Frequently Asked Questions (FAQs)
Choose your question below or scroll down the page at your leisure. Where a more techincal understanding is required, please go to our Detailed Technical Information page.
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Colour the concrete
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Finish the concrete
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Maintenance
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The PeterFell System
Is the Peter Fell System right for you?
No product is suitable for absolutely everybody and while the PeterFell System can be used in a vast array of applications, it has some properties which may not suit some clients. Our goal is to ensure you get a project that perfectly matches your expectations and so we would like all our clients to understand the pros and cons of concrete as the final surface.
The Surface of Concrete - characteristic mottliness
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The PFL system will compliment and enhance the natural surface variations of concrete and because the colouring is integral it works with the concrete in achieving a very natural look. In modern house design this introduces richness and tone, and introduces a new and vibrant feel to the space. Unlike surface treatments which are more uniform in appearance, the PFL system achieves a timeless appeal. For those who like a concrete option but would prefer a more uniform colour, we recommend you use pavers and you can contact our recommended paver manufacturers here. |
Cracking
Cracking is a common characteristic of concrete, as all concrete shrinks as it moves from a liquid to a solid. The mechanism is well understood by the industry and controlled by the use of Construction Cuts usually done in the first 48 hours after pouring (Refer to concrete cutting). But there is still the small risk of uncontrolled cracking. While this is unlikely as a good concrete contractor will take steps to minimise the risk, it is still possible and is a risk that needs to be considered during the design phase. We offer a service to recommended where Construction and Decorative Cuts should be made and encourage you to use this.
Other surface blemishes are possible such as craze cracking - the very fine, hairline and web-like cracks that sometimes appear. These have no structural implications and often add further character to your finished product.
Measling
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When wet sometimes darker patches can be seen that disappear once the surface dries. It is the nature of the sealer that they sometimes have these, it won't happen everytime but it may happen some times. This is called 'measling' and is caused by microscopic holes/ctracks in the sealer that allow small amounts of water into the surface. The exact mechanism is caused by a number of factors and it is difficult to predict when it will occur. More textured surfaces will have more wear points for the sealer coating which may also let in |
Colour
Due to concrete being a natural material, and also the different effects different placing methods can have, the final colour will not always exactly match the samples we present. In essence you are choosing a tone, but this is only very rarely a problem for customers. For notes on choosing a colour click here.
Why should I use concrete?
Concrete is one of the oldest and most widely used construction materials, and possess many inherent qualities which can benefit designers, architects, engineers, and most importantly the end user.
The following factors together contribute to make long lasting, low maintenance buildings that are some of the most comfortable to live in and efficient to run.
| Durability | Well designed and well placed concrete offers exceptional durability and long life in any structure. |
| Versatility |
Building in concrete provides an extraordinary range of applications and surface finishes, providing the opportunity for architectural expression to go hand in hand with structural integrity. |
| Health and Comfort | The use of concrete can also contribute to improved occupant health and comfort. For more information on the use of concrete in creating healthful environments please visit www.smarthomes.org.nz |
| Environmentally Friendly | Well designed concrete buildings require less energy and resources to run and maintain (see 'Thermal Efficiency' below). Advances in concrete technology and manufacturing processes mean concrete is now being viewed as a key material in New Zealand's pursuit of sustainable development. For more info see our links section |
| Thermal efficiency |
Concrete acts as a thermal 'sponge', absorbing heat during the day to help cool a building, and then releasing that heat when the ambient temperature drops at night. |
| Fire resistance | Concrete provides the best fire resistance of any building material. It cannot catch fire, it does not burn, emit smoke or toxic fumes in the event of a fire. |
| Acoustic Insulation | Concrete's mass and damping qualities are easily used to achieve good acoustic performance. |
Why should I use the PeterFell System?
