A Passion for Polished Concrete

Jeff Kasella, owner of Minnesota-based Polished Concrete Plus, transformed his career in the concrete business after a hip replacement necessitated a shift from physically demanding concrete placement to decorative concrete work. Having been involved in concrete since age 13, assisting his brother-in-law and father, Kasella sought a less strenuous yet equally engaging aspect of the industry. In 2013, while working for a contractor with various divisions, including Polished Concrete Plus, he began to focus on decorative projects, serving both commercial and residential clients. Initially, his work involved tile patterns and logos on floors, and he successfully completed larger projects like a school gymnasium. In 2017, Kasella acquired Polished Concrete Plus, along with its existing assets and new equipment necessary for polished concrete projects. His first significant commercial endeavor under his ownership was for a Coborn’s Cash Wise store, part of a larger employee-owned company with numerous retail locations across the Midwest. He has since continued to work on multiple Coborn's projects. While commercial projects constitute 80% of his business in terms of square footage, Kasella also undertakes significant residential work. One notable early project involved finishing 4,500 square feet of floors, including break rooms and a warehouse walkway, for a Fingerhut warehouse addition that his father had originally poured. Driven by a desire to innovate beyond standard polishing, Kasella began experimenting with creating realistic wood grain patterns on concrete. After initial trials in his garage, he convinced his mother to allow him to apply this finish to the concrete floor of her new patio home, which is built directly on a concrete slab. This initial residential success led to approximately 10-15 patio home polish projects annually. The wood grain finish involves a micro-topping technique where multiple layers are applied, and epoxy applications are strategically placed with tape to control color and grain patterns. Kasella uses his shop as a showroom, displaying test samples to help clients visualize and select their desired looks. This approach has proven highly successful, with 13,000 square feet of wood grain finishes produced for residential customers in 2018. For his work, Kasella employs HTC Duratiq T8 polishers, paired with Ermator Vacuums, highlighting the versatility of the T8 which allows for diverse tooling combinations from brands like HTC, SASE, and JON-DON to meet specific floor requirements. For staining, densifying, and stain guarding, he uses Ameripolish products, and for any repair work, Metzger/McGuire products such as SRG, Rapid Refloor, and EP80 joint fillers are utilized. Kasella emphasizes the unique, hand-stained nature of each plank in his wood grain designs, noting a significant improvement in efficiency since his first wood grain project. What once took three people six hours to complete 600 square feet can now be achieved for 1,700 square feet in the same timeframe. He continuously experiments with different top colors to add depth to his designs, finishing projects with densifier application, polishing, stain guard, and buff polishing. Kasella manages a team of seven, including himself, augmented by college students during the summer for outdoor decorative concrete projects. His company operates seven polishing machines, enabling up to three crews for smaller residential jobs or continuous operation for large commercial projects, allowing Polished Concrete Plus to transform ordinary concrete slabs into distinctive and beautiful floors. #PolishedConcrete #DecorativeConcrete #WoodGrainFinish #ConcreteArtistry #FloorDesign #JeffKasella #ConcreteRefurbishment #ResidentialConcrete #CommercialConcrete

This article discusses various methods to enhance the appearance and durability of concrete surfaces, transforming them from their basic, utilitarian state into aesthetically pleasing and long-lasting features for homes, both indoors and outdoors. Concrete, often perceived as cold, grey, and unattractive, can be significantly improved through a range of protective and decorative applications. A primary concern for concrete surfaces is protection from environmental elements. Concrete is highly porous, acting like a sponge that absorbs moisture from both the ground below and precipitation from above. This moisture absorption is a major cause of concrete failure, leading to corrosion and degradation, effectively returning the material to its original state of gravel. Therefore, protecting concrete from ice, salt, and general weather exposure is crucial for its longevity. For indoor concrete surfaces, coating is essential not only for aesthetic reasons but also to mitigate dust. Concrete continuously releases dust, which can become airborne and affect indoor air quality. Applying a sealer or an epoxy coating can effectively contain this