Vertical Wall Stamping – Salt Lake City Installation
In West Jordan, Utah you will find a building that takes the breath away from any concrete contractor. Formco, Inc. a foundation specialist in Utah took the time this winter to bring their new 30,000+ sq ft commercial facility to life. With the project details and designs being planned out in 2007, work started in January 2008.
Kirby Justesen, owner of Formco, had envisioned a building that was rustic and elegant. As he contemplated his design, he continued his research into “Green” concrete products and techniques that would make his facility cost effective and environmentally friendly. As he created the exterior shell of his building, he utilized a technique from the ICF world. Using a cast in place system, he created a wall that was 6 inches of concrete and 4 inches of foam. With the walls up it was time to figure out what to use to create his rustic dream. Here are the areas that needed attention:
- Exterior Building Walls
- Interior Columns and Pillars
- Interior Floors
- Exterior Concrete Fence Walls
Exterior Walls:
The design was to take vertical concrete and create realistic looking rustic wood, stone slate and larger rocks. Their install team on any given day averaged about 5 members who had never applied decorative concrete in any fashion. As the project began in January 2008, they found themselves in the dead of winter. Realizing the potential for disaster they partnered with SureCrete Design Products to guide them with knowledge, technique and products. As they began installation they tented sections of the building and warmed the walls to a temperature above 40 degrees.
Formco’s building was in need of a quality vertical wall stamp material along with a sprayable ICF coating. Using a combination of SureCrete’s WallStamp and WallSpray, single component vertical mixes, and utilizing stamping tools from 3 different vendors they created their rustic masterpiece. After seeing installations of major wall stamp manufacturers, they realized WallStamp had superior adhesion and the ability to build out the material faster with less waste falling to the ground.
To ensure that the colors would be realistic, they went with a water based penetrating stain called Eco-Stain. The outcome was a natural color across the entire building that they could customize and was eco-friendly. They finished the project with a clear Water based sealer from SureCrete. Total sq ft vertically stamped was over 7,000.
Interior Columns and Pillars:
After realizing how easy it was to create realistic looking wood and stone on the exterior. The Formco team brought the same look and feel into the interior. Taking the same vertical wall stamp and their wood stamping tools, they transformed their plain columns, pillars and beams into masterpieces. Using color packs and Eco-stain the balanced the color and finished it with a water based sealer.
Interior Floors:
As Formco looked at traditional carpet, tile or wood floors they realized that these options were temporary solutions that would wear quickly and constantly be replaced. With “Green” still in their mind they turned to Densifing and polishing the 1st floor. On the second floor they used SureCrete’s SureSpray / Eco-Stain / and SureCrete Water Based sealer. In doing so they took these eco-friendly products and created large Spanish looking tiles. Utilizing a SureSpray base coat and custom tape they created the grout lines. Applying a 2nd coat of SureSpray they stamped the desired pattern in and created an elegant floor upstairs.
Exterior Fence Walls:
With experience in form liners and their ability to create concrete walls, it was an easy choice of what to do on their exterior fence. With the detail that can be achieved by these form liners their only concern was using a coloring system that did not cover over the detail like paint would. Initially they had entertained the thought of acid staining. In keeping with their “Green” theme they went with SureCrete’s Eco-Stain. A water based stain that using technology of micronized pigments that penetrate deeply and use the porosity in the concrete to create the natural variegated stain look. With this stain being UV-stable they had over 29 colors to create a variety of shades and colors. To finish the project they sealed it with SureCrete’s 30% clear sealer.