Detailed Technical Information
By detailed we mean detailed! This is the place where keep the answers to every question we have ever been asked. There is a huge amount of information so please use the list below to help find what you need:
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Planning
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Colour the concrete
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Lay and Texture the concrete
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Cut and Grout the Concrete |
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Finish the Concrete
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Miscellaneous Specifications
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Planning
The Differences between Placing Coloured Concrete and Normal Concrete
All of the following points are described in detail in the sections below and this list is meant as a summary only.
Experience
Any competent concrete contractor can place coloured concrete - but like anything it is better to use a contractor with some experience. In the 'Where to buy' section we list experienced contractors in each area.
Care
Non-coloured concrete is often covered with lino, carpet or tiles, while coloured concrete is the final visible surface, therefore care must be taken by all involved in the project to protect the concrete from staining during construction. Click here for more detail.
Planning
As the concrete is the final surface extra care should be taken to ensure the cracking risk is minimised. Cool, overcast weather is ideal for pouring concrete. It should not be poured if rain or frost is forecast. Very hot days (especially if there is a lot of wind) should also be avoided, if it is good weather for drying the washing, it is not a good day to pour concrete. Don't be afraid to postpone pouring if the weather looks risky.
Coloured concrete poured on different days can be different colours. Do not butt up areas of concrete against each other where the concrete has been poured at different times as it is difficult to match exactly. Concrete pours should be planned to minimise butting areas, or where it cannot be avoided try to separate using steps, timber inlays or similar.
Ground Preparation, Polythene and Reinforcing
The area to be concreted should look smooth and firm before the reinforcing steel is placed, with no soft or muddy areas.
Use polythene under external slabs as well as internal to reduce the chance of ground water compromising the sealer. If this is not used, the contractor should spray the ground surface with water just prior to the concrete being placed. This is to stop moisture being drawn from the concrete mix into the ground, which prevents the concrete from setting too fast.
Reinforcing steel should be spaced off the ground and well secured against accidental movement.
Water Addition
Changes of the water to cement ratio change the colour, so:
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Do not add water to a truck half way through a discharge
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Do not add unevenly add water to the surface of the slab when finishing
Anti-vaps
We recommend the use of anti-vaps (such as Sikafilm from Sika, or Masterkure 111CF from BASF), for all coloured concrete placement, to maintain bleed water and minimise cracking risk.
Screeding
If the floor is to be ground or exposed, do not shake out screed on screeded areas as a line of paste will result.
Machine Trowelling
We recommend that all surfaces be machine trowelled, or at the very least hard hand steel trowelled, to maximise the surface durability. Any surface effects like mag floating, exposing, or rock salt addition can be done afterwards.
Cutting
Expansion or control cuts and joints should be done 24-36 hours after pouring, and be planned to incorporate the decorative cuts being made later. Peter Fell Ltd offers a service to help the planning of both types of cuts.
The decorative cuts for indoor work should be done before the internal framing is erected so the cut goes to the wall. This means there may be a delay for the builder in erecting the framing when compared with a normal floor- make sure the builder knows this beforehand!
Final Surface
There are many different possible surface finishes so be sure there is clear agreement between all parties about what the client expects.
Contractors
While the PeterFell System requires no specialist applicators or training, it is recommended that all aspects of the system are carried out by appropriately skilled, competent trades people. Peter Fell Ltd provides all necessary products along with full application instructions, however Peter Fell Ltd does not provide any labour or contractors.
For notes on choosing a contractor, provided by the Cement and Concrete Association, click here.
We strongly recommend that one person, owner, project manager, foreman or concrete placer, is given the responsibilty for the coloured concrete work and coordinates all subtrades involved, and they should have a full understanding of the system prior to the commencement of any work. As with any project, the successful application is dependent on the competence and workmanship of the contractors employed. Similarly, as there is the potential for multiple trades people to be employed to work on the same project, it is essential that all parties are aware of the system requirements at all times.
Architects/Specifiers
The PeterFell System can be specified for any project involving concrete.
The most common problem we see with specification is a lack of understanding of the product. Hence we encourage all designers to contact us if they have even a small question as it can save a lot of time.
> We have set up a special page for Architects and Specifiers here
Concrete Contractors
In most projects a concrete contractor will organise the concrete placing, cutting and finishing. If desired, owners can coordinate this themselves and carry out the finishing process themselves also.
We have set up a special page for Contractors - click here.
Concrete Placers
We would recommend using a placer with strong experience in colour projects (ask to see them), but there is little difference between the placing of standard grey concrete and PeterFell coloured concrete so no specialised training is required.
We do not recommend amateurs/DIYers do the concrete placing job themselves.
Concrete Cutters
It is recommended that all concrete is cut by a professional concrete cutter.
The Construction Cuts position and Decorative Cut patten should be determined at the design stage and marked out with clear set out points and dimensions on the drawings. For smaller jobs the cutter should discuss and agree with the owner exactly where the cuts are to go.
In no case should the cutting be done with a hand-held blade. Curves are an exception but it is difficult to get a clean cut.
Concrete 'Finishing' Contractors
The PeterFell Finishing Process can be completed by any competent handy person. Full product information and application instructions are provided in the 'PeterFell Finishing Process Guide'. For full application instructions or clarification on this process or any of our products please contact Peter Fell Ltd.
Colour The Concrete
The PeterFell System is an integral colour system, where a liquid colour (oxide) is mixed through the concrete. This results in the permanent colouring of the concrete which, unlike surface coatings, will not chip off or wear away. This colour method also means that each PeterFell floor is unique as each floor displays individual natural variations in colour.
It is the natural variation in colour that 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. While the colour dosing is tightly controlled, the final colour is influenced by a number of elements, which are discussed here.
Concrete Colour Dosing
When choosing a PFL Special Colour all that is required is the colour number, i.e. no dose rate or kg per metre of concrete need be specified as each of the colours have a specific dose rate. This dose rate cannot be altered as this will affect the colour.
