Decorative concretes An overview
Concrete is one of the most versatile building materials available, and can be designed and placed to the most exacting structural demands or the most discerning aesthetic requirements. It also ranks as one of the more sustainable building materials.
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Contemporary concrete usage has evolved beyond its origins as a basic construction material. It can be manipulated into structurally creative and artistic expressions, defying common perceptions of what a mixture of sand, cement, stone, and water should look like. Contrary to the half-held belief that concrete is a dull material that is used unimaginatively, it can be used in an exciting and inspiring way while benefiting from being a highly durable building material.
Brad Bowman's early success with stamped concrete may have been the catalyst for decorative-concrete innovation, but it is the larger realization that concrete offers almost limitless potential for architectural expression that has propelled the industry to the range of diversity seen today.
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With the explosive growth and faster phase in construction and new innovations in the designs of buildings, the use of innovative designs in decorative concretes, are gaining recognition and hold very good future in the coming decades in India.
This article mainly brings out the journey of decorative concretes, how the decorative concrete methods have evolved over a period of time and various methods of decorating the ordinary looking dull grey concrete to an elegant fabulous.
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 systems include stamped concrete, acid staining, decorative overlays, polished concrete, concrete countertops, vertical overlays.
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History of Decorative Concretes
There are many branches of the decorative concrete industry that have built up over the last 50 or 60 years across the world but some of the earliest evidence of the birth of the industry dates back to the early 19th century. Between 1890 and 1920 many companies, especially precast companies who produced members for building facades, used colours and stains to make their work more interesting unique. Some mixed pigment into fresh concrete for a casting; others submerged their castings in solutions similar to chemical stains.
Early in the 20th century it became accepted fact that metallic oxide shades do not fade in the ultraviolet glow from sunlight. Craftsmen from the concrete industry started making use of pigments to apply colour onto concrete.
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Invention and patenting of stamped concrete by Brad Bowman.
Brad Bowman caused significant interest in decorative concrete with his invention. He developed and patented the tools and process for stamping patterns in concrete flatwork. The genius of his work is that others could use his process to install their own creative ideas.
As a contractor, Bowman installed exposed aggregate concrete walls and slabs in USA. By 1950 he began experimenting with ways to pattern his work. He first tried a single wooden blade, and then two blades set apart the width of a brick, and finally platform stamps that imprinted several pattern units at a time. His first stamps were of wood, then sheet metal, and finally cast aluminium platforms. In 1970, the Bomanite Corp., using his patents, franchised contractors across the United States to install decorative concrete using this process. Bowman's fascination was with the creative process-a passion that stayed with him until his death at age 90.
Bowman's cast aluminium tools were heavy, had a limited life, and printed only patterns, not textures into the concrete. Jon Nasvik became the first to develop urethane stamps that were light and long-lived. In the late 1970s he built a plastic stamp that imprinted both pattern and texture on fresh concrete. The first pattern for commercial use was a broken used brick pattern but over time there was a huge expansion in the designs available for imprinting.
The methods of applications and designs have drastically changed following the stage whether the users were exposed to only a handful of designs and standard building tools used in other industries. As the industry kept growing, an increasing number of companies ventured into the field of manufacturing concrete products. With such market conditions, manufacturers began producing materials in higher quantities and the designs too became more intricate.
Today the decorative concrete market is growing faster than any other segment of the concrete industry in developed countries, with hundreds of manufacturers and thousands of contractors. But none of this could have happened if not for the development of strong, durable concrete. It takes highly skilled concrete finishers and an understanding of concrete basics to install work that makes owners want concrete.
Indian Scenario
In India use of decorative concrete applications started somewhere in 2001 after the establishment of commercial Ready-mixed concrete plants in 1995 .The decorative concrete industry is slowly gaining acceptance in metros like Bangalore, Mumbai, and but there is very long way to establish itself as an Industry like USA , Europe and Australia.
Many major Ready-mixed concrete companies like RMC Readymix (India), Lafarge India , Ultratech Concrete , ACC Concretes and many other RMC Producers have started producing decorative coloured concretes which are used for making stamped concrete ,stencilled concretes and Concrete polishing which is a very good sign for the growth of t decorative concrete industry in India. There is a need to develop a network of Decorative concrete applicators that are well trained to execute decorative concrete applications in India.
