Technology for the preparation of stamped concrete. Do-it-yourself printed stamped decorative concrete or press concrete Pol master com do-it-yourself stamped concrete

Stamped concrete (or press concrete) is a technology for finishing a horizontal surface with the final imitation of natural stone, tiles, paving stones or any other material. Printed is becoming very popular these days due to some of its characteristics. Firstly, this material is very durable and reliable, resistant to temperature extremes (from -50 to +50). Secondly, it does not wipe off and retains its color (and you can give any color and shade to a decorative printing solution). And thirdly, the material looks aesthetically pleasing and harmonizes perfectly with any architectural style.

Printed is strong, durable and resistant to various weather conditions.

And thanks to its immunity to acid and alkali, it can be used in various workshops and in a manufacturing plant.

The laying technology differs from the usual laying only in that it involves the procedure of reinforcing, coloring the top layer, its formation and sealing.

Marking and preparing the trench

Laying should begin with the preparation of the base. The future section of the decorative mortar is outlined with twine. If a pedestrian zone is planned, then a 30 cm layer of soil is removed, and for a transport section - 50 cm. The bottom of the resulting trench is leveled and compacted, a vibrating plate can be used. Then the formwork is installed along the edges of the trench, and gravel is poured onto its bottom, which is compacted. From above, the gravel is covered with a layer of sand, filled with water and compacted again.

To achieve optimal plasticity, plasticizers are added to the solution, from 0.3 to 0.8% of its mass. The essence of adding plasticizers is that they reduce the amount of water during mixing, which reduces the number of pores in concrete and prevents its destruction from temperature changes.

Necessary raw materials for laying: cement (it is desirable to use M350 and M400), water, sand, plasticizers, protective sealant varnishes, fiber fibers and dyes.

Cooking and styling technology

A mortar is prepared in a concrete mixer from cement and sand with the addition of fiber fibers. For one part of cement there are three parts of sand, and for 1 cu. m of concrete add 1 kg of plasticizers.
The prepared solution is laid slightly above the level of the formwork in order to easily level the coating in the future. To give decorative qualities, a dye is applied to the surface. For 1 sq. m accounts for 2 kg of paint.

The surface is suitable for the molding process after 4-5 hours. Before molding, a special component is applied to the surface, which prevents the surface from sticking to the molds.

The technology of drawing a picture, or "printing" is very simple. It is performed using special molds with a relief pattern. After their laying, the surface is pressed with a rammer. Then the forms are carefully removed, and the seams are made with a marker chisel.

Concrete becomes hard after 2-3 days, and after this time, the release agent must be washed off the surface. After another 5 days, the surface is treated with a sealant varnish.

Stamped concrete is popular among gardeners and summer residents due to its low cost and ease of operation, and its laying technology is quite possible without the involvement of specialists.

• Recruitment
• How much can you earn?
• What documents are needed

Characteristics of stamped concrete

Today, decorative or stamped concrete is a very popular paving material in many developed countries. With the help of decorative concrete, you can create unique surfaces that imitate various coatings (wood, paving stones, stone) and blend harmoniously with any style of architectural landscape.

The popularity of stamped concrete in construction is due to the fact that it is practically not affected by temperature changes. Decorative concrete is resistant to aggressive acidic environments, fats and oil products, so it is increasingly being used to cover city streets, parking lots, gas stations and industrial enterprises. The strength of stamped concrete exceeds that of traditional materials such as tiles and asphalt. A big plus of this coating is its environmental safety.

The main raw materials for creating decorative concrete are cement (M350, M400), water, sand, plasticizers, fiber fibers, protective varnishes, sealants, dyes and separating components.

Technology of laying decorative concrete

Briefly, the technology of laying decorative concrete looks like this. First, the base is prepared for laying. This stage is no different from laying conventional concrete. Lighthouses are placed, the trench is leveled, formwork is installed.

Next, a concrete mortar is prepared in the concrete mixer from cement and sand at the rate of 1/3 with the addition of reinforcing fiber. Also, plasticizers are necessarily added to the concrete solution at the rate of 1 kg per 1 m3 of concrete. The use of a plasticizer is that it reduces the volume of water when mixing the mortar, thereby reducing the number of pores in the concrete.