PFL Special Colours are manufactured specifically for each job. They are batched for specific load sizes to simplify dosing at the plant, reducing the chance of incorrect colour dosing. Peter Fell Ltd must be notified immediately if load sizes are changed as this will affect colour dosing and the colour will need to be re-batched. All buckets are clearly labelled with bucket weight, load number, number of buckets per load, and total oxide required per load. All oxides are weighed to an accuracy of 0.01 kg, and all mixes are swatch tested prior to dispatch to ensure absolute accuracy and quality.
The Advantages of Liquid Colour
We use liquid oxides for our colours because:
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They mix better
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They result in a more even colour
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There is no risk of 'balling' as sometimes occurs with powders - balling is where a lump of oxide does not mix through, changing the final colour.
Concrete Colour Samples
Please click here for more on concrete colour samples
Lay and Texture the Concrete
Concrete Admixtures
Standard admixtures including air entrainer, set accelerators, set retarders, water reducing agents and superplastericisers will have minimal impact on the PeterFell System. However, calcium chloride based accelerators, can affect the colour distribution i.e. increase the colour 'mottliness'.
It is recommended that in hot weather retarders are used to delay and control the concrete set time. In cold weather, non-calcium chloride accelerators and/or superplastercises should be used to improve handling and performance of the concrete
Concrete Textures available
Our Design Choices page is a tool that details suitable textures and sealers for patios, drives, floors etc.
The concrete finish determines the surface texture and influences the concrete colour and so it is most important that the correct finish is specified for the intended application. It is the concrete finish that determines the slip resistance of the concrete surface (for more information on slip resistance click here). Finishing of the concrete will also influence the final concrete colour, and therefore the overall appearance of the finished floor. It is essential that the desired finish is clearly communicated to the concrete contractor to ensure there is no misunderstanding.
Smooth Surface
| Finish | Technique | Notes | Class | Coefficient of Friction (wet*) |
Machine or
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Standard internal finish, or where smooth, hard surface is required. |
Steel trowelling (manual (U3)or mechanical(U4)) of floated finish when concrete is sufficiently hardened. Machining will harden the surface. |
U3/U4 |
0.3-0.45 |
Ground/Polished(Click here for more detail) |
Concrete surface is mechnically removed exposing the aggregate (pebble) and generating a very smooth surface. |
Surface is removed by grinding, and then refined with subsequent passes. The Australian CCCA has an excellent Briefing Paper titled 'Polished Concrete Floors' - click here |
U11 |
0.15-0.6 estimate |
Salt and Pepper
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Tip of aggregate is exposed on the surface, giving concrete a speckled effect. |
Top 1-2 mm of surface removed exposing the tips of aggregate |
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Light Grind
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Pebble profile is visible but colour is dominant |
Top 2-3 mm of surface removed exposing tip of aggregate |
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Medium Grind
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Pebble profile is clear but not heavy |
Top 3-4 mm of surface removed exposing prominent aggregate profile. |
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Heavy Grind
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Aggregate profile is prominent, giving terrazzo appearance to concrete surface. In this case the background colour is heavily influenced by the stone colour.
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Top 4-5 mm of surface removed exposing aggregate profile
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Slightly Textured Surface
Sandstone
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Surface is treated with PFL Surface Preparation, exposing sand and fine aggregates, giving sandy grainy texture. |
PFL Surface Preparation diluted 10:1 and applied 2 or three times until required texture achieved. |
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0.55 - 0.90 estimated |
Magnesium/wood trowel
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Surface opened up with sweeping trowel marks. |
Trowelling (manual or mechanical) of floated finish when concrete is sufficiently hardened. |
U2 |
0.65 - 0.85 |
Sponge/texture roll
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Dimpled roller or sponge passing over suface |
Concrete is treated with sponge of textured roller following machining to impart texture. |
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Salt
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Pitted surface in the same shape of rock salt. |
Rock salt is broadcast over placed concrete, leaving pitted holes in cured concrete surface. The Australian CCCA has an excellent Data Sheet titled 'Rock Salt Texturing' - click here for more |
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Light Broom Finish
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Uneven lines, usually linear, marked on the surface. |
Soft bristled broom used to texture machined concrete finish. |
U5
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0.65 - 0.85 estimated |
Rough Grind
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Surface is ground with rough blade, scoring the surface and exposing the aggregated profile. |
Surface is ground using coarse grinding head(80 or 100 grit) |
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0.65-0.75 1 |
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Textured Surface
Exposed Aggregate |
Aggregate is exposed at time of placing, resulting is pebbled texture and appearance. |
Concrete is treated with an appropriate agent to expose aggregate. The NZRMCA has a paper titled 'Exposed Aggregate' - click here The Australian CCCA have a Paper titled 'Exposing Flatwork' (horizontal surfaces)- click here |
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0.40 - 0.90 |
Heavy Broom Finish
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Heavy bristled broom passed over machined concrete to generate coarse brushed concrete surface. |
Firm bristled broom used to texture machined concrete finish. |
U6
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0.65 - 0.85 |
Shot/Sand Blasted |
Surface is blasted, exposing sand and fine aggregates |
Concrete surface sand/shot blasted |
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* Values taken from New Zealand Building Code, Clause D1 - Access Routes, Acceptable Solutions1, Table 2: 'Acceptable slip Resistance for Walking Surfaces', except as marked
1 Value from Opus Report from Kumutoto Plaza, Wellington - click here for more info.
Colour and Texture in Walls
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Colour and texture can be used in vertical surfaces as well - a technique that offers many advantages but which is still not particularly common in NZ. Walls are generally cast in-situ, on-site tilt-up, or in a precast factory. Our Design Choices Tool shows options for all - click here for more. The Australian CCCA has an excellent paper titled 'Colour and Texture in Concrete Walling' - click here. They have another paper titled 'Guide to Off-form Concrete Finishes - click here. |
The wall shown is from a development near Russell in Northland with an exposed concrete finish. Special surface retarder can be applied to the shutters prior to pouring and the concrete is exposed once the shutters removed. This can be uneven as you can see in the picture.
Slip Resistance
The PeterFell System encompasses a diverse range of concrete surface finishes, from smooth ground floors to textured exterior surfaces. The slip resistance of any PeterFell floor is determined by the texture of the concrete surface.
