Seminar Report on Decorative concrete

2015-2016

INTRODUCTION

Decorative concrete is the use of concrete as not simply a utilitarian medium

for construction but as an aesthetic enhancement to a structure, while still
serving its function as an integral part of the building itself such as floors, walls,
driveways and patios.
The transformation of concrete into decorative concrete is achieved through the
use of a variety of materials that may be applied during the pouring process or
after the concrete is cured, these materials and/or systems include but are not
limited to stamped concrete, acid staining, decorative overlays, polished
concrete, concrete countertops, vertical overlays and more.

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Stamped Concrete
Stamped Concrete is the process of adding texture and color to concrete to make
it resemble stone, brick, slate, cobblestone and many other products found in
nature including wood, fossils, shells and many more. This limitless array of
possibilities combined with great durability and lower cost than natural products
makes Stamped Concrete an easy choice for new construction and renovation
projects.
The installation consists of pressing molds into the concrete while the concrete
is still in its plastic state. Color is achieved by using Dry Shakes or Color
Hardeners, Powder or Liquid Releases, Integral Colors or Acid Stains. All these
products may be combined to create even more intricate designs.
Stamped Concrete may be used on driveways, patios, commercial roads and
parking lots and even interior floors. Stamped concrete is a desirable finish to
concrete areas, however with time and wear the color dyes fade and the surface
looks patchy and unpresentable. There are many re-coloring options which can
completely restore and rejuvenate the color and presentation of faded stamped
concrete.
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Concrete dyes
Concrete "dyes" take many different forms and compositions and can be used
on both residential and commercial concrete applications, including
sound/retaining walls, bridges, countertops, floors,[1] etc.
Early concrete dyes consisted of generic printing inks that were dissolved in
mild solutions of alcohol and applied to concrete surfaces to add a wide array of
color to plain gray concrete. When alcohol-based dyes are exposed to sunlight,
the color either lightens or fades out completely. Therefore, alcohol-based dyes
were more prevalent in interior applications where direct sunlight or other forms
of ultraviolet (UV) lighting was not present.
Manufacturers later began dissolving the same printing inks in different carriers,
such as acetone, lacquer thinner and other solvents, hoping to achieve increased
penetration levels. In addition, UV inhibiting agents were added to new dyes to
help with the UV instability issues. However, slight fading (5-8% per year) still
occurs when the dye is exposed to direct sunlight.

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Colored concrete can be obtained from many ready mix concrete companies and
many have color charts available.
Acid Staining
Acid staining is not a dyeing or pigment-base coloring systems, but a chemical
reaction. A mixture of water, mineral salts and a slight amount of muriatic acid
is applied to the concrete surface. This chemical reaction with the existing
minerals (primarily lime) in the concrete over a period of one to four hours
creates new earth tone colors on the concrete surface. The concrete surface is
later scrubbed to remove excess stain and neutralized by a basic solution of
ammonia and water or baking soda (less likely to cause whiting later) to help
raise the ph level back to normal level. Due to inconsistencies in the surface
level of concrete floor, acid staining creates a variegated or mottled appearance
that is unique to each slab. The color penetration ranges from 1/16 to 1/32 of an
inch. Older exterior concrete surfaces may not color as well as interior surfaces
because the environment has leached or percolated out the mineral content. As
well, any exposed aggregate (rocks) in worn concrete will not accept staining.
Chemicals commonly used in acid staining include Hydrochloric acid, Iron
chloride and Sodium bicarbonate.

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Water Based Staining

Water Based Stains are similar to acid based stains in the sense that one can still
achieve a translucent look like acid; some stains are able to achieve an opaque
color and/or a translucent effect. The main difference is that acid stains react to
the concrete and change the physical make up of the concrete material, whereas
water based stains are more of a "coating" that bonds with the concrete. There
are many variations of water based stains that have come into the decorative
concrete industry that perform in a number of different ways. Some are polymer
based, acrylic and epoxy.
Overlaying
Concrete overlays date to the 1960s when chemical engineers from some of the
larger, well known chemical companies began to experiment with acrylic paint
resins as modifiers for cement and sand mixes. The result was a thin
cementitious topping material that would adhere to concrete surfaces and
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provide a newly resurfaced coating to restore the worn surface. Concrete

overlays lacked the long-term performance

[2]

characteristics of acrylic resins.

