says. “It becomeslike glass and the fresh concrete doesn’tbond.”

There are even products thatcombine the best of both worlds. Pirrosays his company regularly uses anepoxy-modified cementitious bondingagent, which also provides an anti-corrosion coating, for doing spall repairand other types of concrete repair work.The product allows his crew to coat

biggest mistake a contractor can makeis inadequate preparation: “There mustbe surface prep before the bondingagent. Not having it thoroughlycleaned, or if the preparation you docauses microfractures in the surface, cancause an overlayment to becomedelaminated.”

Surface preparation starts withcleaning the surface, clearing it of

rebar and concrete substrate at thesame time.

Needs analysis andpreparation for successAny discussion of bonding agentswould be incomplete withoutaddressing the importance of — andmethods for — substrate preparation.According to Blankenship, the single




A self-drying,self-leveling topping is bonded with a re-emulsifiablebonding agent. These bonding agents are sprayed and scrubbed intothe dry,clean,properly abraded surface.They must be completely drybefore installing self-leveling topping.

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contaminants. A range of techniques isavailable for profiling the surface forbonding agent application, andKreielsheimer says contractors shouldperform a needs analysis before makinga decision on which material to use,asking questions like: “What is thesubstrate? What is the cementitiousmaterial you’re bonding to it? Howmuch abuse will the finished surfacereceive?”

The surface can then be preparedusing one of a variety of methods,including acid etching, sand blasting,shot blasting, scarifying, or bushhammering. In most cases, the rougherthe prepared substrate, the better thebond. While contractors disagree onwhich method works best, all agreethat preparation is critical to ensureadequate bond.



Stirring up new recipes for

ConcreteCountertopsby Susan Brimo-Cox

Concrete countertops are morethan a trend. As more andmore homeowners and

designers specify concrete countertopsin new homes and in remodelingprojects, concrete is making apermanent place for itself as a materialof choice for countertops across thecountry.

Of course, the cost of countertopmaterials varies around the nation, butif you compare concrete to otherpopular products what you wouldprobably find is this: A typical tilecountertop is less expensive than aconcrete one. Solid surface materialsrun about the same or a little less.Granite and marble often cost more.

The advantages of concrete as acountertop material range from itsphysical characteristics to aesthetics —from its durability to its flexibility. AsMichael Karmody, a founding partnerof Stone Soup Concrete inNorthampton, Mass., points out, “Withconcrete, you can have any shape youwant. Concrete is a structural material;you can vary textures. We can grind itto expose the aggregate or leave it as it

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comes out of the mold. … It’s easy toinlay [and] emboss textures. It’s a reallygood sculptural material.”

Creative potential aside, there aresome who may wonder about theweight of concrete countertops.However, weight really isn’t an issueany more than natural stone. Karmodyexplains that a granite countertopweighs about 22 pounds a square foot.Concrete 1.5 inches thick weighsabout 18.5 pounds a square foot; at twoinches thick it weighs about 25 poundsa square foot.

Concrete has some disadvantages,such as its vulnerability to staining andit not being as rock-hard as granite. AsFu-Tung Cheng, principal and chiefexecutive officer of Cheng Design inBerkeley, Calif., philosophicallyobserves, “I frequently tell people thatyou have to be objective aboutconcrete. You have to play to thestrengths.” Fortunately, the contractorswho have enjoyed the challenges ofcreating concrete countertops for manyyears have worked out many of the“bugs,” and the results are more reliableand consistent.


Concrete countertops tips and tricks:● Contractors report that design mixes are frequently adapted to individual jobs.

Pouring a whole job on the same day helps ensure consistent curing.● The “how-to” part is an important aspect of using a prepared concrete mix.

Find out what you’ll be getting and make sure you’ll have the information youneed to go with it.

● Melamine makes an excellent mold for pre-casting. Rubber forms work wellfor molding special details.

● Many contractors vibrate pre-cast molds after pouring toget the air bubbles out. The vibration also helps aggregateto sink to the bottom, which becomes the top when thecountertop is de-molded.

● Contractors who pre-cast generally de-mold theircountertops within three to five days. They also like to wait 28 days beforedelivery and installation, though some have worked shorter turn-around timeson occasion with no ill results.

● The finish is the wear surface protecting the concrete or engineered cementproduct from abrasion and staining. A variety of sealers can be used. If you askaround, you’ll find different contractors prefer different products for differentreasons. Penetrating sealers give the surface a more natural look. They alsoallow the surface to develop a patina. Depending on the use and abuse thesurface gets, a wax maintenance schedule may be recommended. Topicalsealers, such as urethane and epoxy, encapsulate the surface and make it prettyimpenetrable, but they have a plastic look and are difficult to repair.

● Although concrete is durable and can take heat, advise your clients to usetrivets and cutting boards, and to wipe up spills promptly to avoid staining.Clients should also avoid using citrus-based cleaning products and acidicliquids, such as vinegar and lemon juice, on concrete countertops protected bypenetrating sealers.

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Concrete countertops are not foreveryone, though. “Concrete has anearthy aesthetic — mottled color, somecrazing. It’s OK for it to have somepatina,” Cheng says. If people want“slick,” concrete is probably not thematerial for them.

“There are criteria people use inselecting countertop materials —granite is a typical standard,” Chengexplains. It boils down to the issue ofwhat constitutes what’s acceptable, headds. “Contractors who experiment orpush the envelope will help set thestandard of what’s acceptable.”

How-to depends on whomEach contractor who has experimentedand refined his or her concrete countertoptechnique has found individual solutionsto this creative process.

Karmody says his “mix design is nottoo different than what they used in theHoover Dam,” but he does use admixes,fiber and fan-shape reinforcement, andother innovative techniques to createunique products for each of his clients.“Everybody wants something different,so all colors are custom and are includedin our standard product.”

His custom finishes include marblingcolors, adding dye late in the mix so thecolors appear like flames in the finish,acid etching, and embedding objects,such as sea shells, stones, brass and voidsfor drainboards.

Steve Eyler, owner/operator of Eyconin Myersville, Md., created his mix designbased on a Glass Fiber ReinforcedConcrete design — tweaking it to workwith and enhance his product. “It gives itmore structural and flexural strength. [I’m]not as concerned with compressionstrength, but more concerned withflexural strength.”


control and more artistic options. Andyou can get a better surface. But thereare times when pouring on site is theonly option. For example, Cheng pourson site when he is creating a wall thatbecomes a cantilevered countertop inone monolith pour.

Pre-casting means seams.Contractors use a variety of materials tofill them: from silicon caulk, to grout, tomarine epoxy. Something mostcontractors agree on, however, is that


Another technique Eyler has beenperfecting is using sandwich panels toreduce the weight when a thick slab isrequired. He has developed specificprocedures that allow him to sandwichin a lighter material, such as Styrofoam,inside the center of a thick slab withoutcompromising the countertop’s structuralintegrity or finish characteristics.

Many contractors prefer to pre-castconcrete countertops for many reasons:It is less risky. You have more creative

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seams don’t have to be a negative. Ifthey can’t be placed inconspicuously,they work well if they play into theoverall design of the countertop.

