Setting a Standard for Decorative Concrete the ACI’S New Guide Shows What’S Possible and Tells Contractors How to Accomplish It

42 D+D AUGUST 2014 Decorative concrete requires special materials and methods to achieve a consistent, high-quality aesthetic finish. Here, a mix of integral color and penetrating, reactive stain turns concrete into a design element at the Morton Arboretum, Lisle, Ill. Photo courtesy of Butterfield Color. Q+ Got a concrete problem? Concrete A Ask the experts: [email protected]. Setting a Standard for Decorative Concrete The ACI’s new guide shows what’s possible and tells contractors how to accomplish it. By Jamie Farny, Portland Cement Association, colored concrete can amount to more than 30 percent in some and Larry Rowland, Lehigh White Cement Co. major metropolitan markets. Some ready-mix concrete producers add pigment to 50 percent or more of their products. Q: What can I offer customers to help their concrete projects re- Yet many installers remain unaware of decorative concrete’s po- ally stand out — and help my business stand apart from the tential or don’t know proper installation methods. Owners may not competition? get the results they seek. Some find decorative concrete cost-pro- Decorative concrete is often described as one of the fastest grow- hibitive. ing segments of the concrete industry. While estimates are un- Recognizing these knowledge gaps, in December the American available for the overall quantity of decorative concrete installed, Concrete Institute (ACI) published a comprehensive guide to the 43 Concrete Q+A materials and methods used to produce decorative concrete finishes. With input from all segments of the industry, ACI Committee 310, Decorative Concrete, de- veloped the 45-page Guide to Decorative Concrete (ACI 310R-13) on materials and techniques for imparting aesthetic finishes to concrete flatwork. The committee engaged a variety of experts to share techniques and hands-on experience. They created what the ACI believes to be a guide reflecting proven techniques and the latest information available, but with standard materials and processes rather than proprietary systems. As a guide, ACI 310R is written in non- mandatory language and is “intended for guidance in planning, designing, executing and inspecting construction. … If items found in [the guide] are desired by the Ar- chitect/Engineer to be a part of the contract documents, they shall be restated in mandatory language for incorporation by the Architect/Engineer.” This said, it is conceivable that many will use the document to develop project speci- fications. Some might use it to help identify effective means for quality control of their projects. And many will surely use it as an idea generator. More than 80 color photo- graphs depict projects and techniques. Many of those techniques can be combined for unique effects. In addition to at- tention to the specified materials, mixture designs, concrete placement, curing, protection, sealing and other treatments, this guide also considers the effects of these treatments on the overall aesthetics of fa- cilities. Users may find many ways to make A transparent, water-based stain colors this polished concrete floor at the College of Dupage, Glen Ellyn, Ill. Though often judged on appearance, decorative concrete surfaces like this one must also stand up to use. beautiful concrete flatwork, applying best Photo courtesy of Butterfield Color. practices established by leading applicators and suppliers. of Concrete Artisans, Newtown, Pa., material producers, specialty finish appli- started ACI Committee 310 after recogniz- cators, designers and educators. The re- Experts Gather in Common ing disconnects in the decorative concrete sult of their six-year effort details Cause, Language industry. recommendations for the production of The guide got its start in 2007. Michael To tackle the issues, ACI Committee 310 cast-in-place decorative concrete flatwork. Smith, longtime ACI member and founder brought together concrete contractors, ACI 310R addresses decorative overlays, 44 D+D AUGUST 2014 have experience with these special materials and methods have been reluctant to specify or place decorative concrete. The Guide aims to take the mystery out of producing decorative finishes. Techniques for coloring and texturing plastic concrete and hardened concrete, for example, are described by finish type. Understanding Key Variables Polished concrete finishes have emerged Many of the techniques detailed in the ACI’s new guide to decorative concrete can be combined for unique as resilient, environmentally friendly and effects. Here, an antiquing release agent is used with integrally colored stamped concrete to create the appearance of old-world stone pavers. Photo courtesy of Butterfield Color. attractive options. Durable and low-maintenance, polished concrete eliminates the dry-shake hardeners, embedments, em- terms attempts to standardize the differ- need to cover perfectly good concrete with bossing, engraving, etching, imprinting, in- ing terms that have grown up over the glued-down topping materials, such as lays, stains, stamping, and tooling and years and supplements standard ACI CT- vinyl composition tile or carpet, that don’t application of decorative overlays. 