Peter Fell Ltd has an established reputation for producing exceptional coloured concrete environments, primarily, but not exclusively, stunning coloured concrete floors. The company has gained the position of market leader through a culture of quality in all aspects of business - we source only the best materials, and our fully trained staff provide full support throughout any project. We strive to be a partner and to do all we can to achieve the desired result for all parties.
| Universal Application | The PeterFell System can be used anywhere concrete can. The choice of surface finishes available means the PeterFell System provides hard flooring solutions for virtually all applications from smooth internal surfaces to non-slip pool surrounds. |
| Simplicity | It's concrete! The PeterFell System can be executed by any competent concrete contractor, with the sealing able to be done by any competent handyperson. There is no need for specialist applicators or complicated machinery. |
| Permanent Colour | In the PeterFell System the colour is incorporated into the concrete, and is not simply applied to the surface where it is prone to wearing or fading. This results in the permanent colouring of the concrete, no matter what the application. |
| Complete Solution | Peter Fell Ltd provides all materials required to transform concrete into an aesthetically pleasing, long life, low-maintenance floor. In addition to providing colour, Peter Fell Ltd has an extensive range of products to protect and maintain the concrete in optimal condition. |
| Cost effective | Compared with other flooring options (i.e. carpet, wood, tiles, and linoleum), the PeterFell System is one of the most cost effective flooring options on the market - especially when the total lifetime cost is considered. As most new buildings start with concrete, the PeterFell System simply transforms this base element into the final surface, saving time and money. |
| Large Colour Range |
Our range of over 60 colours is New Zealand's largest. This is due to our novel use of liquid oxides to colour the concrete. The liquid colours mix better through the concrete, are easier to handle, and will not ball ensuring an even colour. |
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Proudly Kiwi |
We do not simply buy an overseas system and sell it here - the PeterFell System has been developed in New Zealand utilising thorough research and testing. We only source products from reputable international and local suppliers which can withstand the demands of our unique country. |
| Service | Above all else, at Peter Fell Ltd we pride ourselves on our customer service. All our staff are fully trained, and ensure all our clients are fully informed on all aspects of the PeterFell System, and are able to make educated decisions. |
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Where can I use the PeterFell System?
The PeterFell System is designed for use in new concrete only as the colour is mixed through the concrete, not applied to the surface.
However, existing concrete floors can still be cut into various patterns and sealed to protect from staining and marking. For more information on options for improving existing concrete surfaces please contact Peter Fell Ltd.
The PeterFell System can be used anywhere concrete can. Some common applications include:
Interior
The PeterFell System can be used to generate high-gloss floors ideal for formal living or simple, clean, low maintenance floors perfect for kitchens or family areas.
Exterior
Low maintenance, slip resistant coloured concrete is ideal for decks, pool surrounds, courtyards, patios, driveways, and paths.
Residential
The PeterFell System provides low cost flooring option for all residential hard flooring requirements, inside and out.
Commercial
The durability of concrete, enhanced by the PeterFell System is perfect for high use commercial applications or stylish retail outlets.
What does a PeterFell floor look like?
The PeterFell System is typified by the inherent diversity of colour, texture and finish of the concrete. For this reason every PeterFell floor is unique.
As the colour is added to the concrete, and subsequently disperses naturally through the concrete, PeterFell floors display natural variation in colour. This variation in colour, or 'mottliness', typifies the PeterFell System. This variation is random, and is dependent on a number of factors including the colour, texture, and finish of the floor. To view online gallery of PeterFell floors click here. To understand what factors affect the colour click here.
How much does the PeterFell System cost?
As there are a large number of variables involved, it is difficult to give a single price that covers all possible applications of the PeterFell System. However, as rough rule of thumb, the approximate cost over and above a normal concrete floor is approximately $50 per m 2
This is an estimate only and covers all products and labour to execute the PeterFell System based on our experience nationally for a typical floor in a typical area. This price does not include the cost of the concrete or any associated labour charges for the preparation and laying of the concrete, and will also vary depending on the type, size and location of the project. This cost is designed to provide a cost comparison with other hard flooring options (i.e. carpet, tiles, etc) as these are usually laid on concrete anyway.