The overlay optionSome contractors have been busyrefining the use of engineered cementoverlay products to create countertops.

“I’ve found a lot more advantagesthan disadvantages,” says Matt Jecker,owner of Stone Craft L.L.C. inSpringfield, Mo. “The biggestadvantage is the fact that we can pourour overlay material less than a half-inch thickness, allowing it to dry faster— speeding up production.” From startto finish, he can complete a job in fivedays. And, he adds, the material isstronger than standard concrete.

Rune Borgir, founder of CementElegance Inc. in Bend, Ore., also usesan overlay product for his countertops.“One of the keys to our success is wehave fast-drying, fast-curing time. Wecan pour in place — seamless, one pour— regardless of the configuration.”

The material is often poured over aplywood or MDF substrate.

Jecker says by using overlay he canfashion sculpturally-detailed edging.“We manufacture all our own edgingand we’re able to create very finedetailed forms. … We can shape theedge in advance so you can pour curvedcontours, arches, round table tops” andmore.

Engineered cement overlay productslend themselves to numerous coloringoptions. Borgir explains the primarycoloring methodology is integral color,but you can also get creative with dyes.“Color washes — generally subtle tints— bring color and life to the surface.”Then there are faux coloring and fauximprinting techniques which have“become more popular because we canmimic stone patterns.”

Acid stains, chemical stains, inlays,colorations in the sealer, it all adds up tounique, one-of-a-kind countertops. Topengineered cement’s denser, tightermatrix with a finish coat — again, frompolyurethane to high-level epoxy,


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depending on the final effect desired —and you wind up with a nonporoussurface that, Borgir and Jecker report, ismaintenance free.

Breaking into this marketsegmentConcrete contractors can often makethe transition from sidewalks tocountertops fairly easily because theyare familiar with the characteristics ofconcrete. But concrete experience isnot required.

Ric Filiaci and Joy Zimberlin, co-owners of Something Concrete L.L.C.in Schenectady, N.Y., say there was alot to learn about concrete andtechniques when they launched theirbusiness in 2002. Both have degrees indesign, but Filiaci did a lot ofnetworking and learned the basics ofthe craft by reading, and talking to andmentoring with people already in thebusiness.

“It’s amazing how different theproduct is with each craftsman that

applies himself to it,” observesZimberlin. Now, with the basic processand techniques down, they are workingto establish their signature look.

They are entering the market placeby offering their services throughkitchen design houses. Somethingthey have found very useful iscreating 1-foot-square, 11⁄2-inch thicksample boards for each project. Eachsample board has two treatments.“One side has more grinding toexpose the aggregate. The other sidehas just gentle sanding and buffing —more like right out of the mold.”Zimberlin explains. There also aretwo different surface treatments oneach side for client comparison. “Afood-grade penetrating sealer, buffedwith wax, and a food-grade topicalsealer, which has a more plastic look.”The sample board shows clients whatthey can expect and gives them abetter reference to make choicesabout the surface finish and sealerthey desire.




important to know how to addressthose issues.”

Many contractors are savingthemselves a lot of trial and error byusing prepared mixes.

As Marshall Hoskins, sales andtechnical representative for SpecialtyConcrete Products Inc. in WestColumbia, S.C., explains, preparedmixes, such as DURA-TOP CountertopMix, make for an easier installationprocess. The mix incorporates all that is

For more information, visit the followingWeb sites. Some of the firms listed offertraining classes and/or prepared mixproducts.Cement Elegance Inc.

www.cementelegance.comCheng Design

www.chengdesign.comEycon www.eycon.usSomething Concrete L.L.C.

somethingconcrete.comSpecialty Concrete Products Inc.

www.scpusa.comStone Soup Concrete

www.stonesoupconcrete.comStone Craft L.L.C.

www.counterfitsystems.com

needed, so it eliminates the need for manyinstallation steps needed for regularconcrete, such as admixtures and, in mostcases, a steel support system. Pre-coloredmixes, he adds, also help ensure consistentcolor match from batch to batch.

Multiple-size aggregate is used,depending on the thickness of the pour,as well as colored glass and Terrazzoaggregates that can be exposed bygrinding.

“Tops can be both pre-cast or pouredin place. Generally, the job scope,dimensions and the contractor’s abilitydetermine which method is best for ajob,” Hoskins says.

Prepared mixes are an especially goodchoice for contractors who don’tnecessarily want to specialize incountertops, Cheng says. “Buying a mixthat’s ready to go is for the contractorwho wants to add a product line to whatthey already do. … They don’t havesomething that’s foolproof, but you have amix design that’s researched and tested.”

Cheng, whose company offersNeoMix, points out that prepared mixeseliminate the need to warehouse materialand let contractors get right into thecreative process. “We’re trying to make itso easy and so cheap, why should anyonedo anything else?”

The advantages of classesand premixed products“Classes are a great segue in gettingintroduced to the potential [of themedium],” Cheng points out. “Gettingyour hands into it gives you a good headstart; more than reading a book.”

Classes also help contractors knowwhat kinds of problems they may runinto.

“It’s important to know potentialhazards,” Jecker cautions. “It’s


http://www.cementelegance.com

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http://www.eycon.us

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It always seems that the rigors of winter movemost forcefully against us when we’re dealingwith that third or fourth snowfall. Backs throb

and tempers strain to accommodate MotherNature’s tantrum.

There is, however, one way to rein in thenuisance of dealing with snow and ice: by meltingit away! Snow shovels, plows, blowers, salts andother chemicals … not required. By introducingyour clients to this technology, you can help themhave a stress-free, accident-free winter.

A snowmelting system works with electric heat,or by circulating warm fluids through tubing insidea surface, so that walkways, driveways, and otherareas remain dry and clear. Since mostsnowmelting systems are “hydronic” (usingcirculated fluids to heat these outdoor masses),that’s what this article will focus on.

These systems are ideal for residential uses andfor commercial applications — especially criticalareas like hospital and senior-housing entry areas,helicopter pads and delivery ramps. Asnowmelting system performs a valuable, perhapslife-saving, function.

It’s also the perfect complement to an artfullystained, stamped or otherwise decorative concretesurface. Why shouldn’t your craftsmanship beadmired year-round?

Here are some of the benefits that you can sharewith potential customers. Icy surfaces are nolonger a threat. Home or facility maintenancecosts are reduced because snowplowing iseliminated or reduced, and ice-melting chemicalsaren’t required. These chemicals kill landscaping,require cleaning when tracked inside, andseriously degrade concrete and asphalt.

And, consider this: The cost of the system is morethan returned with one avoided “I slipped and fellon your sidewalk” lawsuit. Even insurers recognizethe value of these systems, rewarding commercialbuilding owners with reduced insurance rates.

Typically, most of the components of a snowmelting system, especially the heating plant,sensors and controls, are installed by a plumbingand mechanical contractor. But concretecontractors should be involved when it’s time toembed the heating elements in the slab.

