2006 Decorative & Durable Designs Concrete Pavement Awards

While volume of residential construction activity may have ebbed, especially in the last half of 2006, no decline was evident in the quality of decorative

While volume of residential construction activity may have ebbed, especially in the last half of 2006, no decline was evident in the quality of decorative flatwork, as demonstrated by entries submitted for the 2006 Concrete Pavement Awards Û Decorative and Durable Designs program. Cosponsored by Concrete Products, Interlocking Concrete Pavement Institute, and the American Society for Concrete Contractors’ Decorative Concrete Council, the competition showcases outstanding achievement in a range of applications excluding highway work. To that end, judges weigh each project’s design, craftsmanship, and site suitability to select winners in five categories: Precast and Cast-in-Place for Residential and Commercial projects, plus Specialty. Featured this month are winning and honorable mention cast-in-place projects to be followed by precast category winners in February.

COMMERCIAL – 1ST PLACE

Getty Villa
Malibu, California

Awarded to:
Shaw & Sons Construction
Costa Mesa, California

The natural appeal of the Îstrata wall,Ì prominently featured in Getty Villa, is a product of elaborate planning and exacting designs: Mother Nature’s hand is visible chiefly in the fine details, such as 10 select aggregates seeded or integrally combined with each of 12 concrete mixes comprising the project’s horizontal and vertical surfaces. Multiple bands of unique finishes, each depicting a different material, such as stone or wood, characterize the strata walls that provide an architectural motif unifying disparate buildings while rendering them distinct. Due to the variety of sedimentary materials incorporated in the concrete mixes, over a year of shop drawing was coordinated with construction plans to produce a complete finish timetable keyed to mix design schedules.

Shaw & Sons provided over 97,000 sq. ft. of Lithocrete for the project, including over 6,000 vertical square feet for walls, curbs, stairs, and benches. Where a neutral and uniform appearance was desirable, Reliance fine aggregate was introduced. Among two varieties of cement used for the project, Terminal Island Type II cement naturally provided a greener hue and Colton Type II produced a grey, putty color.

COMMERCIAL – 2ND PLACE

Discovery Canyon Campus
Colorado Springs, Colorado

Awarded to:
Colorado Hardscapes
Denver, Colorado

Concrete supplier:
Transit Mix
Colorado Springs, Colorado

While recent research has pinpointed the first appearance of concrete in the Great Pyramids of Egypt Û predating pozzolanic concrete in Roman construction by 2,500 years Û Discovery Canyon Campus incorporates concrete throughout the earth’s history as part of a display illustrating the globe’s evolving constituents. A 22- _ 3.5-ft. concrete sediment wall, 20 inches wide at the base tapering to 12 inches at the top, required a 3-in. low-slump mix integrally colored with Davis Colors’ Sequoia Sand. As placement was interrupted nine times to create layers, workers troweled variegated lines and sloping sides; inserted mosaic pieces along the form boards; spread additional river rock, obsidian aggregate, and red granite; and, applied color hardener to accent sediment lines. Bomanite Auburn chemical stain and Okon penetrating sealer finish the wall.

Water is indicated by a swirl-finished slab tinted with Blue Frost color hardener and highlighted with Con-Color stain. Stenciled molecule clusters were added, as well as black paint-stained dinosaur, trilobite and human footprints.

The 2,400-sq.-ft. Proto Plaza features a DNA strand with saw-cut and topical-stained V shapes traversed by angled, sandblasted bands illustrating the DNA’s linear direction. Colorado Hardscapes’ Sandscape Texture provides a finish for the pattern surrounding 5-ft.-wide sections of gray concrete.

COMMERCIAL – HONORABLE MENTION

Promenade Shops at Saucon Valley
Center Valley, Pennsylvania

Awarded to:
Architectural Concrete Design, Inc.
Levittown, Pennsylvania

Concrete supplier:
4 Winds Concrete
Bethlehem, Pennsylvania

Contributing to the flagship status of the Promenade Shops at Saucon Valley anchoring Pennsylvania’s first lifestyle center, decorative pavement complements the natural wood and stone fa¡ade accents of upscale stores, boutiques, and restaurants comprising the Lehigh Valley mixed-use development. The 125,000-sq.-ft. hardscape encompasses storefronts, walkways, crosswalks, and feature areas exhibiting an Old World European Fan design, a Random Slate pattern similar to flagstone, as well as fractured-slate and salt-skin textures. Seamless embossing skins allowed simulation of natural stone, custom cut to occupy large areas where actual stone placement would have been impractical or inappropriate. Application of Scofield color hardeners containing silica sand increased surface durability and abrasion resistance by at least three times, the installer notes. Color warmth was provided by a Steadman Buff base coat and a reddish-brown Russet hardener. Additionally, a liquid release or bond break was used to promote a dust-free environment and create an antique or mottled effect.

