Baluster

[azall]

I am in the process of making concrete baluster and outdoor type of designs. I am having a few bug holes and some area that require fill up/patching.

I am trying to find an effective solution to this problem that will give my casting concrete a smooth and uniform finish and will also resist the weather condition.

I want to find out the best possible way to approach the problem, without being too labor intensive.

I am located in NY any suggestions?
Regards,

Marc

***

"To KNOW and yet not to do is not to know."

***

"No one would make a greater mistake than he who did nothing because he could do only a little."

 

[boo1]

Consider vibrating the mold or changing the mix. We reciently started using self consolidating Concrete to improve our surface finish.

 

[Ron]

Agree with Boo1...the mix should be vibrated, but it should not contained too much water as that can cause "bug holes".

 

[azall]

Where do I go from here?
what are your suggestions?
Apparently, some people are using an overlay type of product to cover the concrete or mortar, depending on their method of choice.
It seems to me that the end result is acceptable to the market in NY.
I can clearly see that a smooth product was added on top of the baluster to give it a smooth finish. It is somewhat hard to tell what product that they are using.
Any help is appreciated.

regards

marc

 

[boo1]

Often we have applied a skin coat to improve surface finished to finished concrete. The skim coat can be simple cement mortar to a polymer-modified overlay system, and can be toweled, brushed, or sprayed application. But I think a correct mix combined with vibrating the mold will create a better product without the additional surface finishing step.

 

[azall]

I have about 300 units. How do I salvage them? What kind of products would you recommend?

regards

Marc

 

[Zambo]

azall,

As you have probably found out repairing the bug holes is not the main problem, colour matching so that the whole concrete surface is uniform is the more difficult job. As boo1 suggests you could try a polymer-modified skim coat. In Europe and Asia, Sika and Fosroc are suppiers of concrete repair materials. Fosroc manufacture a product called Renderoc FC which would be suitable.

I suggest you buy a couple of products and try them out.

 

[azall]

It is becoming so expensive, trying different product on the market. I'll try Sika by next week.

Someone in the field looked at my product and suggested that all I need is to to use some kind of stone to smooth out the product and finish it with white cement and water.

I'll keep you posted.

 

[boo1]

We often finish the green product, just when we remove the mold. A stone or a hand grinder works great.

 

[jheidt2543]

As boo1 mentioned, we too would "rub" or "wet stone" concrete walls and curbs while they were still green - right after form removal.

If the surfaces are real irregular, where a flat stone or grinding wheel won't work well, you can brush on a mixture of sand, cement and Sononborn's Acryl 60. Acryl 60 is a latex bonding agent. Follow the directions and test it on one to verify texture and final result.