ulie is a onetime registerednurse who took a class onstaining concrete to findways to bring color to herbasement floor and walls.Todd was shoeing horseswhen he encountered an

intriguing “bluestone” pavement anddecided he had to learn how concretecould be made to look like that.Today, Julie and Todd are among

the wide spectrum of people whohave turned their curiosity about thedecoration and coloring of this an-cient building material into careers inthe expanding universe of decorativeconcrete.

Career changerJulie Thompson is president of De-

signing Concrete Inc., based in Wood-stock, Ill. She wasn’t planning a careerchange when she took that long-ago

14 PWC JULY/AUGUST 2010

Neb., is flourishing.The stories of Julie and Todd may

seem like drastic career departures.Then again, decorative concrete is abold new world, limited only by one’simagination.There’s some technology involved, to

be sure, and skills to hone. But the keysare a willingness to work hard andlearn, say veterans of the trade.

An affinity for designThompson started her business more

than seven years ago, after deciding thatit represented a good opportunity forwomen like her, who possess a knackfor style, design and color.An early “breakthrough” job was the

Children’s Garden at Morton Arbore-tum, in Niles, Ill., where she created atree-leaf design with stains and engrav-ing on thousands of square feet of walk-ways. She had templates made for the

Cementitiouscreations filla growing niche.

class and began experimenting withthe techniques at home.But sensing opportunity, she eventu-

ally left health care behind and startedher own business, bringing artistry tothe raw canvas of gray concrete.Todd Rose was introduced to the

field years ago, among the horses ofBeaufort, S.C., when he happened toask about a bluestone pavement at thefacility where he worked.The surprising answer: “It wasn’t

stone; it was concrete.”Rose’s reaction: “I knew if you could

take a commodity product like con-crete and make it look like that, you’veinvented a better mousetrap.”Already mulling a change in ca-

reers, Rose embarked on a mission tolearn the secrets to such transforma-tions. Today, more than 10 years laterand 1,000 miles away, Todd RoseDecorative Concrete in Lincoln,

ConcreteCanvasJJ By Joe Maty

Odyssey of discoveryRose’s bluestoneepiphany began anodyssey that ledhim to work at TheStamp Store, anOklahoma City con-crete-stamping busi-ness, where hebecame marketingand training direc-tor. The job “did aworld of good” inintroducing him tothe technology andmethodology of dec-orative concrete.He went on to

work for three yearsas decorative-concrete manager for aNebraska concrete contractor, thenstarted his own business about threeyears ago.

“We’ve done very well,” he says.The company’s reach has now ex-panded to Omaha. Its capabilities in-clude stenciled and stampedconcrete, staining, polished concrete,

epoxy overlays and coatings.Rose is currently seeing strong de-

mand for overlays on existing interiorconcrete in sustainable building proj-ects. “We install a thin overlay of poly-mer cement, then stain and seal withwater-based sealers,” he explains.The methods include application of

acid stains and water-based dyes. “Itdepends on the look they are after,”says Rose. “With acid stains, you’relimited to earth tones. If you want deepor bright colors, you have to go towater-based stains.” Sealers are typically based on water-

borne epoxy and polyurethanechemistries, although epoxies are re-stricted to interiors, due to the ten-dency to discolor under UV exposure.Rose also offers stenciled concrete,

mostly for exteriors. He finds the effect“more authentic” than stamping and farless costly than pavers. Stenciling is more common with new

concrete but can alsobe used on existingsurfaces. Typically, theprocess entails pour-ing the concrete, plac-ing the stencil, andadding color hardener,sometimes referred toas “dry shake.” Textur-ing is often added withsome type of roller,and the stencil is re-moved.The result is a sur-

face with the look ofstone or brick—“everything from her-ringbone brick to

flagstone, cobblestone or rustic brick,”he says. The final step is a sealer, usu-ally a solvent-based acrylic, for exteriordurability and color enhancement.