Underlying the skillful surface treatment is solid construction comprising a 3,500-psi, air-entrained, fiber-reinforced mix placed over a compacted base of no less than four inches of 34-in. stone. Concrete thicknesses range from four to five inches in pedestrian areas to six inches for vehicular byways. Concrete joints were both saw cut and hand tooled.

COMMERCIAL – HONORABLE MENTION

Glens Oaks Park
Clearwater, Florida

Awarded to:
Increte Systems
Odessa, Florida and Nelson Construction
Palm Harbor, Florida

Concrete supplier:
Cemex, Inc.
Sarasota, Florida

Transforming a golf course into Glen Oaks public park required construction of over 25,000 sq. ft. of pedestrian walkways, footbridges and retaining walls. Increte’s Stone-Crete Architectural Wall System in a Sedona pattern was selected to simulate natural stone common to the region. The realistic stone pattern was further enhanced by Increte’s integral coloring.

RESIDENTIAL – 1ST PLACE

Gildehaus Residence
Bentonville, Arkansas

Awarded to:
Ozark Patterned
Concrete, Inc.
Lowell, Arkansas

A pool deck as durable as the large stones it resembles was achieved by means of a 3,500-psi, air-entrained, Ê-in. coarse-aggregate mix placed on a minimum 3-in.-thick, Class 7 compacted base and reinforced with #3 rebar at 24-in. centers. A color hardener and release further fortify the surface while contributing to a natural stone appearance.

Because the owner sought a distinctive look incorporating massive, straight-edged stones, rock-joint tools and seamless texture-imprinting mats were used to create a large, random, cut-stone pattern covering 3,627 sq. ft. A table cast in the pool mirrors the shape of the pool edge and matches the deck surface in color and texture. Board imprinting tools were used to texture the pool-house interior slab and porch, encompassing a total of 400 sq. ft.

RESIDENTIAL – 2ND PLACE

Texas Tuscan Residence
San Antonio, Texas

Awarded to:
Land Design Texas
Boerne, Texas

Concrete supplier:
Alamo
San Antonio, Texas

The 11,000-sq.-ft. installation comprises a welcoming front entrance, including a circular drive, motor court, entry walk and porch, plus a lush backyard environment in a cohesive landscaped setting. The 8,000-sq.-ft. entryway consists of 4-in.-thick, colored, stamped concrete reinforced with 6-gauge wire mesh placed over a limestone compacted subbase. The character of weathered stone is achieved by the application of Scofield’s Lithochrome color hardener and antiquing release, Lithotex Pennsylvania Slate Pattern texturing skins, and Cureseal-S finish coat.

The backyard features a seamless blend of natural and fabricated elements, as the pool deck, gazebo slab and covered patios of colored, textured and scored concrete echo the spa’s native boulders over which water spills into a natural-shaped pool. Water in the pool appears to flow through a vanishing-edge feature into a ravine transformed into a stream and water garden. The decorative pavement consists of 4-in.-thick concrete reinforced with #3 rebar placed over a limestone compacted subbase with substantial grade beams due to a pool deck five feet out of grade. Scofield flatwork products, including color hardener and antiquing release as well as texturing skins and sealant, contribute to the natural stone appearance.

RESIDENTIAL – HONORABLE MENTION

Glass Residence
Rogers, Arkansas

Awarded to:
Ozark Patterned
Concrete, Inc.
Lowell, Arkansas

Concrete supplier:
Central Redi-Mix
Springdale, Arkansas

Several techniques are expertly employed to create a hardscape complementing the French Country home of stone with brick accents, as well as the brick pool house. Fortress Stone imprinting tools produce a cut-stone look for the pool deck, while an Old English Herringbone Brick pattern Û grouted to match the pool house and home accents Û lends authentic appeal to the parking area, patio, and pool house veranda. An inlay scored and dyed in the pool house front entry forms a permanent rug. Steps and sidewalks of imprinted rock texture also feature grouted, imprinted brick borders. Additionally, the rock texture provides a border for the colored, broom finish drive. The pool house floor is scored and stained. Overall, the installation includes 5,095 sq. ft. of imprinted surface; 1,600 sq. ft. of colored broom finish; and, 1,248 sq. ft. of stained slab.

Resistance to freeze/thaw cycles is ensured by a 3,500-psi, air-entrained, Ê-in. coarse-aggregate mix reinforced with #3 rebar at 24-in. centers and placed on a minimum 3-in.-thick, Class 7 compacted base. L.M. Scofield color hardener, Concreation Inc. release, and Kemico acid stain for flash highlights were applied to the pool deck and all matching Fortress Stone sidewalks and borders. The Old English Herringbone Brick pool house veranda, parking area and sidewalk borders required Concreation color hardener and release before grouting. Scofield’s Chromix Integral color was used for the broom-finish drive, while the pool house floor was treated with acid stains by Scofield (for the field) and Kemico (for the border).

