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Cement
& Concrete
Association
of NewZealand
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INFORMATION
B U L L 8T IN
i.
CONTENTS
Part 1 - Commentary on Standard
Specification
COST OF FINISHES
CATEGORIES OF FINISH
Off-the-form surfaces
Exposed aggregate surfaces
Unformed surfaces
MATERIALS AND WORKMANSHIP
FINISHING TECHNIQUES
Tie rod holes
Surface dressing
Minor repairs/patching
Cleaning
SUMMARY
REFERENCES
Appendix A
- Blemishes in Concrete
Surface Finishes
GENERAL
Variationsin colour and texture
and ConstructionMatters.
Structuraldetailing
Formwork
Releaseagents
Relativelysmoothsurfaces
INTRODUCTION
DETERMINATION OF FINISH
Cements
Aggregates
- Type A
Off-the-form finish
Characteristicsof form materials
Surfacingsapplied in the mould
Surfacingsapplied after casting
Wet off-the-form finish
Trea tm en t dunng
. setti ng - Type B
F
tr
trn
ace- own ea
en
Face-uptreatment
Coloured concrete surfaces
Mix design
Preliminary contract work
Supervision
Weather conditions
Batching
Mixing
Stn.kmg
.
R
d.
erne laI wor k
Pl
acIng
an
compac
Ion
PART1 - COMMENTARYON
STANDARDSPECIFICATION
~~ ch~racteristics
thatarecoveredby the
specIfication are:
Surface plane variations
INTRODUCTION
This Bulletin was originally produced following
the publication of New Zealand Standard
3114:1980 'Specification for Concrete Surface
Finishes' to provide information on the
background and use of this code, both by the
specifier and by the contractor (see also
Information Bulletin IB 18 for examples of
finishes).
NZS 3114, which was revised in 1987,
provides the format which enablesthe statement
of the concrete finishing requirements of the
specifier to be translated, through contract
documentation, to the contractor. The standard
is divided into three parts.
1. Off-the-form
surfaces
2. Exposed aggregatesurfaces
3. Floors, exterior pavements and inverts
The appendix describesthe various blemishes
and their probable causes.
The application of the standard permits
appropriate qualities of finish to be assignedto
all surfacesbeing constructed, and attention to
be drawn to specific needs and requirements to
be emphasisedto the contractor.
InIS
- Il,or exce...~
"~""~ ti ,..~~\
The
factor
& ..~ "X"
~~
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THESPClflfRSCtiCCKLIST
Q
ED
recommended
to consider the check lists in
F
.
Igures 1 and 2 .
CHECK LIST
RECEIV
I
MAKE TRIAL PANEL
I
DEFINE TEXTURE SPECIAL
EFFECTS
SIMIlAR EXISTING FINISH
LIMITS ON FORM JUNCTIONS
LIMITS ON TIE LOCATIONS
REBATES WEATHERBAND DET'LS
YES
CONSIDER:
1. MIX DESIGN - STRENGTH, FINISH
WORKABILITY, AVAILABILITY
2. FORMWORK-RIGIDITYTIGHTNESS REUSE
3. RELEASEAGENTS - COLOUR, VARIATION
4. RETARDERS- SPREAD,CONTROL
5 COLOURlNG-AGGREGATESPIGMENTS
6. DEFECTS- SCOUR GROUT LOSS
7. CURING - EFFECTIVENESSDURATION
8. STRIPPING - TIMING RELEASE
AGGREGATESIZE
"
COLOUR
EXPOSURE
BEDDING MATRIX
ACCEPTANCE
OF TENDER
FOR SRP
1 CASTING ORIENTATION
2 CURING METHOD
3 DETAILS TO INCLUDE
4 TIMING OF COLOUR INSP
5 AGGREGATE REQUIRED
DISCUSS SRP
MIX, ORIENTATION, REBATES,
CURING METHOD, JOINTING,
SHEET LAPS, TIES,
ADMIXTURES
PATCHING
ACCEPT S.R.P.
8
COLOUR VARIATION
PHYSICAL IRREGULARITIES
BLOWHOLE FREQUENCYSIZE
REBATES JOINTS FASTENERS
DEFECT TREATMENT
RECEIVE:
METHODOF APPLYING
REMEDIAL
ACTION
MIXDESIGN
CURING
METHOD
-"'
CATEGORIES OF FINISHES
Off th r.
rf
- e-ionn
... su aces
This category covers the concrete surfacesthat
are primarily dependent on the formwork for
texture and finish. As such the most effective
results are gained by attention to detail before
plane
variation
Colour
Surface
dressings
Physical Irregularities
.
