Our construction process is quite different than what has become accepted as traditional stamped or patterned concrete. We have developed this approach to create a product that is more durable, more realistic looking, and offers better quality control over the entire course of the job.
We begin with a four inch structural slab that is reinforced with ½” reinforcing rod and 2 ¼” structural synthetic fibers which are utilized for three dimensional support . These long fibers offer much greater crack control than either ½” or ¾” fibers that are normally used for stamped concrete. On top of this structural slab, we pour 1 ½” of integrally colored, 3 dimensionally reinforced, high performance concrete with an added water repellant. This overlay is embossed with a texture and a pattern to create a cast-in-place concrete tile with the look of brick or stone that is guaranteed not to delaminate. The tools that we use are the old fashioned “cookie cutter” type stamps which create the look of individual concrete tiles. The impressions that are made in the concrete to define the pattern are grouted and tooled to establish the look of traditional custom masonry. We design the saw cuts and construction joints to fall within the grout joints in order to make them less obvious-we do not just indiscriminately cut across the pattern. Finally the entire surface is rubbed with a grindstone to eliminate any sharp edges that might be uncomfortable for barefoot traffic.
The end result is a product that represents the realistic look and beauty of traditional custom masonry with the durability of heavily reinforced concrete, done in a cost effective way.
