Metrocrete

Here’s a list of what you need to make molds for concrete countertops and tables.

1. Melamine - melamine comes in plywood size sheets. Prices have gone up. Cost about $38.00 for a 4′ x 8′ sheet, 3/4′ thick. It’s heavy, you should be able to get your lumber yard to cut to usable size.

2. Ladur Wire - This is your reinforcement. Thinner than a pencil. Cut to size with a Bolt Cutter. Do not use rebar, it can ghost through the concrete and cracks can form along the rebar.

3. Red Duct Tape - Red duct tape, use along foam sink cutouts.

4. Foam - you will need foam the thickness of your countertop for the sink cutout. For your faucet knockouts you can use foam. An easy system for creating faucet knockouts is to use a 1 inch diameter thin metal pipe and hammer into foam. When you pull out you will have a perfect cylentrical piece of foam. Tape around with your red duct tape.

5. Drill - cordless are convenient and don’t have a cord to get in your way.

6. Screws - make sure they are long enough and thin. Fat screws will create a bow in the melamine which will be evident in your finished product. You will need to countersink your screws so have the appropriate bit.

7. Table saw- Your finished product will reflect your mold. Cut with precision or have your lumberyard make the precise cuts you need.

It’s really important to have all the tools and products you need for each step. Buddy’s video shows exactly how to template and make molds. But don’t rely on memory. Whether you’re a contractor or a DIY concrete countertops require planning.  Make a list of exactly what you will be using and keep organized.

Write down a list from these posts, then watch the video. If you have any questions go visit the Buddy Rhodes website and look at the FAQ page.  There’s even an Ask Buddy feature.

Casting concrete countertops requires preparation , just follow the system outlined by Buddy and his team.

Once the mold is built the next step is Buddy’s concrete countertops recipe.

You may also want to visit the DIY Network. They have additional information about mold fabrication. For a more visual education of building the mold review the video at Metrocrete.TV

Buddy Rhodes video detailing how to build concrete countertops starts with building a template for a pre-cast countertop.

There are two ways to casting concrete countertops

1. Pre-Cast - This process is building your countertop in your shop and then installing like with granite.

2 Cast in Place - this is the process of building your concrete countertop right on your cabinets. The surface is then burnished which is the hard trowel process I mentioned in the first post.

The process we will be covering is pre-cast.

The process of templating is fairly simple and exact. If you follow the steps your countertop will be perfect.

The templating process is achieved with Luan, thin strips of wood for making a frame. Don’t just try and measure your area. The template process is exact. Imperfections in wall angles will be picked up with the template. The template process will ensure that your countertop fits like a glove.

Here’s a list of what you need to build your template.

1 Nails

2. Hammer

3. Hot Gun and glue stick - I found Bostitch hot gun and glue sticks for about $20.00 at http://www.buyonlinenow.com/viewproduct.asp?SKU=BOSGR25

4. Combo square  - under $10.00 online

5. Exacto Knife

6. Magic Marker - you will need to mark which is front,  sides and back

7. Luan - thin strips of wood

As you read through these posts about precast concrete countertops you can stop by the Buddy Rhodes web site by clicking the bag of mix on the right. The web site has numerous photo galleries, tips and a preview of the 90 minute video which is avialable at Metrocrete.TV

Photo courtesy of DIY Network

 Buddy Rhodes is one of the pioneers in the fabrication of Decorative Concrete Countertops and other specialty concrete items like benches, tables and fireplaces.

Buddy’s background is as a ceramist. He has a unique artistic perspective that has led to the creation of his own mix and style.  Buddy and his team have created a 90 minute video showing how to build countertops in 3 different methods

1. Veined Concrete - this is Buddy’s signature style. A unique style that can be applied to countertops and many other custom uses.

2. Hard Troweled - This method produces a natural burnished result. Polished concrete Countertops that you may have seen are achieved with this style.