RESIDENTIAL – HONORABLE MENTION

Price Residence
Grand Rapids, Michigan

Awarded to:
Decorative Concrete
Resources
Saginaw, Michigan

Concrete supplier:
Grand Rapids Gravel
Grand Rapids, Michigan

Replacing an asphalt driveway with 4,500 sq. ft. of decorative pavement, meticulous craftsmen brought a stunning design into bold relief. Removal of the asphalt surface was followed by proof rolling of the existing subbase. New slabs comprising 4-in.-thick colored, stamped concrete reinforced with wire mesh were placed over a 6-in.-thick, compacted, granular base. Realistic hues were achieved with integral color, dry shake color hardener, and powdered release materials. Also accentuating the appearance of natural stone was close attention to curved edges, clean mortar joints, and distinct surface textures.

SPECIALTY – 1ST PLACE

Thomas Road Baptist Church
Lynchburg, Virginia

Awarded to:
Lloyd Concrete Services, Inc.
Forest, Virginia

Concrete supplier:
Lynchburg Ready Mix
Lynchburg, Virginia

In three weeks, workers placed 15,000 sq. ft. of flatwork in time for the 50th anniversary of Thomas Road Baptist Church. Setting the stage for another half-century, the floor was constructed of 4-in.-thick, 3,500-psi concrete containing 1- to 0.19-in. aggregate (#57 stone). Trowels were used to finish the surface, which was acid stained with Scofield Lithochrome Chemstain. Three colors Û Fern Green, Antique Amber, and Faded Terracotta Û form vivid patterns throughout the installation.

SPECIALTY – 2ND PLACE

Canton Rotary Club Symbol
Canton, Michigan

Awarded to:
Action Concrete Services
Canton, Michigan

Concrete supplier:
Osborne Concrete
Romulus, Michigan

Intricate formwork with precise measurements was required to accurately reproduce the Canton Rotary Club Symbol. On a 6- to 8-in. crushed-concrete base compacted in lifts, a six-sack, air-entrained mix was poured at a 4-in. slump. Solomon’s Marigold integral color and a mixture of two Walnut release powders provided a natural tint for the installation. In addition, border and teeth components were treated with a Walnut release combined with sealant. For realistic texture, a Caesar Stone skin was used to stamp field inlays, while teeth and borders were imprinted with an Ashlar Slate pattern.

Pioneer-colored Hollandstone pavers form the brick areas, which are inscribed with the names of donors. Circling the perimeter of the Rotary Gear are custom-fabricated precast pillars bearing inscribed brass plaques. Easily accessible for the handicapped, the entire project was finally sealed with three thin coats of Prosoco DuraSheen Sealer containing an additive that prevents slippage when the surface is wet.

SPECIALTY – HONORABLE MENTION

Pasquale Restaurant
Lima, Peru

Awarded to:
Increte Systems
Odessa, Florida and Increte Peru
Lima, Peru

A vertically stamped overlay, handsomely executed, comprises the Pasquale Restaurant exterior. Increte’s Thin-Crete Stamped Overlay System required application of a ?-in. layer of grout to the structure’s 4,000-plus-sq.-ft. outside walls and stamping them with a 5-ft.-square Slate Patterned Skin. To achieve a rich color and enhance the texture’s relief, Increte’s Sun Gray color hardener was added, as well as a Dark Gray powder release. Finally, further protection and luster were ensured by coating the surface with Increte’s Clear Seal.

SPECIALTY – HONORABLE MENTION

Del Sur Ranch House
San Diego, California

Awarded to:
T.B. Penick & Sons, Inc.
San Diego, California

Concrete supplier:
Vulcan Materials
San Diego, California

Demonstrating that environmentally friendly construction can be attractive as well, Del Sur Ranch House project principals set their sights on San Diego’s first Platinum Leadership in Energy and Environmental Design [LEED] award. To earn additional points toward that end, they selected T.B. Penick & Sons’ Save the Fish (STF) pervious concrete system for a 10,270-sq.-ft. outdoor parking lot. After placing the mix to a thickness of 8_ inches over a 6-in. Class II subbase, installers applied a power screed. A custom integral color developed specifically for the job ensured a complementary fit with other project elements. While providing structural capacity and maintenance properties comparable to a conventional mix, the contractor notes, the pervious pavement facilitates irrigation as rainwater seeps directly into the ground, reducing stormwater runoff and improving water quality.