13 ACI Concrete Terminology. last as long as the concrete beneath. The Through its discussion of these and Decorative concrete requires special ma- guide covers grinding and polishing con- other techniques, the guide offers a com- terials and methods to achieve a consis- crete, explaining how to specify the class mon vocabulary for the decorative concrete tent, high-quality aesthetic finish. To date, of grind and level of gloss to yield the de- industry. A chapter on definitions of trade many designers and installers who don’t sired aesthetic for almost any project. It Click our Reader e-Card at durabilityanddesign.com/ric Click our Reader e-Card at www.durabilityanddesign.com/ric 46 D+D AUGUST 2014 The guide aims to take the mystery out of producing decorative finishes. Here, the 5,000-square-foot (465-square-meter) stamped concrete patio at a residence in Saratoga, Calif., is colored with dust- on broadcast colorant in shades of nutmeg on walls and trim, and cappuccino on the deck. The spiral galaxy designs are created with a glow-in-the-dark aggregate. Photo courtesy of Tom Ralston Concrete. ments should never detract from concrete’s durability. To achieve a long service life, decorative concrete may require that a few extra considerations be addressed. For example, where appropriate the guide refers readers to other ACI documents, details the key variables in slab prepara- dust, dirt or act as a medium for microbes. such as ACI 308.1 for curing, and then pro- tion and placement, such as floor flatness, The guide addresses these and other vides specific suggestions for things that that affect the appearance of polished “green” attributes in a section on sustain- should be handled differently for decora- floors. ability. tive concrete. The guide clarifies special As with any decorative concrete finish Decorative concrete is often judged pri- practices unique to decorative concrete to when properly applied, polished concrete marily on appearance, but it must stand up ensure that it gives clear, consistent rec- is environmentally friendly. It won’t harbor to use, too. Imparting decorative treat- ommendations. Click our Reader e-Card at durabilityanddesign.com/ric H 48 D+D AUGUST 2014 Repairing Concrete concrete finishes is reduced maintenance While much of the guide covers the compared to other building systems. process of placing new concrete installa- While particular material producers or tions, there is also a big market for repair product manufacturers are knowledgeable and renovations. Sometimes budgets, time about guidelines for maintaining their fin- frames or other remodeling considerations ishes, it’s important to have a basic under- don’t allow for complete removal or re- standing of what can affect a decorative placement. Concrete that is structurally finish and the best ways to protect it for sound and in relatively good condition can long-term durability and appearance. The be aesthetically improved with the right guide includes a chapter on general rec- materials and techniques. ommendations for maintenance of decora- The guide discusses surface preparation tive finishes. and crack repair to existing slabs to ready The guide can aid facility owners in un- them for application of new decorative derstanding what constitutes appropriate treatments. It also describes special proce- care for their decorative concrete, whether dures and tools used for accomplishing they maintain it themselves or contract it these repairs and the products required to A rehabbed terrazzo floor in a Veterans of For- out. Many decorative contractors have es- make them. eign Wars Hall gleams after being polished to a tablished solid businesses in maintenance. 1,500-grit finish. A penetrating oil and stain re- Retailers with high-traffic stores, for ex- pellent provides protection. ample, offer maintenance opportunities in- Maintaining Durability, Photo courtesy of Joe Reardon, SASE. Aesthetics cluding spot repair and periodic resealing One benefit common to many decorative of decorative concrete floors. Click our Reader e-Card at durabilityanddesign.com/ric 49 Concrete Q+A A polished decorative overlay reflects windows and equipment in a concrete products manufacturer’s training area. The overlay was ground, densified and polished to a 1,500-grit finish. Photo courtesy of Joe Reardon, SASE. Supporting a

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