Acrylic resins provided good UV resistance, but lacked long term water
resistance and adhesion characteristics needed to provide a long term and
permanent solution.
Polymer cement overlays

Construction of a polymer cement overlay to change asphalt pavement to brick

texture and color to create decorative crosswalk and traffic calming in highpedestrian area.
Polymer cement overlays, consisting of a proprietary blend of Portland cements,
various aggregates and polymer resins, were introduced over 20 years ago. The
purpose of adding a polymer resin to the cement and aggregate is to greatly
increase the performance characteristics and versatility of conventional
cements, mortars and concrete materials. Unlike conventional cement and
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concrete mixes, polymer cement overlays can be applied thinly or thickly

without fear of delamination or typical product failure. In addition, polymer
cement overlays are much more resistant to damage from salt, petrochemicals,
UV, harsh weather conditions and traffic wearing.
Originally intended for use as a thin surface restoration material for concrete
substrates, polymer cement overlays were introduced into the architectural
concrete and commercial flooring industries in the early 80s. Subsequently, its
use in these industries has become standard. Polymer cement overlays are
regarded as economical in providing long term, durable renovation without the
need for costly and continuous repairs associated with deteriorating concrete
surfaces.
Polymer cement overlays are used for interior and exterior applications ranging
from:
Skim coat/broom finish concrete resurfacing Restore and protect
damaged, pitted, flaking and stained concrete back to the look of a new
concrete surface.
Concrete regrading & leveling Repair and level concrete surfaces that
have settled.
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Existing substrate redecorating and renovating Alter the appearance of

existing concrete or wood substrates through applying "thin stamped" or
"thin stained" overlays, creating new textures, colors and designs. For use
on commercial or resident pool deck, this frequently takes the form of
"splatter textures" or "knockdowns," in which polymer cement is applied
to the existing concrete substrate in a moderately textured finish (average
of 1/8 thickness) in various patterns. Often, the texture is knocked down
with a trowel to slightly modify the appearance and feel of the finished
application.
Stamped overlays
Rubber imprinting tools (stamps) are impressed into thin pre-mixed concrete
overlay material shortly after it is placed to create natural stone or brick
textures. These rubber imprinting tools are manufactured from molds created
from authentic stone or wood. Release agents are used to help release the
stamps from the concrete without sticking. Release agents come in either a
liquid or powder form and are available in a wide range of colors.
Epoxy coating

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Applied over acid stained, dyes and/or overlays to seal and protect. Some
epoxies are also colored.
Polishing
Concrete can be polished with Mechanical grinders and diamond pads of
increasing grit sizes. Diamond pads come in many grit or mesh sizes. Common
sizes start with 6 grit and can go up to 8500 grit although concrete can only
maintain a shine of about 800 grit, it can be helped by adding a concrete
hardener such as sodium silicate or lithium silicate which will allow concrete to
hold a 1800 through 3000 grit shine. The work is accomplished in multiple
stages by passing over the concrete with successive grit diamond pads until it
has a hard-glassy finish. Both acid stains and concrete dyes can be used during
the polishing process.
Engraving
Existing concrete can be remodeled by cutting lines and grooves into its surface.
Geometric patterns, straight or curved lines and custom designs can be cut
directly into the surface of the concrete creating the look of tile, flagstone,
cobblestone and many other common surface patterns. This is usually achieved
using tools like an angle grinder fitted with diamond blades, but is more
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effectively accomplished using specialty tools designed specifically for cutting

designs into the concrete.
Form liner
Concrete can also be cast into unique and detailed designs using urethane form
liner. These projects can be seen around the United States and the world,
usually on sound/retaining walls, building exteriors, and bridges.
Generally, this process starts with the sculptor, who creates the design to be
used in the concrete using clay, polyurethane or wax. When the original art is
complete, a cast is made using synthetic liquid rubber, and from this cast, form
liners are produced in the reverse image of the original.
The form liner then acts as a mold for the concrete to be formed against. Once
the concrete is set, the form liner is stripped from the hardened concrete surface.
The concrete is permanently textured with the pattern of the form liner.
Architectural & Decorative Concrete
Concrete is one of the most widely used construction materials in the world.
One special subset is called architectural and decorative concrete, which refers
to a substance that provides an aesthetic finish and structural capabilities in one.

