Method Statement

Stamped Concrete Floor

Description: Stamped Concrete is cast in-situ decorative concrete flooring where concrete slab is colored &
textured while the concrete is in plastic stage to stimulate natural stone designs. The enhancing the colors &
protecting the textured surface with special sealers.

Materials:
ALFA Premium color Hardener
BETA Antique release agent
GAMA Sealer
Misc. polyethylene sheet, polypropylene fiber & hydrochloric acid diluted 1:20.

Tools:
Texturing mats & pounder
Hand held wood floats, magnesium floats & stainless steel trowels
Concrete saw cutting power tool
Other hand tools such as edgers touch up tools & aluminum chisels.

Limitations:
Do not mix or cast concrete if:
1. Rain is expected in the proceeding 24hrs. period after application.
2. Ambient temperature is expected to exceed 35⁰c.
Avoid working in the direct sunlight or windy weather.
Temporary protection from weather must be provided all the duration period.

Sub-grade preparation: The sub-grade under stamped concrete slab can make a big difference in the
overall performance & structural integrity of the finished concrete slab.

Match the thickness of the concrete slab (for example slab thickness of 10cm) then the compacted
sub-grade layer must be minimum 10cm. Therefore, a layer of road base at thickness of minimum
15cm before compaction must be laid.
All the road base layer must be installed uniformly to ensure & provide the following:
1. Uniform thickness of concrete slab.
2. Drainage slop to provide sloped concrete slab surface.
3. Well compaction achieving 95% to prevent settlement.

Mix design: It should contain the following:

* Minimum cement content 250kg/m³ * Maximum aggregate size 10mm

* W/C ratio should be less than 0.55 * Slump should not exceed 100mm
* Addition of polypropylene fibers at the rate of 0.6kg/ m³

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 Avoid addition of any admixture containing calcium chloride.
Do not add any water reducing admixtures.
Retarder admixture can be used is site if the temperature speed up the setting time of concfrete.

Casting of concrete:
a. Erecting forms: to ensure a proper stamping job pay attention to the following:
1. Drive the stakes flush with or slightly below the top edge of the forms.
2. Set the forms to the correct elevation of the slab & the proper slope.
3. Lay the polyethylene sheets on the compacted sub-grade between the forms.

b. Installing reinforcement.
The thickness of slab on grade (compacted to 95%) & arrangement of steel reinforcement must be
designed according to the intended use of max load. Either vehicles or pedestrian only.
For example: the thickness of 10cm for slab on grade (compacted to 95%) and steel mesh of 8mm
diameter welded in a (20x20)cm grid laid at the middle of the slab to 1/3 the depth from the top will be
sufficient to support vehicle traffic of maximum 5 tons load.
Note: if the axel load is greater than 2.5tons consult the structural engineer for determination of the
necessary reinforcement given the intended use & the condition of the sub-grade.

c. Placing Concrete:
1. The best approach is to have the ready mix truck to the placement area & deposit the concrete
right from the chute.
2. Place the concrete as close to its final destination as possible to avoid segregation.
3. Spread, screed & vibrate (if necessary) the concrete so that it completely fills all the space inside
the forms.
4. Using wood or magnesium floats, start float the concrete surface to the desired level & flatness
before the appearance of excess moisture (note: avoid using any steel trowel).

Notes:
Avoid using any steel trowel in this step.
To eliminate any high low spots strike off the surface using aluminum beam or wood stick .
Try to bring enough cement paste to the surface while striking off to help wetting out the
hardener.
Never float or trowel a surface that has standing bleed water on it.
To remove the excess bleed water use a rubber hose of plastic conduit to be laid on the
surface & be dragged to the outer edges driving the bleed water out of the slab.

5. Keep the surface open until bleed water stops coming out of the matrix & the surface becomes
saturated dry (the water do not sprinkled in the surface.)
Notes:
Do not attempt to absorb bleed water by applying the hardener at an early stage (water must
not sprinkled in the surface.)
The necessary moisture for the hardener must come the concrete matrix after saturation in
order to develop a proper bond & assure adequate density of the surface.