Below is an approximate breakdown of this price estimate to give you an idea of the pricing structure.
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Step 1 - Colour the Concrete |
PFL Special Colours are specifically dosed for each job dependent on colour and concrete type. Price is estimated on standard dose in standard concrete. |
approx $12 - 16 m 2 |
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Step 2 - Texture the Concrete |
Concrete requirements i.e. type and strength of concrete, site preparation, and laying, are very project specific. As Peter Fell Ltd does not provide any concrete or labour it is recommended that a concrete supplier or concrete contractor is contacted for price information. |
n/a |
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Step 3 - Cut the Concrete |
Cutting is simply charged per metre, and subsequent cost is directly related to total amount of cuts. Contact concrete cutter for current rates per lineal metre |
approx $5 - 7 m |
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Step 4 - Seal the Concrete |
The 'PeterFell Finishing Process Guide' encompasses the grouting of cuts, clean up, surface preparation, and sealing of the concrete. The price given is a cost estimate for this process including labour and all materials. This cost will be greatly reduced if the work is conducted DIY. |
approx $20 - 30 m 2 |
How do I get PeterFell coloured concrete?
The PeterFell System can be incorporated into any concreting project, no matter how big or small, no matter where in the country you are.
Peter Fell Ltd provides products and instruction enabling the generation of coloured, cut and sealed concrete floors, but does not provide any concrete or labour. However The PeterFell System is reliant on good concrete placing practice, but does not require any specialist applicators or additional processes and so can be applied by any competent concrete contractor. For some placers in your area please click here
Peter Fell Ltd is more than willing to provide full job specification and application instruction, as well as assistance and advice to any architect, specifier, building manager, contractor, applicator, or home owner.
Step 1 - Colour the concrete
Choosing a concrete colour from the wide range available is the first step in the PeterFell System. When choosing a colour, a number of aesthetic and practical considerations need to be taken into account. The colour choice must consider the nature of integral colour that results in a natural and unique coloured floor which cannot be reproduced.
While the supplied colour is always constant, the final appearance of the colour in the concrete will always vary. The major factors to consider when selecting a PeterFell colour are listed on the following page. We strongly recommend visiting our showroom, or contacting your local ready mix concrete plant, to view samples of PeterFell coloured concrete before making any colour decisions.
How is the concrete coloured?
The PeterFell System uses an integral colour method - the colour is mixed throughout the concrete. This results in the permanent colouring of concrete, it is not a surface coating and subsequently will not chip off or wear away. We use a liquid system that ensures even colour distribution and no risk of balling or colour concentration which can occur when powders are used
The other common method for colouring concrete is the dry shake method, where a colour (generally a powder oxide) is applied to the surface of freshly placed concrete and trowelled into the surface. This method is limited by the range of powder oxides available, and as the colour is only on the surface it is prone to wear over time and is heavily reliant on the quality of workmanship. Because it is a surface colouring the look is different to liquid oxide and it can look more 'plastic'.
There are other means of colouring concrete, such as concrete stains, concrete paints and tinted sealers. All of these products are surface coatings, so again are prone to fading, chipping and wear. Also if there is contamination of the surface there could be aeasthetic and durablity issues.
When choosing a colour, a number of aesthetic and practical considerations need to be taken into account. For more information on choosing a concrete colour click here.
We strongly recommend visiting our showroom or visiting one of the 150 locations around the country to view samples of PeterFell coloured concrete before making any colour decisions.
What colours are available?