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This material is made to be seen. Whether creating broad expanses or minute

details, concrete permanently captures the chosen look. Achieving an
architectural or decorative appearance usually requires that something different
be done to the concrete. Whether that involves special forms, special finishing
techniques, or special ingredients, the variety of effects is almost unlimited.

Original art by Carolyn Braaksma, Denver, Colorado

Concrete is one of the most widely used construction materials in the world.
One special subset is called architectural and decorative concrete, which refers
to a substance that provides an aesthetic finish and structural capabilities in one.
This material is made to be seen. Whether creating broad expanses or minute
details, concrete permanently captures the chosen look. Achieving an
architectural or decorative appearance usually requires that something different
be done to the concrete. Whether that involves special forms, special finishing
techniques, or special ingredients, the variety of effects is almost unlimited.
White Portland Cement: A Key Ingredient
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White cement concrete is a brilliant architectural

material. Whether plain or pigmented, it allows for a broad spectrum of colors from bright whites and pastels to saturated colors. It can be textured, patterned,
or shaped to almost any form, allowing architects to be truly creative in their
designs. Imagination becomes architectural reality with white cement.
What makes white cement so architecturally appealing is its versatility. It can be
used for:
o Cast-in-place concrete
o Precast concrete
o Tilt-up concrete
o Repair and retrofit applications
o Masonry and mortar
o Stucco finishes
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Good Looks and More

From large to small items, structural to decorative members, white cement is the
key to good looking concrete and masonry construction. A versatile appearance
allows white cement concrete, which is pigment-friendly, to fit in with any
environment. Beyond aesthetics, its light color offers energy efficiency and
safety.

These qualities can be used to advantage for:

o Bridge parapets and barrier medians
o Light reflective floors
o Exposed architectural concrete
o City streetscapes: curbs, gutters and planters
o Landscaping
o Building accents
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Whether inside or outside, white cement concrete provides a hard-wearing,

durable surface that stands up to heavy use.
Technical Aspects of Designing with White Cement Concrete
White portland cement has essentially the same properties as gray cement,
except for its color. An important quality control issue in the industry, the color
of white cement depends on raw materials and the manufacturing process.
Metal oxides, primarily iron and manganese, influence the whiteness and
undertone of the material. White cement is manufactured to conform to ASTM
C 150, Specification for Portland Cement. Types I and III are the most common,
but Types II and V are also produced.

Mix designs for white or colored concrete are

formulated with respect to the following ingredients, paying particular attention
to the resultant effect on color:
o Type and color of cement

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o Type and dosage of pigment

o Type and dosage of chemical admixtures
o Type, gradation, color, and cleanliness of fine and coarse aggregates
o Type and dosage of supplementary cementing materials: calcined clay,
slag, white silica fume
o Consistent proportions, especially maintaining a uniform water-cement
ratio
It is always recommended to develop a mix design and build sample panels in
advance of starting a white cement concrete project. That way, mixtures can be
refined and improved and material usage can be optimized. The mockups serve
as references for color and surface appearance during the construction phase of
the project.
Materials & Applications
Architectural and Decorative Concrete

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Concrete is one of the most widely used construction materials in the world.
One special subset is called architectural and decorative concrete, which refers
to cement-based products that provide an aesthetic finish and structural
capabilities in one.
These concrete materials are made to be seen. Whether creating broad expanses
or minute details, concrete permanently captures the chosen look. Achieving an
architectural or decorative appearance usually requires that something different
be done to the concrete. Whether that involves special forms, special finishing
techniques, or special ingredients, the variety of effects is almost unlimited.
For more information see PCA's Finishing Concrete with Color and Texture,
PA124.
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Masonry

Masonry is one of our oldest, most established

building techniques. Evolution in materials, mix designs, and engineering allow
for the construction today of even stronger masonry buildingsstructures that
will last for generations.
Concrete masonry units are available in a rainbow of colors, textures, shapes,
and sizes, offering building designers the chance to create structural walls that
are also beautiful. Architectural concrete masonry units offer a natural
appearance that is striking in urban applications, and blends in with the natural
beauty of rural areasalways complementing the buildings surrounding
environment.