Snowmelting classificationsSnowmelting systems are generally grouped intothree classifications based on the amount of snowactually melted at design conditions:● Systems designed not to melt snow while it’s

falling, but afterwards.

SnowRemovalGot YourCustomersDown?Melt Their Troubles Away!by John Vastyan

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● Half the snow is melted during snowfall, therest afterwards.

● All snow and ice is melted while falling.

Snowmelting LoadsIt takes a lot of energy to melt snow: about five tosix times the load required to heat a building ofsimilar size. For example, it may take only 30-40Btu/hr per square foot to heat the inside of astructure with a floor-warming (radiant heat)system. But it can take up to 150 Btu/hr-square footor more to melt snow and ice and ice from asurface. When a snowmelt is first started, muchenergy is lost when it’s moved from the heated pipeto the surrounding ground, which is frequentlyfrozen hard. Because the warmed fluid gives off heatas it travels through the slab, installers prefer to laythe tubes in a spiral or serpentine pattern todistribute the heat evenly.

The Importance of InsulationInsulation substantially reduces operating cost.When added under the slab and at its perimeter,heat loss into the ground is reduced, and the slabheats more quickly. The preferred material isusually 1- or 2-inch thick rigid polystyrene foam.

Insulation also helps channel the heat in thedirection it’s wanted. Contrary to popular belief,energy doesn’t necessarily rise. It travels — in anydirection — from hot to cold, from areas of highconcentration to low concentration. This worksgreat for interior spaces. But outdoors, four“thieves” work in tandem to steal the heat.

Thief #1: Ground. Heat is literally sucked intothe surrounding ground. Heat loss to the ground isabout 10-15 Btu/hr-square foot.

Following are examples of snowmelt applications:HelipadsWith space becoming more and more precious, many hospitals areforced to install helipads on building roofs. These rooftop helipads canbecome extremely dangerous when coated with ice and snow.

SidewalksSidewalk snowmelts can increase business and decrease liability.Customers are more likely to shop stores with sidewalks that are freefrom ice, snow and chemicals.

For residential applications, Doug Davis, owner of Davis Plumbing& Heating, Columbia Falls, Mont., regularly uses PEX or EPDMtubing under stamped concrete driveways, entry areas, patios andsidewalks to keep the snow and ice at bay.

“I’ve been doing snowmelt systems for 12 years,” he said. “Buildersin this area recognize that we take our work seriously and that we’rereluctant to use anything but the very best materials available.”

School entrancesYoungsters are protected with a snowmelt on duty. They keepaccidents at a minimum and prevent chemicals from being trackedinside.

StairsIt’s all too common for stairs to become slippery and dangerous duringthe winter season. Why shouldn’t they, too, be safer and easier tomaintain?

Hospital entrances“Because they are usually considered critical systems,” says Whitworth,“these systems are most frequently ‘idled’ during the winter months —operated at a reduced output — to decrease system lag time (the timerequired for the system to reach operating temperature and startmelting snow). When the sensors detect precipitation, the system isthen operated at full output.”

Parking garage rampsSnowmelting systems ensure that cars driving in off the street cansafely negotiate up and down parking garage ramps. System sensors areusually placed away from the ramp so that they can detect snowfall, orprecipitation, and temperature.

Loading docks and rampsHere, moving the goods isthe essence of business.Another great applicationfor snowmelt.



Thief #2: Atmosphere. The atmosphereworks even harder than the ground to swipe theheat you’ll be putting into the slab. That’s whyenergy must be fed into the slab continuously.Loss to the atmosphere can be up to 90 Btu/hr-square foot. That’s a lotta’ heat.

Thief #3: Water. As the snow or ice turns intowater, it runs off into drains, storm sewers andinto grass. This water runoff carries preciousenergy away from our slab, too. Care must betaken to ensure the water runoff from thesnowmelt system has a place to go. If notadequately designed for, water will run off the slaband “pool” in low spots around the system andfreeze. It may be necessary to heat drain pipes andwater runoff areas.

Thief #4: Evaporation. As melting snow and iceturn from liquid to gas, more energy is carried off.This energy must also be replaced by our heatsource.

High-tech tubingTypical snowmelts employ tubing buried in aconcrete slab. The most popular tubing used iseither cross-linked polyethylene (PEX), orsynthetic rubber (EPDM). Both varieties oftubing have a long history of performance andlongevity.

According to Keith Whitworth, a designengineer at Springfield, Mo.-based Watts Radiant,a leading supplier of radiantheat and snowmelttechnology, tubing comes in avariety of sizes, typically 1⁄2" ID(inside diameter) to 3⁄4" ID.The flexible tubing ties intosupply and return piping atdistribution points, or“manifolds,” that come inpairs: a supply manifold wherethe tubing starts and a returnmanifold where the tubingstops. The layout is usuallyeasiest if these manifold pairs are locatedtogether next to the “zone,” or area to besnowmelted.

Tubing is spaced from 6 to 12 incheson center and circulates a solution thathas been heated to 110°F to 140°F. Tubespacing is varied according to the degreeof snowmelting required.

Tubing is usually strapped or tied torebar or rewire. Even if rewire is not

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stapled into rigid insulation, or otherwiseconnected to a compacted base.

At expansion joints, where slab movementcould cause stress, it’s necessary to take specialprecautions. “We recommend slipping the tubingthrough collars cut from plastic pipe or pipeinsulation and placed several inches below theexpansion joint,” explained Whitworth.

“Another key precaution,” he added, “is that thesystem must be pressure-tested before and duringthe concrete pour to ensure that no damage hasbeen done to the heating elements during instal-lation.”

… and,finally,maintenance:A hydronic system requires maintenance. Inaddition to maintaining the boiler and pumps,Whitworth explains that the glycol/waterantifreeze must also be checked periodically toassure its effectiveness.

Principles of OperationOn-off operationSome snowmelts are operated only when there isice or snow. These “on-off” systems are operatedin the presence of precipitation when the

needed for structural reasons, it is needed to keepthe tubing from floating to the surface of theconcrete during the pour. A minimum of 2 to 3inches of covering must be maintained over thetop of the tubing. Tubing can also be clipped torewire, hooked to a base material with turf hooks,


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

ambient temperature is below 35°F. While lesscostly to operate, these systems take longer to startmelting ice and snow because they must firstincrease the temperature of the slab.

Idled operationIn order to help systems respond faster, somesystems are idled, or operated at reduced outputuntil precipitation is sensed with a temperaturebelow 35°-38°F, when the system is operated at fulloutput. These systems permit faster system response,and no snow or ice accumulation is permitted.

Sophisticated controlsAutomatic controls that sense slab temperatures,outdoor temperatures, and precipitation can alsobe used. They’re more costly, but allow greatersystem control.

What’s the system cost?Snowmelts themselves are not that expensive tooperate — especially the “on-off” types — since,typically, they operate only a few times a year.The biggest cost with a snowmelt system is theup-front price.



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Snowmelt systems anddecorative concrete:a greatmatchWhether your client needs to melt snowon a New Jersey walkway or warm theentrance to an emergency room inNome, a properly installed snowmeltsystem will readily answer the call. Andwith some beautiful decorative concreteto finish off the job, you will havebrought both beauty and utility to thesite.