The PeterFell colour range consists of over 60 colours. All PeterFell colours are assigned a 3 digit code (our colours do not have names), and are divided into 7 colour categories:
| 100. Neutral | A neutral palette of colours to complement any environment. |
| 200. Sandstone | A range of colours encompassing the natural elements of sandstone. |
| 300. Terracotta | Traditional terracotta colours are represented in this range |
| 400. Brown | Encompasses varying brown tones, from light fawns to dark rich chocolates |
| 500. Stone | Strong colours that capture the natural elements of slate and stone. |
| 600 Charcoal | Classic range of charcoals and greys, the ultimate in minimalistic style. |
| 700. Aqua | A bold range of blues and greens tempered by the natural depth of concrete |
The first digit of the colour conveys the category in which the colour is classified, for example colour 189 is a neutral colour, while colour 673 will be a charcoal colour.
> To view colour range online click here
> For assistance on choosing a concrete colour click here
Where can I see the coloured concrete?
Visiting the Peter Fell showroom in Auckland is well worth it as it has over 40 coloured concrete floors to view, all with different textures and sealers, for details click here.
Outside of Auckland, PeterFell colour sample boards can be viewed by visiting one of 150 locations around the country.
Can I get samples?
Yes - Peter Fell Ltd has actual concrete samples, complete with PeterFell Sealers to help with colour selection (see following page for sample details). We offer a service to send up to four colour samples on request to be used for colour selection. It is strongly recommended that prior to a request being made that the full colour boards be viewed as described above.
Step 2 - Lay the concrete
The surface texture is created when the concrete is laid and it is this texture which defines the overall look and feel of the concrete floor. Primarily, the texture will determine the slip resistance of the floor, but will also determine the level of glare, the achievable gloss finish of the floor, and influence the final appearance of the colour.
Where do I get concrete from?
There are a number of ready mix concrete suppliers in New Zealand and Peter Fell Ltd supplies colour to ALL of them.
> For details of concrete suppliers in your area click here
Who lays the concrete?
As PeterFell colour is added to the concrete at the concrete plant, the concrete is laid much the same as for standard concrete, subsequently, PeterFell coloured concrete can be laid by any competent concrete contractor.
The concrete contractor placer will determine the texture and finish of the concrete. It is recommended that all concrete is laid in accordance with New Zealand Standards (refer to the 'PeterFell Technical Specifications Guide' for further details), with additional reference to the specific finish required.
>For a list of contractors in you area click here
Is laying coloured concrete different to laying normal grey concrete
Yes and No. Any competent concrete Contractor can use the PeterFell System, and the Finishing process can be done by any competent handy person.
The main difference is one of care during construction - as the concrete is the final surface it must be protected during construction.
For a full discussion on the issues click here.
What textures and finishes can I have?
There are a huge range of concrete textures and finishes available, each of which will influence the concrete colour and overall appearance of the floor. The table below outlines the basic types of concrete finishes - for more detail and picturesclick here.
As the concrete contractor creates the concrete surface the desired texture and finish must be clearly communicated to the concrete contractor.
Smooth Finish |
We recommend that all surfaces be finished with a power float, or hard hand steel trowel. This gives the best durability. While colour typically appears lighter for smooth finished floors as the light reflects more off the surface, heavy use of a power float can darken the concrete colour. |
Non-Slip Finish |
Varying degrees of texture can be imparted on the concrete to generate a non-slip surface, applicable for most external applications. Typically the more texture a surface has the darker the colour.
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Exposed aggregate |
Typically rounded pebbles are used in this product and these are exposed on the surface of the concrete. This results in a unique pebbled look and 'bumpy' texture, very popular on drives and paths. The colour will be strongly influenced by the aggregate |
Ground or polished concrete |
Grinding is the process where the surface of the concrete is mechanically removed, generating a very flat surface and revealing the aggregate profile. Polishing is simply a higher quality grind involving multiple (up to 12) passes over a floor using successively finer grinds (a process analogous to using finer and finer grits of sandpaper). The colour in these finishes is strongly influenced by the aggregate, and typically appears darker. |
Sandstone Finish |
Hardened concrete is treated with a concentrated acidic solution (PFL Surface Preparation) to break down the surface, exposing sand and concrete fines. This generates a unique look and texture similar to that of sandstone. This finish should be executed by an experienced contractor familiar with the process. The colour appearance will be significantly altered, typically becoming darker and more intense. |
Will my concrete crack?