New Zealand Building Code (NZBC) stipulates that access routes, defined as walking surfaces such as decks, patios and steps on the approach to the main entrance to housing and common areas of communal residential and multi-unit dwelling accommodation, have a coefficient of friction (µ) of 0.4 for flat surfaces. This slip resistance requirement is designed to safeguard the movement of people into and out of buildings. For details on slip resistant requirements refer to NZBC Clause D1 - Access Routes.
In the PeterFell System, the coefficient of friction is determined by the concrete surface. For a complete list of slip resistant surface rating refer to NZBC Clause D1 - Access Routes, Acceptable Solutions 1, Table 2: 'Acceptable Slip Resistance for Walking Surfaces'.
The correct application of PeterFell sealers will not significantly reduce the slip resistance of the concrete surface. However, if the sealer is applied incorrectly, there is the possibility that the sealer will reduce the coefficient of friction.
PeterFell offers an anti-slip compound (PFL Anti-Slip) which can be impregnated in PFL Glaze sealer. Use of PFL Glaze Sealer with PFL Anti-Slip has an estimated µ of 0.55-0.90*. PFL CoverSeal, which is applied over PFL sealers on internal floors, has a coefficient of friction of >0.5 #.. While these products have sufficient slip resistance, the concrete surface is still the key determinant of slip resistance in the PeterFell System.
The Australian CCCA has a paper titled 'Slip Resisitance of Polished Concrete Surfaces' - click here for more.
* = NZBC D1/AS1 Table 2, Portland cement concrete surface (finished in compliance with NZS 3114), coated and grit impregnated.
# = Amercian Society for Testing and Materials (ASTM) Method for Static Coefficient of Friction of Polish-Coated Flooring Surfaces as Measured by the James Machine. see www.astm.org/Standards/D2047.htm for more information.
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Case Study - Kumutoto Plaza, Wellington Waterfront
(Note this project does not use PeterFell colour).
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The Kumutoto Plaza project was a high profile redevelopment of the Wellington Waterfront. After much consideration and testing they used in parts rough ground concrete, created with 80 grit grinding heads, without a sealer. The sealer was not used as any water will then soak into the surface which would reduce the amount of pooled water at the surface. Importantly they had the surface tested by Opus in Wellington for slip resistance and it satisfied requirements with a slip resistance of 0.71. This should be used as guide only as every project is different and individual testing may be required. Note: No colour was used in the project, but the result would be the same if it had been. |
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Designer: Studio Pacific Architecture in association with Isthmus Group, Wellington
Curing of Concrete
Curing is the maintenance of satisfactory moisture content in concrete following placement to allow proper hydration of the cement. It is through this hydration that the concrete strength and durability are established.
Consequently as a first step in hot or exposed sites (i.e. prone to wind and extreme weather) it is recommended anti-evaporation compounds (such as SikaFilm, or BASF Masterkure 111) are used to stop rapid loss of moisture. It is the first 24 hours which are the most critical, during which time curing should be closely monitored. The curing process will be affected by site conditions, most notably temperature and humidity, which contribute to moisture loss from concrete.
No curing compounds are to be used in the PeterFell System. Curing compounds form a film on the concrete surfaces that reduces water loss to aid concrete curing. However, this film prevents the sealer applied later from penetrating and binding to the concrete surface, ultimately leading to delamination.
Hence, it is recommended that water is the only curing agent used on PeterFell coloured concrete floors. Water should be applied to the surface in a mist or fine spray. Care should be exercised when wetting the surface to ensure hoses or other devises do not mark the concrete. Materials that retain water (i.e. sand or hessian cloth) can be used to aid curing, however care must be exercised in timing and application as not to damage the concrete surface. Polythene sheets can also be used to stop water loss, and also aid in the protection of concrete during the curing process (for details on the protection of concrete click here (link below)). For more information on concrete curing refer to NZS 3109 Specification for Concrete Construction, Clause 7.
Protection of Concrete during Construction
Concrete in its raw state is very porous, and prone to marking and staining. As the concrete is the final surface in the PeterFell System, extra care should be taken to protect the concrete while curing occurs. During construction or landscaping there are a multitude of potential contaminates present on site. It should be emphasised to all contractors that the concrete is to be the finished surface and that extra care should be taken.
The best way to protect the concrete is with polythene - black 250 micron sheets are recommended. To ensure even curing, wet the slab lightly prior to overlaying the polythene. Ensure polythene has no folds as this may lead to line mark staining. The use of polythene may be difficult in external situations due to environmental limitation i.e. wind. The polythene can be held in place by taping - use strong adhesive building or agricultural rubber type tape. The concrete slab must be dry around the edges to ensure the tape can correctly adhere. The polythene should not be secured using weights or similar as they will potentially affect colour developments in the concrete.
Avoid stacking of materials on top of the polythene as this creates microenvironments on the concrete surface. As an extra precaution during construction, old carpet can be placed over the polythene. Cardboard and other cover boards can also be used, however these can curl and create a work hazard. Do not lay any carpet or similar material directly on the concrete surface as material may leach out and stain and mark concrete, and these materials do not provide adequate protection against liquid contaminants. In these areas moisture is drawn to the surface creating a reflective mark of the load that is difficult to remove.
It is essential that all protective covers are removed in sufficient time to allow the concrete to dry completely prior to application of the sealer. Concrete dries slowly so the longer the polythene is off the slab the better, but this will depend on the progress of construction and how much potential there is for contamination - obviously for the painting stage the polythene should remain on! Protective covers should be removed at least one week prior to sealing.
Any concrete surface must be completely dry prior to the application of any sealer. Moisture trapped under the sealer can cause the sealer to whiten (termed 'blooming'), or in extreme cases result in sealer delamination. To facilitate the drying process, protective covers may be lifted from internal surfaces once curing is complete and the site is weather tight. Externally, once the slab is cured the polythene may be discarded or replaced with more protection that allows the concrete to dry more efficiently i.e. cardboard. However, once the polythene is removed, caution should be exercised to minimise the risk of staining and marking of the concrete surface.
