If you are using a typical stain you normally encounter a reactive, polymer, water based or dye that can deliver a variety of different color effects. Eco-Stain is a product unlike the above listed. The 29 UV-stable colors work on any surface that has porosity. There is NO reaction to the surface. It is a water based pigment that penetrates a porous surface through the absorption of moisture. As the surface absorbs the moisture out of the product it penetrates and leaves the pigments in the pours of the substrate. With this feature you have no clean up, no neutralization just a small drying window and the ability to seal. Here are some trick and tips for use of Eco-Stain on Concrete Countertops

Pre Cast Concrete Countertops (No slurry, veining or difference in porosity)

• Profile your surface with  a dilution of water and SCR (Super Concrete Renovator) before any applying Eco-Stain. In most cases a dilution of 3 parts water and 1 part SCR is ideal.

Pre Cast Concrete Countertops (with slurry, veining or difference in porosity)

• Using a rough sand or grit, remove any excess concrete or burrs that are undesired.
• Wash piece with diluted SCR, rinse and allow to air dry, usually 30 minutes is fine.
• Fill holes or veins with Xtreme Series Slurry mix and allow to dry.
• Lightly sand excess slurry with 400 diamond pad or equivalent sand paper.
• Apply LD 1800(Lithium Densifier) to the surface of your piece, with clean water rinse LD 1800 off the surface before it dries on the concrete( approx. 20 minutes)

NOTE: LD 1800 will help give the areas that are slurried and the existing countertop the same density therefore allowing the stain to absorb more evenly.

Now you are ready to apply Eco-Stain. Methods of application include; HVLP, Cup Sprayer, sponge, rag, or flooding the surface.

NOTE: If desired color is not achieved, the stain can be removed using a dilution of SCR and water 3/1.  Reapplication of slurry and densifying may be necessary before staining again.

Once the desired look is achieved, seal using a SureCrete recommended penetrating sealer.

We hope that you enjoy this stain as much as we have!

Start by combining SureCrete’s Lithium Densifier (LD-1800) with the Xtreme Series Polishing Pads and you will enjoy a blemish free densified precast concrete surface, that is now ready for your choice of sealer. Lets looks at the step by step process for this technique:

APPLICATION & TECHNIQUE

1.) Begin by flooding the surface of your precast concrete countertop with LD1800, a  Lithium Densifier, a few square feet at a time. Using the polishing pad of your choice to start with; 50, 100, or 200, begin to grind. These first three pads will determine the amount of material and aggregate exposure you wish to expose. The slurry caused by grinding mixed with the Lithium Densifier will fill the holes. As the lithium densifier reacts with the slurry, it pushes it into the pin holes and fills them in. Keep grinding until the lithium densifier is completely dry and move to the next area of your precast concrete countertop.
2.) If you have started at the 50 pad the next pad would be 100…Again flood surface with LD1800, your lithium densifier,  and grind with the 100 pad until the LD1800 is dry.
3.) Once your precast concrete countertop has been ground at the 100 pad the next pad would be 200 pad…Again flood the surface with lithium densifier and grind that area until the LD1800 is dry.
4.) The next logical pad after the 200 pad is the 400 pad. This pad begins the polishing process and no new pin holes should develop, therefore no more densifying is needed.
5.) After the 400 comes the 800 and then the 1500 if desired. Stop at the 400 pad if your intention is to use a sealer. Going above this pad may tighten the precast concrete and cause your choice of sealer to have potential adhesion issues.

NOTES & TIPS

• If the pad is new and has never been used before there is a resin over the diamonds, this must be removed before use! The best method to accomplish this is to turn on the grinder with the pad and grind on a semi rough, flat piece of concrete for a few seconds. RPM’s are not to exceed 4000.
• This process does NOT work with Honeycomb polishing pads as they do not trap enough dust to mix with the lithium densifier in order to create your slurry mix.