John Vastyan is president of CommonGround, Uncommon Communications,based in Manheim, Pa. He specializes incommunications for the radiant heat,hydronics, plumbing and mechanical and HVACindustries, serving regional, national and interna-tional business-to-business manufacturers and tradeassociations.


“Considering the cost of insulation, tubing,boiler and pump system, and all installations, asnowmelt system will usually cost between $6 to$12 per square foot, with commercial systems atthe higher end,” says Whitworth.

… and the operating cost?On-off system cost:The cheapest system to operate has a simple on-off function. As an example, a Class II system inBuffalo, N.Y., may cost about $0.21 per squarefoot per year. The same system in Chicago, Ill.,may only cost $0.12 per square foot per year.Minneapolis or St. Paul may be in the range of$0.25 per square foot per year.

Idled system cost:Because they operate any time the temperature isbelow 38°F, it will clearly cost more to operatethese systems. Considering that they may operatefor up to 1⁄3 of the year (about 3,000 hours), thetotal system energy would be 300,000 Btu/year.Hospitals may have waste heat from steam orcondensate that may be readily available, greatlyreducing or eliminating energy needs.

Hacker Industries800-642-3455www.hackerindustries.com

Schluter Systems800-472-4588www.schluter.com

Watts Radiant800-276-2419www.wattsradiant.com

Wirsbo800-321-4739www.wirsbo.com


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Alternative Finishes: YourContractor to ContractorTraining

Some people are good at doing, whileothers are better at teaching others

how. When you find you have a naturaltalent in both directions, it generallypays to run with it.

That strategy has definitely workedfor contractor Wes Vollmer, of SanAntonio, Texas. Vollmer, who haseleven years of decorative concreteexperience, has spent the past sevenyears consulting on jobsites around thecountry. He opened his own trainingschool in San Antonio a couple of yearsago with great success.

The overwhelming response to histraining has caused him to take it a step

further. In February, Vollmer will open decorative concretetraining schools on opposite coasts — near Los Angeles andin Atlanta. The schools will operate under the supervision oftop-notch contractors in each area: Dale Drath and MikeAllen of Drath & Allen Concrete in Atlanta; and DougCarlton of Carlton Concrete Co. in Visalia, Calif.

At the ASCC annual meeting, held in Dallas inSeptember, Vollmer gave a presentation on his specialty:acid staining. He kept it basic, concentrating on tools,preparation and the essential steps of the process. The class,filled to overflowing, was a huge success, he says, adding thathe was “bombarded by people who want information.”

Vollmer believes in keeping beginning classes at a basiclevel and encouraging contractors to build their skills overtime. “Instructors always shows their best work [in theclasses],” he says. “It’s great, but it’s confusing. I wanted toshow how you can get to that level.”

Vollmer’s schools will open in February under the name“Alternative Finishes: Your Contractor to ContractorTraining.” The classes will not be manufacturer-backed, sothey won’t push any particular products. All classes will betaught by experienced professional contractors (not salesreps) who have no less than 10 years experience.

“We’re going to offer really good, hands-on training,”Vollmer says. “We’ll simulate a real job, not make little bittysamples. Every day we’ll figure out problems.”

Classes will cover acid staining, overlays, stampedconcrete, walls, countertops and much more. “We’ll offerunique finishes that no one else knows about,” Vollmer says,declining to give away any secrets.

You can find out more about Wes Vollmer’s new trainingcenters by visiting Alternative Finishes’ new Web site atwww.alternativefinishes.com.


Industry Focus


http://www.alternativefinishes.com

Well-stocked trailer educates contractorsand customers

When Jeff Patterson saw the decorative concrete businessheating up a couple of years ago, he saw a lot of

possibilities for his company — and for contractors in his area.But he also saw that many contractors lacked the expertise to

do the job right. And that most homeowners didn’t know whatkinds of choices were available.

“So I came up with this trailer idea,” says Patterson, vicepresident for business development for Muller ConstructionSupply, based in San Jose, Calif.

Patterson outfitted a 7' by 12' trailer with samples of thecompany’s decorative concrete products (Muller is a Rafcodistributor and also carries products from manufacturers such asWhite Mountain, Glaze-N-Seal, and Davis Colors) and startedtaking it around to home shows and contractors’ offices. He’s evengone to a few job sites to help contractors educate their customers.This gives homeowners a chance to look at color charts, colorchips, examples of different types of sealers, stamped pieces ofconcrete, and literature about the products.

The trailer cost his company about $10,000, but Pattersonwas able to get half of that back by featuring the logos ofmanufacturers such as Rafco, Kraft Tool and Magnolia Brush onits sides.

At a recent home show, three people who took a tour of thetrailer asked a local contractor for an estimate on decorativeconcrete work. The contractor got seven more calls by thefollowing Wednesday. “It’s a good selling tool for the contractor,and it lets the end-user know what is available to them,”Patterson says.

Over the last five years, Muller Construction Supply has seenphenomenal growth in decorative concrete products. “Our saleshave dramatically increased year after year,” Patterson says. Hegives the trailer a lot of credit. “It’s done a lot to promote decorativeconcrete,” he says. “I literally think it sells jobs.”




Many people’s first experiencewith concrete art is thesurreptitious addition of a

handprint or some initials to aneighborhood project. But the urge toleave such a message to the future is notconfined to adolescents. Whether it’ssentimental knick-knacks or corporatelogos, embedding or imprinting objectsinto concrete gives clients anunmistakably one-of-a-kind addition totheir home or business. Here are sometips on how to add this finishing touchto an interior or exterior project.

A good impression“A lot of contractors are limited by whatthey can buy in the store, but you haveto think out of the box,” says Lee Levigof Concrete Works in Fairfield, Calif. At customers’ request, he has made

Unique ImpressionsEmbedding and imprinting objects in concrete

by Gail Elber


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his work is veins ofpebbles embedded in thesurface.

Some clients willsupply their own objects tobe embedded. Bigelow saysone client brought ahandful of stones and acopper nugget from

England and asked him to make amatching wall fountain and coffee table.


imprints of leaves and branches, but healso uses more exotic things, such asembossed wallpaper. “Just before the finaltrowel, when it’s still pliable, trowel thewallpaper border face down.” He doesn’tuse a release agent; he just leaves thewallpaper there until the concrete hasset, then peels it up.

One of Levig’s signature techniques isimprinting custom stencils, which hecuts out of heavy waxed paper used forpacking produce and discarded behindsupermarkets. For the home of aviolinist, Levig cut out two bars of musicto adorn the entrance to a music room.“It takes a lot of work to do the cutting,”Levig admitted, so he generally uses thistechnique as an accent in a highly visiblearea such as a front porch or entrance.You needn’t cut your own stencils forpopular designs such as flowers andfoliage. Try a craft store, such as Michaels(www.michaels.com), which sells paperand plastic stencils from Plaid(www.plaidonline.com).