..
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..
go
-E
-E
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F6 Surface of high
Architectural or feature
importance.
panels.
Alignment,appearance Highvelocitywater
verylmportant.
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2mm
1/360 E A A P P P
channels.
F5 Structural surfacesof
importance.
Frequent close scrutiny.
3mm
1/270 P A A P P P
moderateimportance
observedfrequently.
in secondary
areas
Building and
engineering structures
viewed from afar.
3mm
1/270 P A A
P P P
S = Specifierto stipulate
P = Precautions
to minimiseeffects
(e.g. basements,chr
parks)
F3 Exposedsurfaces
not subjectedto close
scrutiny.
R = Required
E = Prevent occurrence
= Approval required
.~
~~gg~gate
surfaces
As defined, surfacesenter this category if tl}ey
have exposed aggregate on their surface. The
t d th I .f. ation from Parts
.f. t .
speci Ica Ion ex en s e c assl IC
t surface textureo
aggregae
The primary extensionrelatesto the selection
expose. n a cases
s are requi
provide a means of compliance.
When using exposed aggregatesurfaces,the
specifier must consider and define the following:
The aggregate
1. Weathering and staining characteristics
2. The colour and mineral type
3. The source of the material
4. Exposure depth
5. Angular characteristicsrequired.
8
t
The matrix
1. Colour
2. Texture
3. Thickness.
I
,
.,
I
,
_I
. .
.
Because exposed aggr~ga~~fInIsheswill only
~e.usedwhere the surfaceISvIsible, the formed
fInIshesF4, F5, F6 are extended to accept the
exposed aggregatestandard of F4E, F5E, a~d
to take precautions
Unformed surfaces
us
Ims may e app Ie 0 expose
aggregate unformed surfacesas U5E.
against particular
defects in
I t d.
se ec e mstances.
The constructor is required to provide
adequateprotection for all surfacesfrom the time
--
Technique
Examples
UI
Screeded
U2
Roated
U3
Trowelled
U4
Machine
US
Shallow
textured
U6
Deep
textured
U7
Grooved
US
Grooved
U9
Scabbled
Mechanical hammering of
concrete.
hardened
UIO
Special
textured
UII
Ground finish
Low speed coarse stone grinding to Direct wearing floors such asin warehouses.
remove thin weak surface layers/minor
ridges and to produce an even
"glasspaper" textured surface, that is, not
a polished surface.Used as a second stage
finish to U2, approximately 36 to 48 hours
afterlaying.
6
roads,
'
PART 2 - PRODUCTION OF
CONCRETE SURFACE FINISHES
i
I
18
GENERAL
Various types and uniformities of finish have
been discussedin Part 1, with attention being
given to the finish that is required. To achieve.
the defined finish it is essentialthat a systematic
approach be adopted, using consistently good
quality products. This includes good quality
moulds, forms, compaction equipment and
concrete.
i
i
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I
Off-the-forrn finish
This finish is the most common, often being
referred to as "fairfaced concrete". The finish is
pr?duc~d by the pattern of the concrete form
being mIrrored on to t?e concretesurface.~tmay
be t~e most ~conomical form of production,
provIded adequatemeasuresare taken to avoid
the need for remedial work after stripping. Such
measuresdemand the following precautions:
1. Att~n!iOn to detailing, with adequate provision
for JOints, edges, comers, drips and other
Item
FeatureDefect
Formwork
Preparation
Absorbency
Roughness
Cleanliness
Releaseagents
Evectiveness
Prity
Compatibility
Scaling, chipping.
Local discolouration, shade variability.
Retardation.
Mix design
Low strength
Excesscement
Proportions
Crazing.
Blowholes.
Inadequateventilation
Air pockets,honeycomb.
Excessivedrops
Excessivevibration
Non-uniform
Segregation,steps.
Crazing, laitance.
Plastic cracking.
Impurities
Inadequate
Uneven
Excessive
Contamination.
Crazing, warping.
Colour variation, efflorescence.
Abrasion, scour.
Placement
Curing
!
i
i
Table3
comparison of thesefactors,specificprovisions
to avoid blowholes may lead to hydration
discolourations and vice versa (Figure 6).