WWW.PWC-MAGAZINE.COM PWC 15

engraving on existing concrete, with ce-ment overlays used in some areas. Theearth tones were produced with acidstains, which create color by reactingwith the cement in concrete.Since then, she has created a variety

of designs, including noteworthy proj-ects at parks in Itasca and Lemont, Ill.,with themes reflecting the park namesand motifs—from bumble bees, toshooting stars, to clover on a vine, evento multiplication tables. For the cloverat Clover Ridge Park in Lemont, sheused sandblasting and stenciling, thenapplied acid stain.“I like to use acid stains in exterior

settings, due to the penetration they pro-vide,” she says. If the clear sealer wearsaway, it can be re-applied to reinvigo-rate the stain colors.She also likes “the way acid stain mot-tles. You have a natural reaction withthe concrete, and you get the mottling. Ialso feel it’s more durable, as it goesdeeper into the concrete.”Thompson also offers concrete polish-ing and application of epoxy coatings. See CONCRETE on next page

Photos: Todd Rose Decorative ConcreteExterior stenciled concrete creates an authentic brick look at far lesscost than pavers, says Todd Rose, of Todd Rose Decorative Concrete.

Ahal Contracting Co.Ahal Contracting Co. has done decorative concrete since the1970s. Projects include a casino floor transformed by a starburst.

16 PWC JULY/AUGUST 2010

‘I could see it taking off’Shawn Wardall saw a future in dec-

orative concrete after more than 20years in construction. His introductioncame in the early 1990s, when thecompany he worked for applied con-crete stains on a hospital expansionproject.“I could see it taking off,” says

Wardall. In 2000, he and some partnersstarted their own construction com-pany, and decorative concrete becamea fast-growing part of that business.Eventually, he decided to focus fulltime on the niche, sold his shares inthe business, and started SpecializedConstruction Inc. in Waterloo, Wis.“There’s tremendous opportunity,”

Wardall says. “There’s so much youcan do with concrete—from the dura-bility standpoint, from the fact it’s a re-newable resource, the sustainability ofconcrete, and the potential for cus-tomizing.” Wardall works hard with clients to

match the right decorative-concretesystem to their aesthetic and functionalneeds. Horizontal surfaces, mostly in-terior, make up most of his work,which includes new construction, ren-ovation and restoration. His portfolioincludes overlays, polished concreteand staining.Notable recent projects include an

office building in Verona, Wis., whereWardall created a medieval-castle lookon new concrete. The project involvedconcrete polishing and applying fivedifferent dyes to create the impressionof a stone floor. A lithium silicate den-sifier was used in the polishingprocess; denatured alcohol served asthe stain carrier, due to the chemistry’spenetration capability.Polished concrete has been a strong

growth area for Wardall’s company. Hecredits the technology’s sustainability,its “green” profile, low maintenancerequirements, and aesthetic appeal:

“It’s just a great win-win scenario foreverybody.”Another memorable project was a

floor at the Potawatomie tribe’s head-quarters in Crandon, Wis. There,Wardall executed a design that repre-sented sacred tribal symbols. He usedstencils and water-borne stains, with aurethane sealer topcoat.Success in his trade requires cre-

ative thinking and a willingness tolearn the variety of techniques avail-able, Wardall says.“It takes a certain type of individ-

ual—one who thinks outside the box—to get into this. If you’re tied to onekind of work, it may not be of interest.”

The age of polishingThat kind of flexibility and vision

have made Ahal Contracting Co. ofBridgeton, Mo., a veteran in the deco-rative field. The company, establishedin 1945, started doing stamped-con-crete work in the 1970s, says ArthurPurdy, architectural division manager.Today, Ahal’s portfolio includes con-

crete polishing, microtopping, acidstains, dyes, exposed aggregrate andacid washing—“just about anythingyou can possibly do with concrete,”Purdy says.Low-maintenance concrete polishing

with acid stains and dyes has made it a See CONCRETE on page 18

hit with large commercial contractors,especially for grocery stores, educa-tional facilities, and other institutionaland commercial facilities.“Everybody is looking for low main-

tenance,” Purdy says.In concrete polishing, the floor sur-

face is prepared with diamond-grind-ing machines, followed by applicationof chemical densifier/hardeners. Astain or dye may be applied for color.The surface is then polished with pro-gressively finer-grit diamonds, and asealer is applied for protection.“We see it both ways, with color and

without,” Purdy says. In fact, he adds,the client on one recent school projectopted to color half of the floor and keepthe other half natural.For lower-cost polishing, the concrete

surface may be ground, then the hard-ener/densifier and dye applied. This re-quires fewer grinding/polishing steps.