Embedding objectsFor a truly one-of-a-kind project,instead of just imprinting objects, youcan embed them in the surface. LeeLevig has spotted computer chips in theexposed aggregate at the DiscoveryChannel Store in Sony’s Metreonentertainment complex in SanFrancisco. He also reports that theAnimal Kingdom attraction at WaltDisney World has a faux dirt road madeof concrete embellished with twigs, tiretracks, and boulders.

In his book, Concrete Countertops:Design, Forms and Finishes for the NewKitchen and Bath (Taunton Press, 2002),Fu-Tung Cheng showcases countertopsinlaid with marble slabs, semipreciousstones, auto parts, fossils, coins, and evenGumby. For molded countertops, Chengattaches the objects to the mold with avery thin layer of silicone caulk, pours theconcrete, then peels off the caulk whenthe mold is removed. The caulk recessesthe object slightly under the surface,which allows him to polish the surfacewithout damaging the inlaid object. Forsmooth objects such as coins, he attaches

a bit of wire mesh to theback with epoxy adhesiveto give the concretesomething to grip.

Phil Bigelow(www.philbigelow.com)has developed a castingprocess that results inwhat he calls EmbeddedStone Concrete (ESC). Although thedetails are a trade secret, a signature of

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http://www.michaels.com

http://www.plaidonline.com

http://www.philbigelow.com



You can embed large objects, too. JeffGirard, founder of Formworks, acompany that makes concretecountertops and licenses its methods toother artisans, has embedded movableauto parts in the counter of a store thatsells racing memorabilia.

What works,what doesn’tGirard, who is a civil engineer, says thatnot everything a client may suggest issuitable for embedding. “Wood is notreally compatible with concrete becauseit swells with moisture (which couldcause cracking), shrinks when it driesout, and can rot. Plastic may or may notbe compatible simply because theconcrete may or may not stick to it.Aluminum is not a good metal toembed because it readily oxidizes in thealkaline environment.”

Surprisingly, glass isn’t a goodcandidate for outdoor applications. “Itmight seem like a good material becauseit’s chemically similar to sand, but glassactually can lead to the eventual self-destruction of the concrete,” Girard says.“Most glass reacts with the cement pasteto form a silica gel that surrounds thepiece of glass. This is the classic alkali-silica reaction that plagues some naturalaggregates. The silica gel forms at a ratedifferent from the curing rate ofconcrete, and it swells with moisture.

“Over time, as the concrete’s moisturelevel changes, the gel swells and shrinks,causing pop-outs and eventually forminga spider web of cracks in the concrete.This is not the case with indoorapplications, because the moisture levelsinvolved are much lower.”

Formworks embeds a lot of ferrousmetal objects in indoor countertops, andtheir exposed surfaces do rust, even ifsealer is applied. However, Girard saysthat the rust adds a nice appearance tothe concrete. One of Formworks’characteristic touches is the addition ofcurled steel shavings to the concrete.They’re called “industrial fossils,” andthey do impart a fossil-like look andrusty accents to the surface.






Commercial stampsYou may want to imprint something notfound in nature. If you need a two-dimensional custom silhouette or logo,Concrafter (www.concrafter.com) canmake a custom rubber stamp from yourdrawing. The company also has standarddesigns and letters. You dampen thestamp, place it on the troweled slab, andstrike it to make the imprint, then move itto another location and repeat if you wantto. To add texture to the surface, TheoHunsaker of Concrafter suggests paintingretardant inside the outline of the stampwith a brush, to expose aggregate insidethe silhouette. The company also hasstandard designs and letters.

If a three-dimensional imprint is whatyou want, L.M. Scofield has a catalog ofstamps for imprinting everything fromfanciful butterflies to animal tracks.They can also cast a stamp from yourthree-dimensional object. Staining theimprinted image adds realism.

A little goes a long wayDon’t overdo impressions, or the surfacewill become very busy. “Less is more,”observed Sherry White, L.M. Scofield’smarketing manager. “If you use it as anaccent, it’s extremely effective. If youcovered an entire area with it, it wouldbe less effective. It’s like — you don’twear three ties.”

Before you take custody of yourcustomer’s irreplaceable fossil or familyheirloom, experiment by embedding orimprinting objects into some samplepanels so you have an idea of how firmthe concrete should be before you startembedding. If polishing with diamondwheels will be part of the process, getfamiliar with what happens when yourun the wheels around or overembedded objects. Photograph thesesamples for your portfolio, and you’llhave yet another technique to add valueto your customers’ projects.

And if you do end up embeddingthose family heirlooms, your work willbe a step toward immortality: You won’tjust be creating beautiful things, you’llalso be perplexing future archaeologists.


http://www.concrafter.com


Shot BlastersAn essential tool for floor prepby John Strieder Ph

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Shot BlastersAn essential tool for floor prepby John Strieder

concrete, most shot blasters are used on large industrial andcommercial jobs, from cleaning parking lots to scouring linestripes off highways. “To come into a residential home anduse a shot blaster is pretty rare,” Ferchaud says.

But small-job contractors use them too. The rough profileguarantees a good bond, and the work can be done in afraction of the time it can take with other equipment.

Shot blasters can be used to blast decorative garage floorsbefore coating. On new construction sites, they can scrapethe dusty top surface off rained-on concrete. They have evenbeen used to stencil patterns, from company logos to leavesand seashells, on concrete.

Shot blasting is essential before applying an overlay, saysDave Pettigrew of Diamond D Concrete. “Some manufac-turers won’t even warranty their product without blasting,”Pettigrew says. “You have to give the existing concrete atooth so you can attach to it.”

Give it a shotTrevor Risher’s Seattle-based outfit, WashingtonShotblasting, shoots five million square feet a year, much of itas a sub for small or mid-size contractors. “I have differentshot blasters for different types of jobs,” he says.

Ashot blaster fire scores of tiny BB’s at the groundover and over again. It duplicates a simplemechanical action — a metal object hitting a

crushable piece of material — and duplicates it very, veryquickly. If you want to tear a layer off a slab of concrete, thesemachines will certainly do the job.

But shot blasters have the same downside as shotguns: Theend result is not exactly tidy.

That’s not a problem if you’re prepping a new warehousefloor for a thick layer of epoxy. But for decorative concretecontractors who shot blast, the questions “why,” “when,” and“how” are much more crucial.

A shot blaster is the tool of choice for concrete contractorswhen prepping a surface, says Greg Ferchaud, national salesmanager for SASE Co. Inc., which distributes Italian-madeTrimmer shot blasters. Shot blasting gives the surface a roughprofile so coatings and sealers will bond snugly with a floor.“You scarify, diamond grind or shot blast — that’s how youprep a floor,” he says. “Shot blasting requires the mostattention of the three. It can be the most productive, but itrequires the most parts to be replaced.”

Shot blasters were developed to scour nonskid coatings offthe steel decks of aircraft carriers. When it comes to



A good machine costs $30,000, hesays, so if a contractor only blasts one joba year, it may be more cost-effective tohire a specialist like himself. But heacknowledges he occasionally loses goodclients when they finally decide to buytheir own machines.