Stucco

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Stucco, or portland cement plaster, is a versatile

facing material that can be applied to flat or curved surfaces either inside or
outside any building or structure. Stucco has great appeal as a surface finish
because of its utility, low first cost, and minimum need for maintenance.
In its hardened state, plaster is a desirable facing material: hard, strong, fireresistant, and color-retentive. Because plaster is also breathable, or able to
transmit moisture vapor, water that gets behind it does not become trapped. That
makes it resistant to rot and fungus. Plaster has proved to be a durable wall
cover in all climates, whether wet, dry, hot, or cold.
The final appearance of the finish coat can be varied by changing the size and
shape of the aggregate, using colored cement, adding pigments, changing the
consistency of the finish mix, the method or equipment used for plastering, and
the plasterer's skill in manipulating the finish coat.

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Pervious Concrete

Pervious concrete, is one of the hottest

topics in land development today. As owners, architects, land developers, and
concrete professionals become familiar with its benefits, the interest in pervious
concrete continues to grow. Pervious concrete is porous and provides a solution
to the EPA regulations that call for decreasing the amount of surface water
runoff and initially treating the runoff.

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Break New Ground with a Time-Tested Material

Masonry combines beautiful design possibilities

with versatility and value, durability and low maintenance, in any size, style, or
climate.

From civic and cultural facilities to institutional settings, buildings designed

with masonry stand the test of time. Masonry also is an investment in living
well for home owners. With its ability to withstand extreme temperatures, fires,
and natural disasters, masonry keeps adding value to residential properties.

Masonry is also the sensible choice for educational buildings. For school design
that innovates and is proven to perform, again and again its masonry.

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Masonry Products and Properties

Masonry units are available in sizes, shapes, colors, textures, and profiles for
practically every conceivable need. Historically, units came from a variety of
sources and included materials such as rock and stone, either natural or cut.
Today, units most commonly used are concrete block or clay brick, offering
standardized sizes and mechanical properties. The units are joined together by
mortars made from a binder consisting of one or more cements for masonry,
sand, and water. Portland cement plaster, or stucco, is made from the same
material as mortars, and as such, is sometimes considered to be a masonry
product as well.
Masonry is widely used to construct small and large structures because of its
attractive appearance, minimum maintenance, safety (fire resistance and
wind/earthquake resistance), and economy. Masonry provides an effective
barrier to sound and reduces internal temperature variations and peak loads on
heating and cooling systems. It provides architectural freedom and versatility
with striking aesthetic appeal. Almost any shape of structure is possible.

When high winds occur, reinforced masonry buildings resist the pressures and

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flying debris that can knock down or damage less robust construction. Masonry
can offer fire resistant qualities that saves homes.
Masonry also resists weathering and vandalism. The durability and minimum
maintenance extend a buildings useful life, providing an enduring, high-quality
appearance.
Masonry Products
Modern masonry products include portland cement plaster (stucco), cements for
masonry, mortars, concrete block, and clay brick. These materials can be used
on the interior or exterior of structures in a wide range of environments. Loadbearing walls serve a structural purpose, while veneers and claddings,
frequently used as architectural finishes, also function as weather barriers.
Whichever materials are used, modern masonry construction provides
durability, safety, aesthetic appeal, and other benefits in a cost-effective
manner.
Brick
Brick is the oldest manufactured building material. The earliest brick, made
from mud (sometimes with added straw), was invented almost 10,000 years
ago. Clay brick started to appear about 5,000 years ago, when builders
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borrowed pottery manufacturing techniques to improve its strength and

durability. From some of the oldest known structures to modern buildings, clay
brick has a history of providing shelter that is durable, comfortable, safe, and
attractive.
Cements for Masonry
Cements for masonry include masonry cement (ASTM C 91) and mortar
cement (ASTM C 1329). They are hydraulic cements designed for use in mortar
for masonry construction. Masonry cement consists of a mixture of portland
cement or blended hydraulic cement and plasticizing materials (such as
limestone or hydrated or hydraulic lime), together with other materials
introduced to enhance one or more properties such as setting time, workability,
water retention and durability. These components are proportioned at the
cement plant under controlled conditions to assure uniformity of performance.
Concrete Masonry Units
Since 1882, when the first concrete block was molded, concrete
masonry units have become a standard building material.
Concrete blocks create structures that are economical, energy
efficient, fire-resistant, and involve minimal maintenance. In
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addition, concrete masonry allows architectural freedom and