Job Process

* Square Footage – 110,000
* Floor Application – Superflat SOG (Slab on Grade) Placement
* Joint Caulking
* Floor Scrubbing
* Application of LD-1800 (SureCrete Lithium Densifier)

Bryan Birdwell, President of Birdwell Builders, choose SureCrete products to compliment his technique and experience as he planned out another project worthy of a Golden Trowel Award. He mentioned that the floor was to be placed with a overall Floor Flatness and Floor Levelness (As you can see in the pictures).

With the floor being superflat, they moved onto hardening and increasing the surface PSI of this Industrial Paper Facility. With many quality densifiers available, Birdwell felt a Lithium Densifier was the smartest choice. Knowing that sodium and/or potassium sodium hardeners can leave a high concentration of salts deposited upon the surface and increase the potential for surface spider cracking was one reason. He also liked that SureCrete’s LD-1800, a lithium densifier, was VOC compliant and environmentally friendly.

The process for applying the lithium densifier was simple. They began by applying the LD-1800 on the surface via a pump up sprayer and scrubbed that into the surface while making sure that the Lithium was wet at all times. After 15 minutes they then rinsed the LD-1800 off the slab with water and a floor scrubber.

The end result was a job that the consumer was pleased with and another entry for Birdwell Builders as they work toward their 12th Golden Trowel Award. If you would like to learn more about the benefits and applications of Lithium Densifier please contact SureCrete Design Products.

Our team took the time to speak with many contractors and understand their concerns in repairing the spalled concrete versus tearing the damaged slab out and pouring a new slab. In doing so we noticed a technique that addressed the contractors fears while delivering a sound and consistent repair and resurfacing solution to spalled concrete. Below are the top concerns that guided the development of their technique and the products they used for application.

How do we remove the loose spalling concrete?

Most contractors will begin with an aggressive pressure washing or scarifying of the concrete surface. The goal of this process is to remove all lose concrete and create a sound surface. A turbo tip and a pressure washer of 3,500 psi or greater will generally be sufficient.

How do you control or stop the current spalled damage to the concrete?

Prevention of further damage to the spalling concrete is not an exact science. A sound option for prevention is the use of a Lithium densifier. The use of a Lithium Densifier will harden and increase the surface PSI and increase the durability. Use of conventional sodium or potassium sodium hardeners are not recommended as they may leave a high concentration of salts deposited on the surface of the concrete and may add to surface cracks.

What material should we patch the spalled concrete areas with?

With Freeze-Thaw an important part of the equation in deciding upon a material, Flash Patch is an ideal material choice that delivers a hard surface while giving you a chemical and mechanical bond to the concrete slab. In addition to those attributes this material allows you to patch all areas of the spalled concrete surface. Once applied your down time is  a matter of 15-30 minutes, then you can begin applying  your resurfacing topcoat material.  Flash Patch is a single component (just add water), cement based concrete patching compound. With a quick set time, this product allows you to stay on the job site and delivers a compressive strength of over 6200 PSI.

How do we create a freshly broomed surface over the spalled concrete?

If the desire is to provide a fresh broomed concrete surface, a product like SureBroom is a smart choice. This product is a single component (just add water) mix that delivers a fast cure time and a compressive strength of 6100 PSI. With two coat process the only tools you need is a metal squeegee and a horse hair or nylon horse hair concrete broom. This system delivers simplicity of technique and  a low material cost.

What can be done to delay or prevent deicing chemicals from affecting the new surface?

Use of a solvent acrylic sealer provides deep penetration capabilities and the ability to minimize the slick surface texture. A product with 20% solids delivers the needed attributes which aids in repelling deicing agents and preserving the renewed surface from Spalling and other causes which deteriorate and the surface. A common question after application is how often should we reapply sealer? We would love to give a solid time table like 2-5 years but the simple fact is many factors come into play that decrease the life span of a sealer.

How can you tell if your sealant is weakening? Try a water test. When water is applied to the surface it should bead up as water would on a waxed surface. If the water beads your protection is still sound. With regards to the sheen or gloss look of the surface, that is determined by the individual and their desired look.

To see a live video of this resurfacing material, please visit www.SureCrete.TV
If you would like to know more about the products mentioned in this article please contact SureCrete Design:

Toll Free 1-800-544-8488
Email: Whatsnew@SureCreteDesign.com