Decorative concrete is a great option for pool decks, patio’s, porches, driveways, and sidewalks. While we are accustomed to the process involved in installing decorative concrete, many of our customers are very interested in how this installation is achieved.

Our latest project was for the City of Hickory and the Hickory Crawdad’s baseball team. This project consisted of installing two new walkways and then stamping the concrete with an antique brick pattern.

The first step in the installation of new concrete is to properly form the area. The standard pour depth for concrete is 4 inches.

It is important that the surface is smooth and level. Uneven areas in the ground will require more concrete and thus, increase the cost of the installation.

Once the area has been properly formed and graded the installation of new concrete can begin. We used a 3000-psi concrete with pea gravel for this project. Pea gravel is much easier to work with when stamping concrete.

For this pour we are using an integral color called brick red. Integral color is mixed into the concrete at the plant. This process allows for a more even color throughout the concrete.

Concrete must be level. In order to achieve this a screed must be used. Screeding concrete will remove excess concrete from higher areas and help fill in lower areas.

Once the screeding process is completed it is time to begin troweling, floating, and edging the new pour. Floating is the process of smoothing the concrete and helping to remove moisture. As water evaporates from concrete it allows the concrete to firm up and brings us closer to being able to stamp.

Once the concrete has been troweled, floated, and edged, the new concrete will look like this.

It is at this point that standard concrete would be either machine finished or broom finished. Decorative concrete adds several other steps.

In order to properly stamp concrete the concrete must be firm enough to withstand the pressure of the stamps and the individual(s) standing on the new surface. However it must be wet enough for the impression to take into the concrete.

Before the stamping process begins we spray a release agent onto the concrete. This allows the rubber stamps to pull away without sticking to the concrete. This is very similar to spraying a pan with cooking spray prior to cooking.

After the concrete has been prepared with the release agent the stamping process can begin.

The rubber mats fit together to form a pattern. After the mats have been placed they are tamped down with a special tool. The tamping process transfers the pattern from the stamps into the concrete.

Specialty tools can be used to correct imperfections that might occur during mat transfer.

Once the concrete has been stamped we allow it to finish curing over night. Once the concrete has set we move to the finishing stages of the project. These final steps will include color washing and sealing the new concrete.

In order to give the new concrete a more natural look, we use a silicon based coloring agent.

A small amount of this charcoal color is added to 5 gallons of water.

The colored mixture is then placed into a watering can and poured directly onto the stamped concrete surface. This process is called color washing. This will add additional color and it will help to antique the finish.

After the color washing is complete the concrete will look like this...

Stamped concrete is never finished until it has been properly sealed. We use an acrylic concrete sealer for all of our decorative concrete installations. The sealer helps protect the concrete as well as adding a “wet” look to the finish.

Because this is a commercial installation, we added red quartz sand to the surface. This adds traction and will make the concrete much less slippery. The sand is not visible on the finished product.

Here is the completed walkway...

Remember, we have many different style and color options when it comes to stamped concrete designs and decorative concrete. To get a quote on your own decorative concrete project, contact Stone Bond Construction online or call (828) 256-7915.

What is epoxy? This is one of the most frequently asked questions that we receive at Stone Bond. There are many lengthy and scientific answers to this question but the simple answer is that epoxy is a type of plastic. Stone Bond epoxy is a two-part epoxy that we make from our own proprietary blend. Each kit that we offer, whether in 1-gallon form or in 10-gallon form, comes with equal parts of hardener and resin.

So how does the epoxy work? The liquid hardener and liquid resin do not form epoxy until they are actually blended together. Once equal amounts are combined together, a chemical reaction starts. Because of this chemical reaction, epoxy does not technically dry. Instead of drying the epoxy actually cures. Once the hardener and resin are combined, the mixture will begin to heat. This heating is what allows the epoxy to cure and ultimately become hard.

Because of the chemical reaction that begins when the epoxy resin and the epoxy hardener are combined, there is no way to stop the curing process. Epoxy is also a somewhat finicky material in that it responds differently in hot and cold temperatures. When the winter chill comes, epoxy will become very thick, almost like molasses. However in the heat of summer epoxy can become as thin as water. Because of this, the temperature will dramatically effect the time it takes for epoxy to cure.

For example, if the outside temperature is around 80 degrees, epoxy has a pot life of around 15 minutes. However if the temperature is around 40 degrees, the same epoxy will have a pot life of approximately 25 minutes. This is what makes our 2 part epoxy better. You can mix as little or as much as you desire, depending on the situation.

Stone Bond epoxy is unique from most other epoxies in that it is clear and it mixes with equal parts of each ingredient. Clear epoxy is great for a variety of projects because it does not discolor your base or the materials that you are working with. Being able to mix your epoxy in equal parts is a double bonus because it allows you to mix small quantities and store any un-mixed epoxy until it is needed at a later time.

We have proudly produced our own epoxy since 1993. The same epoxy that we offer to the public is the very same epoxy that we use on a daily basis. Our epoxy can be used in a variety of ways and over the next few weeks we will be showcasing some of the projects that you can tackle on your own. To give you an idea about some of the ways that Stone Bond epoxy can be used here is a quick list:

Epoxy Ideas

* Resurfacing existing epoxy stone decking

* Epoxy Countertops

* Surfacing a tabletop

* Decoupage doors

* Transforming garage floors

These are just a few of the many ways that you can use epoxy. Stay tuned to the Stone Bond epoxy blog to get inspiration for your next DIY project and don’t forget to purchase your epoxy here.