dust. Decorative features, such as solid colors, colored chips, or colored quartz, can be added to epoxy coatings to create stunning visual effects, making concrete resemble high-end materials like marble or granite and adding a "wow factor" to the space. Polyaspartic coatings are highlighted as a popular and efficient option. These coatings dry quickly, allowing for foot traffic within two hours of application. They are also non-fading and non-yellowing, maintaining their appearance over time. Beyond simple coatings, concrete can be manipulated to create the illusion of texture. By introducing acids that react with the concrete's natural minerals, a flat slab can be made to mimic weathered stone or slate. Water-based concrete stains offer another way to revitalize dull, grey patios, making outdoor areas more inviting. Grooves can be cut into slabs in grid patterns, and with the application of a beige stain, a patio can be made to look like it's constructed from stone blocks. Before any staining or coating, concrete surfaces require thorough preparation. This typically involves grinding or shot blasting to open the concrete's pores, ensuring proper adhesion of stains or dyes. Cracks in older surfaces should be filled during this preparatory phase. Grinding can also address other imperfections such as frost damage, tree root intrusion, settling, uneven surfaces, and trip hazards. Even concrete steps with residual paint or glue can be prepped and resurfaced. Polishing is another technique for concrete, achieved using a metal diamond grinder to produce a reflective sheen, though not necessarily a mirror finish. This process involves adding a densifier to fill microscopic pores and then a sealer for stain protection. Polished concrete floors in garages can deter tire marks, grease, and automotive fluids, giving the space a showroom-like appearance. The cost of concrete treatments varies depending on the complexity and type of coating. Simple epoxy coatings can start at around $3 per square foot, while decorative, high-performance coatings can be $9 per square foot or more. Polished floors can range from $3 per square foot for a basic honed finish to $12 or more for advanced treatments. It is important to assess the concrete's condition before treatment. If a surface has been previously sealed or has absorbed excessive moisture, it might be difficult to stain or coat. A simple test involves sprinkling water on the surface: if the water beads, the old sealer needs to be stripped; if it is absorbed, the surface is ready. For moisture testing, taping a piece of plastic wrap to the surface for a period can reveal condensation or dampness, indicating the need for professional consultation. #ConcreteFinishes #HomeImprovement #DurableSurfaces #PolyasparticCoatings #ConcreteStaining #SurfacePreparation #HomeRenovation #DecorativeConcrete #MoistureProtection

Bob Harris, the Senior Director of Decorative Concrete Consulting and a Principal for the SSI Team, is a globally recognized expert in the decorative concrete industry. A third-generation concrete finisher and former President of the Decorative Concrete Institute, Harris has dedicated his career to advancing architectural decorative concrete through pioneering ideas, extensive education, and practical application. His expertise is particularly notable in concrete repair, where he possesses a unique ability to make repairs undetectable. Harris has been a prominent speaker at major industry events, including the World of Concrete for 15 consecutive years and World of Concrete in Mexico City for four years. He served as Master of Ceremonies at the Con/Expo Con/Agg demo in Las Vegas in 2002 and has participated in numerous speaking engagements for the Decorative Concrete Council. His international teaching experience spans countries such as Canada, the Caribbean, Germany, England, Greece, Indonesia, Ireland, Italy, Mexico, and South Africa. He is the prolific author of several books, with over 37,000 copies sold worldwide. His 'Guide Series' covers critical topics such as Stained Interior Concrete Floors, Stamped Concrete, Concrete Overlays and Toppings, and Polished Concrete Floors. Beyond his written works, Harris has produced educational DVDs for his own brand and for organizations like the Portland Cement Association, AGC-Laborers, and the Concrete Network. His insights are also regularly featured in articles for _Concrete Network_, _Concrete Decor_, and _Concrete Construction_ magazines. Before his current role, Harris spent nearly a decade with a major decorative concrete product manufacturer, where he eventually directed product training. In this capacity, he conducted hands-on architectural concrete training seminars globally and was instrumental in technical support, research, and development. His contributions to industry associations, including ACI, ASCC, and DCC, have significantly advanced the education and training necessary for decorative concrete