Cutting & Grouting
Concrete cutting is an essential component of the PeterFell System. There are two types of cuts used:
| Construction Cuts: | Essential to control the natural shrinkage and cracking of concrete. Constrcution Cuts must be correctly positioned, cut to the correct depth, and be executed within 24 hours of the concrete being poured. |
| Decorative Cuts: | Used to generate a pattern on the surface of the concrete. |
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All cuts should be marked in crayon. Do not use string lines or coloured chalk as they are difficult to remove. Specification details for both types of cuts are described below. Peter Fell ltd offers a service to guide the placement of both types of Cuts. Please send your plans to us, no bigger than A3 a scale, and we will email you back what we think is a good solution. This service is offered solely to guide the construction process and we cannot be held responsible if cracking does occur. |
Construction Cuts
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The placement of Construction Cuts must be determined prior to commencement of any concrete work. As concrete hardens (cures), excess water evaporates causing the concrete to shrink and so crack. Construction Cuts should be executed shortly after the concrete is placed to control shrinkage cracking. As the concrete hardens, cracking occurs beneath the sawn slot. As shrinkage begins almost immediately following placement, it is imperative that the Construction Cuts are executed within 24 hours of placement. Cutting too early causes ravelin or aggregate dislodgement, causing joint spalls. Sawing too late may mean uncontrolled cracking. Liaison between concrete cutter and concrete placer is paramount to ensure cutting is executed at the correct time. All Construction Cuts should be continuous, not staggered or offset. Cuts must incorporate any changes of angles in slab layout. When the Construction Cut cannot be carried to the edge of the slab, due to either physical or design limitations, a crack is likely to radiate from the end of the cut to the slab edge. Whilst the positioning of Construction Cuts is determined by the concrete design, consideration should be given to the placement of the Decorative Cuts i.e. if a decorative diamond pattern is desired, the Construction Cuts can be employed at a 45 degree angle, instead of 90 degree angle which would generate a square pattern. Construction Cuts are typically 3 mm wide and cut to a depth of one third the depth of the concrete. Vertical loads are transmitted across the joint by aggregate interlock between the opposite faces of the crack, providing the crack is not wide. If the saw cut is too shallow then random cracking will occur. If the saw cut is too deep, aggregate interlock may be insufficient to transfer vertical loads. Concrete slabs should be cut allowing a maximum area of 16 m 2 for an average slab (approximately 100 m 2). Decorative Cuts (see following section) should be placed over the Construction Cuts to incorporate them into the cut pattern and enable the cut to be grouted. While cutting is the most common jointing process, other procedures can be employed. Consult with an engineer or concrete technician for other jointing options. |
Decorative Cuts
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Unlike Construction Cuts, Decorative Cuts are employed simply for aesthetic effect. Subsequently, these cuts can be placed anywhere in the concrete and can be executed at any time, even months after the concrete is placed. However, it is recommended that Decorative Cuts are done 5 - 10 days after the concrete is placed, as at this stage the concrete will be of sufficient strength to enable a clean cut face, and still be soft enough to allow ease of cutting. If the concrete is too soft there is an increased chance that aggregate can be dislodged during cutting, resulting in jagged cut edges. If a continuous Decorative Cut pattern is required, ensure cutting is complete before any framing or other physical obstructions are placed on the concrete. If such limitations exist, cuts can be made parallel to the framing (or obstacle) to generate a border. Decorative cuts are wider than Construction Cuts - typically done with a 10 mm saw blade (generating 9-13 mm cut), and only penetrate 10-15 mm into the slab. The only limitation on the width and depth of the Decorative Cut is that they need to be able to be grouted, which is difficult if they are too thin or deep. Decorative cuts are placed over Construction Cuts (see diagram below) to allow grouting, and to integrate the Construction Cuts into the decorative pattern. The placement of the Decorative Cuts is limited only by the Construction Cuts. For ideas and draft Decorative Cuts please contact Peter Fell Ltd. |
Grouting
All Decorative Cuts should be filled with PFL Non-Shrink Grout. As Construction Cuts are only 3 mm wide, it is recommended that Decorative Cuts are re-cut over the top of the Construction Cuts, even if no other Decorative Cuts are being used, to allow cuts to be properly filled (for more information on concrete cutting see above).
PFL Non-Shrink Grout is a specially designed shrinkage-compensated grout with excellent substrate adhesion, is non-corrosive, non-toxic, and impact resistant. Grouting should not be conducted as for ceramic tiles as this will result in staining of the concrete. It is recommended that grouting is conducted using a PFL Grout Gun. Although it can be applied by trowel providing cuts are lined with PFL Grout Tape to prevent contamination of the concrete surface surrounding the cut.
PFL Non-Shrink Grout can be coloured using ANY colours in the PeterFell colour range. Most commonly, the concrete colour is also used as the grout colour. As PFL Non-Shrink Grout is a slightly darker base colour than concrete when colour is used in the grout it will also appear darker, offering a subtle contrast whilst retaining the same colour tone as the concrete. However a lighter or darker colour can be used for a contrast, or the grout can be left in its natural colour. As the colour is added to the grout on site, colour tone can be adjusted to suit individual requirements.
While PFL Non-Shrink Grout is engineered with a unique 2 - stage shrinkage compensation mechanism and displays excellent substrate adhesion, in cases of excessive slab movement, due to design or environment, any stresses or cracking will occur down Construction Cuts (what they are designed for). This movement can result in cracking (typically fine hairline cracks) or 'popping' of cementitious grout - even of PFL Non-shrink grout with impact resistant compounds. In these extreme cases a more flexible joint sealer should be used
> For all product information click here.> For full application instruction refer to the PeterFell Finishing Process Guide.
Finish the Concrete (Seal)
A key aspect of the PeterFell System is the PeterFell Finishing Process - the process to apply the Sealer. All concrete floors should be sealed to add lustre, richness and shine to the floor but also to enhance the colour, and protect the surface from staining and marking.
The PeterFell Finishing Process encompasses concrete cleaning, preparation and sealing of concrete floors.
> To download 'PeterFell Finishing Process Guide' click here.
Clean up
It is essential that all construction debris, rubbish, marks and contaminants are removed from the concrete prior to sealing. Failure to properly clean the concrete surface can compromise sealer application and lead to sealer delamination. Sealing will also highlight any marks or stains on the surface, which once sealed, will be very difficult to remove. Clean up with PFL Neutralise and Cleaner should also occur prior to treatment with PFL Surface Preparation (see below) as the acidic surface preparation may react with contaminants to further damage or mark the concrete.
