Using Texture Mats to Create Stunning Decorative Concrete Hardscapes

By Perry Vayo and Clark Branum, BRICKFORM

Completed sealed random stone.

Today?EUR??,,????'???s Landscape Contractor is faced with an extensive array of products to choose from when designing concrete hardscapes. Texturing and coloring choices have increased dramatically over the years. The older texturing tools, called ?EUR??,,????'??cookie cutters?EUR??,,????'?? have taken a back seat to the more advanced urethane, texturing mats.

Layout the design so that it is a multiple of the size of the texture mats you will be using. That way your patterns will start and finish cleanly and produce the best appearance for a specific pattern.

A. Preparing the substrate.

Plan the layout so that the long lines of a given pattern run across the line of sight. This will produce a more pleasant appearance in the final work. Use existing structures such as retaining walls or buildings as points of reference. Consider columns, planters, walls, steps and drains so that the pattern placement has a natural stopping point.

Where needed, rebar and wire should be installed and all slabs should be at least 4” thick.

Creating a Strong Foundation

Next, you need to address the sub-grade. Since the sub-grade is the foundation for the new concrete, the importance of preparing it correctly is critical. Be sure that at the time of the pour the sub-grade is completely dry, as recommended by The American Concrete Association (ACI). It should be uniformly compacted and there should be no frost present. You can use a crusher-base or construction sand-base over the natural soil to facilitate uniform drainage. The general rule is that the depth of the sub-base should equal the depth of the concrete. The proper concrete mix should be considered. Consult with your local ready-mix producer for the proper mix for your particular project and your area. Your ready-mix producer may want to be aware of your requirements:

B. Rebar reinforcement may be needed on some projects.

?EUR??,,????'???? Clean, well-graded, non-reactive aggregate.

?EUR??,,????'???? Batch-to-batch uniformity is essential

Placing and Coloring using Color Hardener

Surrounding areas should be protected to prevent unwanted discoloration. Newly placed concrete should be screeded then wood floated to an even surface, graded to within +/- 1/8” in ten feet in any direction. When working in hot and windy weather use an evaporation retarder to prevent cracking from rapid drying at the surface.

Once the bleed-water has evaporated, but the concrete is still plastic, apply the color hardener evenly, using the broadcast method. Do NOT add additional water to the surface during finishing. The necessary moisture must come from the concrete to create the needed density for the color-hardened surface. For best results, the color hardener should be installed in two applications.

C. Screeding concrete using a wooden 2X4.

The first application should use approximately two-thirds of the material. The surface is then floated.

A second application should use the remaining third of the hardener. The surface should be re-floated and then troweled. Keep a small quantity of color hardener on hand, in case any touchups are needed.

D.The broadcast method for applying hardener and release is the most widely used method.

Creating the Texture

The concrete should be firm enough to support the weight of the finisher but still soft enough for the texturing tool to imprint the surface without excessive force. Inexperienced installers should limit the size of the areas they work.

?EUR??,,????'???? Broadcast a dry release agent in a contrasting color onto the concrete, stopping just ahead of where you plan to place the first mat. Liberally apply the release on each mat prior to placement. Release agent must always be used, and should be applied in an even coat just thick enough to prevent the damp concrete from bleeding through to the mat. A word of caution – over-application of the release powder will prevent the texturing tool from making a crisp imprint on the concrete surface.

E. Color hardener is floated into the surface of the fresh concrete.

?EUR??,,????'???? Use square forms as a reference line. Place the first mat in position on the corner of the form where the concrete was first poured. Using light, even force, tamp the mat straight down into the concrete with a pounder until it is flush with the surface.

?EUR??,,????'???? Repeat the process, placing a second mat next to the first mat, taking care that the mats are kept tightly aligned until firmly embedded into the concrete. You will need enough mats to span the width of the area, plus enough to begin the next row.

F. Placement of texture mats after antique release has been broadcasted.

?EUR??,,????'???? Texturing ?EUR??,,????'??skins?EUR??,,????'?? and ?EUR??,,????'??floppies?EUR??,,????'?? should be used in tight areas and companion touch-up tools are necessary.

When you have finished the entire area, check your work and fix any imperfections you find. Touchup work needs to be done while the concrete is still workable. If any flaws are found, repair them using floppies, skins, and touch-up wheels designed to work with the main tool. Let the concrete set for at least three days and then wash off the excess release agent to the degree necessary to reveal the color below and the desired results. After the new surface has been allowed to cure for 28 days, finish it with an acrylic-based quality sealer. This will bring out the richness of the color and protect it from wear.

G. Remove the release with a broom and water to the degree necessary to the achieve the look.

Many manufacturer?EUR??,,????'???s of decorative concrete products offer workshops and demonstrations on how to use their products and tips for a perfect installation, so check it out. Designing with decorative concrete can increase your portfolio and your profitability.

Building Blocks

1,000 to 1,500: Dollars, the average cost of a set of tools used in concrete texturing.

3-5: Days after installation, textured concrete should be pressure-washed with 2,000 PSI pressure washer. Source: Pacific Concrete Images

28: Days, recommended length of time to allow a new surface to cure, before applying an acrylic-based sealer. Source: BRICKFORM