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Hardener application :Before starting application the color hardener note the following:

Divide & mark the floor into sections of known areas.

Set aside the proper amount of materials to be applied to each section.
The color hardener should be applied over two shakes at the rate of minimum 3kg/m² for the two
shakes.
2/3 of the materials (2kg) in the 1st shake & 1/3 (1kg) or little more in the 2nd shake.

1. Apply the materials by dry shake over the surface at less than knee height & distance no more than 1.0m.
2. Start with the edges of the slab since they set quicker.
3. After each shake the surface must be thoroughly floated (after the powder absorbed water) by
magnesium trowel in order to work the material into the surface.

Note:
Do not trowel the surface between the two shakes.
Never sprinkle water to the surface while floating.

4. After floating the final shake & the surface has hardened sufficiently, start toweling using the blue steel
trowels in constant medium pressure to ensure uniformity of the surface.
Note:
Do not over trowel to avoid trowel burn & discoloration.

Release agent application: After completing the concrete surface treatment with the color hardener &
while the concrete is still in the plastic condition, inspect the concrete surface by pressing it with the thumb
with light moderate pressure , if it produce an indentation of 6-15mm , so it is time to broadcast the release
agent.

Broadcast the release agent at less than knee height & to a distance of no more that 1.0m at a rate of
175gm/m².
Use a soft, long bristle (6’’) mason’s brush by dipping the brush into the material & then broadcast
evenly across the surface following the previous limits.
Application should occur within a single shake.
Apply until a uniform thin layer covers the surface.
Avoid over-application as it might cause disappearing of texture details.
Excess powder could be removed by vacuuming or sweeping gently.
Leave the concrete to hardened enough to walk on, at this moment stamping should start.

Texturing:

Time of texturing the surface may begin immediately once the concrete hardened enough to walk on.
Number of mats as a general rule must be enough so that the area covered is sufficient for 3 workers
can stand & move easily on the stamps.
Start pre-texturing the slab perimeter with a skin mat of a matching texture design.
Once the edges have been pre-textured, texturing of inside area may begin.
Establish the first row of stamps on a straight line starting from the corners (use string line to check
stamped alignment)

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 Impress the stamps into the surface by walking on the mats followed by a light tamping with the
pounder.
A third person may be needed to details the joints with a touch up wheel.

Curing: Powder release agent does not need curing as it works as a curing agent.

Joints:

1. Control joints should be spaced a max distance of 24-36 times the slab thickness.
2. Control joints should be cut to the depth of at least ¼ slab thicknesses using electrical saw
immediately after concrete has set.
3. If the slab is abutting other building element such us manholes, column, walls and foundations
create an expansion joint & fill it with expansion material before casting the concrete against it.

Removing the release agent & washing:

Start sweeping as much of the dry release with a soft bristle broom as possible.
Repeating the cleaning more than once until little dust is remaining & you cannot remove it.
If pressure washer is not available, wet the surface down with a garden hose then spray a cleaning
solution ( mild detergent or citrus base) over the surface & start to scrub in a circular motion with a
medium stiffness bristled broom.
Pour more water & repeat scrubbing until all loose release agent is removed.
Note: Rotary floor buffer & detergent scrub can be used.
Leave the surface to dry before apply the sealer .

Sealing: To protect the concrete surface & to enhance the color, it is highly recommend sealing the surface
with a choice of special sealer immediately after removing the release agent.

Avoid application in direct sunlight or during strong wind.

On hot days apply early in the day when the temperature still low & the concrete surface is in the
shadow & still cool.
Sealer can be applied by roller, brush or spray pump.
A-6mm nap roller is recommended for smooth surfaces.
A-9-12 mm nap roller recommended for rough surfaces.
Two application of sealer is preferred with an interval of 24 hrs. between the two coats for drying.
Foot traffic is allowed after 24 hrs. of the last application & 72 hrs. minimum for heavy traffic.

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Tel. no. +9714-4572508 Fax no. +9714-4572509
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