After the mixture is ready, the process of laying and smoothing concrete begins. Concrete is laid a little above the level of the formwork, so that later it can be easily leveled. Upon completion of the smoothing of concrete, to give decorative qualities, a dye is applied to the surface at the rate of 2 kg per 1 m2 of area.

After 4-5 hours the concrete surface is ready for the molding process. Before molding, a special separating component is applied to the concrete, which prevents the surface from sticking to the molds.

Then you can proceed to the direct application of the pattern to the concrete using molds that have a relief pattern. This process is also called "sealing" of concrete. After laying the molds, the surface is pressed with a rammer. Next, the molds are carefully removed and seams are made using a marker chisel.

After the concrete takes on sufficient hardness, and this will happen after 2-3 days, its surface must be washed from the separating component. And 5-6 days after pouring, the surface is treated with a protective varnish-sealant to reduce the destructive atmospheric effect on concrete.

What equipment to choose for the production of decorative concrete

The main equipment for the production of decorative concrete are:

• Concrete mixer, almost any industrial option is suitable, price from 20,000 rubles;
• Press forms. This is the highest cost item. The cost of one form starts from 10,000 rubles. In total, 15 different forms or 150,000 rubles may be required;
• Tool. In the work, you will definitely need chopping laces, press tampers, carvers, an extension handle, a groove trowel, a trowel, a edging machine and other auxiliary tools. The total cost of purchasing a tool is from 50 thousand rubles.

In total, about 220 thousand rubles will be needed to start a business. It's not that big money.

Recruitment

The main difficulty of this business is not so much in investments and technology, but in the right selection of employees. The number of workers required for production is calculated based on 3 people per 50 m2 of material. The salary of each of them depends on the amount of work and averages 17-30 thousand rubles.

Before starting work, it is desirable for each employee to pass a special. course on laying decorative concrete. Usually such courses take place in 3-4 days.

How much can you earn?

The price of laying decorative stamped concrete depends on a number of factors, such as the complexity of the work, the material used, the laying time, etc. On average, the cost of laying one linear meter is 1200 rubles. As a rule, the working front is several tens of meters. On average, the execution of one order can bring from 50 thousand rubles and more.

Customers can be private homeowners in cottage settlements, government organizations that want to decorate the streets of a city or a park in a unique way. Decorative concrete is ordered by legal organizations to create an unusual design for a shopping center, cafe, restaurant, office building.

To improve sales performance, it is recommended to create a portfolio of your organization. It is mandatory to create samples of decorative concrete products for visual demonstration to the customer. You also need to take photos of your work, make booklets and business cards and distribute them in all available ways. It will not be superfluous to create your own website. Now a lot of orders, especially in the capital, come through the virtual network.

Where to begin

Decorative concrete is gaining popularity not only in Russia, but also in other CIS countries. Demand creates supply. But first you need to choose a production method. The most common is the printing method, which is obtained by stamping and chemical impregnation. You can also use the stencil method or the spray method.

What documents are needed

For the production of decorative concrete, you need to register as an individual entrepreneur or LLC (the second option is preferable) and select the USN taxation system. OKVED code 26.6, which concerns the production of products from concrete, plaster and cement. Permits are not required. A certificate is also not required, but desirable.

Stamped concrete has gained real popularity over the past few years. To create an original surface and a unique texture, stamp technology is used. After processing, the concrete will look like natural wood, stone paving, slate slabs. It attracts attention with increased strength and long-term operation.

Technology development

Thanks to the development of stamped technology, specialists can create a lightweight floor covering. On its surface there will be a beautiful and original pattern. Concrete can be used to decorate a summer cottage, streets and city parks.

There are several main advantages:

• unlimited possibilities for the implementation of any design ideas and solutions;
• minimum costs for the purchase of raw materials;
• beautiful and unique relief on the surface.

Decorative printed coating is different from other surfaces that are presented on the construction market. This technology first appeared in the United States of America. It was used for arranging runways at airports.

Concrete is easy to process, so the surface can be given a rough texture and any texture. One of the main advantages is minimal costs and low cost of production. Thanks to this, the presented concrete coating entered the world market. Now it is used to improve suburban areas and sidewalks.