As concrete hardens, excess water evaporates causing the concrete to shrink, and so cracks can occur. This issue is well understood and through the proper use of Construction (expansion) Cuts, proper site preparation, and good concrete placing practice the risk can be significantly reduced. But cracks can still occur even with all precautions taken and so for any floor there is a chance it may happen.
>To download a brochure on concrete cracking put out by the New Zealand Ready Mix Concrete Association click here.
How do I protect my concrete during construction/landscaping?
Concrete is a porous substrate, meaning it is easily stained and marked (which is also why sealing later is critical). As the coloured concrete will be the final surface, it must be properly protected from staining and marking during construction and landscaping. Also, as the floor needs to be properly cured before sealing (at least 28 days after laying) it is recommended that concrete must be protected with polythene during any construction or landscaping.
However, the polythene must also be removed at least one week, preferably longer, prior to sealing to allow the concrete to dry completely.
Step 3 - Cut the concrete
Cutting is essential in controlling concrete cracking, but in the PeterFell System cutting is also used as an aesthetic tool to add visual interest.
Do I have to cut my concrete?
Absolutely - all concrete must be cut to reduce the chance of cracking as the concrete dries. These cuts are called Construction Cuts (also called Construction joints, Expansion Cuts, or Expansion joints) and are typically 3 mm wide and one third the depth of the concrete. These cuts must be correctly positioned and executed within 24 hours of the concrete being poured, or there is a significant risk of concrete cracking (unless other jointing methods are employed). Placement of construction cuts should be determined prior to commencement of any concrete work.
What is the difference between a Construction Cut and a Decorative Cut?
In the PeterFell System the Construction Cuts (see above) are complemented with additional cuts, called Decorative Cuts. These are used to generate a pattern in the concrete - they are only 10mm deep and typically 10mm wide.
Decorative Cuts are usually done 1-2 weeks after the concrete is poured, so a good clean edge is achieved. On internal floors this may delay the erection of the framing. They serve no structural role and are simply used where desired to generate a unique pattern for aesthetic purposes. But they must incorporate the construction cuts into the pattern.
> For more information on concrete cutting click here.
> Peter Fell Ltd offers a service to aid the placement of both types of cuts - please send your plans along with what type of pattern to us.
What size cuts can I have?
One of the benefits of the PeterFell System is the ability to customise the size and shape of the cut pattern. The only limitation on the cut pattern is the placement of the Construction Cuts. All other cuts can be placed wherever required to generate any desired pattern.
Who does the cutting?
All cutting in the PeterFell System can be conducted by any competent concrete cutter, usually arranged by the concrete contractor.
What are the cuts filled with?
All decorative cuts should be filled with PFL Non-Shrink Grout. PFL Non-Shrink Grout is a specially designed shrinkage-compensated grout with excellent substrate adhesion, is non-corrosive, non-toxic, and impact resistant. It is recommended that grouting is conducted using a PFL Grout Gun (it can also be applied by trowel, providing cuts are lined with PFL Grout Tape) to stop contamination of the area next to the cut.
> For information on the grouting of cuts refer to the PeterFell Finishing Process Guide.
Step 4 - Seal the concrete
All concrete surfaces should be sealed. The sealer prolongs the life of the concrete colour, and protects the concrete from staining and marking. The sealer also determines the final look and finish of the floor. A range of sealers are available from Peter Fell Ltd to suit any project.
Do I need to seal my concrete?
Yes - sealing is essential to enhance and protect coloured concrete. Sealing will determine the final appearance, both colour and texture, of the concrete. Sealing stops 'dusting' (efflorescence) forming on the concrete surface which masks the concrete colour (often mistaken for colour fading), maintaining the true colour. More importantly, sealing protects the concrete from staining and marking, an essential aspect of any flooring system.