Infosys campus at Mysore has used pink coloured decorative concrete extensively for their walkway to give a very elegant look to the campus replacing granite flooring. Pink coloured concrete supplied by RMC Readymix (India) at Mysore for Infosys has been the source of attraction since many years.
Decorative Concrete Systems
Decorative Concrete Systems - Concrete designs are one of the hot new trends for concrete patios, concrete floors, entryways, countertops, pool decks and more. From expansive new homes with elaborate concrete driveways to budgeted one-room remodels showcasing a stunning, stained concrete floor, the attraction is continuing to grow when it comes to using concrete for decorating. Concrete is no longer plain, grey and boring, it is now thought of as a beautiful decorative element.
- Decorative Concrete systems are excellent for,
- Roadways
- Park ways
- Walk ways
- Swimming Pool Decks
- Drive ways & Patios
Coloured Concretes
For many admirers of decorative concrete, the best attribute is that each installation is totally unique. Concrete can assume nearly any shape, design, pattern or texture. But the one characteristic that most distinguishes decorative concrete is colour, whether used subtly to blend with nature or boldly to make a dramatic design statement.
Frankly, unless you're a purist and prefer concrete in its plain-gray state, there's no reason not to enhance it with colour. The number of different products for colouring concrete has never been greater, and many manufacturers offer an extensive palette of shades to choose from for coloured concrete. And although you'll pay more for coloured concrete, the amazing transformation will be well worth the investment. In the hands of a creative contractor, these colouring mediums permit an endless array of decorative effects, from rustic earth-toned sidewalks and patios that harmonize with the surrounding landscape to vibrant multicoloured floors that double as works of art.
Decorative Concrete Applications
Concrete designs are one of the hot new trends for concrete patios, concrete floors, entryways, countertops, pool decks and more. From expansive new homes with elaborate concrete driveways to budgeted one-room remodels showcasing a stunning, stained concrete floor, the attraction is continuing to grow when it comes to using concrete for decorating. Concrete is no longer plain, grey and boring, it is now thought of as a beautiful decorative element.
Today's homeowners, builders, and designers recognize the value in using concrete in their designs and plans. Decorative concrete transforms traditional grey concrete into warm brown floors, expensive slate-looking patios, and weather-resistant outdoor kitchen countertops, to name a few.
Decorative concrete/decorative cement lets you decide which hue of red will give you that spanish tile look on your pool deck at half the cost, and what personal mementos you'd like to embed in your new concrete countertop kitchen island. The advancements in concrete tools, concrete stains and dyes, textures, and patterns have made concrete the most versatile, durable and cost-effective material on the market.
Out Door Applications
Concrete Patios
Despite stiff competition from wood decks, the concrete patio is gaining in popularity as an essential element in today's backyards in countries like USA and Europe. According to a survey conducted by the National Association of Home Builders, the share of new homes with patios jumped from 35% in 1995 to 46% in 2005, heralding concrete as the most popular patio material in USA. In seven of nine geographical regions identified in the study, poured concrete is the most commonly used outdoor surface material in luxury-home construction coming in ahead of concrete pavers and natural stone. With more decorative options than ever before, concrete patios are attracting homeowners who want an outdoor surface that offers the ultimate in design versatility.
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Concrete patios also have the edge when it comes to durability and low maintenance. In addition to serving as a gathering zone for lounging and entertaining, concrete patios allow homeowners to seamlessly blend interior and exterior living spaces. They are the perfect decorative flooring surface for outdoor kitchens and living rooms, complete with cosy seating areas, fireplaces and water features. What's more, this outdoor floor offers unlimited design options. When enhanced by stains and integral colours, concrete patios can be colour coordinated to match a home's exterior or landscape. They can also be stamped or engraved in patterns that mimic other popular paving materials, such as brick, flagstone, slate and tile.