Opportunities for renovation and construction

Decorative coated concrete is a familiar concrete mass, on the surface of which a decorative imprint is applied. Among the large and varied selection, the following imitation options are presented:

Thanks to such opportunities and the proposed assortment, each person will be able to make his choice. Construction companies often use such masonry to decorate the territory near the entrance to an office building.

Application area

Decorative coating has found wide application in various fields of activity. Stamping an impression on a concrete pavement is used to design:

Over the past few years, concrete has been actively used to decorate parking paths and parking lots. Such a coating looks original and unusual. Decorative material will be a great option for a gas station or stairs. If the builders carry out complex restoration activities, the craftsmen will be able to create masonry under worn stone or old brick.

Varieties of stamps

On concrete, you can create different printed impressions. For this, various stamps are used, which are presented in a wide range. They are made from different materials:

Forms are hard and soft. The further relief of the surface depends on their strength. If the density of the matrix is ​​high, the print will be of better quality during production. When an elastic form is applied during production, certain difficulties arise. This is due to the fact that you have to make efforts during stamping.

Benefits of Stamped Concrete

Thanks to modern technology for creating a decorative surface on concrete, manufacturers can recreate various patterns. The following advantages can be distinguished:

To obtain high quality concrete, it is necessary to follow the technology and the established classical recipe. All activities must comply with state standards. The result is a high quality product that will last for a long time.

What is the complexity of the process

In the process of work, it is important to follow several rules and recommendations that will affect the final result. There are several problems that most often occur during the stamping process:

Everyone can try their hand at making stamped concrete. At home, it is difficult to obtain high quality products that will meet the requirements and standards, and also last for a long time. There is a generally accepted technology for creating decorative stamped concrete in the home workshop.

Stages of work

In the process of work, it is important to follow a strict sequence in order to create a decorative coating. There are several main stages:

This is followed by washing and varnishing, which helps to make the material completely sealed. Each stage has its own characteristics and rules. If you follow all the recommendations, you can create printed concrete with your own hands.

Workplace preparation

To prepare the site, you need to monitor the weather conditions. The day should be dry and warm. It is allowed to make concrete if the air temperature outside is not lower than +6 degrees Celsius. It is important to prepare the basis for subsequent work. For this, the following technology is observed:

At the last stage, it is important to ensure the optimal distance to the soil level. Should remain at least 5-7 centimeters.

Concreting process

Another important stage for creation is concreting. Work is carried out strictly in the prescribed sequence:

Thanks to the use of polypropylene fiber, the possible occurrence of cracks and problems on the surface of the concrete base can be prevented. As a result, the service life of the concrete mass increases.

Use of hardeners

Before starting to make a decorative impression, it is necessary to treat the surface with a special hardener. It helps to increase the strength level of concrete. The hardener is a dry mix in powder form, which contains the following components:

• coloring pigment;
• fine quartz sand;
• granite, presented in the form of crumbs;
• binder fillers.

The particles that make up the composition help to fill the concrete pores as much as possible. Additionally, the surface is painted. Hardeners help increase the strength of concrete, make the array more dense and hard. To perform processing, the following sequence must be observed:

Due to the special composition of the hardener, the color of the array becomes more uniform and stable. When the surface becomes even, it is necessary to take care of its compaction.

At the end of the work, the masters need to apply a release agent. It helps prevent the concrete from sticking to the matrix. During production, the concrete is painted. Among the large selection, you can find the optimal shade.

The release agent is a liquid or dry mixture. Masters choose the best option depending on the requirements and convenience of work. The mixture is applied with a brush. In conclusion, the surface is sanded to the corners of the site. The last step is stamping. Printing technology can be used after the concrete base reaches the required level of plasticity.

If the concrete is too dense, then the impression will be fuzzy. To track the level of the array, you need to press your finger on the concrete cover. Another important requirement is the correct stamped concrete technology.

If the print has a depth of up to 5 mm, you can start creating a stamp. Special forms are laid out over the entire surface and numbered. Masters need to designate a sequence.

Next, the tamping technique is used or the matrix is ​​​​pressed with its own weight. Masters must ensure that the concrete coating calmly hardens within 2-3 days. If there are defects or other damage on the surface, textured sandpaper or a hand roller must be used.