For further product information click here, and for full information on the cleaning and preparation of concrete surfaces for sealing refer to the PeterFell Finishing Guide.
Surface Preparation
Following Cleaning, the surface should be prepared for sealing through treatment with either PFL Surface Preparation or PFL Eco Surface Preparation prior to application of any sealer. These solutions mildly etch the surface and remove surface laitance (efflorescence) present on the surface of all new concrete. If this laitance is not correctly removed the sealer will not be able to adhere correctly to the concrete surface, resulting in the delamination of the sealer.
This standard application (mild etch) is essential in the preparation of the floor for sealing, and will not alter the inherent floor characteristic. However, if it is desired, PFL Surface Preparation can be used to alter both the texture and finish of the floor by adjusting the solution strength and treatment time. It is essential that PFL Surface Preparation is correctly diluted and that a test area is completed to ensure dilution is appropriate for the intended application. The list below gives an indication of the effects of different dilution effects of PFL Surface Preparation or PFL Eco Surface Preparation.Use of different PFL Surface Preparation strengths
| Dilution | ||
| Mild etch | Recommended for preparation of internal floors, or areas with minimal surface laitance. Will not significantly alter the texture and colour of the floor. | 30:1 |
| Medium etch | Recommended for preparation of external surfaces, or areas with significant surface laitance. Prolonged treatment exposes sand (and eventually aggregate), increasing surface texture and changing the concrete appearance. | 20:1 |
| Heavy etch | Recommended only when heavy exposure or Sandstone Finish (see Appendix C) of concrete surface is required. Will significantly alter the appearance and texture of the concrete - proceed with caution! | 10:1 |
> For further product information click here.
Concrete Sealers
Sealing Introduction
Sealing is essential for adding shine, lustre and richness to the concrete colour and protecting the concrete from staining and marking - without it the concrete quickly becomes dull and lifeless and the colour was not worth adding. Peter Fell Ltd offers a top quality range of sealing and finishing products (outlined below) designed specifically for use on concrete floors. They have a range of different properties to match different situations - click here to see the Design Choices page. With this tool you choose what application you will be using the sealer for eg patio or a drive, and then the appropriate sealer is shown for the different surfaces.
All internal floors should utilise PFL Coverseal (below) for enhanced performance
Our concrete sealers are all of the best quality, developed in New Zealand for New Zealand's unique conditions. Most importantly they have a very high solids content ie they aren't a very dilute solution like many of the numerous sealer products on the market. This is the key issue, and often the hardest to find out - the higher the solids the thicker the resulting coating and so the longer they will last. Cheaper sealers generally don't wear well as they are usually low solids. All of the Peter Fell range of sealers have the highest possible percentage solids and hence durability. Do not be swayed by cheap sealers - you will get the little that you paid.
We have a range of four sealers:
- PFL Glaze Sealer - high solids solvent based acrylic coating
- PFL Acrylic Sealer - high solids waterbased acrylic coating
- PFL Epoxy Sealer - new generation water based 1:1 epoxy coating
- PFL Natural Sealer - impregnating non-waterbased sealer for a natural concrete finish
The C2 system is not a product we supply but that we recommend. It is an American system that gives a high gloss and very durable finish. It is offered with a 10 year material warranty but must be applied by a registered applicator.
For full product information and application instructions refer to the 'PeterFell Finishing Process Guide', or contact Peter Fell Ltd.
PFL Glaze Sealer |
This is our biggest seller and for good reason. A high-solids solvent based acrylic coating for interior and exterior use, giving a 'wet look' (for a non-wetlook, use a primer). The high solids means a more durable coating is created which will last a long time, and being solvent based means it also maximises durability. When considering using this indoors, note that the pungent smell can linger for sometime. It will pass eventually but for this reason many people choose the PFL Acrylic or Epoxy. |
PFL Acrylic Sealer |
A no VOC, high-solids water-based acrylic with a natural look, for interior and exterior use (but not on driveways or garages). Very popular for use indoors, along with the PFL Epoxy Sealer. Being a water-based acrylic means it gives a natural look when compared to the wet look of the Glaze sealer. It also doesn't have the have the smell issue of the either. |
PFL Epoxy Sealer |
A new generation, no VOC, fast curing, water-based, 1:1 epoxy providing a coating with increased durability for interior applications. It is more than the Glaze Sealer but much greater durability.
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PFL Natural Sealer
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Impregnating sealer to retain surface texture while providing stain resistance. PFL Penetrating Sealer is absorbed into the surface of the concrete, and after the carrier has evaporated it hydrolyes in the pores and capillaries, and then condenses to form a hydrophobic zone, but the breathing activity of the substrate remains. Ideal for use on high traffic commercial situation where a coating type sealer would wear. It does not increase slip risk as it does not alter the slip resistance coefficient of the concrete.
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| C2 Gloss System | High Durability system that must be applied by registered applicator - Click here for more info |
The C2 Hard is not a sealer as such but a hardener used only in industrial and workshop applications - click here for more info.
Sealer Comparison
We have developed the Design Choices Tool which matches Sealers with applications which suit their properties - click here for more.
