Decorative Concrete

Presentation

by Dennis Ahal
Ahal Contracting Co., Inc.
There are many methods and uses of
decorative concrete, for both exterior and
interior applications.

Concrete has come a long way from when

it was used as a pathway to keep you out
of the dirt.
One of the oldest methods used was scored joints,
to not only control cracks but also to create a
design.
Exposed aggregate is a method that has
been around for a long time. The best,
most durable method is to use a high
proportion of aggregate in the mix rather
than seeding the surface.
This mix looks extremely dry but is actually a 4”
slump concrete that has a high aggregate content.
The concrete is struck off. Any surface voids are
filled in with concrete, not with paste.
The surface is bull-
floated and closed up
with a hand float.
Again, any void areas
are filled in with
concrete and not paste.
A surface retarder containing dye is sprayed on the
surface to ensure complete coverage. The slab is
then covered with a polyethylene sheet to prevent
air contact with the surface.
Either later that day or the next day, depending on
temperature, the surface is broomed and washed
to remove the surface cementitious coating and
expose the aggregate.
The view when approaching
the walk appears as a
gravel path. The smaller
the aggregate, the denser
the amount at the surface.
One of the ways of
disguising expansion
joints is through the
use of brick borders
or imprinted
concrete strips.
One of the ways of
decorating concrete is
through the use of
integral color. Bag
material has been
used for many years
but some coloring
systems now use a
liquid color agent.
The color always appears
darker while the concrete is
wet.
This integrally colored concrete is being used to
grout rocks in a small decorative stream bed.
This walkway was
designed to resemble
a dirt pathway which
would be handicap
accessible even after a
rain.
This walkway consists of traprock aggregate and
charcoal gray integral color. It is being given a
light acid wash to remove any film residue before
being sealed with a penetrating sealer.
Notice the high aggregate content at the surface.
When dry the walkway appears much lighter, even
though is has been sealed.
 You can use a glossy surface sealer, but this
must be maintained since it will deteriorate
through wear and UV breakdown.
This area received a light colored integral color to
blend with the aggregate so it appears as a gravel
path. The area where sprinklers have wet the
walk appear darker. This is what a glossy surface
sealer would look like.
This project used the
same aggregate but
two different integral
colors to highlight
the main walk area
and the borders.
Expansion joints are used for crack control and to
show a pattern. Control joints are somewhat
difficult to install in exposed aggregate since the
joint tool tends to push the aggregate down and
leave an area of plain grout.
This walk received
areas of integrally
colored concrete
along with plain gray
concrete to create a
contrast. Integral
colors give the
concrete a tone but
not an intense color.
This amusement park entrance used integrally
colored concrete with diamonds of surface applied
color hardener, which created interest and hid
drains that occurred at some of these areas.
These adjacent areas used two different integral
colors. The bench wall that separates them is also
concrete.
The second method of coloring concrete is through
the use of dry shake surface applied color hardener.
This method gives a deeper, more intense color.
The material which is broadcast onto the surface
adds to the durability of the surface.
The color hardener consists of color, cement,
and silica quartz aggregate.