Characteristics of form materials.
The range of patterned and smooth textured
finishes is considerable. Some examples of
materialsusedto imprint patternsare discussed.
To b .sandblastedto raisethe grain rough
c~~ be:~elledor champhered for fluting;
clapboard fashion for bold texture etc.
Smooth board surfaces' For the smoothest
possible board marked fi~ish only dressed
tongued and grooved boards or grooved
,
~
.
.
Blowholes:formfaceswhich have an
..
incidence
ofsurface
blowholes.
Inthisregard
plasticfacedply whilst producinga smooth
surfaceislikelyto havea higherincidenceof
blowholes(Figure5);
plywoods.
These
tendface
to give
darkpolished
areas caused
by form
vibration
during
'.
.
-.
surface can
10mnotional
diameter
(halfscale
size).
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withhorizontal
raisedjoints.A betterfeature
f.
reducti.ons
in.load
cap'acity
an~ increased
maintenance
of steelformsis necessary
to
backing shuttering.
Mineral oil based release agents must not
be usedsincethesesoften the rubber. Castor
oil or lanolin are suitable release agents. On
shallow profiles no releaseagent is necessary.
It is recommended that concrete be allowed
to harden for 48 hours before demoulding
when not using a release agent. The rubber
liners should be cleaned down with water
brushing after striking and then lightly oiled
with vegetable or animal oil.
.
..
Surfc:-cmgs applied m the mould
(restricted to precast products).
- GRC.GRC
10
Figure7. Useofcementboardasformw~rk/inertoproduce
an evenc%uredtextured
finIsh.
6
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forms,grooveand
S d d
prea an screed
sand
"""""""'""'""'~="""C""'cc
Spreadandtamp
aggregate
intosand
Locate reinforcement,
inserts and fi~in\ls
Face-downtreatment
Wash sand off
aggregate before
placing concrete
'ila
~
. ,fa
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indentbattens
Figure8. San?bedtechnique
for face-down
special
finish
casting,
Th
'
th d
df
aggregate,
and
.
..
IS especially
.
f
or any size 0
suitable
for
exposIng
a medium
exposure
(cement
an d su rf ace
.
F.
8
the larger SIZ~S(Igure).
..'
. The technIque ca~ be applied m particular to
tilt-up slab construction.
The aggregatetr~nsferm.ethodcan be us~dfor
small areas of vertical casting. p:-ggregateIS.
pre-selectedand glued to a backIngsheetwhich
is placed in the mould and subsequentlystripped
off after casting has embedded the aggregate.
S rf .
1. d ft
ti
u acmgs app Ie a er cas ng
(
I )
precaston y .
The finish is that of the facingmaterialwith the
concreteprovidingstrengthand bond to the
element(ceramictile, brick, or stone).
Attentionmustbepaidto thecompatibilityof
11
6
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Figure10. Polypropylene~b~e
to hold shape In Its concrete
wet state.showingits ability
Figure11. polypropylene
Texturesand patterns
achievedusing
concrete.
pigments during
popular method
300mm
1I r11j'-
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!
3. Consisting striking times for face formwork
where used, or consistent trowelling
techniques for horizontal surfaces.Different
trowelling times or applications can give
colour variations;
4. Consistent curing methods used throughout
job. Variation in curing can give riseto serious
colour discrepancies.
Coloured aggregates: Both colour and texture
can be added to concrete surfacesby using
coloured aggregateswhich are exposed. The
methodsand depth of exposureare the sameas
those describedelsewhere(i.e. retarder, brushed,
sandembedded etc.).The significantdifferences
between this type of colouring and pigmented
concreteis that the surfaceusuallyhastexture as
well as colour. The exception is when the
hardenedsurfacesare mechanicallyground (see
later section)thus exposingsectionsthrough the
aggregate.
It is important that the coloured aggregateused
is of consistent colour and composition. It is
recommendedthat sufficientcoloured aggregate
is stockpiled at the beginning of the job to ensure
this consistency.
A list of generally availablecoloured aggregate
is given in IB 11.
Treatment after casting-=.Iyp~
R I ti I
th rf
eave y smoo su aces
Acid etching: The finish is achievedby washing
the hardened concrete surface with an acid
solution (10% hydrochloric acid).This will react
with and soften the cement paste which is
removed by washing. Featureswhich require
consideration when this technique is applied
include stability of the aggregate under acid
attack, the protection of hardware and the
protection of surfacesnot to be treated.