>For information on which sealer to use click here.
How do I seal my concrete?
All concrete surfaces can be sealed by following the PeterFell Finishing Process - the final steps in the PeterFell System. This process is outlined below and includes the grouting of cuts, surface preparation, and sealing of the concrete.
>To download the PeterFell Finishing Process Guide click here.
Can I seal the concrete myself?
Yes - concrete can be prepared and sealed by any competent handyperson. All required products and full application instructions are available from Peter Fell Ltd.
>For sealer product infromation click here.
>To download the PeterFell Process Finishing Guide
click here.
How long does the sealer last?
No concrete sealer will last forever. The floor life of the sealer is very much dependent on preparation and application of the sealer. For typical application PeterFell sealers have a floor life of approximately 3 - 5 years. This is a guide only and is is not guaranteed as in-service life of the sealer is very much dependent on preparation and application of the sealer, and use, which are beyond the control of Peter Fell Ltd. The floor life of internal sealed floors is significantly prolonged through use of PFL CoverSeal. All PeterFell sealers can easily be re-applied to provide ongoing protection of the concrete surface.
Can I seal my existing concrete?
Yes - existing concrete can be prepared and sealed by any competent handyperson.
For product information and application instruction refer to the PeterFell Finishing Process Guide or contact Peter Fell Ltd.
Why should I use PFL Coverseal on my internal floors
We recommend all internal floors be treated with PFL Coverseal for enhanced performance and stain resistance.
PFL CoverSeal is a water-based, high gloss, anti-scuff, stain repellent floor treatment for use on interior sealed concrete floors. It is a sacrificial coating and works much like a wood polish for say a table. It gives a high gloss, non-slip, and stain resistant finish to interior sealed floors. A unique stain blocking additive provides increased resistance to most common stain-causing agents, while a cross-linked metal additive provides increased slip resistance.
Maintenance
The PeterFell System requires minimal on-going maintenance. However, there are several processes that should be followed to maintain your concrete floor in optimal condition.
How do I keep my internal concrete floor clean?
Once the floor is sealed and treated with PFL CoverSeal very little maintenance is required. PFL CoverSeal contains anti-scuff and stain repellent components to reduce surface marking. It also acts to maintain gloss levels on internal surfaces. As PFL CoverSeal acts as a sacrificial coating to protect the floor over the sealer, PFL CoverSeal must be re-applied to internal floors twice a year, subject to wear rate.
All internal floors can be cleaned with PFL Neutralizer & Cleaner using a cloth or mop. For full product information and application instructions refer to the PeterFell Finishing Process Guide or contact Peter Fell Ltd. Do not use amonia or amine containing cleaners or detergents.
These detergents are very harsh and will cause irreparable damage to PFL CoverSeal (and other PFL Sealers), necessitating sealer re-application to restore gloss and finish to the floor.
How do I keep my external concrete floor clean?
Once the concrete is sealed very little maintenance is required. The area can be cleaned by hosing or water blasting. Any spills or contaminants should be cleaned with PFL Neutralizer & Cleaner using a mop or yard broom. For full product information and application instructions refer to the PeterFell Finishing Process Guide or contact Peter Fell Ltd.
How do I clean moss and algae off my concrete?
Moss, lichen and algae can be removed from concrete surfaces using PFL Algaecide. PFL Algaecide is designed to kill moss, lichen, and algae, making it a more effective method of removing these contaminants than water blasting or cleaning alone. In targeting these organisms directly, it will also delay their return, reducing ongoing maintenance.
While PFL Algaecide is designed to eliminate living moss, lichen and algae, it will NOT remove dead organisms. These are generally distinguishable as black surface contamination (as opposed to green contamination characteristic of living organism), and can only be removed by water blasting or cleaning as described above.
For full PFL Algaecide product information and application instructions click here.
