DIY Network

Concrete Flooring: Preparation and Application From "Rock Solid" episode DROC-103

The demolition is complete and it's now time to prepare the floor for the concrete application. It's time to create!

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	The space lacked character and nuance...
	with average, everyday tiling.
	So, Derek and Dean called on concrete experts Jason and Brandon...
	to help with installing concrete flooring...
	which added warmth and texture to this Maryland kitchen.

Materials:

Demo

Chipping hammer
Hammer
Chisel
Safety glasses
Screw gun
Roofing rake
Flat shovel
Shop vac.
Brooms
Dust pan
Plastic wrap or clear plastic
Tape

Preparation and Application

No. 30 asphalt felt
Metal lath
1.5 in. galvanized finish staples
1.5 in. finish stapler
Heavy duty 2h 4 gal. oil-lube compressor
Air hose for compressor
Utility knife w/blades
Safety glasses
12 in. all purpose pattern snips
Heavy duty work gloves
Hammer
Elite Crete Texture Pave
Elite Crete Portion Control Colorant (optional)
Several 5 gal. buckets
Heavy duty 1/2 in. drill w/ low speed and min. 500 rpm
4 in. paint and mud mixer
Squeegee
Gauge rake
1 1/2 in. putty knife
Several measuring containers of various sizes – 10 qt., 2.5 qt., and smaller
Mask

Finish

Elite Crete Thin finish
Elite Crete Portion Control Colorant (Color: desert beige)
Several clean 5 gal. buckets
Heavy duty 1/2 in. drill w/ low speed and min. 500 rpm
Squeegee
2 in. paint brushes
22 in. hand trowel
Several measuring containers of various sizes – 10 qt., 2.5 qt., and smaller
All-plastic 2 gal. pump sprayer

Acid Staining

Acid stain
High gloss clear sealer
Ammonia – 1 gal.
Clean mops and bucket
5 gal. bucket with spreader screen
Paint roller with extension handle
2 in. painter's tape
Roll of 12 in. masking paper
Commercial shop vac.
2 – 2 gal. all-plastic pump sprayers (such as a gardening pesticide sprayer or deck sprayer)
Safety glasses
Rubber gloves

	Figure A
	Figure B
	Figure C

Preparing for Concrete Application

1. Attach number 30 asphalt felt to the wooden subfloor (figure A). The asphalt felt acts as a moisture barrier. In the short term, it protects the wooden subfloor from the concrete’s moisture. In the long term, it protects the concrete floor from any moisture that may enter through the wooden subfloor and damage the floor or sealer.

2. Begin in a corner of the room, unroll the asphalt felt and tack it to the floor using 1.5 inch galvanized finish staples and the finish stapler attached to the compressor. A manual stapler could be used as well, but if the project is larger, a pneumatic stapler is more effective. Staples should be galvanized so they won’t rust over time.

3. At the end of the room, cut the asphalt felt with your utility knife and begin the next adjacent row of asphalt felt. Lay the asphalt felt so that it overlaps the adjacent row by two inches.

4. Apply the metal lath to the floor (figure B). This should be applied in the opposite direction of the asphalt felt so that the two cross. This should also have a two inch overlap. Use a hammer to flatten the overlap so it does not stick out.

5. The metal lath should be secured to the floor with the stapler gun and the same galvanized staples. There should be approximately 20 staples per square foot or a staple every two inches. The metal lath should be securely attached to the floor; there should be no give when you press on it.

Figure D

6. Piece the metal lath together so it covers the entire floor (figure C). Cuts should be made with wire snips and wearing gloves.

Applying Concrete Base Coat

1. The first layer of the concrete floor is made of Texture Pave (figure D), and will constitute most of the thickness of the floor. Texture Pave is a self-leveling cementitious topping, which is typically used for stamped concrete overlays, but we used it to create a solid concrete base.

2. Mix the Texture Pave in five gallon buckets. For each 55 pound bag of Texture Pave, mix four quarts of water. Mix using the paint mixer attached to the 1/2 inch drill. You can add color to shorten drying time, but for the first coat, it is not necessary.

Figure E

3. As you mix your Texture Pave, pour it onto your prepared floor (figure E). Pour it and spread it one bucket at a time. You will use your gauge rake and squeegee for this step.

4. Set your gauge rake to a quarter of an inch. The gauge rake is a specialty tool that will drag across the top of the metal lath giving an even depth across the floor of a quarter of an inch.

5. Spread your Texture Pave using your gauge rake (figure F). Be sure to get the product into the corners of the room. In hard to reach corners, spread the product using the squeegee or a 1-1/2 inch putty knife. The gauge rake will leave marks in the cement behind it. These can be smoothed out by lightly running the squeegee across the surface of the concrete.

6. Allow the Texture Pave to dry for ten to twenty hours (figure G). Once completely dry, the floor will be lighter and uniformly colored.

Figure F

Figure G

RESOURCES :

Concrete Floor Products
Elite Crete Texture Pave
Elite Crete Thin Finish
Elite Crete Portion Control Colorant (Color: desert beige)
Brand Name: Elite Crete
Website: www.elitecrete.com

Concrete Acid Stain Products
Kemiko Stone Tone Stain (Color: malay tan)
Kemiko Stone Tone Sealer
Brand Name: Kemiko
Website: www.kemiko.com

Tools
Home Depot
Website: www.homedepot.com

GUESTS :

Jason Thoelke, Owner
Brandon Hobbs, Supervisor
Creative Concrete Solutions, Inc.
1210 Hogan Ln.
Conway, AR 72034
Phone: 501-764-4477
Fax: 501-764-1534
E-mail: ccs.conway@aol.com