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PFL Acrylic Sealer |
PFL Epoxy Sealer |
C2 Gloss System |
PFL Natural Sealer |
Chemistry |
High solids solvent based acrylic | High solids water based acrylic | Water-based 1:1 epoxy | Sodium/lithium silicate, water based | Silane/Siloxane in a mineral spirit carrier
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Appearance/Type |
Wet look Coating Natural look can result if a primer used |
Natural Coating | Natural Coating | High-Gloss Coating | Natural Impregnating |
Durability
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High
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Good | Highest
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Highest | Will slightly improve concrete
surface durabilty |
Applications: |
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Interior |
Yes, but fumes can be uncomfortable
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Yes
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Yes
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Yes | Not recommended, but could be used
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Exterior
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Yes
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Yes, but cannot be used with PFL Anti-slip
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No
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No | Yes
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Limitations
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Cannot be used on driveways or garages Cannot be used with PFL Anti-Slip
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Cannot be used outside as will it yellow under UV
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Cannot be used outside |
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Application requirements |
Concrete must be dry
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Concrete must be dry
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Can tolerate a slightly damp surface | Concrete must be dry | Concrete must be dry
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Coatings |
Two coats (sometimes more depending on absorbancy of concrete surface) | Two coats (sometimes more depending on absorbancy of concrete surface) | Two coats (sometimes more depending on absorbancy of concrete surface) | Can only be applied by registered applicator | Two coats (sometimes more depending on absorbancy of concrete surface) |
Recoat
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2-5 years depending on wear (will be much longer when used with PFL CoverSeal) | 2-5 years depending on wear (will be much longer when used with PFL CoverSeal) | 2-5 years depending on wear (will be much longer when used with PFL CoverSeal)
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10 years + | 5 Years +
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Comments |
Can be applied by competent DIYer
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Can be applied by competent DIYer | Can be applied by competent DIYer |
Can only be applied by registered applicator 10 year material warranty |
Can be applied by compentent DIYer |
Full Specifications |
(Full Product Data sheet here) | (Full Product Data sheet here) | (Full Product data sheet here) |
> For other product information click here.
The C2 Flooring System
This is an American flooring system now represented in NZ with a network of Registered Applicators country-wide.
Peter Fell act as agents and will pass on any enquiries to a local applicator who will contact you to discuss the project - click here to submit an enquiry
The C2 System offers a number of advantages:
- Latest lithium based technology - traditional sodium or potasium silicate based hardeners are now superceded.
- A 10 year material warranty
- A nationwide network of Registered Applicators
The two products we recommend are as follows. To see where they are appropriate use the Design Choices Tool - click here.
C² Gloss
This system can be used on both normal and ground/polished/honed concrete, for both residential and commercial applications. This revolutionary system will allow you to achieve a fantastic glossy and durable finish. It requires one application of C² Super Hard and three applications of C² Seal.
- Stain resistant against acids, fats, grease, and oils
- Planet Safe, water based, contains no solvents, non-toxic, no smell, non-mutagenic & non-carcinogenic (safe in food preparation areas), non flammable, fast drying, easy to apply
C² Hard
For use in industrial and commercial flooring situations
- Advanced sealer, hardener & densifier for concrete
- Lithium silicate/colloidal silica treatment
- Much more effective alternative to conventional sodium or potassium silicate surface hardeners
- Deeply penetrates and reacts with concrete
- Safer and easier to apply than conventional sodium or potassium silicate hardeners
- Increases abrasion resistance by up to 60%
PFL Coverseal
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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. |
Other features of PFL CoverSeal include:
- Treated floors exhibit exceptional gloss
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Does not require buffing
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Retains high gloss under scrubbing
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Increased slip resistance.
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Increased scuff and scratch resistance.
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Easy to apply and re-apply.
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Safe to use -- water based, low odour, no fumes.
To packaging and application guide please see our Product Info page
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Miscellaneous Specifications
The following points cover miscellaneous specification of the PeterFell System. If further information is required on any of these matters please contact Peter Fell Ltd.
Colouring only Part of a Concrete Floor
The PeterFell System does not have to be used exclusively for all concrete in a project. The PeterFell System can easily be used where only a portion of the concrete is required to be coloured i.e. other areas covered with carpet, wood flooring etc. For example, a lot of people do the kitchen and dining room with coloured concrete and the rest of the house with carpet.
The coloured concrete should be placed first and taken to at least one metre past where other flooring is to be used. Care must be exercised in placing, especially in regard to cross contamination of grey concrete into the coloured area. Contractors must be vigilant when finishing to avoid contaminating the coloured concrete with plain concrete from work boots and equipment. All tools should be thoroughly cleaned when moving from plain to coloured concrete. Communication with contractors on these matters is essential to ensure successful execution of the PeterFell System.
Exposed Aggregate Concrete
The PeterFell System can be integrated into projects using exposed aggregate concrete. This type of concrete uses different types of aggregates (stones) which are then exposed on the surface to give a unique stoney texture and appearance. This type of concrete is commonly used for exterior applications such as driveways and paths, or areas where the unique stoney texture is beneficial.
The primary aesthetic consideration when choosing exposed aggregate concrete is the aggregate itself. In New Zealand there are wide range of natural aggregates offered, encompassing a range of different sizes, colours, and combinations of stones. It is advisable to contact your local concrete supplier to determine the available aggregates in your area. The PeterFell System can be used to provide a complimentary (or contrasting) background colour to the aggregate selected.
The PeterFell Finishing Process is also strongly recommended, even in situations where no colour is added to the concrete, as sealing exposed aggregate concrete will not only protect the surface from staining and marking, but also enhances the natural colour of the aggregate.
Concrete Overlays
The PeterFell System can be used to colour concrete overlays exactly as for standard concrete flooring. All concrete overlays should be undertaken with due diligence to ensure optimal structural integrity. It is recommended that all overlays are bound to the existing substrate i.e. using a wet-on-wet epoxy bonding agent. The overlay should be of an appropriate thickness, typically four times average aggregate size with a minimum depth of 50 mm. For any overlay under 80mm, cuts in the existing slab should be transferred to the overlay, and all cracks should be 'bandaged'. Consultation with an engineer or concrete professional is strongly recommended for all overlay projects.
Underfloor Heating
The PeterFell System can be used with all types of underfloor heating. The primary consideration when using any heating system is the placement of Construction Cuts. These cuts are required in all concrete, coloured or plain, and should never be omitted. Care should be taken in the preparation and placement of piping, wiring, or heating coils. The placement of all sub-floor components should be clearly defined prior to the placing and cutting of the concrete to ensure successful integration of the heating system into the concrete floor. Typically, heating components are placed 500 mm from any Construction Cut. All components should be secured in place at regular intervals to prevent movement during concrete placement. Communication with all relevant contractors is essential to the successful integration of any under floor heating system in concrete.