Increasingly, technologies appear in construction that can create works of art from familiar coatings and materials. Such a transformation is possible even with such an ordinary material as concrete. Through the use of polyurethane or metal stamps, a dull concrete surface can look like stone paving, wood decking or slate slabs. Such concrete is called stamped, printed or press concrete. About him, as well as the possibility of creating a printed surface on your own, we will now talk.

The essence and possibilities of using this technology

Stamped concrete is ordinary concrete, on the surface of which decorative embossing is applied with special stamps. A relief pattern can imitate any material: brick, paving stones, boards, animal skins, weathered stone, cracked earth. You can pick up stamps with leaf patterns, dinosaur footprints, animal figures.

Stamped concrete is especially popular for decorating patios, pool areas, garden paths, sidewalks, gazebos, floors in restaurants and showrooms. This technology becomes indispensable for complex restoration work. For example, when it is necessary to recreate the destroyed part of the old pavement. Finding exactly the same materials, naturally aged, is often not possible. And with the help of stamped concrete technology, exact copies of an existing old brick or half-worn stone are easily created.

Variety of Stamped Concrete Dies

The first stamped concrete dies were made of cast aluminum and were massive molds equipped with handles. Such matrices are well suited to imitate ordinary brick or stone patterns. But they can't copy complex textures. A completely different matter is modern polyurethane stamps. They are cast on real materials, the texture of which must be copied. As a result, incredibly authentic textural effects can be achieved with polyurethane molds.

Ready-made stamps can be purchased at many hardware stores or centers. When choosing, pay attention to the degree of rigidity of the form. The denser the stamp, the easier it is to make a clearly visible pattern with it. Forms that are too soft and pliable are more difficult to work with and require more effort during the printing process.

Self-production technology

Stamped concrete technology is quite simple, but you need to take it up only with a certain amount of already existing skills in working with concrete. Otherwise, the result may not be what you expected. Problems may arise for the following reasons:

• concrete quickly hardens, after which the use of stamps does not give a clear embossing on the surface;
• to perform embossing with stamps, physical force must be applied;
• errors in embossing a concrete surface are difficult to correct;
• stamped concrete technology requires the worker to be able to handle special tools to form and smooth the surface.

If you are confident that you can deal with potential problems, you can proceed to create a concrete pad and perform stamping work.

Step 1. Site preparation

The basis for stamping is an ordinary concrete platform with reinforcement, made of concrete grade M350 and higher.

The technology for creating such a platform:

• with the help of a peg and a cord, they indicate the boundaries of the site on which stamping will be carried out;
• remove the top layer of soil (depth 15-20 cm), ram the soil bottom;
• pour a crushed stone pillow (thickness 10-15 cm) on the bottom of the recess, ram it;
• formwork from boards is installed along the site boundary;
• a reinforcing mesh is laid in the formwork, raising it above the ground level by at least 3-5 cm (by placing stones and bricks under the mesh);
• concrete is kneaded manually, using a concrete mixer or ordered ready-made;
• concrete is poured into the formwork, a metal rule is used to obtain the required level of the site;
• compact concrete with a vibrating screed;
• the top layer of concrete is smoothed with a trowel, achieving smoothness and uniformity of the surface.

Step #2. Application of colored hardener

A colored hardener is applied to still fresh concrete, which simultaneously colors the surface and increases its strength. Color hardener is a powder, which contains coloring pigments, binder filler and ground particles of granite and quartz sand. Due to the dispersion of the mixture, its particles penetrate into the pores of concrete and fill them. The concrete surface becomes denser and stronger. At the same time, the particles give the concrete a lasting color (about 30 tones - to choose from).

Work on applying a colored hardener begins after the initial setting of the concrete surface. You can navigate at the moment when all the water that has come out from the surface has evaporated.

Color hardener powder is spread over the concrete surface by hand, from the center of the site to the edges. At the same time, they perform movements similar to throwing a bowling ball. They scoop up a portion of the powder, take their hand back and throw the mixture forward with a sharp movement from waist level. This principle of powder application minimizes the number of particles flying through the air.

The first layer of hardener should be absorbed into the concrete, which takes 5-10 minutes. During this time, the surface of the concrete is smoothed by rubbing the dye into it with a magnesium trowel. Corners are also processed with corner trowels to make them bent, neat.