Let’s say you’ve reached that point —you expect to use a shot blaster on atleast four or five jobs a year, so buyingone makes sense. How do you go aboutshopping for one?

Bruce Williams, owner of B WManufacturing Inc., based in GrandRapids, Mich., says shoppers should lookat reliability, production rate, and ease ofmaintenance and servicing. “A lot oftimes what I do is refer people to ownersof the equipment,” he says.

Allen Slater, product specialist with Blastrac, a leadingmanufacturer of shot blasters, says five variables impact eachblasting project: the travel speed of the propulsion device; thequantity and size of the abrasive; the tenacity of the coating tobe removed; the desired end result; and the size of the machine.

However, he says, the most important question is a basicone: How many square feet of production do you need perhour?

Machines with blast widths between 10 inches to 30inches will cost roughly the same, he says, but below 10inches, the price drips drastically.

The first shot blaster you buy should be small, for edges,corners, tight spots and test patches, he says. “You have tohave the small one. Even if you have a 30-inch, how are yougoing to get in and do restroom stalls?”

Another variable is the way the shot is propelled out ofthe machine. Most machines are “center-fed,” meaning theabrasive flows into the center of a centrifugal wheel. Butsome big riding models are “paddle-fed,” in which the shot isfed onto a wheel peripherally. Paddle-fed models work bestwith medium-size to large pieces of shot, but they throw withless velocity than a center-fed wheel, so they distribute amore even shot pattern.

“They deliver a more even profile than center-fed,” saysWilliams, whose company makes a paddle-fed machine.“Center-fed machines leave you with lots of hot spots. A lotof times they hit harder on one side than the other.”

The shot itself is almost always steel and round, but itvaries in size. Pieces typically used in blasting range between17 thousandths of an inch (S-170) and 46 thousands of aninch (S-460) in diameter. The size of the abrasive dictateshow much energy or force it exerts, and bigger shot will domore damage in a smaller period of time.

Today’s diamond grinders provide fierce competition forshot blasters, Ferchaud says. They are so powerful that they

don’t require a shot blast before polishing, and they prep afloor quickly. “Diamond grinders have put a big dent in theshot blaster business,” he says. “It’s just the latest way ofdoing it and it’s better in a lot of applications.”

But shot blasters have advantages over diamond grinders.For one thing, given two machines of the same size, the shotblaster will be faster, Ferchaud says.

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http://www.concrete-texturing.com


While diamond grinding can clean a surface, it doesn’topen pores like a shot blaster, Williams says. “The poresallow the material to soak down into the concrete furtherand give you a better blending surface.”

Risher of Washington Shotblasting says diamondgrinding can replace shot blasting on some jobs, likeprepping for stains. But when prepping for overlays andcoatings, it’s a poor substitute, he says. “Diamond grindingleaves too smooth a surface to have a mechanical bond. Itwill fail faster. Most coating manufacturers will recommendshot blasting. The biggest concern they have is adhesion.”

Problems to watch forThe shot blaster is easy to use compared to other machines indecorative concrete, Williams says. “It’s really self-explanatory.I sell to guys who are just getting into the business all the time.They actually love the machine. Once you’ve done it one ortwo times, you’ll know what you’re doing within reason.”

But problems crop up quickly. For starters, the machineleaves “tiger stripes” or “cornrows” when rows overlap, andthose can be tough to cover up if you only intend to laydown a light coating.

Just turning on the machine without thinking candamage a floor. If you go over your surface too quickly, you

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leave stuff behind. Too slow, and you remove too much.(Start with small shot and run the machine quickly,Risher advises, slowing down or switching to bigger shot asneeded.)

Thicker epoxies are harder to blast through. And shotwill just bounce off elastomeric or rubberized coatings.



Urethane coatings will transmit the energy of the blast tothe concrete underneath, crushing it. Then the top just peelsaway. But the peelings can clog the screen in the hopper ofthe machine.

Adhesive coatings and glues will also cause problemsfor shot blasters. The machines create frictional heat, and

that heat can make an adhesive sticky again,gumming up the shot inside the machine. “Onceshot sticks to anything, shot sticks to shot, andthen you have to dump the whole load,”Ferchaud says. “If they don’t hit something hardenough to rebound, they just die.”

A shot blaster will also be less effective if used ona floor that has been blasted before. You can end upwith a very rough profile. “If a floor was well-prepped prior to coating, the coating is tougher toget off,” Slater says.

For all these reasons, training and support fornovices is critical. “I don’t sell a shot blasterwithout training unless they’re buying their secondmachine,” Ferchaud says. “If there’s any piece ofequipment you need training on, it’s a shot blaster.”

Shot blasters must also master a number ofvariables in terms of electronics, environment and

upkeep. “Shot blasters are very high-maintenance,”Ferchaud says. “A shot blaster is a self-destructing piece ofequipment. All that abrasive stuff is constantly goingthrough the machine.”

Slater agrees. “To get consistent results, you need toconsistently maintain the machine,” he says.


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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.



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.

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Advanced Polymer TechnologyArchitectural Toppings and Resinous Flooring

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Phone: 1-800-777-0454www.coyotescrubber.com


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Acid Stains (CONCRETE STAINS)Our line of unique 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

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Solvents on the way “OUT.”Be on target and in compliance.One of a kind multisurface “water

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Hit the Bullseye



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Stencils from Universal Templates

Universal Templates manufactures plastic adhesive-backed templates/stencils for the decorative

concrete industry. The company has 15 different patterns,which can be purchased in 250 sq. ft. rolls (3 ft. wide x 84ft. long) or in 500 sq. ft. rolls (3 ft. wide x 168 ft. long).The adhesive backing and easy layout saves job time andlabor costs. These templates/stencils are generally for aone time use.

The templates are also available without adhesive(bare), for newly poured concrete. These are available in500 and 1,000 sq. ft. rolls. The bare templates can be usedmore than once if care is taken when removing andcleaning them.

The templates can be applied to exterior or interiorfloors, walls and ceilings. Patterns include cobblestone,brick (in various patterns), flagstone, Mediterranean tile,pavers and more.

For more information, call (888) 568-4128 or visitwww.universaltemplates.com.

PRODUCTPROFILES

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.



To advertise in theConcrete Decor

Concrete Marketplace call toll free

877-935-8906


http://www.universaltemplates.com



Flattooing!

Surface Gel Tek (SGT) has introduced a new processcalled Flattooing, the art of tattooing images into flat

concrete surfaces. The Flattoo process uses Flattoos — vinyladhesive designs — and Tek Gel for Stenciling Micro Etch.

Flattooing offers the applicator year-round income opportu-nities because the entire process is easily used indoors. SurfaceGel Tek has a catalog of stock Flattoos, but all custom artworkdesigns are welcomed.

The Flattoo process increases income potential and decreasesoverhead. The cost of SGT’s stock Flattoo designs averages $6 persquare foot. Tek Gel for Stenciling Micro Etch costs about 15 centsper square foot. The remaining tools needed for most any job ismasking tape, a paintbrush, protectiveplastic, rags and a bucket of water. It’s thatsimple.

