The
Process
Consultation
Upon
initial consultation the client chooses the style of
balustrade, the concello design and any other features
necessary to reach a final design concept. A hand
sketch will be drawn for clarity and final approval.
Preparation
The concello is hand designed and created
by using 2” board. From this design a mould will then
be made to pour the concrete mixture. This mould is made
from fibreglass and designed to make the uniform, solid
and attractive concello which will enhance the
appearance of the finished project. The concrete is
freshly poured, allowed to set for 24 hours and then
removed from the mould. Two weeks are needed to allow
the concello to cure before placing.
The balustrades are made concurrently and
allowed the same amount of time to cure.
Security
When
we first arrive at the work site, the first step is for
the client to advise us of any problem areas, such as
subterranean gas, electric, cable or telephone lines, or
septic tank, water sprinklers, and so on... This permits
us to minimize any possible damage to the later, during
the excavation.
Prior to starting your concrete project,
we must examine every little thing in order to eliminate
any obstacles that could cause inconveniences, or
disadvantage our work. We also look at the plans and at
the access.
Excavation
All excavation is done by hand and small
machinery.
Crushed stone or concrete is dumped,
usually in a laneway or in a barricaded site on the road
depending on conditions, and accessibility.
We dig, as the plans indicate, up to 12"
inches in depth and crushed stone is then placed and
well compacted.
Framing
Once
the excavation finished, we are ready to install the
forms. These forms are either made of metal and/or wood.
We then place the crushed stone and
compact it well.
To stabilize the project we next lay down
the rebar -- depending on the project, we may also use
steel mesh.
The project is now ready to receive the
concrete!
Concrete, Deforming and Finishing
Depending on the size of the job, we may
mix the concrete by hand. This is generally how the
Dominican people have done it for centuries, however, if
it is a large project we will bring in trucks. If it is
at all possible, we back up the cement truck right to
the project area, in order to save time. Otherwise, we
bring in the concrete to the project area via
wheelbarrows.
Then the concrete is freshly poured,
levelled and trowel.
Balustrades
The
balustrades, concellos and columns are then placed in
the design pattern. Another form is made for the base
and the top of the balustrades. The concrete is freshly
poured, levelled and trowel.
Painting, Staining and Sealing
Painting and staining can be applied on
very old concrete and brand new concrete. You must not
expect the stain to be uniform. Stained concrete
surfaces are delicately shaded with many different
tones, hues and nuances.
It is with the use of a brush, roller, or
air sprayer, that we apply the chemical stain or paint.
The stain reacts and embeds into the
concrete (usually within 24 hours), and the residue is
washed away.
Once the concrete dries, a sealer is then
rolled unto the entire concrete project.
The sealer is applied in the same manner
as the chemical stain. Usually, one coat is sufficient,
and provides a nice, uniform sheen.
This sealer provides protection against
the harsh weather conditions and against any foreign
materials that could directly contact and damage the
concrete.
Maintenance
Maintaining
your concrete is important in order to keep its
brightness and shine, and in order to keep it well
protected. The cleaning and sealing of your concrete
project must be done. Dusting can easily be done with a
water hose and should be done periodically.
We recommend that you seal your concrete
project every 2 to 3 years.
Once the sealer is applied, your
concrete’s colours will be recaptured and your concrete
will return to its original luminosity and beauty as the
first day it was installed!