As an investment, concrete patios typically cost less than patios made of brick or natural stone because they are less labour-intensive to install. The lower price tag combined with the wide array of patterns and colours available make concrete an economical choice for most budgets. Plus, concrete is easily formed into any shape to accommodate backyard space restrictions.
Upgrading your backyard with a decorative concrete patio is also an investment that will provide many years of enjoyment while improving the look of your landscape. Concrete is easy to maintain and can stand up to the harshest of weather conditions. Unlike paving stones, you won't have joints between units where grass and weeds can sprout. And unlike wood, concrete won't warp, rot or require periodic staining.
Concrete Driveways
It wasn't long ago when deciding on a driveway material was easy: asphalt or concrete. Today, the "concrete" choice has expanded to include an astounding array of decorative concrete options. Sometimes referred to as a cement driveway or as painted concrete, decorative concrete is one of the most reasonable ways to make the entrance to your home look more elegant.
Although plain gray concrete flooring is still installed most often, more people are catching on to the dazzling effects possible with decorative concrete and seeing the instant curb appeal a decorative driveway can give to any home, no matter what the style If you already have a concrete driveway, you can still give it a decorative makeover. The concrete industry has introduced many products and methods that can rejuvenate or resurface existing plain-gray driveways.
To make sure that your concrete driveway looks good for many years to come, there are important steps your contractor /applicator should follow during installation. How well your driveway looks and performs long-term is largely related to the quality of workmanship and materials that go into it. Finally, if you're concerned about the environment, concrete is one of the "greenest" materials you can use to build a driveway.
Concrete Pool Decks
One of the biggest trends in outdoor design today is an attractive decorative concrete pool deck, a coloured, textured and inviting area surrounding the pool that does more than provide a safe, slip-resistant deck for sunbathing and barbecuing. In ground pool decks are now given nearly as much attention as the interior design of the home.
Decorative concrete has opened the doors to creating pool decks that complement the exterior of the home, meld with the outdoor environment, and replicate exotic and traditionally expensive materials.
The benefits of concrete are many. It can provide an extremely durable surface, as compared to a tiled deck or even stone. With the new techniques for stamping and applying decorative concrete, any look can be created at a fraction of the cost. Concrete today has emerged - extremely flexible in its application.
Concrete Walkways
Concrete walkways or sidewalks are more than just a way to get wherever it is you're going-they can provide much-needed curb appeal to your homes and buildings, and they are fast becoming a point of artistic expression by way of a multitude of decorative concrete options available.
While plain gray concrete is still the most often surface installed, as seen on most concrete sidewalks, there are numerous decorative concrete alternatives sure to dress it up, taking your sidewalk from boring to amazing. The best part is that most of the options will work just as well on an existing walkway, because the concrete industry has rapidly developed many decorative products that can be applied to existing plain concrete walkways.
Concrete has become the new material of choice for designers across the U.S. Decorative concrete in all of its stained, coloured, moulded and personalized glory is popping up in retail stores, trendy restaurants, offices and homes everywhere. Now you can find out why!
Decorative Concrete Pavers
The use of concrete pavers, often referred to as paving stones, is growing rapidly on both commercial and residential construction projects. Interlocking pavers form a patterned surface which can be put into service immediately. Pavers are manufactured in various textures and colours. A big benefit of pavers is that they can be removed and re-installed, which reduces future service interruptions.
The use of concrete pavers is expanding rapidly. There is plenty of growth to go: in Europe there are 100 square feet of pavers installed per person annually whereas, in the United States it is only 1 square foot per person. Pavers can be installed on your driveway, on a walkway, and on a patio. Pavers come in a variety of patterns, colours and styles to suit most any design idea.
Countertop Applications
It's well known fact that concrete has become a material that individual home builders and designers are requesting and weaving into their homes, offices, retail outlets, restaurants, etc., in the most amazing ways. But leading the charge in the concrete craze are concrete countertops. Now a day’s concrete counters are becoming popular, in countries like USA and other developed countries and similar trends are likely to happen in India also due to more and more decorative precast manufacturers establishing their manufacturing facilities here in the coming years.