A more durable emery aggregate can be used

for high traffic areas.
The correct application
for this color hardener
is two coats, usually at
90 degree angles from
each other when
possible, to assure
adequate coverage.
As you can tell from the
lack of hard hats and the
model of the truck, this
photo was taken a
number of years ago.
However, the process is
still pretty much the
same. The color is
worked into the surface
with a bull float.
The edges are
run with a tool to
create a nice
clean edge.
In this photo, a
stamping plastic is
laid on the surface
and imprinting
tools are placed.
The tools are tapped
into the concrete
surface to create a
pattern.
The finished areas show a pattern with expansion
joints used to control cracking. These joints are
imprinted deeper to receive a grout in the joints.
The grouting makes the cobblestone pattern look
more authentic. The advantage of using concrete
is that the slab is reinforced with rebar and stays
together as one unit.
This close-up of the grout shows the loafing of the
cobblestone pattern, created by stamping plastic
and deeper joints. Since the slab works as a unit,
there is no stress on the individual grout joints.
This grouted walkway is a running bond brick
pattern.
This basket weave
patio has other colors
broadcast onto the
surface to create
interest.
This walkway and step
project was placed
next to an old stone
foundation. Imagine
the hand work that
would be required to
fit pavers adjacent to
the stone.
This restaurant area used an 18” x 18” tile with
grouted joints.
This atrium area
used surface
applied color
hardener with
tooled joints, which
were grouted.
This project used multiple colors and patterns to
define areas and foot traffic patterns.
The areas of the landings were adjusted slightly to
fit the steps.
This was a 2” topping over existing concrete which
contained many joints. A ¼” rubber mat was used
to separate the topping from the sub-slab.
Polypropylene fibers were used in a pea gravel
mix, and dry shake color hardener was applied.
This area received imprinted color hardener as an
accent, with a picture frame tooling of the joints.
This is actually an extra step and needs to be
defined in the specification.
This is an imprinted area adjacent to an integrally
colored salt finish area. The banded areas are cut
with hand tools.
The salt finish is achieved by broadcasting rock
salt and troweling it into the surface. The salt is
washed away a day or two later, leaving voids.
This area consists of an integrally colored field
which received a broom finish. The borders have
color hardener and are hand cut. This method,
while expensive, is less costly than pavers or bricks
cut to fit this circular pattern.
This area was also hand
cut. These types of
areas were used as
accents so, although
they cost more, they
did not materially affect
the entire project cost.
The darker borders were poured with the main
areas in order to save labor on forming and
finishing.
This sample area shows a tooled joint being
installed in fresh concrete.
Strips of masonite are placed in the joint to
separate different colors as they are applied to
various areas of the surface.
Fields and borders can be placed at the same time,
saving forming and placing costs while receiving
different colors and finishes.
Separate colors are being applied to adjacent
areas of the same slab.
The color hardener is floated and troweled into the
surface.
Edgers are run on
the separate colors
before imprinting.
The final product, showing multiple colors and
finishes:
This area received a highlight, or flashing, of other
colors to add an accent.
This shows a fishscale pattern merged into a
running bond pattern, but the slab was placed as
one piece.
Notice the expansion joint separating two slabs
and the herringbone pattern placed with the
limestone border, which is a separate color and
pattern.
Logos can be incorporated into the design.
Another logo:
Notice the grouted joints:
Another method of
imprinting requires
the use of a release
agent, which prevents
imprinting tools from
sticking to the slab
surface.
The slab is finished
as previously.
The release agent is broadcast onto the surface.
The release agent most often is of a contrasting
color to the color hardener.
Texture mats are placed on the surface of the
slab. These mats impart not only a design or
pattern, but also a texture.
This is an overhead view of dry shake color
hardener on the surface, before and after being
floated and troweled into the surface.
There is also a release agent on a portion of the
surface (gray area), some of which has been
imprinted with a texture mat.
Texture mats come in various sizes and textures.
They are tapped
into the slab
surface to impart
both pattern and
texture.
Texture mats are flexible, to allow imprinting next
to vertical surfaces such as windows and walls.
Sometimes they are overlapped to eliminate
excess pattern lines.
Notice the clefting
on this 5’ x 5’ slate
texture mat.
This is a 12” pattern
with little contrast
between the color
hardener and the
release agent. Some
of the release agent
remains on the slab
surface, giving
highlights and a feeling
of depth to the texture.
This shows the
use of two colors
and three
patterns. The
border against
the wall was
placed with the