Micro magicMicrotopping refers to installation of

relatively thin layers of polymer-ce-ment overlays. Unlike polishing, mi-crotopping makes sense if the concretefloor is damaged or flawed. The thin ce-ment layers hide imperfections, andcolor and designs can be created on theoverlay, says Purdy.

CONCRETE from last page

Photos: Specialized Construction Inc.Shawn Wardall of Specialized Construction Inc. created a "Dungeons and Dragons" basement rec room. The dragon's flames fill the main part of the room surrounding the "sphere of life."

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“If you have damage, polishing willbring that through,” Purdy warns. “Itwon’t hide it, either with or withoutcolor.” (This should be made clear upfront to clients, he adds.) On the otherhand, polishing creates a harder sur-face than microtopping. Planning is especially important in

polishing and coloring, Purdy adds.Something as simple as scaffoldingplaced on a newly cured floor by an-other trade can cause curing variationsthat can leave shadows.Ahal’s work also includes stamping,

where impressions are placed in anew concrete surface that is either in-tegrally colored (with pigments incor-porated into the mix) or hassurface-applied color. These designsare completed with hand-tool cuttingnear walls.

18 PWC JULY/AUGUST 2010

color of a dye will add $2 or $4 persquare foot.

Trends brewingIn the shifting world of trends, Rose

reports, exposed aggregate is currently“hot,” while polished-concrete feveris slightly cooling, losing ground toterrazzo.With exposed aggregate, the con-

crete is poured and a chemical ap-plied to keep the top layer fromimmediately hardening. The cementpaste at the top is then washed off toexpose the aggregate in the concretemix. The effect is gaining popularityfor patios, office building entryways,retail stores and other settings for itsslip resistance and style.Whatever the trend, Rose’s company

also fields “odd requests for some-

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CONCRETE from page 16

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Old buildings, new businessWith new construction on the wane,

remodeling of existing concrete is onthe rise, Thompson reports. One com-mon approach involves applying apolymer-cement overlay to renew thesurface, followed by staining.To determine the exact approach and

design for each project, Thompson vis-its the site for a look at the architecturalstyle. “You don’t want to do a contem-porary design with a traditional site,”she explains.Of course, the client’s budget also

plays a role. A modest project mightuse only one stain color, while a moreambitious one might have multiplecolors and more detailed patterns,Thompson explains.Polishing can also vary in cost. A

basic approach might keep the con-crete’s natural color, while adding the See CONCRETE on page 21

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CONCRETE from page 18thing unique in a floor or counter-top.” He cites a concrete-overlay floorhe did in a microbrewery, using thebrewer’s own beer as a carrier in fourdifferent stain colors. (The projecttook a PWC Green Award; see theMay-June 2010 issue.)Although the result is more of a cu-

riosity than a significant technologyinnovation, Rose says it offers a hintof the creative opportunities possible.“This is what I love about decora-

tive concrete. It’s so flexible, in termsof price, function and aesthetics.”The “beer stains” took “a little bit of

experimenting,” he adds. Caution wasneeded, as applying the stain to thenewly placed overlay too early couldcause the polymer cement to emul-sify.

The knowledge imperativePerhaps the most important lesson

that Rose has learned over time is toget as much information and educa-tion as he can. “Go to more than onemanufacturer’s training, And, howshould I say this… take everythingthe product rep says with a grain ofsalt. I’ve seen people go broke due tothe chemistry involved in what wedo.”Trial and error may be enlightening,

but it’s also costly. For example, henotes, freeze-thaw cycling can wreakhavoc with liquid-applied products,and a green-color acid stain will turnblack if applied to concrete that’s lessthan six months old.“Stick to the basics,” he advises.

