STEP-BY-STEP PROCESS : Stenciled concrete on fresh concrete
Tools :
- A bull float with round ends and rotative adapter to level ridges, fill voids, and smooth the surface in preparation for troweling.
- A fresno trowel to trowel the slab
- A set of aluminum handles to fix on fresno trowel and bull float.
- A hand concrete edger to produce a radius at the edge of a concrete slab.
- A roller tamper (optional) to depress the aggregate into the slab and brings the fat to the surface.
- A roller or a sprayer for sealer
Step 1 : Preparation
In the first place, you have to prepare your construction site into the standards rules for realize a traditional concrete screed. Your subgrade should be carefully prepared, compacted and levelled. Set the forms to the correct elevation and make your levels for draining water.
Cut the stencils from the roll before you pour the concrete so you can place them quickly once it is formed.
Step 2 :Pour concrete
The thickness, reinforcement and dosage of the concrete must comply with the standard of your country.
Pour the concrete, then screed and float it to the right level.
Concrete must be placed within half an hour of mixing. Place your concrete into your formwork. A roller tamper can be used to quickly level slab for final finishing and push down exposed aggregates. Don’t forget to respect the slopes necessary for the flow of water.
Bull floating should be done immediately after "screeding". This process should be finished before excess moisture or bleedwater appear on the surface.
Step 3 :Apply the stencil
The stencil is placed and worked one strip at a time. Because the stencils are die cut, the strips must be aligned in a specific manner to ensure pattern continuity, similar to aligning strips of patterned wallpaper.
Have two people, one on either side of the surface, place a length of tape through the center to the edge. Lay out the lengths of stencil, starting from the center and working toward the edges. Use a trowel to fix the stencil to the concrete to create a raised pattern.
Step 4 : Tint the exposed concrete with a color hardener
Sprinkle Masters Color Hardener over the exposed areas. This process is best done immediately after stencil application, while the concrete surface still has enough moisture to be absorbed by the hardener. Use a bull float to float the color to the edges of the form. Use a trowel to close the surface. Depending on the color, you may have to apply 2 coats.
Step 5 : Remove the stencil
Remove the stencil with a person standing on either side of the slab and lifting the stencil straight up from the ends, when the concrete is dry enough that the form does not adhere to the surface. As you remove the stencil, you'll also pull up concrete chips and dust around the edges.
Step 6 : Protection
The day after the pour, clean away the finer debris. Then, apply a first coat of sealer, for instance Masters Ecolex Sealer (water-based) or Masters Outside Sealer (solvent). Be careful not to apply the sealer too heavily, which could trap moisture in the slab.
Let you concrete screed dry at least 28 days before applying the second coat.
To avoid a slippery effect when the surface is wet, it is possible to incorporate Non slip powder to the first coat of sealer.
Routine maintenance
- For general cleaning, use low-pressure water or scrub the surface with a mild detergent.
- Stenciled concrete is colored with a dry-shake hardener and protected by several coats of sealer. Periodic resealing, as needed, will keep the surface looking its best.