December 29, 2010
Concrete Zen is excited and honored to announce their presence on the cover of Concrete Cartel Magazine. Concrete Cartel is Brandon Gore’s new magazine in the concrete trade world that discusses techniques, innovation, and emerging trends in decorative concrete. Nicole is featured sitting in one of our planters, and Buddy Rhodes, one of the pioneers in the concrete industry, mentioned us in his “thanks”. We are ecstatic to be recognized by Concrete Cartel, and look forward to further issues of the exciting new magazine!
November 14, 2010
If you’ve followed our blog, you’ve realized that there are endless possibilities when it comes to the application of concrete. The shape, form, size, and finish are completely customizable. Our most popular applications are countertops, overlays, and planters. However, the versatility of decorative concrete has led Concrete Zen into other interesting ventures such as manufacturing furniture. Concrete Zen has made benches and tables on a few different occasions. For instance, here is Nicole polishing slurry on a cone bistro table for the City Theater.
Not only can concrete be formed into furniture or countertops, but it can be used as an overlay on floors and walls. Overlays can give a space a completely different look by coating an extremely thin layer of concrete over virtually any existing surface. We have gone over top of ceramic tile and brick with ease. Concrete Zen continues to look for new and innovative ways to use concrete in every project we complete. Looking forward to exciting projects ahead!
October 9, 2010
In an effort to make all of our projects and ventures as green as we can, Concrete Zen has been using a product called SoyCrete on several recent projects. SoyCrete is a green alternative to acid stains that are harmful to the environment. SoyCrete is an architectural concrete stain that has the durability, flexibility, and control of an acid stain without all of the damaging environmental effects. The bio-based stain is made from rapidly renewable resources such as natural plant oils, and is combined with 100% soy ester pigments that allow for maximum penetration into the substrate and creates a barrier that is water, mold, mildew, and UV resistant. In addition, SoyCrete has the capability to be customized to any color. The use of SoyCrete on projects can also contribute by earning points towards a LEED certification in both the Materials & Resources and Indoor Air Quality divisions. SoyCrete has proven to be a trusted product to Concrete Zen, here are a few photos of a fireplace hearth in which we used the green product. Concrete Zen purchases SoyCrete from Artemis Environmental in Pittsburgh, PA.
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September 9, 2010
Concrete Zen recently completed a project for the City Theater in Pittsburgh, PA. The new PPG Courtyard at the theater will be used as a gathering area for theater-goers for cocktails, intermissions, and a general hang out space during theater hours. The burgundy and gold colors kept with the scheme of the theater, adding a bunch of color to the courtyard. The ground was engraved to create control joints with a tool from Engrave A Crete, and the cone tables, benches, and planters were all made using the Buddy Rhodes pressed technique which ensures their strength and durability for whatever weather may ensue. The project was a success, and we hope that patrons of the theater will enjoy the space for years to come!
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July 25, 2010
GFRC Counter with Drainboard and Ammonite
Integrated Concrete Sink with Petrified wood as erosion point.
GFRC - Alkaline Resistant Glass Fiber Reinforced Concrete is the most common method we use at the Concrete Zen Workshop. This counter was designed by a local artist in the Pittsburgh area. This is one part of the entire counter which includes: Custom made extra deep sink mold with petrified wood as erosion point, integrated drain board with trivet rails that will have copper placed in them, integrated cutting board adjacent the sink that seams with other section, integrated fruit bowl, recycled black glass (set by the client at the shop), and Mr. Ammonite front and center. This section piece is a little over 9′ at 1-1/2″. We are able to make custom molds that may suit all of our creative clients’ needs.
