The Concrete Condition
To Stain or To Stamp Concrete... That is the Question
by Keith Kimberlin President, BOSS Resurfacing & Outdoor Living on 01/24/12
I recently receieved a request from a customer to explain the "unspoken" differences between Acid Stained Stamped Concrete overlay on a typical retro-fit floor. I hope this provides you with information you may need to help with your decision making process.
There are major differences between stamping and staining and I will explain the differences in detail along with the related issues that you need to know about each product including the differences in price.
STAMPED CONCRETE
Our Mega-Crete HD stamped overlay system is the most popular product in our long line of products. After the surface has been prepared, (Using our proprietary formulation and installation techniques) our Mega-Crete polymer modified stamped concrete overlay system is integrally colored and applied 3/8" thick over any stable surface. Using our HD (high definition) stamps, we mold and shape the material to resemble any pattern you choose. Using a secondary coloring process, we antique the surface creating the most realistic high end floor on the market. Some of the most popular patterns include "Ashlar-Italian Slate", "6 inch distressed wood planks", "English Fieldstone", and “Arizona Flagstone" to name a few. A few of the benefits of the stamped process include:
- Most all imperfections such as tac-strip holes, gouges, glue lines, stains and rough patches caused during the original finishing of the concrete are covered up never to be seen again.
- No need to remove the baseboards or moldings.
- You get a High-End architectural finish for a fraction of the cost of what pattern we are copying.
- The finished product is impact resistant (come by the show room and see the hammer test)
- The product is waterproof. Unlike most of the finishes that we resemble such as wood and sandstone.
- Very low maintenance
- Price range is $6.50-$9.00 per sq. ft. depending on selected options STAINED CONCRETE
Stained concrete floors are also beautiful, and the color lasts forever. Because it is not a paint or a covering, it doesn't chip off the floor. Acid stain contains phosphoric acid or mild hydrochloric acid. It also contains an inorganic metallic salt. The acids open the pores in the concrete, and then the salts react with the free-alkali (or free Portland cement) in the surface concrete to produce a desired target color range. Depending on the age, porosity of the concrete, or the presence of penetrating contaminants (such as paint overspray, oil, sealers and chemical spills to name a few) the the salts are absorbed into the surface of the concrete and attach themselves to the free alkali in varying degrees and produce different shades of color. The finish looks more like marble than a uniform painted finish, and no two floors ever come out the same. After the floor is cleaned and stained, it must be washed with an ammonia solution to neutralize the residue left by the acid. Then it is washed again with plain water at least twice. Not only is there an huge array of colors to choose from, but you can actually design a masterpiece on your floor with acid stains and scoring.
However, since acid stain is a surface treatment only, preexisting defective conditions will still be visible and in many cases accentuated by the staining process this includes (but is not limited to) gouges, pad-glue lines (glue residue left behind from a carpeted area), paint or clear coat lacquer overspray, tac-strip holes, cracks. and lay-out markings (these are the markings that the original home owner may have painted or drawn on the floor to position furniture or show where they want a wall or built-in placed) . Some staining contractors or companies try to make these conditions palatable to the consumer by calling them "character marks" or try and convince the customer that this is more of a raw look or warehouse look. I guess beauty is in the eye of the beholder.
Another major issue with thin floor systems is the base board location issue. In houses with carpeted floors, the baseboards are typically set at 3/8"-1/2" from the floor surface. Therefore, when the floor is complete, not only do you have issues with the visible, and now accentuated, tack strip holes but you also have to deal with this major aesthetic issue right above them. In most cases you cannot lower the baseboards because the finish above the baseboards typically do not continue behind the baseboard (e.g. faux finishes, wall paper and texture) and by moving the baseboard down you will have an unfinished strip of wall located above the baseboards.
Therefore; you are left with two options as it pertains to the baseboards. The first option is complete R&R (removal and replacement) of all baseboards. This option will require the purchase of a wider baseboard in order to maintain the same top placement location of the baseboard. The other (less costly) option is to install quarter-round trim at the bottom of the baseboard to hide the gap. But even these two options come with their share of potential problems. For one, the quarter-round method (though cheaper) is not always the most attractive of the two options and in some cases will not work with the current baseboard profile. But by far the biggest issue is the potential undulations in the existing slab or concrete surface causing intermittent gapping. These undulations, or waves, in the concrete are created during the initial pouring of the concrete slab and are covered up when the carpet is install (along with every other defect). All of these conditions are typical conditions, and can only be corrected with an overlay.
A polymer modified concrete overlay will cover all of the defective conditions including (for the most part) baseboard gapping. For customers that just have to have a stained concrete floor but don't want all of the afore mentioned visible defects, overlayment is the only cost effective resolution. The problem with overlayment and staining is that is may be cost prohibitive as you have to pay for both processes (overlay then stain). By the time you do this, the Mega-Crete stamped overlay system now becomes the most viable cost effective option.