The Australian CCCA has an excellent paper titled 'Concrete Floor Heating' - click here for more
Decorative Concrete
The PeterFell System can be augmented with a variety of materials to change the appearance of the finished surface. The list below shows some common methods for creating decorative features in concrete. The overall design, structural impact, and the effect on the concrete colour and finish, should all be taken into account when considering a decorative feature. It is also imperative that all contractors involved are experienced in the application of the decorative effect, and that appropriate preparations and correct application techniques are employed.
Grinding/Honing/Polishing |
This is the process where the surface of the concrete is mechanically removed exposing the aggregate and generating a very smooth surface. See special section below for more details.
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In-lays |
Virtually any material can be placed in the surface of the concrete for decorative effect. See special section below for more details.
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Murals/Painting |
This decorative effect has been around for centuries, and encompasses a wide range of applications, from detailed murals to corporate logos. It is essential that the materials used to create the art work are compatible with concrete i.e. won't leech through the concrete. It is essential that a sealer is placed over the art (and the surrounding concrete) to protect from wear and damage.
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Edging/Borders
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A number of elements can be used to border concrete or as a mowing strip. These elements may add textural variation (i.e. concrete pavers) or simply change the appearance of the concrete (i.e. grinding a border pattern). Integration of these elements into the PeterFell System is dependent on the materials or processes involved. Consult with Peter Fell Ltd and/or contractors for application advice.
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Channels
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A common decorative tool is the use of channels in the concrete which are then filled i.e. with loose river pebbles or decorative grasses (e.g. mondo grass). Channels are also a convenient way to integrate drainage and irrigation into concrete design. Channels can be generated in a number of ways, most commonly by boxing out the channel and pouring separate slabs. Consideration should be given to the material used to fill the channels and their impact on the concrete.
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Broadcast Aggregates (Seeding) |
A range of materials can be integrated into the surface wet concrete for decorative effect e.g. shells and glass. The material must be compatible with concrete. Do not use sodium based glass products, as these will cause alkali aggregate reaction, damaging the concrete. Care should be taken to ensure material is correctly integrated into the surface, and will not be removed by subsequent treatments i.e. grinding. The material used should also be practical and not pose a health and safety risk i.e. no sharp edges.
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Surface Effects |
The placing and finishing of concrete determine the surface properties of the concrete. Manipulation of the surface can also be used for decorative effect. An example is the Sandstone finish achieved through the use of PFL Surface Preparation. This process exposes sand and fine aggregates in the concrete which not only alter the texture of the concrete, but also the appearance.
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Concrete Grinding/ Concrete Polishing/Concrete Honing
Grinding
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Grinding is the process where the surface of the concrete is mechanically removed, generating a very flat surface and revealing the aggregate profile. Grinding can be incorporated into the PeterFell System, offering an alternative to standard coloured concrete. Aesthetically, the key component of a ground floor is the concrete aggregate. In these floors, the PeterFell colours offer a complementary (or contrasting) background colour. The grinding of a standard concrete will expose the natural angular shape of the aggregate. The grinding of speciality aggregates, such as those used in exposed aggregate concrete, provides a greater diversity in cross section shape and colour in the finished floor. Consult with your local ready mix supplier or grinding contractor for available aggregates when considering grinding. Aggregates and other foreign matter (i.e. glass and shell) can also be seeded into the concrete surface for decorative effect. Care must be taken when seeding material into the concrete surface to ensure it is properly incorporated. Grinding is usually a two phase process. The 'First Grind' removes most of the required surface layer, while the 'Second Grind' refines the surface to create the finished floor. The 'Second Grind' may encompass several passes over the floor to achieve the desired surface. Grinding can be conducted as a 'dry' or 'wet' process. Wet grinding is the recommended method as it is the most efficient, although this generates significant mess which needs to be considered from a site management perspective. It is recommended that the 'First Grind' is done 10 - 20 days after the concrete is poured, as the concrete has not gained full strength and framing or other obstacles may not yet be erected. The 'Second Grind' should be done before the lining goes on the framing, although may vary depending on other project requirements. The floor should then be protected for the duration of construction. A number of ground finishes are available. There are no industry standards that define these finishes, however listed below are the terms used at Peter Fell Ltd when describing and specifying different ground finishes. These finishes will impact on the appearance of the concrete colour. The more of the aggregate exposed, the darker the colour will appear. In all applications, the desired finish should be clearly communicated to the grinder to ensure the desired final surface is achieved. |
| Grinding Depth | Finish |
| 1 - 2 mm | 'Salt and Pepper' grind |
| 2 - 3 mm | Light grind |
| 3 - 4 mm | Medium grind |
| 5 + mm | Heavy grind |
Polishing
Polishing is simply a higher quality grind involving multiple (up to 12) passes over a floor using successively finer grades of grind (analogous to 'grit' of sandpaper). Polished floors are also treated with densifying agents to increase surface smoothness and increase surface light reflection.
All ground floors should be sealed. It is important to realise that grinding exposes air voids and may make pits in the concrete surface. The voids must be filled prior to sealing - sealers do not act as fillers. This is typically achieved by applying a light skim coat over the surface and re-grinding. The choice of sealer is important as it must form an even coating on the ground surface. As most sealers will not soak into the aggregate, but will penetrate into the surrounding cement matrix, following the application of several coats an uneven 'dimple' effect can result. For this reason epoxy type sealers are recommended as they provide an even coating.
To improve the slip-resistance of the ground floor (which are very smooth and subsequently can be slippery) non-slip additives or an even graded sand should be incorporated into the sealer.
In-lays
A wide variety of material can be placed into concrete for decorative effect. Commonly used in lays include wood, tiles or ceramics, steel, and brass. Initial consideration should be given to the practicality of the proposed in-lay with respect to durability and safety i.e. sharp or brittle materials should be avoided. Any in-lay should be properly planned and care must be taken in the execution.
Positioning of the in-lay should also be considered, ensuring the in-lay does not compromise the structural integrity of the concrete i.e. increase the probability of concrete cracking. In-lays can be fixed in a number of ways, and the method of application dependent on the materials being used. There are two general techniques, the direct method in which the in-lay is fixed first and the concrete poured around it, or indirectly, where an area is boxed off when the concrete is poured and the in-lay inserted later. Care should also be taken that the in-lay will not have a detrimental effect on the concrete i.e. does not leech chemicals or colours into the concrete such as tanalized or stained wood. The in-lay must remain stable as movement may cause the material to be dislodged (i.e. warping wood) or compromise the integrity of the concrete.
