The HOW TO SERIES documents are designed to give step by step instruction on the exact procedures it takes to complete various jobs. Keep in mind that some of the instruction may vary slightly compared to other documents published by Elite Crete Systems. For questions pertaining to those variations, please feel free to contact your Technical Support Representative.
Job Overview: 1/4" Thin stamped overlay on existing concrete
The job below started off as a concrete sidewalk and driveway with typical surface pitting. Of course, tear out and replacement was an option but one that would cost much more than the homeowner wanted to spend or could afford. Although this document will detail all application procedures as it pertains to applying an exterior thin stamped overlay on a sidewalk and driveway, the same instructions can be used to apply the same finish to a driveway, commercial pool deck, patio, sidewalks, etc.
1. Pressure wash the concrete with a 3,000 PSI power washer. Using a rotating turbo tip will increase the productivity immensely. Take your time while pressure washing as your objective is not simply to clean the concrete but to also remove any loose concrete that simple rinsing will not achieve. It is not uncommon for it to take 5 hours to pressure wash a 1,000 sq. ft. pool deck or driveway.
2. Start with an all plastic sprayer or watering jug and mix 1 part muratic acid to 8 parts clean water in this container. The reason for all plastic is because the muratic acid will corrode metal parts. It is important to add the acid to the water, not the other way around. Adding water to acid can make the acid splash out and on you. Keep in mind you are working with acid and proper safety attire such as protective eye wear is recommended.
3. Spray or pour the acid and water solution on the concrete. You will see and hear a light fizzing of the surface. This is normal. Continue until the entire concrete substrate has been completed.
4. Using the same plastic sprayer or watering jug, mix 1 part ammonia to 8 parts clean water and apply to the concrete surface in the same manner. This acid and then ammonia wash will not only open the pours and capillaries of the concrete but will also neutralize the pH of the water in the concrete as well.
5. Rinse the surface off with water from a garden hose.
6. Mask off the garage door, down spouts, mulch and anything else that you do not want to get your initial skim/base coat on. It is important to use good masking tape. Blue or green masking tape is suggested for easy release once the job is completed.
7. Mix THIN-FINISH™ in a 5 gallon pail according to the mixing instructions for a skim/base coat.
8. Wet the concrete again with a sprayer or hose. Although you do want the concrete to be wet, you do not want puddled water. If there are puddles remaining, use a push broom to spread the water and remove the puddles.
9. Using a hand squeegee (also commonly known as a magic trowel), apply the THIN-FINISH™ as thin as possible at a rate of about 225 to 275 sq. ft. per bag. You can do this on your hands and knees by simply holding the hand squeegee or more experienced installers can attach a handle or pole to the hand squeegee and apply the THIN-FINISH™ while standing up. While applying the THIN-FINISH™, remove areas of build up as you go to eliminate the need for rub bricking once completed.
10. When applying THIN-FINISH™, you must also honor any tool joints or expansion joints during this application. Failure to honor the joins may result in failure at those joints. Honoring expansion joints on thin stamped overlays is as simple as treating each section of the concrete surface between the expansion joints as separate slabs of concrete. In doing so, you will only apply the thin stamped overlay to one section before moving to the next section. This will be explained later in this document. For detailed explanation on how to honor various types of joints, please contact your Technical Support Representative for detailed instructions.
11. Once the initial coat of THIN-FINISH™ has completely dried, get ready to apply the next coat of THIN-FINISH™ that will act as the “bond” coat between the first skim/base coat and the TEXTURE-PAVE™. It is very important that the first coat of THIN-FINISH™ is completely dry. A good test is to try to adhere a piece of masking tape to the darker areas. If the tape does not stick it is not dry enough to continue to the next step.
12. Using a garden hose, saturate the surface very good. The objective is to completely saturate the concrete so it does not pull excess water out of your overlay that you are about to apply. If the concrete is not saturated and it does pull water out of the overlay, this can lead to stamps sticking and/or product delamination.
13. Mix another bag of THIN-FINISH™ that will be used as your “bond coat’ for adhering the TEXTURE-PAVE™ to the first coat of THIN-FINISH™ that you have already applied.
14. Mix one to four bags of TEXTURE-PAVE™.
15. Wet the surface of the concrete again. Saturate it but use a broom to remove any standing puddles of water.
16. Begin with applying the THIN-FINISH™ in the same manner in which you applied the first coat. The surface must remain wet and the THIN-FINISH™ must not dry before the application of TEXTURE-PAVE™. Since you do not want the THIN-FINISH™ to dry before the addition of the TEXTURE-PAVE™, only squeegee out enough THIN-FINISH™ for the amount of TEXTURE-PAVE™ you have mixed and ready to apply. Example, at this point you have four bags of TEXTURE-PAVE™ mixed. Each bag of TEXTURE-PAVE™ will cover 25 square feet at ¼” depth. Therefore you only want to apply THIN-FINISH™ to 100 square feet.