The acid action is noticeably greateron poorly
compacted concrete. Thus uniformity of
compaction and mix are influential in attaining
consistenttexture. Although the depth of texture
is dictated by the time that the acid is left on the
surface,it is usualto exposethe coarseaggregate
(between5 and 10 minutes)for best consistence
of result. During this time the reaction gives off
considerable fumes making ventilation
important.
Light blasting: blasting techniques involve the
use of sand or other abrasives to remove the
,
,
surface of the concrete. The abrasive is ejected
by hose directly on to the surface,with the depth
of exposure being dictated by the type of
abrasive, the pressure used, the distance from
the surface and the age of the concrete. On
14
I
~
mixing,placingandcompactionof theconcrete.
3 '
2
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1
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1:
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Figure12. Toolsusedin creatingfinisheson hardened
concrete:1 and2-pointtools:3-rollercomb:
4 - bushhammer:5 - combchisel.
~Ij
16
---
COST OF FINISHES
The cost will vary significantly throughout the
country and depend both on the plant set-up
(f
'
,
) h k ll
h
or
precast
UnIts
t e s i of t e operators and
a variety of other,factors.
As a general guide the following list indicates
I
('
d
d
f
t) ,
a typica
cost structure: m ascen mg or er 0
cos
1 S
th fini
ff th f
f" h
moo
0 - h e- orm miS .
2 , Painted
Surface dressIng
A typical specification for bag rubbed surface
dressing is as follows:
FINISHING TECHNIQUES
In a large expanse of wall it is generally not
2 ~rface d( ~o~dihon. ,
.
e grou miXs o~ld consistof 1 part cement
to 11/2to 2 parts fine sand, !he sand s~ould
be ~lean and free of ,deleteno us matenals,,
'
,fa
'
,a
'
The
'
White
cement
orwhite
sand
maybeused
m
placeof aproportionof theordinaryportland
cement and sand.The grout should have the
consistencyof thick cream,
'
'
'
th t
t I
d
ie ro s are e pe a are en ire y remove
'
exposed
'
'
holes
should
be
filled
as
I
t
rubbed thor
hi
oug
y m a Circu ar mo ion over
the area With cIean burIap or sponge rubber
4 pads
After the gr0 ut has sene
tiff
d suffiCiently any
'
'
'
'
'
'
"
~I
..
MmoT reD~~g
Reference to the type of finish will indicate the
requirementsto match colour and texture of any
repair in addition to the structural requirements
of the filling or patch.
During construction every effort should be
made to obtain a finish that does not require
patching; patching adds to the cost of finishing
and usually becomes more conspicuous with
age. If well-made formwork has been properly
erected, and concrete of proper workability has
been well compacted during placing,
honeycombing should not occur and pat.chi~g.
should not ~e needed..The extent to which It IS
safe to repair by patchIng depends upon the
?epth, ?osition an~ extent of the honeycombing
m relation to the size of the member. If
reinforcement is exposed or the honeycombing
occursat vulnerable positions suchasat the ends
of beamsor columns, it may be necessaryto cut
out the member c?':npletely, or in part, and
reconstruct. A decIsion <?nthe procedure ~o be
adopted should be obtaIned from the engmeer.
If only patching is necessary,the defective
concreteshould be cut out to a depth of at least
25mm o~ until solid con.creteis reached, the
~dges?emg c~t perpendicular to the surface,or
Cleaning
Following the surface dressing procedures for
stoning or bagging, it may be necessaryto
consider the removal of other stains.
Oil may be removed by using5-10% solution
of muriatic acid scrubbed onto the surface of a
wetted concrete and subsequently well rinsed
clean with water.
There should be no fins or mortar projecting
between form boards or panels of plywood
unless a rough texture is desired, but if there
should be an occasional small fin that is
objectionable it may be broken off carefully with
a hammer.
Rough spots, stains and hardened mortar or
grout can be removed by rubbing lightly with a
If possible, with
~small
underc~t.
An areaextendIngseveralcentimetres
be~ond
SUMMARY
The finishing of concretesurfacesusually reflects
the general workmanship and soundness of the
construction.Although no more or lessimportant
than other phasesof concretework, the finishing
is of importance to a much greatercrosssection
of people than the actual core of the job. Not
only the people directly affected by the job but
also any observer, casually, or interested in the
project in a specific way, will judge and pass
comment, based on the visual finishing.
