To help you understand the process involved in placing your new exposed concrete finish we have outlined the stages below.

Planning the job involved a visit from us to measure the area you want finished.  This should have included discussions on any problems you have had in the past with water run off, subsidence or any other issues that may affect the finished product.

 

Stage 1 - Excavation, Boxing and Preparation 

This part of the job is nearly always noisy and dusty or muddy so be prepared for some disruption.  You may or may not have access to your property so may need to make arrangements for parking etc

 

 

Stage 2 - Pouring  

This again will involve heavy machinery (at least one concrete truck) on the property so be prepared fro some disruption.

 

The concrete is poured and the sprayed with a Rugasol. This chemical ensures that the top 3-5mm layer of the concrete does not harden so that it can be exposed.

 

You should note that at this stage the concrete in no way resembles the finished product, but be patient as the process is only half completed.

 

Due to size of job if we have to pour on several days or at different times in the day you could end up with variations.

 

Around 24 hours later the placer will wash off the top layer to reveal the stones.  

Two to three days later depending on drying conditions, we return to strip the boxing.  This may also include washing any surrounding buildings that may have been effected by the process.

 

On this day we will undertake any expansion cutting that may be required. It should be understood that all concrete cracks and this is almost impossible to eliminate without great expense. To this end we encourage the concrete to crack in predetermined locations.

 

This is achieved by what we call Bolster Cutting and Grooving undertaken on the day the concrete is poured, or by concrete cutting downward within the cut line thus no crack is visible.

 

Cracking may occur within 4 hours if pouring this cannot be controlled.

 

 

Stage 5 - Sealing the finished concrete! 

This is also dependent on drying conditions as the concrete cannot be sealed until the surface is completely dry.  If it is sealed too early then whiting may occur (sealing over moisture in the concrete leaving a white effect on the surface).  In the winter months we may primer seal allowing foot traffic until the weather allows it to be sealed properly.
Before sealing takes place the concrete must be clean of all dirt and dust so try and keep the surface clean for our visit.

 

Two coats of sealer are applied in the same day.  Between the two coats of sealer we apply a grit to minimize slip.  After a second coat is applied you can walk on the surface in an hour or so but keep your vehicles off for 24 hours.

 

You should allow between 7 to 14 days for us to undertake and complete your job.  As you will be aware, weather and its effects can cause delays to occur that are often unforeseen.  Your patience will be rewarded if you allow us to complete the job as we should.

 

At this stage the job is complete and you will be the proud owner of an Exposed Concrete surface.

 

 

It is now up to you how the concrete looks and wears over time.  Periodic washing with a light detergent is a good idea to keep grease and dirt at bay.

 

We recommend that to ensure the best looking finish, 12 to 18 months after the original sealer has been applied you should consider resealing the surface.

 

This is a very easy task and simply involves washing the surface free of dirt, grease and dust with a soft broom.  When the surface is clean and dry, one coat of sealer is all that is required and must be applied with a non acrylic broom.  This should last for up to 3 years.

 

The sealer can be obtained directly from us.  If you prefer to have the job resealed by us then we will be happy to provide a quote for labour and materials.