3. Ground Finish - This is the process of a grind and polish system that exposes the aggregate in the concrete.

Buddy Rhodes and his team from San Franciso have put together a great video describing these 3 methods for how to make concrete countertops.

The video is available on Metrocrete.TV where you can watch immediately, any time on your desktop or laptop.

The next few posts will review the video and highlight tools you need, where to get them and uses for Decorative Concrete using the Buddy Rhodes system.

 I will also cover along with the video how to install concrete countertops.

If there is anything in particular you want covered please make a comment.

The pictures below tell the story a lot better than I can.

If you’re creative and want to expand your business into a unique artistic craft then you have to check out this site.

Nathan Giffen based in Chicago created Vertical Artisans as an online school teaching the art of concrete carving. Memberships to the site entitle you  1 year access to all 30 or so tutorial videos, articals and the Vertical Artisan Community.

This is not a casual put your toe in the water site. This is serious business that is for serious passionate contractors and artisans.

Just look at the pictures. If they reach your soul then go for it. Give Nathan a call or speak to some who are members of his unique club.

The applications are completely custom and not formed like stamped concrete.

You’ll find a large high end market, here are some uses

1. Pool design
2. Hotel design
3. Landscape design
4. Custom old world wine cellars
5. Restaurant Interior design

And lots of basement remodeling ideas.

Yearly subscrition is $795.00. If you use the promotional code “Metro”, you get $195.00 off for a cost of $600.00.  Then come back and promote your projects for the world to see.

Last week I visited the Sawgrass Beach Club in Ponte Vedra Florida. 99% of the concrete at the club was covered with a concrete overlay including stairs and walls.

The project was completed over 10 years ago and still in excellent condition. There are a few spots that could use some small patches. Considering the exposure to intense sun and salt I would say it has held up extremely well.

I hope these images answer some questions about durability, function and curb appeal potential of concrete overlays.

The first photo does not have an overlay. Don’t know why.

I’ll try and be brief with this post about tools you need to maintain floors.

1. Mops - Microfiber mops with a heavy pad are an excellent tool for dry or wet mopping decorative concrete floors. Use for both residential and commercial floors. Rayon mop heads work well with cleaning products. Should I mention a bucket?

2. Burnisher - High speed electric burnishers with 1500 - 2000 RPMs work great on High Solids floor finishes. They cost about $700-$1,000 and are a worthwhile investment. They are easy to use and quiet. In most cases you will use a soft pad like a white or champagne (green) . There are numerous brands on the market. Here is a picture of a model manufactured by Mercury Floor Machines.

3. Pads - check with the manufacturrer of your floor finish. If you use Accelerator by Formula Technologies you can use a brown Hogs Hair Pad after the first application and then swithch to the soft pads after that. Pads shown are from 3M

4. Floor Scrubbers - for larger floors it might be a good idea to get a floor scrubber for cleaning your floor. Here is a model manufactured by Mercury Floor Machines.

In my last few posts I went over proper methods to maintain floors and some products that work for specific floors.

The key is to maintain your concrete floor finishes and sealers. All floors will wear down. The wear is due to foot traffic and frequently using the wrong products and methods for maintenance.

Residential floors have minimal foot traffic and require little maintenence other than occasional dry mopping with a heavy microfiber mop or neutral cleaner like Lemonworks.

Retail and Restaurant floors need the wax or finish coat to protect the sealed decorative floor. Even with all the proper cleaning any finish coat will wear and get scratched. Most scratches are too small to see unless you get down close. Dirt, dust, sand etc. eventually gets in the scratches and stops light reflection.

If you look at the picture below you will see the difference between a new coat and unsealed coat. When your floor loses the shine the best solution is what is called the Scrub & Recoat Process. The finished part is the look you want to maintain

Scrub & Recoat is the process of using a mild floor wax or finish stripper to remove just the top layer and then reapply 2 coats of finish like Acclerator. Accelerator is a high solids (30%) finish. When your floor is new 2 coats of Accelerator or other high solids finish coat is applied. The Scrub part removes 1 coat, then recoat with 2 coats. You now have 3 coats. If you stick with this system, over time you will build up the floor finish creating a highly durable more visibly appealing floor.