18
.
--
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REFERENCES
NZS 3114 S
.fi ti
f C
.
peCI ca on or oncrete Surface
FmIshes SANZ 1980.
C tr I f BI
.h . C
on 0 0
emiS es In oncrete. W, Monks,
Cement .&. Concrete Associati
. .'on UK , 1981.
(now Bntish Cement AssocIatIon)
APPENDIX
A
- - t- -- .- -- - - -
structural, protective
in the one product.
- BLEMISHES
- ---- - - -- -
IN
CONCRETE
--.
- - - - -- -- --
of Blemishes in Concrete".
19
Description
Inherentcolour
variation
Materials:Inconsistentgrading,colouror
source,aggregatetransparency,
material
changes.Concrete:Incompletemixing,
segregation,
or variationin proportions,
ingredientommission.
/
'
moisture movement
within or from the
fresh concrete)
II
Formwork:
Variable
absorbency,through
joints,
variable
vibration.
Releaseagent: Uneven or inadequate
application. Curing uneven.
Dye discoloration
Oil discoloration
Retardation
Matrix near the colour of sand and lacking in Formwork: Retarder in or on form face;
durability
timber or plywood retardation.
Releaseagent: Water soluble emulsion;
creamor oil with excessivesurfactant(surface
active agent). Unstable cream; unsuitable or
excessivechemical releaseagent.
Banding
~
~
Description
Drying discoloration Variation in shadeof surfacefrom light to dark Curing: Different conditions.
Reinforcement: Inadequate cover.
20
Lime bloom or
efflorescence
Contamination
Dusting
Description
Honeycombing
I
Blowholes
Grout loss
Scouring
Steps
Plastic cracking
Form scabbling
weak,or damaged.
Releaseagent:Ineffective,inadequate
a
"8'
j
I
~
J
1
Unsatisfactory
or excessively
wet, or both.
!
!
Dishing
21
'
Description
Scaling
I
Spalling or chipping Piecesof concrete removed from the
hardened surface.
Deeper and usually more severethan scaling
Crazing
Scouring and
abrasion
Holes
Irregular cavities
Warping
Shrinkage cracks
22
6.
.
APPENDIX B A CHECKLIST OF
SPECIFICATION, DESIGN AND
CONSmUCTION MATTERS
a
.,
Structural detailing
.
. . .
. .
1. CrackIng can be mmImIsed by specIfyIng
more, smaller diameter bars rather than
fewer, thicker bars to provide the same
cross-sectionalarea of steel reinforcement.
2. The reinforcement should be wired securely
together or welded to fonn a rigid cage that
will not be displaced during concreting.
3. The correct cover should alwaysbe provided.
For ease of placing, it should be at least 11/2
times the maximum size of the coarse
aggregate.
4. The cover should be maintained by bar
spacers,secured at regular intervals, or by
battens that are withdrawn as placing
proceeds.
Cements
11 All the cement for one job should preferably
be from the same consignment; it should
certainly be from the same works.
Aggregates
1. The sand should be unifonn in colour and
grading throughout the contract.
2. The coarse aggregateshould be obtained in
separatesizesand recombined in the required
proportions.
18
Release agents
1. Releaseagents should be applied only to
clean fonn faces. Clean brushes, cloths or
sprays should be used.
2. The covering should be complete, unifonn
and very thin.
SupervIsion
1. The quality of the finished work will be
dependent upon the experience and the
calibre of the supervisory personnel.
Weather conditions
1. Extremes of temperatures may have an
untoward effect on the concrete.
B
h"
atc IDg
Striking
1. The top of the concrete should remain
covered until striking.
2. Striking times should be the same wherever
possible- the target time for all verticalfaces
is 2 days.
3. After the formwork has been removed, the
concreteshould be protected from accidental
damage.
4. All~posedsurfacesshouldbecoveredwith
polythene sheeting to prevent drying out.
5. Rustfrom projecting reinforcementshould be
prevented from washing over the face of
finished work.
Remedial work
1 R
d. I
k.
the need for repairs
. should be avol.ded by
.
erne
la
wor
IS
se
ld
om
en
ti
re
success
Iv
155N 0114-8826
c'.if:.;c~
ccan Z[II]
Cement& ConcreteAssociationof NewZealand
;-~
Level 6/142 Featherston Street
PO Box 448 Wellington
New Zealand