I hope this information helps you with your decision making process. Please feel free to give me a call or stop by the showroom to look at these and other options available and when it is time to decide I would appreciate the opportunity to give you a quote on whatever you choose.
Thanks again,
Keith Kimberlin
President
BOSS Resurfacing & Outdoor Living
817-481-2277 o
http://www.bossresurfacing.com/contact.html
The Concrete Condition- Introducion of Mega-Crete / December of 2009
by Keith Kimberlin President, BOSS Resurfacing & Outdoor Living on 12/29/10
Sunday, December 20, 2009
Distributed and installed initially by Boss Resurfacing out of Grapevine Texas, the Mega-Crete product line has been sold in five other states thus far and is expected to be available nationwide within the next year or so. The proprietary Mega-Crete "High Definition" Stamped Patterned Concrete overlay system product and process is available and sold only to certified contractors who have taken the training class at the Boss Resurfacing training facility in Grapevine, Texas. The prospective installation contractors that attend this four day class can expect a rigorous training schedule that requires both memory retention, hands on evaluation and previous experience in the trade in order to pass the required test before the product can be purchased. "Quality is an attitude" says Kimberlin "and you can't teach attitude. This business is not for everyone and that is why we don't sell to everyone. The problem is, there is too many companies out there today that went to a two day 'deminar' at one of the, now many, local decorative concrete supply houses and left with just enough knowledge to get them in trouble. We train our customers on the science and provide unlimited technical support to help them to succeed. Let's face it if they don't succeed we don't succeed"
Though the Mega-Crete "High Definition" Stamped Patterned Concrete overlay system product is now available, the main marketing launch will not begin until early 2010 where the initial focus will be in the North Texas area. Many companies, however; are beginning to offer Mega-Crete products to their customers but use Boss Resurfacing installation crews to install the product until their crews have passed the required project repetition requirements set by the Mega-Crete corporate office. Once it has been determined that the prospective companies crews have met the minimum requirements for installation they are observed for two projects before becoming certified installers of the system. The Boss Resurfacing crews are highly skilled individuals that have been trained in the art of HD Stamping and Boss resurfacing is currently one of five companies in the North Texas areas that even offer this amazing new product.
This Unique Mega-Crete "High Definition" Stamped Patterned Concrete overlay system and HD Compound installation process has been tested by traditional stamped concrete installers and a version of the HD Compound is being developed specifically for this process. Local companies such as Patterned Concrete of Dallas have shown interest in the HD compound and owner Randy Biernacki has show great interest in the prospect of possibly improving their process. "Anything that can help us get an edge I am willing to look at" says Biernacki "We are all about Quality and in our 25 year history our customers expect nothing less".
This new Mega-Crete "High Definition" Stamped Patterned Concrete overlay system technology involves modifying the properties of the concrete surface material providing a smooth glasslike surface to stamp. When toweled in, the HD Compound mixes with the surface material (cream) essentially creating and integral surface admixture that modifies the properties of the surface resembling a polymer modified overlay system. The difference is that the new polymer modified material in the surface comingles with the matrix of the concrete (core) and hydrates simultaneously with the core creating a virtual polymer modified integral bond line that culminates at the hydration plane approximately 1/8"-1/4" below the surface of the cream. The HD stamping process is both chemical combined with technique and both are really important for the process to work. Testing on traditional stamping has yielded promising results and further testing will take place early in the spring when the threat of freezing weather has passed. Kelly Navarro, Quality Manager for a small independent concrete manufacturing company located in the Corsicana area, has indicated his interest in learning the technology behind the HD Compound. "Our interest is to possibly offer a product that will offer better ware properties for our concrete. The Mega-Crete HD Compound seems to modify the cream of the concrete allowing my customers to offer and up-grade product to their customer. This is a good thing for all of us." Says Navarro "We are interested in distributing the HD Compound to our customers under a private label, but the details for that are still being worked on"
Many experts agree that this is truly an original concept in the decorative concrete world and, when made readily available, that we could be witnessing the next level in decorative concrete as we know it today.
The Concrete Condition "Crack Repair"
by Keith Kimberlin President, BOSS Resurfacing & Outdoor Living on 12/27/10
On this ever shifting, seemingly seismic piece of the earth's crust we all live on, whether here in the North Texas area or anywhere in the country, there are two unequivocal facts as it pertains to our concrete; one, "it is gray" and two "it cracks". This article "Crack Repair" is to inform the lay-person about the basics of concrete cracking, the causes, and the methods used by professionals to repair this unsightly and damaging concrete condition. This article will specifically address crack repair on surfaces where an overlay will be installed. Overlays considered include, but are not limited to: polymer modified concrete overlays, tile, stone, epoxy, and other hard surface products that will be bonded to the repaired surface.
When most of us see a crack in our concrete, we immediately assume that the concrete is damaged beyond repair or that we have some type of structural problem that can only be fixed by removal and replacement. It is this unapprised thought process of the consumer that keeps many concrete removal and replacement companies in business. Though there are some cases where removal and replacement are recommended, the truth is, not all cracks in concrete require this extreme and costly repair.