Concrete Floors
It has become the new material of choice for designers and homeowners across the United States and in European countries. Concrete floors in stained, coloured, painted, and personalized glory are popping up in retail stores, trendy restaurants, offices, and homes everywhere. Staining concrete floors offers numerous options for interior rooms including nearly limitless designs, colours, and even health benefits.
One of the most common places you'll see decorative concrete these days is under your feet. Whether it's acid-stained, painted, overlays, micro toppings, radiant floors, or a unique personal floor, concrete floors offer a range unlike any other material. Concrete flooring, sometimes referred to as cement flooring, no longer has to be gray and boring.
Now colouring concrete, or applying textures, patterns, saw cuts, etc., can bring new life to this traditional substrate. Concrete can be so uniquely designed or so naturally coloured that it blends seamlessly with other elements in a room-oftentimes, you don't even realize it's a concrete floor you're standing on!
"We have stamped concrete, slate, stain, overlays; It's just amazing what technology has done. Many are welcoming, embracing, and anxiously pursuing concrete floors for their own home projects.
The advantages of Decorative concrete floorings are many:
- It enhances the integrity of architect's designs.
- They are easy to maintain.
- It's easy to change, especially if you sell your home; the next owner can place carpet or wood on top of the concrete slab.
- They are a good alternative to carpet if you have allergies.
Staining Concrete
Staining concrete is one of the most popular applications for transforming concrete slabs. Often referred to as coloured concrete, homeowners, designers and builders are drawn to stained concrete because of the unique outcome that can be achieved combining colours, application techniques, etc., on cement flooring and other substrates. The results are limited only by the creativity of those involved in the stained concrete process.
Because of concrete's porous qualities and neutral tone, it is the perfect blank canvas for topically applied colour. Using acid-based chemical stains, decorative concrete contractors have been able to achieve rich, earth-toned colour schemes resembling natural stone, marble, wood, or even leather, giving a completely custom look to cement floors, concrete driveways, patios, walkways, pool decks, concrete walls and more.
Stamped Concrete
Stamped concrete, commonly referred to as patterned stamped concrete or imprinted concrete, is concrete that is designed to resemble brick, slate, flagstone, stone, tile and even wood. Stamped concrete can be used to beautify pool decks, driveways, entries, courtyards, and patios.
| Due to the wide array of options when it comes to concrete pattern, concrete colours, and the cost of stamped, or imprinted concrete in relation to the materials it is a substitute for, the choice of stamped concrete is becoming more popular and frequent.Colours and patterns for stamped cement are often chosen to blend with other stone, tile or patterned concrete elements at the residence. Complex designs incorporating steps, courtyards, and fountains can be achieved when patterns are pressed into the concrete. Stamped concrete can also be blended with other decorative concrete elements such |
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as exposed aggregate finishes and acid-etch staining, along with a particular pattern, such as running bond brick, hexagonal tile, worn rock or stone.
Concrete Overlays
Do you want to permanently cover up surface imperfections in existing concrete? Or turn a plain slab from drab to fabulous looking? With today's decorative overlays, it's easy to give almost any concrete surface, indoors or out door, a complete face-lift and at a much lower cost than removal and replacement. The real challenge is choosing from among the many resurfacing products available and the diverse array of decorative finishes possible. There are multiple options available for achieving any look imaginable with a concrete overlay.
Although cement-based overlays have been around for decades, many of today's systems blend polymer resins with cement, sand, and other additives to improve performance, wear resistance, and aesthetic qualities. Polymer-modified overlays can be applied in layers as thin as a credit card or up to several inches thick without delaminating or failure. They adhere well to existing concrete and resist damage from salt, chemicals, UV exposure, freeze-thaw conditions, and abrasion.
While most types of polymer-modified overlays offer similar performance benefits, each system has its own unique characteristics. Overlay manufacturers use different types of polymer resins, often blending them to produce proprietary products with distinct physical attributes. Many of today's decorative overlays use acrylics or acrylic blends because these resins provide excellent bond strength and UV resistance.
It's important to be aware that not all existing concrete can be resurfaced. The underlying base for an overlay must be sound. If your concrete is heaving, has severe cracks, is spalling due to damage from de-icing salts and freeze-thaw cycles, or resting on unstable soil, resurfacing will not solve your problems. This is when total replacement will be your best option.