Then a second layer of colored hardener is applied. It is necessary to more evenly color the surface and seal it. The powder is applied in exactly the same way as in the first case. After application, the surface is leveled with a steel trowel.

Step #3 Release agent application

The release agent prevents the concrete from sticking to the stamps during the printing process. In addition, it additionally colors the surface of the concrete, giving it subtle shades of color. The release agent is available as a dry powder or liquid. Most often, powder is used, applying it to the concrete surface with a wide brush (maklovitsa).

The brush is immersed in a bucket with a release agent so that the bristles are evenly covered with powder. Then, holding the brush at waist level, they throw their hand forward and “spray” the powder over the surface of the concrete.

After staining, the corners of the site are treated with textured skins.

Step #4 Surface stamping

Before starting stamping, it is necessary to make sure that the concrete has acquired the necessary degree of plasticity and has become similar in consistency to plasticine. If stamping is started too early, the concrete surface will not be able to bear the weight of the workers and keep the print lines. If you are late, then for a clear print you will have to put more effort on the stamps. In addition, the texture of the stamps may not be imprinted at all on very dense concrete, especially at the end of the work.

To determine the degree of density, just press your finger on the concrete surface at several points on the site. If there are prints with a depth of 4-6 mm, then you can start stamping. You can check in another way: place a stamp on the concrete surface (at the edge of the site) and step on it. The stamp must hold the weight of the worker, not sink into concrete, not slide on the surface.

If all tests are passed successfully, you can start stamping. Stamps are laid out on the concrete surface, one after the other. Often manufacturers number the stamps (1, 2, 3… or A, B, C…) to indicate the desired sequence of their placement in the printed design.

To imprint the texture of stamps into concrete, it is often enough just to step on them. Sometimes light hand rammers are used for this.

After the prints leave the concrete surface to cure for 12-24 hours.

Step #5 Elimination of defects

On the concrete surface, where the dies meet, there is often a slight displacement of the cement slurry. Sometimes, due to insufficient tamping, the seams of the printed pattern may look blurry, indistinct. To correct surface defects, the seams and joints are carried out with a hand roller, the irregularities are smoothed out with textured skins.

Step #6 Cutting shrink seams

Several cut seams in the slab provide stress relief and prevent cracking. Such seams can be made in still fresh concrete using a special cutter. Or cut the seams with a grinder after the concrete has dried.

Step #7 Surface washing

The next day, the surface is washed. Wash off excess release agent with water from a hose. After - acid washing (hydrochloric acid) is performed to obtain the desired effect of combining two colors on the surface. During this process, the pores of the concrete also open, which contributes to a better interaction of its surface with the sealant.

Step #8 Application of sealant

The next day, a sealant varnish is applied to the concrete. It performs a number of functions:

• protects the surface from abrasion and wear, as well as from the penetration of oils and chemicals;
• gives the surface a gloss of various saturation (from barely noticeable satin to rich lacquer);
• enhances the color saturation of concrete;
• simplifies the maintenance of the treated surface.

The sealant is applied with a roller, rolling it over the surface. But, if the stamped texture has deep impressions, it is desirable to combine rolling with a roller with additional brushing when applying the sealant. Typically 2-3 coats of sealant are required.

After the sealant dries, the stamped surface will be completely ready for use.

I would like to make a few points:

• If you are using a stamp for the first time and have no idea what it will look like on concrete, do a test print on packed sand.
• Avoid repeating the printed pattern on the surface, especially if the stamps imitate natural materials (stone, wood, etc.). Random compositions will look more realistic.
• To achieve an aged effect on the surface, apply a small amount of dry release agent (in powder form) to the still liquid concrete. Spray a liquid release agent over it. The liquid will dissolve a light layer of powder, after which color accents will remain on the surface, similar to scuffs.
• Make sure that the release agent particles are well pressed into the concrete when printing. Otherwise, it will simply be washed off with water when washing the surface.
• Make sure that the person walking on the stamps during tamping wears clean shoes free of debris and dust. Inevitably, these contaminants will get onto the fresh concrete and ruin the desired texture of the stamped surface.

That's all the secrets of stamped concrete technology! But, before proceeding with self-stamping, we suggest that you watch a short informative video. It demonstrates the main stages of the technology: coloring concrete, applying a separating component and creating a surface texture using stamps.

Technology of laying decorative stamped concrete.

