From countertops to fireplace surrounds, decorative contractors continue to push the limits of concrete. The beauty of decorative concrete begins with the mix, and with several precast mixes available contractors may be faced with the challenge of choosing the best mix to fit their needs.
A made-from-scratch mix requires contractors to have a mix recipe. Jeff Girard, president of The Concrete Countertop Institute, teaches his students to make an aggregate-based mix and a sand-based mix. When making a mix from scratch, contractors will purchase the ingredients separately. “There are concrete mixes that are designed to be very fluid and pourable, and they tend to be an aggregate-based mix more similar to conventional concrete where you have gravel, sand and cement,” Girard says. “Then there is a different style of concrete, a mortar, that doesn’t have coarse aggregates, just the sand, and it is usually made to be stiff and packable.”
Girard warns contractors that decorative concrete mixes aren’t like the standard concrete. “If you are making your own mix, don’t make it like everything else,” he says. “Don’t make sidewalk concrete because it’s not good enough for a high-quality countertop. Clients are picky, and if you don’t have good concrete you have no hope of satisfying your customers.”
Making their own mixes can reduce contractors’ costs, but engineering their own mix design may require a higher skill level. “A concrete contractor on a jobsite pouring a floor or wall doesn’t design his own mix,” says Mike Heidebrink, president of Cheng Concrete. “He calls a ready mix plant that has trained professionals who engineer concrete mixes.”
An alternative to a made-from-scratch mix is a bag mix. Consistency is one benefit contractors have with bag mixes.
“Using a white cement base and mixing the same amount of water and pigment will give you dependable results. I have found when using a portland gray cement mix design the colors will come out slightly different every time — not good when trying to meet the demands of designers and architects,” says Buddy Rhodes, owner of Buddy Rhodes Concrete Products. “We try to take the guesswork out of made-from-scratch mix designs and put more of the contractor’s effort and time into the finishing of the product rather than coming up with different mix designs.”
By using a bag mix, contractors are able to focus on creating the product. “A contractor will get more consistent results with a bag mix,” Heidebrink says. “The contractor is focused on creating the big picture, not the mix. A contractor shouldn’t be dealing with the chemistry behind the product. They are skilled craftsmen that need to be focusing on the quality of the finished product.”
Doug Bannister of enCOUNTER believes security, reliability and dependability are all benefits of bag mixes. “There are people in the countertop business that don’t understand concrete,” Bannister says. “When experimenting, they are going to have to know their limits for whatever they are doing.”
Admixtures and aggregates
There are several admixtures that are essential when making a mix. While bag mixes will include several admixtures, if making a mix from scratch it is essential to include pozzolans. “The common admixtures that are mandatory are pozzolans, which replace some of the cement and make the concrete better in the long term,” Girard says. “Pozzolans are mineral powders that by themselves aren’t cement, but when they are mixed with concrete they react with one of the by-products.”
Another essential admixture is a super plasticizer used to eliminate water. “People want concrete that is easy to move and workable, and the easiest way to get that is to add water,” Girard says. “That’s the worst possible thing you can do to concrete. What super plasticizers do is they give you the extra workability without adding a drop of water.”