Most projects will involve straightfor-ward staining or stamping, he says;highly original artistry is the excep-tion.Nevertheless, continuing education

is a must, he adds.“I learned from people with a great

deal of experience and [from] beingvery hungry for knowledge. In my

opinion, it takes that kind of commit-ment to be successful.”

Joe Maty (jmaty@paintsquare.com)is the editor of www.jacjournal.com,the digital edition of the Journal of Ar-chitectural Coatings. pwc

Circle No. 24 on Reader Service Card

Now at pwc-magazine.com!Get ideas for decorativeconcrete for walls, floorsand even countertops!Do it right. Here are themusts for acid staining success.

Decorative Tips, Treatments and Techniques Stains, dyes, textures and other treatments and techniques can create endless variety and color to transform concrete into visually arresting designs. Here are some ideas. Note: This summary is based in part on a review of decorative concrete methods and materials by Jamie Farny of the Portland Cement Association, published in the June/July 2008 Journal of Architectural Coatings. Other sources also provided information. Flatwork: One of the first decorative techniques for concrete, this involved imprints of images or objects. That has evolved into color treatments combined with imprinting by stamps, to give the impression of natural stones, brick and even wood planks. Walls: Creative wall finishes include exposed aggregate, in which cement paste in the concrete is removed from surfaces to showcase the beauty of the aggregate. Also popular are segmental retaining walls, or SRWs, composed of concrete units stacked together and often colored with pigments and textured for different finishes. Countertops: Decorative-concrete countertops can give the impression of natural stone, or be treated to create other effects. Coloring and texturing: This includes several options.

• Integral coloring. Here, color pigments are incorporated into the concrete mix or applied to

the surface in a “dry shake” form as part of the finishing process. • Stains. These include chemically reactive “acid” stains and water- or solvent-borne dyes and

tints. Acid stains react with the concrete to produce insoluble color compounds with a limited color range. Dyes and tints do not chemically react with the concrete, but they offer a broader color range. Sealers are typically applied after the dye or tint to protect the coloring agent.

• Waxes. These can enhance the effect of color treatments and improve color retention. Paints and coatings: Paint and coatings formulated for concrete can be used for protective and decorative purposes, and are based on various chemistries. Unlike stains, paints and coatings bond and form a film on the surface but do not chemically react with the substrate.

Important considerations include “breathability”— the coating’s permeability to moisture transmission. Impermeable paints should not be applied to surfaces where moisture must exit the substrate. Coatings types that are permeable, or allow transmission of moisture, include acrylics and cement-based products.

Oil-based alkyd coatings should be avoided due to the resin’s interaction with alkali in the concrete. High-performance concrete coatings include epoxies and polyurethanes. Terrazzo and texturing: Concrete’s varied textures include terrazzo, exposed-aggregate finishes, sandblasting and grit blasting, burnishing, and the use of form liners. Traditional terrazzo is based on portland cement and decorative aggregates, or chips, of marble, quartz, glass or another suitable material, polished to a smooth finish. Terrazzo based on an epoxy resin matrix also offers varied color and composition choices, but is a different type of composition than cement-based terrazzo. Terrazzo is best known as a highly decorative and durable floor treatment, but it can also be used for walls and countertops. Polished concrete: Polished concrete involves grinding a horizontal surface with diamond-impregnated pads, applying a chemical hardener or “densifier,” and then polishing with finer-grit diamonds. Stains or dyes also may be used to produce color. Densifier materials include sodium, potassium, and lithium silicates; magnesium fluorosilicates; and proprietary silicate/siliconates.