All in-lays should be carried out by an experienced trades person familiar with both the in-lay medium and the placing of concrete.
Tilt slab & Precast colouring
The PeterFell System can be used to colour tilt slabs and other vertical concrete panels. The oxides are dosed exactly as for standard concrete, and should be specified as such. The same colour considerations should be taken into account when choosing colours for the slabs. It is also beneficial if slabs are cast at the same time by the same manufacturer to minimise colour variation due to environmental factors i.e. temperature, humidity etc.
Precast panels and Tilt Panels have two surfaces, the mould side and the open side, so when designing your surface you must understand the manufacturing process to know which is which, then specify the appropriate treatment.
To see the options for each side see the Precast section of the Design Choices Tool - Click Here
Pod System Flooring
The PeterFell System can be incorporated into projects using pod systems flooring i.e. Firth Rib-Raft, Allied Concrete Super Slab, Atlas Concrete Raft Flooring etc.
In these situations standard concrete should be used to secure the pods, stopping at least 100 mm from the surface. A layer of coloured concrete (at least 100 mm thick) should then be placed immediately over top. The bottom layer of concrete must not be allowed to harden prior to application of the coloured top layer of concrete. Similarly, extreme care should be taken to avoid contaminating the top layer of coloured concrete with the underlying standard grey concrete. Contractors should ensure all equipment (including work boots) are cleaned between placing of standard concrete and the final coloured layer.
Or all the concrete can be coloured which eliminates this contamination risk.
If a shallow pod system is employed it may be more practical (and economical) to colour all the concrete.
Swimming Pool Surrounds
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A common application of the PeterFell System is for swimming pool surrounds as the colour is in the concrete it is not directly affected by chlorine or salt water. Similarly, all the PeterFell sealers are suited for use around pools. When specifying the PeterFell System for pool surrounds ensure particular attention is paid to texture and finish of the concrete as this will determine slip resistance critical in this environment. PeterFell colours can also be used in the coping stones around the pool to complement (or contrast) the concrete colour. It is recommended that the pavers are laid first and the concrete finished up to the pavers or coping -see special section below Consult with Peter Fell Ltd for further information on the use of the PeterFell System for pool surrounds. |
Concrete Stairs
The PeterFell System can be used to colour concrete stairs. Stairs can be generated in situ, or precast off site and installed later. Either way PeterFell oxides can be used to integrally colour the stairs. All in situ poured stairs should be placed by an experienced trades person. The boxing should be constructed so it can be easily dismantled and the face of the rise trowelled. Alternatively, the rise can be plaster rendered following placement and curing of the concrete. PeterFell oxides can be used in the plaster (link to plater) to approximate the concrete colour.
Concrete Bench Tops
The PeterFell System can be used to colour concrete benchtops. The colour is added directly to the concrete exactly as for standard flooring. If the benchtop is to be ground, consideration should be given to the impact of aggregates and type of grinding used on the final appearance of the colour. Similarly, use of aggregates and sands may vary colour from that observed in standard concrete i.e. colour samples. It is not recommended that PeterFell sealers are used on benchtops. PeterFell sealers have been designed for use on floors only, they are not designed to protect the concrete from scratching and markings from knives and utensils, or to withstand direct heat i.e. hot pots. It is recommended that a specialist benchtop sealer is used which has been designed with this use in mind. For more information on concrete benchtops visit the Cement and Concrete Association of New Zealand website (http://www.cca.org.nz/).
Pavers, Coping Stones and Concrete Tiles
While the PeterFell System utilizes concrete as the primary medium, PeterFell colour can also be used in other cement based products like paving slabs and concrete tiles. However, while exactly the same colour may be used in both concrete and in pavers, the final colour may be different due to the different material components i.e. aggregates, sands, etc. Also, pavers are cast in moulds (individual units) and therefore will exhibit less colour variation than in concrete. It is recommended that the colour is seen in paver form, or test samples are completed to ensure colour is appropriate. Consideration should also be given to any sealing or finishing compound to be applied to the paver.
It is recommended that specialist concrete paver sealers are used, not PeterFell sealers. The PeterFell sealers are designed specifically for application on placed concrete floors, and not for the sealing of the more porous concrete pavers or tiles. The most common application for paving slabs or concrete coping in the PeterFell System is for edging around swimming pools, garden edging, or as mowing strip for driveways and paths. This is advantageous in reducing the number of design elements required, with the same colour able to be used in both the paving and concrete.
Click here to find Paving Manufacturers in your area
Plaster Colouring
PeterFell colour can be used in plaster and other similar cementitious mediums, and are simply added to the mix. If it is desired that the plaster colour matches the concrete, the dose of the colour in the plaster can simply be manipulated until the desired colour is achieved. While this is a simple process, it may require several test mixes to achieve the desired colour. It is essential that when manipulating the colour dose in plaster that the colour is assessed only when the plaster is completely dry as the colour will change as the plaster cures. Peter Fell Ltd has recommended dosing information for use of colour in plaster, including weight-to-liquid conversion for ease of application. When ordering colour for plaster is it essential that the total cement for the job is known, as this will determine the amount of oxide required. Please contact Peter Fell Ltd for further information.
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Commercial and Industrial Coatings
While the PeterFell System can be used to permanently colour all forms of concrete, the finishing products applied must be suited to the specific application. For industrial or high use areas, additional compounds or finishes may be required to protect the concrete. These materials will impact on the colour and finish of the floor. Consult with Peter Fell Ltd for further information regarding the use of other surfacing agents.
Suspended Slabs (Slabs above the ground)
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Coloured concrete has been used succesfully in many suspended slab projects. The only issue to overcome is that of cracking, and how to plan for it. Many flooring solutions employ thin concrete toppings and if long spans exist then they may be relatively dynamic. This in itself is not a problem as sawcuts can be employed to minimise the risk. Construction Cuts should be made prior to the props being removed and therefore forcing cracks to occur in a controlled fashion. These can later be overcut with Decorative Cut. It is advisable to ask the engineers on the project for their input. |