main gray slate
area.
This curbing is not limestone. It is concrete with
white color hardener applied.
This area was imprinted and textured to resemble
an old, used brick.
Chemicals were used to stain the surface and add
color variation.
The joints were grouted.
The use of multiple colors and textures can add
interest, and visually separate areas.
Bands or strips of contracting colors can be used
to hide expansion joints.
This shows the use of banding for joint control.
This project uses a pattern to create a defined
drive lane. This surface is all at one elevation.
Another method of coloring concrete is
through the use of stains over new or
existing concrete, or over toppings which
are designed to accept stains.
Slab surfaces are sectioned off by tape or saw
cutting to divide stain colors if patterning is
desirable. This area is being taped and stained.
A stencil is being used to create a design.
This stain is being applied by brush to a new
surface.
This stain was applied to an old slab. Notice the
variation of stain penetration.
Do not expect a stain color to be uniform. This
is part of the beauty of the product. If you want
it to be all one uniform color, paint it.
The use of chemicals, as shown on a previous
project, help give this floor a mottled look.
The use of saw cuts separate the various stain
colors. The use of chemicals help give highlights
to various areas.
The backsplash
and countertop
are concrete.
Saw cuts, chemicals, and various stain colors are
used to accent this area.
This floor was
color hardened,
saw cut, and
stained.
The use of two color
stains give contrast to
this floor. The saw
cuts are only ¼” deep
to separate the stain
areas so they don’t
run together.
The same applies to
this project. This
floor was specified
with no control joints
and light reinforcing.
The design was saw
cut in later at a
depth of ¼”, and
two stains were
applied.
This intricate logo was saw cut and stenciled on a
new floor.
This basement craft area was one of our first stain
projects, performed at an employee’s home.
This logo is over a topping which was poured
without joints, but on which a shrinkage control
admixture was used.
The stain does not take evenly everywhere. Saw
cuts were made to separate the stains.
A stencil was used to protect the lettering, and the
background was sandblasted.
The overall effect is dramatic.
This floor was
colored with a
surface applied color
hardener.
Saw cuts were
made and the
banded areas
were stained.
The joints were grouted.
This slab is being textured with a texture mat.
The border and inset areas are stained to create
contrast, instead of two colors being used in the
finishing process.
This patio was placed using a light beige color
hardener, and a textured slate pattern was used.
The joints were deepened to accept grout.
Individual slate blocks were stained using multiple
colors of stain.
The joints were then grouted.
The front walk and porch received the same
treatment.
The vertical surface of the steps was colored,
textured and stained.
A flowable topping is added over an existing slab.
This slab receives a trowel finish.
The topping is scored, stained and sealed. Notice
the control joint in the original building is honored.
Many intricate
designs can be
incorporated.
Really bright colors:
This project consists of a concrete overlay over a
base slab. The slab was colored and stained.
Many designs can be incorporated into the floor
surface.
High intensity colors are available in certain
overlays.
An exterior retail area:
Terrazzo strips were used to divide the topping
into separate areas to receive different colors of
stain.
The stain has a
mottled, leathery
look.
A sealer was
applied to the
entire surface
area.
A wax was applied over the sealer to take the
wear. The wax can be re-applied periodically in
the high usage areas, without stripping the entire
surface.
The terrazzo strips allow for clean, crisp joints and
corners.
 Periodic
maintenance
keeps the slab
looking bright
and new.
Since this was a topping, the terrazzo strips could
have odd shapes without cracking concerns.
The mottled, leathery look was the result of the
process, not necessarily the intent.
The use of multiple
stains can add to
the results, as long
as everyone
understands that
not every square
foot of the slab will
accept the stain
the same.
The use of stencils and sand blasting created this
design in an integrally colored slab.
The use of surface
applied color hardener,
stencils, and sand
blasting created the
etched writing look in
this floor.
A closer look at the writing:
A closer look at the decorative border:
Here a thin coat of a high intensity overlay
material is being applied.
 Use a separate section to specify decorative
concrete.

 Don’t let someone do your decorative concrete

work just because they were low bidder on the
flatwork.

 Don’t be afraid to negotiate your specialty work,

or at least qualify your contractors prior to bid
time.
 This is a product that is manufactured in the
field, not a factory. Approved samples are
always a must before starting the actual work,
so expectations are the same.
The use of decorative concrete is limited
only by your imagination.
Decorative Concrete
Presentation

by Dennis Ahal
Ahal Contracting Co., Inc.