Concrete Resurfacing
Conventional wisdom holds that old concrete, with cracks, surface discoloration, or surface imperfections, must be removed and replaced if improving the look of the concrete is the goal. But there are many options available for transforming that drab concrete patio, driveway, or floor into a new, decorative, coloured concrete surface. Plus, you'll save money, conserve resources, and eliminate disposal problems.
Completely resurfacing concrete with a polymer-modified overlay is one way to upgrade the look, and you can choose from a wide variety of colour and pattern options. If your concrete is in good condition but just needs a facelift, you can also stain, stencil or engrave it to improve the appearance.
Concrete Polishing
Polished concrete is fast becoming the ultimate no-wax flooring material. Thanks to recent advances in polishing equipment and techniques, contractors are now grinding concrete floor surfaces, whether new or old, to a high-gloss finish that never needs waxes or coatings. Factor in the superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete now a days.
Because polishing is a multistep process, you can choose the level of sheen from satin to high-gloss that meets your maintenance and aesthetic requirements. This versatility makes polished concrete an ideal flooring material for a variety of applications.
Be aware that the process of polishing concrete floors requires a great deal of expertise and the use of specialized heavy-duty polishing machines equipped with diamond-impregnated disks that gradually grind down surfaces to the desired degree of shine and smoothness. Considering the investment in equipment and the skill required, it's definitely not a project for the do-it-yourself.
Advantages - superior durability and performance of concrete, and it's no wonder why more retail, warehouse, and office facilities are opting for polished concrete flooring as an alternative to marble, granite, tile, linoleum, or coated concrete.
Concrete Dyes
| For decorative contractors who use concrete as a canvas for colour, the combination of chemical stains and concrete dyes is a perfect synergy. Although stains have received much applause for their amazing colour transformations, dyes deserve equal kudos. These underrated colouring agents can achieve vibrant tones simply not possible with stains alone."Dyes can get the applicator into more vibrant colours such as yellow, blue, and purple to name a few," The nice thing about working with dyes is that you can mix them at the jobsite to obtain your desired colour. Dyes are often used in conjunction |
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with acid stains to produce a variegated look and, in most cases, complement the already stained floor.
Translucent dyes penetrate the concrete drying in less than one minute in most climates with minimal cleaning required following the application. Therefore, the applicator completes the job about 60% faster than a typical acid stain due to reduced dry time and less cleaning. If you protect the surface with a topical sealer and/or wax you get a very vestal floor. Most water-based, solvent-based, or urethane-based sealers are compatible with dyes. In conclusion, dye is a powerful solution in virtually any application when the installer is seeking rich mottling effects with minimal installation time.
Conclusion
Decorating of concrete is here to stay for long-time throughout the world and fast catching up in India as it continues to be more superior in terms of durability and performance in comparison to traditional flooring applications like marble, granite, tile, linoleum, or coated concrete .
Many Decorative concrete contractors, companies and applicators from USA and Europe have established their business in India by directly opening their office or through franchisee to capture the big potential available in India due to its huge housing requirement, since India is the second largest producer of cement and generally 50 % of the cement consumed goes into concrete making, creating a huge market for decorative concrete applications.
There is a need from the architect’s community, specifiers, builders and the construction industry in India to adopt these new technologies and different decorative concrete options as an alternative to traditional tiling applications.
Authors:
 L. R. Manjunatha |
 Dr. Sandhya R. Anvekar |
References:
1. www.concretenetworks.com
2. Photos courtesy from RMC Readymix(India) for pink coloured concrete and Fibre reinforced stamped concrete.
3. Wikipedia on decorative concretes.
4. www.concreteconstruction.net
About Authors:
1. L.R.Manjunatha, Research Scholar, Bharatiyar University, Sr .Manager –Marketing, RMC Readymix(India) (A Division of Prism Cement Limited); Email : lrmanjunatha@gmail.com.
2. Dr. Sandhya R. Anvekar. Professor & Head Research, MSRIM, Bangalore.