The frequency of the Scrub & Recoat process depends on the wear. In a high traffic grocery store it could be every 6-8 months. Some floors every 3-4 years depending on well it is cleaned. Typically the highest wear and tear is at entrances where grit is tracked onto a floor.

The process is simple and inexpensive. I’m familiar with Formula Technologies products so I’ll reference their products. I’m sure there are many others.

Formula Technologies has a mild stripper called TurboForce. If you have a floor scrubber  mix about 2 ounces of Turboforce with a gallon of water and apply to floor. If you have a smaller area you can mop on adding about 4 ounces per gallon of water. Let sit for about 10 minutes and clean from floor with a squeegy and wet vac.  You know you’ve correctly removed to the top layer when floor loses shine and gets dull.

The beauty of Accelerator is that it can be burnished regularly and will protect the sealer below. A lot of decorative concrete contractors like using Urethanes because they are tough. However if they get scratched they can’t be fixed. If you apply Accelerator you will protect the Urethane or whatever type of sealer is applied.

In my next post I will review some of the cleaning paraphernalia you need including floor machines and mops.

Restaurant Floor Maintenance

Decorative concrete has become a critical part of restaurant floor plans. Architects worldwide are projecting restaurant interior design with stains, overlays and polished concrete. If you don’t maintain your floor correctly it will cost you a lot of $$$. So read on.

The battle is against heavy abuse. Lots of foot traffic, chairs and barstools sliding on the floor, food grease, alcohol, citrus acids. Floors take it hard.

Start with Floor Mats. Floor mats at the entrance are a must. Floor mats at the kitchen entrance also a must. Grease tracked all over from the kitchen is the biggest floor crusher I have seen.

I have seen numerous restaurants ruin their floors because they didn’t pay attention. Maybe they thought concrete is industructable. Maybe they just weren’t thinking about their floor until it was too late.

Let me enlighten you about maintaining concrete floors. First before you make your plans think about maintenance. (And if you’re an architect make sure you understand the product). If you’re not going to maintain your new floor with the right systems and products then stop right now and don’t even consider concrete.  Don’t give the product a bad reputation. Go trash some other floor. Seriously. I get the phone calls. Restauranteurs call complaining about how the floor isn’t wearing well. When I ask them how they are maintaining the floor …. well they did it wrong and ruined the floor. So what do you do?

Well, the good news is that it is inexpensive and cleaning systems are easy. It’s all about the system. If you deviate from the system then you have problems. Maintenance must be like clockwork. There are no shortcuts no matter what kind of floor. Systems, systems, systems!

What I am explaining to you I learned over the course of a year from Formula Technologies.  They make about 30 floor cleaning products. All have specific uses.

Let’s start with Bionix. I did a review (in review category) of Bionix if you want more info. Bionix kills bacteria. Use it to clean bathrooms, wipe on doorhandles, sink faucets, bar tops, backs of chairs. Use it to clean groutlines and along edges of walls, or anything on the floor. Bionix is highly concentrated. Mix 1-2 ounces with a gallon of water. Ends up costing about 35 cents per gallon.

Orangeworks is a food degreaser. This is what you use to clean the food grease off your floor. Use it once or twice a week as needed. It’s too abrasive for daily use. Use waterworks daily. About 25 cents per gallon. Product comes in gallon containers. 1 ounce is mixed with 1 gallon of water.  The biggest mistake most people make is thinbking if they use more product it will clean better. Not true. Too much cleaning solvent and you get a haze on the floor. Orangeworks breaks down the grease and the water is a carrier.

 After the floor is cleaned with Orangeworks you can mop on Grishine which is a floor restorer and gives a polished finish. Gripshine can be burnished with a high speed buffer, 1500 - 2,000 RPM machine with a soft pad.