1. Terms of work

Perform work in dry weather at a temperature not lower than +5 C.

2. Site preparation

• remove the top layer of soil, level, compact
• pour a layer of crushed stone 15-20 cm, level, compact
• put a plastic film with an overlap of 10 cm
• set up the formwork
• make reinforcement depending on the load

3. Characteristics of the concrete mixture

• the concrete grade must be at least M-300 on Portland cement 400-500 with a plasticizing additive SP1 or C3
• concrete mix mobility 10-15 cm (P3)
• in the manufacture of concrete, we recommend using reinforcing polypropylene fiber (fiber) at the rate of 0.6 kg per 1 m3, which prevents cracks and improves the performance of concrete

The composition of concrete during its preparation at the construction site (by volume):

• cement PC 400 - 1 part
• sand with a particle size modulus of at least 2.2 mm - 3 parts
• crushed stone (hard rocks) fraction 5/20 mm - 3 parts
• plasticizer C-3 - 0.5% by dry matter (given in the form of an aqueous solution).

4. Concrete laying

• put the prepared concrete mixture into the formwork
• evenly distribute, compact with a vibrating screed or internal vibrator, level with a rule
• then roll the surface of the concrete with a roller, while upsetting a large aggregate and bringing small particles (a mixture of sand and cement) to the surface
• smooth the surface of the concrete with an aluminum trowel (large or small, depending on the area)
• to process the edges of the concrete around the entire perimeter with an angle trowel

5. The device of the decorative layer

• before applying the color fixer, make sure that there is no excess water on the surface of the concrete (the surface of the concrete must be matte)
• apply evenly by manual dispersion method 70% of the application rate of the fixer (3 kg/m2 for dark colors and 4-5 kg/m2 for light ones), the surface should be evenly painted
• smooth with an aluminum trowel, process the edges of the concrete
• sprinkle the remaining 30% of the fixative, smooth with a steel trowel
• finish the edges with a corner trowel
• before imprinting with textured polyurethane forms, the prepared surface must be coated (sprayed) with a hydrophobic release agent using a long-haired brush, in a thin even layer (consumption 0.2 kg per 1 m2)

6. Printing a pattern using texture matrices

• imprinting of prepared concrete should be carried out without delay, while it is still amenable to light finger pressure
• laying the first texture forms to begin, moving along the entire length of the concrete pad along the formwork.
• to avoid sagging, press the matrices firmly against each other, this creates straight lines at the junctions
• depending on the plastic hardness of the concrete mix at the time of imprinting, the matrix should be pressed into the concrete over the entire area by pressing with hands, feet or tamping (for even distribution of the load over the entire area)

7. Washing and applying a protective layer

• after two days (at least) of hardening of stamped concrete, sweep away excess release agent from the surface using long-haired brushes
• rinse the surface with clean water, use brushes to remove excess release agent, if necessary, apply a 3% hydrochloric acid solution
• prime the surface with acrylic impregnation, on a dry, clean and not hot surface of washed printed concrete (surface temperature should be from +5 C to +30 C) apply a protective acrylic impregnation with a brush, roller or sprayer at a rate of 200 g per 1 m2
• after at least 60 minutes, on a dry and not hot surface (surface temperature should be from +5 C to +30 C), apply a finishing layer, protective acrylic impregnation (matte surface) or varnish for stone and concrete (glossy surface) with a consumption of 200 g per 1m2

8. Temperature shrink joints

• to prevent the formation of uncontrolled shrinkage cracks, saw through the seams with a grinder with a diamond blade or a joint cutter to 1/3 of the thickness of the concrete. The thinner the boards, the closer the seams should be. If possible, the slabs should be square, in extreme cases, their length should exceed the width by no more than 1.5 times.

9. Operating conditions.

• walkable 4 hours after applying the topcoat impregnation with acrylic or lacquer for stone and concrete
• it is not recommended to load the finished surface in the first 12-14 days (drive by car, trolleys, etc.), only light foot traffic is allowed
• it is contraindicated to use anti-icing reagents
• do not use metal objects to remove ice and snow
• renew the topcoat (varnish or impregnation) once every 2 years, in high traffic areas annually (parks, squares, alleys, squares, etc.) to restore the original shine, protect against moisture and wear