Acid Staining Success By Joe Maty Successfully applying stains and dyes to horizontal concrete surfaces requires careful attention to the condition of the concrete, says Howard Jancy, an industry authority on coloring and other decorative-concrete treatments. Jancy is principal of Jancy & Associates, a manufacturers-representative and architectural-consultant firm serving building-materials manufacturers. He has nearly 25 years of experience in the decorative-concrete industry, mostly with Butterfield Color Inc. and L.M. Scofield Company. Making a clean start A critical first step before staining or dyeing is total removal of any sealers, waxes, coatings, oils, or other contaminants that could interfere with the coloring agent’s ability to penetrate the surface, says Jancy. “Check to see if the stain can penetrate by using a simple water test,” he says. “If the concrete is hard troweled, the penetration (of the stain or dye) may not be adequate. If the water beads, you may have to prepare the concrete by mechanically sanding or grinding, or chemically etching to open the surface.”

He adds: “It is important that you test the preparation technique, ensuring it does not negatively change the concrete’s appearance or the anticipated colorations of the stain. Also, the presence of curing compounds, sealers, coatings, or waxes may have the same effect.” A shiny appearance is an immediate clue that these kinds of substances may be present, or that the surface has been hard troweled, he says. With a simple water test, drops of water are placed on the surface. If the water is immediately absorbed and darkens the concrete, the surface is “open,” and the coloring agent will penetrate effectively.

As an alternative, small diluted drops of muriatic acid may be applied on inconspicuous areas of the concrete. If fizzing or bubbling result, penetration is occurring and an acid reaction is taking place. This is generally a positive indicator when working with chemical or reactive stains. Removal options The type of substance or contaminant on the surface can determine the removal method. A concrete-curing compound, for example, is easier to remove than an epoxy coating. The remedy may be as simple as cleaning with a relatively mild soy-gel type agent, or as aggressive as use of stronger chemicals or mechanical abrasion. In any case, the surface should be re-tested after removal and cleaning to ensure that the process was successful. “You don’t always know what’s on there,” Jancy says. “An experienced contractor will know how to assess the situation. It’s part of being a good stain applicator.” Penetration and reaction For acid-based concrete stains, penetration and reaction are required to facilitate effective coloring. But water-based dyes also must penetrate to ensure long-term durability and color, Jancy says.

“There’s no such thing as a standard piece of concrete,” Jancy says. “But the simple answer is, if water can’t penetrate, stains won’t. A shiny, gloss finish could mean a coating, curing compound, or hard troweling. If the floor’s still shiny after you do the prep work, it’s probably not ready yet.” Acid stains are composed of hydrochloric acid and a metallic salt; the acid causes the reaction with the concrete, while the metallic salt produces the color. Mechanical grinding or a chemical treatment can be used to prepare the surface, but acidic agents should be avoided, as they would react with and “consume” the cement’s calcium hydroxide and diminish the stain’s reaction potential. With acid stains, the composition of the concrete can also affect the result. For example, the presence of fly ash in the mix “can throw things off,” Jancy says. Application Acid-stain solutions are typically applied with a garden-type sprayer, and the acid reaction can require several hours. The surface is then rinsed with a mixture of water and a neutralizing agent such as ammonia or baking soda. The mixture is scrubbed into the surface and then removed by flushing with water followed by a squeegee or wet vac.

Avoid splashing onto adjacent surfaces such as wood, metal, or drywall; this could cause etching, staining or blemishes.

Use gloves and goggles to protect the skin and eyes throughout the process, and ensure good ventilation in enclosed areas. Manufacturers recommend flushing and disposing of residues according to local or state regulations or guidelines. Dyes vs. stains Although non-acidic or non-chemical concrete coloring agents are often referred to as stains, Jancy says he prefers the term dyes: small-particle pigments suspended in a water or solvent carrier. Dyes can provide a much broader color palette than chemical (acid) stains, but some users prefer acid stains for the enhanced permanence of the coloring effect and the “mottled” look they can produce. Dyes, on the other hand, can provide a more predictable color result, since there is no chemical reaction and the concrete mix design does not present a variable. A common solvent used with dyes is acetone, which is not classified as a volatile organic compound (VOC), but nonetheless carries flammability and odor issues. Acetone, however, can provide enhanced penetration of concrete and offers rapid evaporation, accelerating the speed of the coloring process. Joe Maty is the editor of www.jacjournal.com, the digital version of the Journal of Architectural Coatings. Contact him at jmaty@paintsquare.com.