to become a prominent feature in modern buildings and landscapes. A significant part of Harris's practical experience includes six years as a senior superintendent, exclusively working on decorative "themed" concrete projects within Disney theme parks. During this time, he personally oversaw or supervised the placement of over three million square feet of decorative concrete, incorporating integral color, dry-shake color hardeners, and chemical stains, particularly in major Disney theme parks in Orlando, Florida. In recognition of his achievements, unwavering commitment to excellence, and innovative contributions that have fostered the growth of the decorative concrete industry, Bob Harris was among the first individuals inducted into the Decorative Concrete Hall of Fame in 2010. He also actively serves as a committee member of ACI 310, focusing on Decorative Concrete, continuing his influence on industry standards and practices. #BobHarris #DecorativeConcrete #ConcreteFinisher #ConcreteEducation #WorldOfConcrete #ArchitecturalConcrete #ConcreteRepair #IndustryExpert

The ULTRAFLOR Architectural Polished Concrete System, developed by Diamatic, offers a solution for high-end architectural finishes for concrete floors. This system is engineered to transform ordinary concrete into durable, decorative surfaces suitable for various applications including retail, commercial, institutional, and architectural settings. The core of the system lies in its ability to produce a hardened, dust-proofed, and reflective surface that is resistant to chemicals, abrasion, and stains. The ULTRAFLOR system integrates high-quality diamond tooling polishing equipment with advanced chemical products. Key components include lithium chemistry for densifying and guarding the concrete, repair materials, pinhole filler, and water-based dyes. The lithium technology is particularly highlighted for its consistent performance over eight years across the U.S., Europe, and Asia. The system's guard products are designed to meet specific protection levels, and a cross-linked densifier is available to prevent salt intrusion in areas exposed to de-icing salts. It is applicable to any interior concrete floor, including older surfaces with cracks or defects, which can be addressed using a polishable repair product and pinhole filler, while structural cracks are managed with appropriate joint materials. A significant benefit of the ULTRAFLOR system is its contribution to reducing overall life cycle costs and maintenance requirements. The process involves full surface refinement through a step-by-step methodology, which results in superior gloss retention, higher distinctness of image, and enhanced resistance to stains and wear. This thorough process ensures the polished results have a significantly longer lifespan compared to other techniques, with maintenance specifications extending the project's life beyond 15 years. Green Polishing Solutions, led by Alan Comins, exemplifies the successful application of the ULTRAFLOR system. Comins attributes 90% of his polishing business to this system, noting the evolution of the industry with improved machinery and chemicals. He emphasizes that lithium-based densifiers and sealers are pivotal for achieving a dust-free, shiny, and durable finish. The process typically involves preparing the surface with various grinding grits, applying Diamatic ULTRAFLOR Flor-Sil lithium densifier, followed by a sequence of polishing pads, and finally sealing the surface with a burnishing pad and Diamatic ULTRAFLOR Flor Finish. Comins highlights the superior clarity and durability of lithium densifiers compared to sodium and potassium silicates, which deliver a brighter, more lasting shine even in areas requiring cementitious repairs. The comprehensive range of ULTRAFLOR products, from void fillers and color dyes to densifiers and wear protection, enables Comins to consistently meet customer expectations with long-lasting solutions. With 80% of his work involving existing concrete refurbishment and 20% on new concrete, Comins anticipates continued growth in the polishing business. Polished concrete, beyond its aesthetic appeal, offers practical advantages such as improved thermal qualities for energy cost reduction and increased ambient light reflection, further lowering electrical expenses. Unlike other flooring materials, properly maintained polished concrete does not require replacement. The article concludes with a technical comparison between lithium and sodium silicates, noting that silicates densify and harden concrete, with lithium offering better penetration due to lower viscosity and smaller particle size, and not requiring rinsing, unlike sodium silicates which produce sodium hydroxide by-product. #ULTRAFLORSystem #ConcretePolishing #ArchitecturalFinishes #LithiumTechnology #GreenPolishingSolutions #SustainableFlooring #ConstructionMaterials #FloorMaintenance #CommercialFlooring