versatility.
Mortar & Grout
Masonry mortar is composed of one or more cementitious materials, clean wellgraded masonry sand, and sufficient water to produce a plastic, workable
mixture. Grout for masonry is composed of similar materials, but is generally
mixed to a much more fluid condition. It may also contain coarse aggregate.
Stucco
Stucco, the common term for portland cement plaster, is a popular exterior
finish for buildings. It provides an economical hard surface that is rot, rust, and
fire resistant, which can be colored and finished in a wide range of textures to
adorn any architectural style.
Masonry is one of our oldest, most established building techniques. Evolutions
in materials, mix designs, and engineering allow for the construction today of
even stronger masonry buildingsstructures that will last for generations.
Aesthetic Variety

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Concrete masonry units are available in a rainbow of colors, textures, shapes,

and sizes, offering building designers the chance to create structural walls that
are also beautiful. Architectural concrete masonry units offer a natural
appearance that is striking in urban applications, and blends in with the natural
beauty of rural areasalways complementing the buildings surrounding
environment.

Safety and Durability

When it comes to fire resistance, masonry is a true performer, offering excellent
protection from fire damage. In fact, post-9/11 research performed on a building
in close proximity to the World Trade Center showed that masonry absorbed
much of the debris impact and helped save the structure from collapsing. In fact,
the building was repaired and restored to use. Masonry structures are also stand
up to high wind forces and earthquakes. More on Safety and Durability.
Sustainability
As with other concrete wall systems, masonry creates walls
with high thermal mass, minimizing temperature swings and
shifting heating and cooling loads to off-peak hours. The
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resulting buildings are more economical, with lower overall

heating and cooling costs, providing a consistently comfortable
atmosphere for inhabitants. Masonry also offers durability as
well as sound attenuationwhich all adds up to a more quiet,
comfortable atmosphere for inhabitants.
Applications
Masonry lends itself to many commercial applications. The
material has been used to create notable public buildings like
churches, courthouses, and government offices. Educational
structures, from elementary schools to Ivy League university
facilities,

can

balance

contemporary

engineering

with

traditional design, offering myriad possibilities that will stand

the test of time.
Technician Training
Two new masonry certification programs one for Masonry Laboratory Testing
Technicians and the other for Masonry Field Testing Technicians are
available. Developed by The American Concrete Institute (ACI), in cooperation
with The Masonry Society (TMS) and other industry organizations, both

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certification programs aim to improve the quality of masonry testing and

recognize qualified technicians.
Both exams include a written portion and a performance portion. Technicians
who successfully complete either exam will receive a 5-year certification from
ACI for field or lab testing. It is suggested that individuals prepare for the
exams through TMS review sessions that combine classroom instruction, lab
demonstrations, and lab practice time. To learn more about the new
certifications, see information at The Masonry Society or the American
Concrete Institute.
.

Industry Resources
Detailed information on designing with masonry and masonry mortars is
available on PCA's Masonry site. There is excellent information on the safety of
masonry regarding fire resistance, high wind force resistance, and earthquakes.

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CONCLUSION
Decorative concrete is the use of concrete as not simply a utilitarian medium
for construction but as an aesthetic enhancement to a structure, while still
serving its function as an integral part of the building itself such as floors, walls,
driveways and patios.The transformation of concrete into decorative concrete is
achieved through the use of a variety of materials that may be applied during
the pouring process or after the concrete is cured, these materials and/or systems
include but are not limited to stamped concrete, acid staining, decorative
overlays, polished concrete, concrete countertops, vertical overlays and more.

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REFERENCES
Fox, Joanne (May 16, 2009). "Concrete Staining Adds Color to Flooring".
Sioux City Journal.
Downs, Stacy (April 10, 2008). "Paving the way for concrete despite freezethaw cycles, driveway should last for years if properly installed".
Chicagotribune.com.

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