Cracks in concrete can be the result of a multitude of conditions related directly or indirectly to soil or existing site conditions, mix design, installation errors, improper steel placement or the lack of steel reinforcement, insufficient grade preparation, and insufficient or inadequate joint design to name a few. Other more complicated and complex causes for cracking in concrete are possible and in most cases, depending on their experience, can be diagnosed by a knowledgeable concrete professional. Before you make the decision to endure the extortionate costs and seemingly inestimable downtime of removal and replacement, you should have the defective areas evaluated by at least two if not three competent concrete professionals.
There are several things to consider when designing a concrete pour that can directly affect the overall performance, longevity, and long term integrity of the concrete. While the mix design is important, the design of the mix is usually controlled and predetermined by the concrete supplier and is not typically prescribed by the installer. In this discussion we will focus on the decisions made and implemented by the setter. Preliminary grade work is the most basic and vital preparation step required for a successful concrete pour. The following basic steps should be followed for proper grade preparation:
1. The intended area of placement should be free of grass and other foliage including tree roots and stumps.
2. The area should be smooth and free of raised areas, low spots and all visible surface undulations.
3. The area should be properly compacted
After the area has been properly prepared a base of cushion sand should be placed inside the formed area to insure the surface is level.
Before we get into the meat of the discussion let us first discuss joints in concrete and their intended applications as joints, and their design, are relative to the discussion.
There are four types of joints in concrete. The first type of joint is called a "structural joint" or expansion joint. A structural joint typically has some type of separation material in(or between) it such as wood, felt, rubber, or foam. These materials are typically used to create separation between two pours. The second kind of joint is referred to as a "cold joint". A cold joint is where two concrete pours meet without a separation material between them. The third type of joint is called a "control joint". A control joint, like all joints, is used to control cracking and resembles a finger groove in the surface of the concrete. An example of a control joint can be observed when you open a candy bar. Just as the grooves in a candy bar are used to break off a perfect little bite sized piece of candy when one applies load to it, the control joint in concrete is a pre-engineered stress concentration point which is intended to crack when it encounters stress from ground movement or shifting. The fourth kind of joint in concrete is called a "crack". Yes, a crack. A crack is an uncontrolled joint. Conversely, a joint is a controlled crack. Therefore, when a structural crack appears it is typically caused by stress s related to a shifting substrate or heaving caused by ground swelling and or shrinking. Common to our geographically indigenous soil conditions, heaving can be caused by the presence of an expansive clay base or even high root system encroachment. The homogenous prescription to repair a crack should not overshadow the underlying cause of the crack. Therefore, the cause should be considered and when possible addressed prior to prescribing the appropriate repair method. If the cause of a crack is not studied any repairs will be futile and additional, more costly, repairs will be imminent.
There are several different types of cracks in concrete. This is important because each type of crack requires a different repair. I am going to list the types of cracks from least to worry about to the most difficult to repair.
The first type of crack is a "check crack" or shrinkage cracks- Shrinkage cracks are easily identified and recognizable. Shrinkage cracks can be distinguished from other types of cracks. What is unique about shrinkage cracks in concrete is that they usually appear to be discontinuous and are in the surface of the concrete only. Most shrinkage cracks are only approximately 1/16"- 1/32" wide. Shrinkage cracks are not considered to be a defect in the concrete. Repair of this type of crack prior to the installation of an overlay is typically not required although I recommend an anti fracture membrane be installed as a safety precaution to protect the overlay from potential (though not likely) reflective transfer through the overlay. The second type of crack in concrete is called a "structural crack". Structural cracks are also known as settlement cracks, shift cracks, and load cracks depending on the area of the country. The cause of settlement cracks can vary but are typically related to pour grade preparation or shifting soil. Structural cracks are continuous and travel from one side of the concrete to the other. Though there is no typical width to a structural crack, they can be as narrow as 1/8" and as wide as 1.0" or more. In this case the crack typically requires injection of a structural epoxy. Though it would seem that the injection of the epoxy bonds the concrete back together, this is not the primary initiative. The epoxy (when hardened) acts as a liquid shim which binds or prevents the inward movement of the crack effectively preventing the crack to close due to any additional movement caused by the underlying cause of the crack. After the crack has been injected an anti fracture membrane should be installed to prevent reflective energy transfer. The third type of crack, which is the least responsive to the afore mentioned repair method, is the "off-set structural crack". An off-set structural crack is when the crack exhibits a raised area on either side of the crack. Also referred to as a twisted crack the off-set crack does not move only in and out but also moves up and down. In this case, shimming of the crack will not work due to the up and down movement thereby rendering the use of an anti fracture membrane useless. In this case, local removal and replacement of the affected area is the only effective repair method recommended.
For more information or questions on crack repair please visit www.bossresurfacing.com or call 817-481-2277