Flattoos come with a protectivebacking; weeded positive, negative orno weeding; and a top masking tape,which helps hold the shape of theFlattoo until it can be placed ontothe concrete surface.

Surface Gel Tek offers monthlyFlattoo Certification classes in the company’s Mesa,Ariz., factory. Classes are held to 10-12 people so everyone getshands-on training. The four-hour class includes: How to make yourown Flattoo; How to order a stock or custom Flattoo; accent coloringusing Stain Mule The Stain Carrier; and Flattoo Certification.

Call Tamryn at (480) 970-4580 for more information.



Stegmeier Corpby David Thompson

Contractors in need of custom wall caps typicallychoose between pre-cast concrete, which is elegantbut pricey, or cinder block caps, which are — and

look — a lot cheaper.Stegmeier Corp. has developed an alternative: a

disposable foam form that allows concrete wall caps to be castin place, creating cantilevered edges that look great but won’tbust the budget.

“With these forms contractors are able to give wall caps tothe consumer for maybe $12 to $15 dollars a linear foot, asopposed to $35 to $50 dollars a foot for pre-cast,” says BudStegmeier, the company’s Western division manager andmarketing manager.

Stegmeier Corp. has long manufactured decking forms andother products used in swimming pool construction, but inthe past three years it has ventured into non-aquatic territoryas well.

In addition to wall cap forms, the company’s newerproducts include step liner forms for producing overhangingtreads and forms for creating concrete countertops withcantilevered edges. All come in a variety of profiles.

The company also makes Slip-N-Join Lumber, a formingmaterial for producing free-form edges on patios, walkways,driveways and pool decks. It bends to a two-foot radius. Andsince it won’t warp like plywood and masonite forms do, it’sreusable.

The roots of Stegmeier Corp. stretch back to 1966, whenBud Stegmeier’s father, Bill Stegmeier, started manufacturingproducts for swimming pool decks in Northern California.Not content with the coping stones and brick commonlyused at the time to cap pool-shell walls, Stegmeier invented adisposable foam form that produced cantilevered edges onconcrete pool decks.

“It turned out to be the best thing that happened to theswimming pool industry in 40 years,” says Bud, who is part ofa group of partners that bought the company when the elderStegmeier retired. “He revolutionized the construction ofswimming pools by coming up with cantilevered decks.”

Cantilevered decking was the first in a series ofinnovations patented by Bill Stegmeier, who at 82 works as aconsultant for the company. He currently holds 25 patents.“Not all are super money-makers, but some are gold,” saysBud. The artificial lava rock, for instance, never really caughton. But the “snap in” removable-top deck drain and themethods for putting fiber-optic lighting beneath the lip ofcantilevered pool decking are big.

The company today has two manufacturing plants, one in



Arlington, Texas(the home office),and the other inHenderson, Nev. Italso stocksinventory atwarehouses inAtlanta, Baltimoreand Orlando.

This geographic spread helps Stegmeier Corp. respondquickly to its nearly 600 distributors. “Orders are in in themorning and out in the afternoon,” says Bud. “If a customerin, say, Palm Beach needs a load of material, they order by faxinto Arlington, Texas, and that order is processed and shippedout of our warehouse in Orlando. Our distributors aren’thampered by long lead times so they don’t have to carry aslarge an inventory as they normally would.”

Products used in swimming pool construction still make upthe bulk of what Stegmeier Corp. manufactures. Its productline includes pool drains, expansion joints and 13 shades ofFrontier Desert Deck, the company’s brand name for thepopular pool decking material known as Kool Deck.

Stegmeier Corp. makes a variety of decking forms forgunite, fiberglass and vinyl-liner swimming pools. Amongthem are forms designed for stamped concrete pool decking,forms that allow automatic pool-cover tracks to be installedwhen decking is poured, and forms that produce a child safetygrip along the edge of a pool. All of the company’s cantileverforms — including those for steps, countertops and wall caps— are made from expanded polystyrene foam.

The company continues to put out new products, such asan aluminum-topped deck drain for large commercial projectsand forms to make backsplashes on concrete countertops,both of which will soon hit the market.

To stay in tune with contractors and see how Stegmeierproducts are faring in the real world, the company gets peopleout to job sites frequently, says Bud, who has several years ofexperience as a concrete contractor himself.

“Most of our new products come from being out with thecontractors and looking and seeing where the problems comefrom,” Bud says. “A lot of companies make a product andnever go out to see it in use, but we have people who get outin the field, and we are working off current experience. That CIRCLE #82 ON READER SERVICE CARD

experience helps us to develop new products, upgrade currentproducts and have the answers people need to know.”

Contractors looking for such answers have a toll-freetechnical support number they can call. “That line drives uscrazy sometimes, but it’s worth it,” says Bud. “We’re very, veryaggressive as far as customer service. We’re second to nobodyin that respect.”

The company’s 35 to 38 employees seem to make outpretty well, too. “Every year we give time off to all of our full-time employees, usually from the 20th of December until thefirst of the year, and we don’t count it as vacation time,” Budsays. “And once a year we have a really big company picnicdown in Arlington, Texas, and we fly everybody from Nevadadown there for a big party.”

As for the future of decorative concrete, Bud sees theindustry continuing to come out with products that allowcontractors to add value to their work. “People are gettingnicer and nicer work at economical prices, and contractorsare making more money and actually having a lot more funwith decorative concrete,” he says.

Using forms to create overhangs on steps, for instance,adds an appealing architectural detail to the finished productwithout adding much to the overall price of the job, Bud says.

“It’s the same pile of concrete, but by using these foamforms you’re getting something really, really striking insteadof just a set of square steps,” he says.



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

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To place your advertisement in Concrete Decor call toll-free877-935-8906

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At the newly designed www.concretedecor.net click on EVENTS &TRAINING and you’ll find more and more training opportunitiesaround the country and in your area. New Fall and Winterschedules are now being added to our Web site.

To have your class schedule listed online at concretedecor.net, call us toll free at 877-935-8906.

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

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

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Discovery and Training SeminarsEasy as 1… 2… 3… for beginners and experts.Advanced hands-on decorative concrete engraving,scoring, cutting, and staining techniques withexceptional equipment. Learn how to make fast,high quality, great paying installs plus how to marketand sell your services. Discover new advancedtools and increase your skills. Free informationpacket.

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Product New

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Scarifiers solveproblems withslabsNew Sawtec scarifiersfeaturing heavier framesand drums are ideal forrepairing common slabproblems: curled joints,high spots, uneven slabs,burned slabs due toovertroweling, trowelmarks and damage due toweather. A variety ofcutter teeth and quick-changing drums allow for

easy reconfiguration to meet a range of applications —from light cleaning to heavy coating or laitanceremoval. For greater control and easier handling,Sawtec scarifiers include a quick lift-off feature andmicro-depth control for fine-tuning the cutting depth.Gas or electric scarifiers are available in sizes from 8" to13" widths. Sawtec scarifiers remove oil, contaminants,traffic lines, epoxy coatings or paint from asphalt andconcrete surfaces. They are also suitable for smoothinguneven surfaces and trip hazards, or for cutting safetygrooves in ramps, walkways and loading docks. Formore information, call (800) 624-7832 or visitwww.surfacepreparation.com.