Julio Hallack, owner of Concrete Innovations by Hallack in Turlock, California, transformed a layoff from a construction supervisor role in 1986 into a successful career in decorative concrete. Initially, he started a landscaping business in California to support his family, quickly realizing his preference for outdoor work and hands-on projects. Hallack emphasized strong business practices from the outset, including consistent branding on company vehicles and employee uniforms. His company diversified into colored concrete after a few years, a move that significantly strengthened its market position. By 1998, Hallack shifted his company's focus entirely to decorative concrete work, discontinuing the landscaping services. Today, Concrete Innovations by Hallack specializes in concrete restoration, decorative countertops, pool decks, stamping, staining, and intricate artwork. The company employs nine individuals and generates nearly $1 million in annual sales, with commercial projects accounting for 70% of the business and residential work making up the remaining 30%. Hallack's success stems from his commitment to staying current with industry trends, continuously seeking new ideas from his travels, and experimenting with products at his 3-acre estate, which includes an 8,000-square-foot showroom and testing facility. He is known for pushing product limits and developing unique applications, such as decorative shower stalls that offer an aesthetic alternative to traditional tiles. Hallack places a high value on education and training, not only for himself but also for his employees. He maintains a low employee turnover rate by offering competitive wages, paid holidays, and performance-based bonuses, which fosters a sense of collective responsibility among his crew. He enforces strict professionalism on job sites, including policies against smoking and alcohol, mandatory drug tests, and requirements for covering tattoos and removing piercings. Recognizing the significant Hispanic workforce in the industry, Hallack has collaborated with L.M. Scofield to translate educational materials into Spanish and has conducted numerous Spanish-language training courses across California. He also served as a translator during demonstrations at the World of Concrete, aiming to mass-educate workers and promote industry growth and pride in workmanship. Over two decades, Hallack has completed notable projects, including the restoration of the historic State Theater in Modesto, California, and the creation of intricate labyrinths. His business continues to expand, with plans to hire more staff and explore new markets internationally, including consulting opportunities in Hawaii and potential training initiatives in Mexico and Central America. Hallack foresees significant growth in the decorative concrete market and a strong future for the concrete industry, particularly in restoration, which he views as a multi-billion-dollar sector. He is committed to securing high-quality contracts and delivering exceptional work. A prime example of Hallack's expertise is his work on nine Save Mart Supermarkets in central California, where his team completes 40,000-square-foot stained concrete floor projects within a strict one-week deadline. These large commercial jobs require extensive pre-preparation, including understanding floor conditions, chemicals applied by concrete contractors, and collaborating with general contractors to recommend suitable water-based curing compounds. Hallack conducts mock-ups on-site weeks in advance to test processes like prepping, staining, stripping, and sealing. Upon taking over a job site, his crew dedicates up to two days to meticulously clean construction debris and address specific challenges like tire marks, utilizing high-quality cleaning equipment to prevent issues such as delamination of stain and sealers. The artistic elements, such as elaborate windmills and greetings, are executed by his most artistic employees, taking several days to complete with multiple layers of stain. Hallack developed an efficient system for staining large areas, adapting 25-gallon farming sprayers for chemical stains to reduce labor and time. He also successfully navigates challenging conditions, such as applying stains in cold weather by extending drying times and using heaters. Neutralizing the floors after staining is a critical and meticulous step, involving repeated scrubbing and rinsing until wash water is clear, followed by a tape test to ensure no contamination remains before applying sealers. He typically applies two basecoats and several finishing coats of sealer, filling expansion joints with colored tile grout to add definition and meet aesthetic requirements, demonstrating his thorough approach to delivering high-quality decorative concrete finishes. #ConcreteInnovations #DecorativeConcrete #ConcreteRestoration #JulioHallack #ConstructionIndustry #VocationalTraining #CommercialProjects #StainedConcrete #Entrepreneurship