I’ll get into Floor machines and pads in an upcoming post so stay tuned.

Thats the sytem. Simple don’t you think? I’m going to  be talking about sealers and waxes so come back and read more.

Thanks to Colormaker Floors for the photo below. Thats a Wholefoods Store with Pentimento Overlay stained with Patinaetch and Someru Dyes. Wholefoods is a pro at maintenance. Their floors look great always.

This post is mainly for retailers, but, hey we all can learn. The next few posts will pertain to restaurant and residential floor maintenance and a few of the processes and equipment for proper maintetnance and floor cleaning.

There are a lot of cleaning products on the market. Some work great but some don’t.  I’m always hearing from retailers who like thier decorative concrete floors and others who are dissappointed with how the floors wear.

The disappointed ones don’t maintain their floors properly. They use the wrong products, wrong systems and are quick to blame the contractor, manufacturer or whoever.

Retailers in main street retail or strip centers have a few enemies to deal with.

1. Asphalt marks - When parking lots get hot especially in southern climates asphalt gets tracked in and stuck to the floor. Petroleum oils from the asphalt will also get tracked onto the floor. There are specific cleaners such as Yellow Out manufactured by Formula Technologies that cure this problem. Use of the wrong products will damage the floor.

2. Corrosive salts - This is a winter problem. Not just for decorative concrete. When salts are spread on sidewalks and tracked inside they start ruining floors. I’m sure there are others but I do know that Fix It was engineered for this purpose. The ingredients in FixIt neutralize the salts, water carries it away. If you get salts on your floor during the winter it will ruin your floors. Take care of your floor.

3. Abrasion - every floor has this issue. Sand and dirt get on the bottom of shoes and become walking sandpaper. A strong daily cleaner will get the dirt out of small scratches. Waterworks does the job. I’ve used it. I never thought it would matter but it does. If you’ve spent the money on a nice decorative concrete floor take care of it.

A retail store on street level will require more maintenance than in a mall for obvious reasons, like weather. In a mall most wear and tear will be at the entrance. By the time foot traffic reaches the stores shoes are fairly clean.

What you need to do is protect your finish coat. Once your finish coat loses it’s shine it’s time for a scrub and recoat. If unfamiliar with the scrub and recoat process come back in a few days. I’m going to do a post about the scrub and recoat process and the various cleaning paraphernalia you need.

Special thanks to Anton Vogt of Concrete Artisan Systems Vancouver BC for the picture below of what a well maintained floor looks like. Concrete Artisan Systems specializes in interior decorative concrete applications and consulting for retailers and restaurants nationwide.  Anton’s years of concrete artistry and experience has enabled him to build an extensive network serving his clients nationwide.

A friend of mine Paul Huneck, owner of Hudson Concrete in Long Island City, New York installed an amazing decorative concrete floor in Manhattan. This floor is sensational. It is the floor for Rita Hazan Hair Salon on Fifth Avenue.

About a month after the salon opened the floor started to get this smeared look and got slippery. The reason was the hair sprays that got on the floor. Then the hair sprays were tracked all over the salon.

It turns out that there are specific cleaners for different cleaning. Most of us think that if it’s blue and is soapy thats the way to clean. Not so. The solution for the hair salon was a combination of a product called Reworks which cleans the hair sprays off the floor and Gripshine which restores the floor shine with a non-slip bonus.

The process of hair salon design as with many commercial spaces overlooks the floor ’til the end as if it doesn’t matter. Floors should be the first consideration with all design. Maintenance is part of the design process. Fortunately Rita hazan Hair Salon was able to find the perfect solution. Many others are not so fortunate and pay a hefty price.

If you are looking for a high end decorative concrete finish there are few concrete artisans with the talent of Paul Huneck.  Paul mainly works on projects in New York City but does travel nationwide with his network of concrete artisans. Paul can be reached at 646-645-4043 or click this link to view his impressive works. Hudson Concrete

Thanks Paul for sharing this image.