Schmidt offers abrasive airblastingsystemsSchmidt abrasive airblasting systems are designed tohandle contractor needs for maintenance blast andpaint operations as well as for the popular decorativesandblasted look or stenciled patterns in decorativeconcrete applications. Blasting systems featurepneumatic or electric deadman controls, optionalremote abrasive cutoff for cleaning the area of abrasive,and normally closed, fail-safe metering and controlvalves. Schmidt systems use significantly less abrasive,minimizing downtime, saving on abrasive costs andrequiring less cleanup and disposal. They are availablein a range of sizes. Call (800) 231-2085 or visitwww.surfacepreparation.com for more information.

New cove trowels fromMarshalltownMarshalltown has introduced abrand new line of inside covetrowels that feature a wood handleand blue steel blade with a rivetedsteel mounting. Blades come in 6" x4", 6"x 6", and 6" x 8" sizes. Allthree sizes have a 1-inch radius and

a 3-inch lip. The trowels are designed to appeal to theprofessional who wants a quality tool that gives bettercontrol. For more information, visitwww.marshalltown.com.

Hand-held shot blaster great forstenciling,cleaning small surfacesThe Blastrac 1-5HH hand-held shot blaster can be usedfor decorative concrete applications such as stenciling— and much more. The1-5HH cleans andprepares small floor andwall surfaces, balconiesand stairways, and smallmetal surfaces (such asweld seams).Applications of this110V unit includecleaning and contouring,etching concrete andnatural stone, decorativeconcrete, paint removal, and preparation for repair andrestoration work. The 1-5HH may be used on eitherhorizontal or vertical surfaces. For more information,visit www.surfacepreparation.com or call (800) 256-3440.

Foam fills cracks,gaps and holesSika Corp. has introduced Sika Boom, a one-component expanding polyurethane foam formulatedspecifically for concrete and masonry applications. Thismulti-purpose foam is used to seal, fill, bond, insulate,and deaden sound in cracks, gaps and holes that are toolarge for a conventional sealant. It is available in 12 oz.and 20 oz. can sizes and is designed for easy dispensingthrough a straw adapter that is included with each can.When applied, Sika boom expands two to three timesits original size and will bond to most constructionmaterials, especially concrete and masonry. For moreinformation, visit www.sikacorp.com.

Crack-chasing saw makes grout lines tooThe Sawtec Crac-Vac cuts to a depth of 11⁄8 inch and isideal for cleanout of random cracks and joints in concrete.


http://www.surfacepreparation.com


http://www.marshalltown.com


http://www.sikacorp.com


It controls dust generated during routing out of cracks and jointsin preparation for the application of repair compounds. TheCrac-Vac has a patented vacuum housing with internalimpeller fan that routes the dust to a reusable dust collectionbag. When mounted on a dolly, it can be used for straight-linejoint cleanout work, or for cutting artificial grout lines fordecorative concrete applications. For more information, visitwww.surfacepreparation.com or call (800) 624-7832.

Floodlights chase awaythe darkBull Dog Power Products’ newSilver Series includes quartzhalogen floodlights that lightup work sites from 5,000 to10,000 square feet. Theseportable, weatherproof lightsfeature 500-watt high-intensityhalogen bulbs and pebble-finished reflectors to diffuselight for broad coverage.Tubular steel tri-pods are

heavy-duty with telescoping masts. All lamps have lenses ofclear, tempered glass and metal guards designed to minimizechance of tipping. They feature extra-wide lamp frames tohelp direct heat away from the housing. The lamps takedown easily and are very portable and lightweight. For moreinformation, call (877) WARNER-1 or visitwww.warnertool.com.

Wet/dry vacuum runs cordless or cordedDeWalt’s new DC500 is the first cordless/corded portabletwo-gallon wet-dry vacuum designed specifically forcontractors. For versatility, the DC500 runs off either abattery pack or a 120-volt AC electrical outlet.

A Gore wet/dry filter from the makers of Gore-Texproducts provides effective dust collection, trapping 99.7percent of dust particles inside the vacuum. The washable,reusable filter captures the finest dust particles, such as drywalldust, and prevents them from escaping out the exhaust.

The vacuum produces ample power to pick up drywall andconcrete dust, fasteners, water, sawdust, wood chips and otherdebris. For convenience, a drain port on the front of thevacuum allows users to empty any liquid in the tank bysimply unscrewing the cap instead of removing the entirecanister lid.

The DC500 has a durable, positive-lock rubber hose witha standard 11⁄4" opening. The detachable hose expands to sixfeet and can be connected to the exhaust port, turning thevacuum into a blower. Heavy-duty canister latches and asealed power unit add durability to the unit. For moreinformation, call (800) 4-DEWALT or visitwww.DEWALT.com.

New 4-Cycle fromHoverTrowelHoverTrowel Inc. hasintroduced a new 4-cyclepower trowel for finishingpolymer flooring overlaysin non-sensitive indoorand outdoor areas. The45-lb trowel is poweredby a quiet, low-emissions31cc Honda engine withenough torque to finishthe most difficult systemson the market today. Asthe demand for thesetroweled systems grows,

the HT-S4C adds even more versatility to the company’s lineof lightweight power trowels, without sacrificing any of thetime-tested features and benefits of its predecessors such asfingertip pitch and speed controls, a telescoping handle,different troweling path sizes, additional weights, and manyblade or float options. Its design makes this engineinterchangeable with existing pneumatic motors. For moreinformation, visit www.hovertrowel.com or call (610) 856-1961.




http://www.warnertool.com

http://www.DEWALT.com

http://www.hovertrowel.com


Artistic solutionprevents skateboarddamage

After Tom Ralston Concrete recently finished a handsome concrete wall for the Pacific Gardens

Chapel in Santa Cruz, Calif., local skateboarders promptlybegan to destroy it while practicing their “railing” and jumpingtechniques. Owner Gary Benito rapidly became frustrated and turnedto Tom to brainstorm a solution.

Neither Ralston nor Benito were thrilled with the solutions aroundtown that use bent rebar or metal plates to deter the skateboarders.

Tom got an idea and within hours went to the Santa Cruz wharf to buy aseashell that was quickly made into a mold. From there an Ardex polymer concretewas used to cast a replica of the shell, adding a piece of rebar in the mold that could beused to fasten to the wall with epoxy. Ralston went one step further and coated theconcrete shells with copper epoxy that was polished with steel wool and “antiqued” to give abluish hue for effect.

Finally the walls were drilled and the shells attached.The wall hasn’t been bothered since the attractive “shells” went up, and Tom Ralston Concrete

has since received a number of inquiries from other building owners looking for an attractive fix fortheir own problems with skateboard damage.

The Final Pour


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vol. 3 iss. 5 october/november, 2003 - decorative concrete · next issue:your roadmap to world of...

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