This is a case study about the functional and aesthetic benefits of Decorative Concrete.

The project is a 5 story Mill style industrial brick building converted to residential Boston Lofts. The building in Bostons South end is like many industrial and older buildings found in many cities in the United States like Brooklyn NY, Baltimore Md. or Chicago Ill.

The floors were wood frame subfloor with a couple inches of concrete. The concrete had hairline cracks and in a few places had a hollow sound. Cracks were opened up and filled with an epoxy injection system (see Emecole crack repair videos at www.metrocrete.tv ).

In areas with hollow sound holes were drilled in the concrete then filled with an epoxy injection system. Once the concrete floor was remediated there were new issues to be dealt with before these Boston Lofts could be put on the market for sale.

Signature Surfaces of Barrington Rhode Island run by Tom Zilian was brought in to take a look and evaluate the options. As is the case with many building conversions floor height is a critical factor. The solution can make or break a real estate redevelopment.

This building had 50 units in the $600,000 – $800,000 range. Thats a $30 million -$40 million project. The solution had to be thin,durable, cost effective and aesthecially in harmony with the historical brick and heavy wood beams in each unit.

Tom Zilian of Signature Surfaces provided the solution utilizing Colormaker Floors Sgraffino Concrete Overlay with a color called Charcoal Suede. This was an ideal match with the historical feel of the building while conforming to code regulations regarding height at the doorways.

For many of the buildings worldwide Decorative Concrete overlays make it possible to convert a building into a higher and better use. There are many neighborhoods with old beat up buildings that cannot be converted economically without knowing the solutions.

Hence these neighborhoods wallow in disrepair. This case of remediating Boston Lofts should serve as example of how Decorative Concrete can help ailing downtowns everywhere. Not only does Decorative Concrete provide unlimited solutions to investors but a substantial business opportunity for those seeking an opportunity in the inner cities.

This solution applies to inner city and main street buildings world wide not just Boston lofts. The toughest construction projects are rehabs. Flooring is frequently the most challenging aspect of a rehab because of door jam heights and stairs. The cost of remediation can be excessive. Concrete overlays and self leveling concrete is frequently the only solution.

If you want to know more about Tom Zilian check out his website at www.signaturesurfaces.net

Tom has been involved with many Boston Lofts over the past 5 years.

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.

Though I know a lot about Dan and how well he runs his business I wanted to interview him maybe to help others that are looking to get into the business.

Q. Dan, what interested you about getting into decorative concrete coatings?

A. 4 years ago when the market was hot everyone wanted to be a general contractor, I was looking for an edge, something different that would seperate me from everyone else.

Q. What kinds of projects do you work on?

A. In the beginning it was anything I could get. No one knew what decorative concrete was, they had never seen it. I worked on concrete countertops, stamping … lots of pool decks, small basements an occasional retail store. Most of the time I was doing projects for nothing just so people could see it.

Q. And now?

A. In the past year it has totally changed. I was lucky last spring afetr the flooding, I got a run on resurfacing basement floors. Everyone’s basement carpet got ruined, I picked up lots of basement jobs and started to get into basement waterproofing. By mid summer for some reason I started to get retail and restaurant projects.

Q. How about over the winter.

A. I was pretty busy mainly with retail and restaurants. I did a floor for Bluu Ultra Lounge in Danbury which came out great, then about 2000 square feet for Juliska in Stamford. I did a basic gray floor there, it fit really well with the image. They didn’t want to take away from what they were selling. Then I did a project for Homeward Bound. They have a few locations, this one was 3000 square feet in West Hartford at Blue back Square Mall, came out nice.

Q. Any other retail?

A. I’m surprised that I don’t get more retail jobs. Stained concrete overlays and self levelers are a great solution for retail stores and restaurants. Most retailers and restaurant owners go for decorative concrete once they see it. The biggest issue is that they don’t know about it. I did a project for Calsanz a martial arts studio in Norwalk a couple years ago and two restaurants in Black Rock section of Bridgeport both about 2000 – 3000 square feet. I’m seeing more and more large basements come in down in Greenwich and Darien. For some reason I don’t get much in New Canaan, I’ve done a few in Wilton and Weston and starting to see more in Westport.

Q. Do you get out of Fairfield County?

A. Actually in the beginning I had to travel a lot to get projects. I guess the word is starting to get out. Most of my business is local maybe 40% retail and restaurants, some office space and about 60% residential. I don’t do countertops anymore but some stamping. Mostly it’s garage floor epoxies and interior concrete overlays. I put down alot of self leveiling concrete. I like to use Mapei M20 Plus which I can stain and seal. Height is always an issue at doorways and stairs plus there’s a lot of uneven concrete. The self leveler helps me get a nice flat floor.

Q. Do you use concrete acid stain, how do you color the concrete?

A. If I use acid stains I dilute them a lot, they’re unpredictable. They look great but the clients, well lets say they are happier when I use dyes, I can always recreate the sample.

Q. Any advise that you can share for someone looking to get in the business.

A. I would say start out with small jobs and stay local. Make sure you have good contracts and all the right insurance and licenses. Focus on one thing like interior floors. get good at one thing. Learn as much as possible about general construction.

Q. Has the economy slowed you down?

A. Not yet, I am booked for a while and starting to pick up repeat business. I just did a Japanese restaurant, Pacifica, in Wilton and another in Manhattan for the same owners. They have another I’m doing this spring for the same owners, about 4000 square feet. Now I’m advising them on all their restaurant interior design and maintenance. I’ve picked up a few new clients who I’m working with on their restaurant floor plans and redesign of some of their other restaurants. It’s taken a few years but now It’s working.