17. Immediately pour the four pails of TEXTURE-PAVE™ onto the wet THIN-FINISH™ and spread with a gauge rake set at ¼” deep. It is important that you do not allow the cams on the gauge rake to fall off the edge of the concrete as this will not allow a consistent ¼” to be applied. You must apply a small amount of pressure on the gauge rake to ensure that the cams remain grounded to the concrete in order to provide a consistent depth. Failure to do so may result in the gauge rake “floating” and create areas of a thicker depth.
18. Use a steel trowel to detail the edges of the concrete.
19. Use a magic trowel on a pole to lightly pull across the fresh placed TEXTURE-PAVE™ to remove the cam lines. Do not push the magic trowel, only pull it. You want to be careful not to put weight on the magic trowel or let it sink into the TEXTURE-PAVE™. The objective is not to make the surface completely smooth, you only want to fill in the gauge rake cam lines.
20. Now it is time to wait for the TEXTURE-PAVE™ to firm up a bit before stamping the stone texture into the surface. This waiting period is dependant on temperature, sunlight and humidity and can take anywhere from 15 minutes to 45 minutes. Test the surface by very slightly pressing your finger tips into the TEXTURE-PAVE no more than 1/16” of an inch. If you can make an impression and very little or no sand and cement sticks to you fingers, you can proceed to the next step.
21. Using a pump up type sprayer, apply CLEAN-PRINT™ Liquid Release Agent to the TEXTURE-PAVE™ and to your THIN-PRINT™ seamless texture skins. It is important to apply enough CLEAN-PRINT™ to eliminate sticking. Estimated coverage rate is approximately 150 square foot per gallon.
22. Lay your first texture skin on the TEXTURE-PAVE™. Lay the next texture skin on the surface and overlap the textures by 3 to 4 inches. More textures skins the better. Step up on the texture skin and press your feet onto every inch but stay at least 4 to 5 inches away from the edges of the texture skins. Once an area is textured, peel the texture skin off the surface by using the edges of the texture skins to not create a suction. Lay the texture skin on an un textured area and repeat this process until all the TEXTURE-PAVE™ is textured.
23. Use a small touch up skin to detail the edges of the concrete.
24. Use a margin trowel to shave or clean up the edges of the concrete and the tool joints that were in the existing concrete. Note: You should not ever bridge a tool joint or expansion joint. They must be honored or they may crack in the near future.
25. Repeat steps 12 through 24 on the next section of concrete. Keep in mind that although you are treating each section of concrete as a separate job, you can proceed to the next section while the initial application of TEXTURE-PAVE™ is firming up before stamping.
26. Once all of the surface has been coated with TEXTURE-PAVE™ it must be allowed to dry. This is not necessarily overnight. You will know it is time to proceed to the next step once all of the CLEAN-PRINT™ has evaporated.
27. Use a pencil to draw out the window box frames in each section of concrete overlay. Do not use red chalk line as it is permanent. Using a 4” hand grinder with an 1/8” blade carefully score the penciled lines. Be sure to wear eye protection, dust mask and be safe. It is not necessary to create a deep score mark. 1/8” to 1/4" is deep enough.
28. Once completed use a leaf blower to remove any cement dust from the score marks and surface.
29. Add 3 ounces of Chocolate PORTION CONTROL COLORANT™ to a gallon of ULTRA-STONE™ Antiquing Stain and mix well. Then dilute that mixture with 3 parts clean water.
30. Using a pump up type sprayer, apply the colored and diluted ULTRA-STONE™ to the surface at a rake of 100 square foot per gallon minimum. The objective is to literally flood the surface and allow the ULTRA-STONE™ to puddled. As the ULTRA-STONE™ begins to separate out it will look as if the first areas are lighter than what you just finished applying. This is not the case. You will feel compelled to apply more ULTRA-STONE™ to those areas. Do not do this as it will result in a darker color variation in those areas. Simply allow the ULTRA-STONE™ to completely dry before proceeding to the next step.
31. Mix CSS EMULSION™ according to the mixing instructions. In this case, the first coat was 1 part CSS EMULSION™ to 2 parts xylene. Apply with either a good roller cover or a pump up type sprayer. Be careful as this solution is highly flammable.
32. Once the first coat of sealer has dried, apply a second coat of CSS EMULSION™ but mix 1 part CSS EMULSION™ to 1 part xylene. This thicker second coat will better protect the finish from stain and wear.
Yes, you are done. This particular sidewalk and driveway was about 950 sq. ft. and sold for $5.75 a sq. ft. for a total of $5,462.50. The contractor on this job has 2 days into the project and only $1,662.50 in total material cost, profiting $3,800.