May 25, 2010
Ice Crystal Coffee Concrete Overlay
Although Concrete Overlays may be common and a popular solution in various parts of the Nation. Pittsburgh is getting a glimpse of this innovative floor system. The application is for old concrete either for slab on grade buildings, previously coated floors , failed/tired ceramic, driveways, walkways, patios. This product can be used in an interior or exterior application. The different brands of overlays in the Pittsburgh area are similar in which they are mixed and applied. The surface is prepared by grinding all of the foreign materials: (old paint, mastic(glue), thinset, vinyl, old sealer …) The cracks (if any ) are ground out to a “V” groove and filled with either epoxy or acrylic modified patch. The surface is then treated with a bonding agent. The concrete overlay is then put on using one of these methods http://bit.ly/3HODgP (Concrete Network). The options are endless: reactive staining, stencils, spray grout pattens, stamps, dyes, or other faux finish designs can apply. This can be an inexpensive way to restore or rehab any floor treatments for a project. Commercial, Institutional and Industrial uses can save ten’s of thousands. The coating creates a “clean slate” that is resilient for high traffic. The coating are permenent and need only to be sealed over time. At Concrete Zenwe have been trained in these methods and strive to apply them in an original organic format. Our costs for the overlays range from $3.00- $7.00 per square foot. The stampable overlays may be a bit more depending on the size of the project. Contact us www.
May 19, 2010
Concrete is a very resilient material for countertops. It is not by nature a green product - cement production and transportation are extremely energy-intensive—but if the aggregate is recycled and locally sourced, and load additives such as VCAS can be added, the energy intensity falls.
Concrete can be molded into custom shapes and dyed almost any color or given distinctive blended looks, though you should inquire about the toxicity of dyes. Once cast into countertops, concrete can withstand heat very well. However, concrete counters should be sealed periodically to limit stains, water damage and bacterial growth, and heat can damage the seal. Certain sealers with nanotechnology can resist 99% of the staining and withstand heat of boiling pots set directly onto them
Treated well, concrete can last a lifetime. At the end of its useful life in your kitchen, it can be reused whole or cut for other projects. Unwanted concrete can be crushed into aggregate for producing new concrete, saving energy used in mining resources to produce new concrete and keeping old concrete out of landfills. - Source USGBC Green Home Guide - B
April 7, 2010
GFRC (Concrete) Sink
Here at the Concrete Zen workshop we manufacture countertops by following green practices. All of our materials for molds are re-used, therefore we cut down on the amount of waste produced. We use recycled glass for aggregate within the countertops. We ad up to 50 % Reclaimed VCAS to the cement content of the admixes. All of the parts for the concrete mix are obtained locally around the greater Pittsburgh area. We use water based sealants and stains that do not have VOCs. –Elizabeth E.
March 28, 2010
Working with Modified Parging Materials
We are working on the new space at the workshop and would like to experiement with our GFRC Face Mix and Vertical Surfaces. We added 3mm glass fibers and adjusted the other admixtures. We used pure white sand and VCAS to get a “whiter” appearence. The cost savings to other bagged goods is tremendous. Now we have to design something to make the walls look good. I was thinking about gallery style white and hanging our sample boards and sample pieces on the wall to resemble art. Another part on us wants to get wild with the walls and see what we can do on the vertical surfaces. Pros: No mesh, Scratch coat may be the finish coat, stronger adhesion, fibers help with cracking, fast cure, staining and design creativity unlimited. Cons: Need to work fast -(3 people per sack mix), need a good trial person, gets messy when spraying, and clean up- Boo. - Brian
March 23, 2010
Pont du Gard, France - Roman Aqueduct 19 BC
A pozzolan is a generic term for additives found in white cement, mortar and concrete products. Concrete stands the test of time due to pozzolans used in ancient Rome obtained from “burned limestone and Santorum earth from volcanic eruptions.”-. VCAS is used to fortify the cementitious mixture to improve its durability and strength. It also ” [serves] to densify and reduce the permeability of concrete, which helps to make it more resistant to deterioration and swelling associated with various exposureconditions.”-Vitrominerals.com. VCAS is a silicate and is a by-product of the fiberglass industry. Using VCAS conserves energy and emissions during the manufacturing of concrete.–Elizabeth E.
