American Society of Concrete Contractors

UC San Diego Mesa Housing Pedestrian and Bicycle Bridge

rzuellig — Fri, 01 Jan 2021 19:58:00 GMT

2021 DCC Award Winner
UC San Diego Mesa Housing Pedestrian and Bicycle Bridge, T.B. Penick & Sons, Inc.

First Place: Cast-in-Place Special Finishes, Over 5,000 SF

UCSD Mesa Housing Pedestrian and Bicycle Bridge is an exciting new addition that enhances the campus experience, promotes a healthy lifestyle, and establishes UCSD as an easily accessible destination.

The design intent was achieved with a two-color transition from a turquoise blue that fades to a cobalt blue. The turquoise area is a blend of three different shades of¼" turquoise glass.

Lighter and darker shades of turquoise provide depth and interest and avoid a boring uniform color. Similarly, the cobalt area is a blend of three different shades of¼" cobalt glass.

The bridge was poured in different sections. One challenge was moving the pour materials onto the bridge, including all the buckets of premixed glass. This required tying ropes to the bucket handles to pull them up onto the bridge, then staging the buckets along the narrow bridge perimeter. The main challenge was pouring such a large amount of concrete and doing the process within a narrow window of time; requiring us to work with a combined team of over 15 workers.

Little Island @ Pier 55

rzuellig — Fri, 01 Jan 2021 19:47:00 GMT

Ruttura & Sons Const. Co., Inc., West Babylon, NY

2021

Little Island is a $250 million Hudson River Park Trust project which takes the idea of piers and parks to a new level. The most visible portion is the pots, fabricated giant cups put together with pieces called petals. 39 sets of formwork were made after extensive 3D computer modeling to create the 132 pots.

While the pots were modeled, cast, and assembled, marine contractors drove the pilings in stages, up to 200 ft. below the river. The project includes a total of 267-cylinder piles, each supporting approximately 250 to 350 tons.

The "jewel" of the project, according to Kevin Zimont, a project executive with construction management firm Hunter Roberts Construction Group, is the 700-seat amphitheater. "Architectural concrete designed for a 100-year life cycle made it difficult to satisfy the architect's wishes," says D. Thomas Ruttura, Ruttura and Sons Const. Co., Inc.

Confluence

rzuellig — Fri, 01 Jan 2021 19:24:00 GMT

2021 DCC Award Winner
Confluence, Coloscapes Concrete

First Place: Vertical Facades, Over 5,000 SF

The basis for the design consisted of cast-in-place, two-sided board form walls with integrated two inch rigid insulation placed in the center of the walls. The height of the walls ranges from four feet tall to twenty-six feet tall and encompasses most of the building footprint, and extending to the second floor in some areas. The material used for the form liner was lx4 cedar planks, randomly spaced.

Final design of the walls included several material types which added to the installation complexities. The walls had several design arrangements that included straight walls from footings, walls with integrated roof areas (placed monolithically with walls), forming configurations which led to tricky material consolidation (large lateral notches), and twenty foot plus wall heights with varying top of wall elevations.

Design of the wall details in general was vague and left to the contractor to provide solutions. The integrated two-inch, rigid insulation centered in the wall was provided by Thermomass. All insulation was prefabricated to fit and shipped to the project for installation.

The project duration for the wall installation was essentially two distinct timelines of approximately six weeks each. Zero lot line boundaries led to limited staging and tight material handling. Confluence is located on a corner lot with high public visibility, and the final product influenced the streetscape design done under a separate contract and designed by another architect.

Harris Re-creation of the Church of San Salvador

rzuellig — Fri, 01 Jan 2021 19:22:00 GMT

2021 DCC Award Winner
Harris Re-creation of the Church of San Salvador, Bob Harris, Structural Services, Inc., and Lee Ann Harris, Decorative Concrete Institute

First Place: Stained & Dyes, Over 5,000 SF

This nearly 1600 SF project is located at the Decorative Concrete Institute facility in Temple, GA. The first step was to stamp a 6" slab with buff integral color using Roman Slate seamless texture. The design was based off a 200-year-old basilica floor in Venice, Italy and has six key elements: the inner medallion, along with different three-dimensional patterns. Once the design was laid out the entire pattern was cut free hand using a 4" angle grinder. Six colors of acid stains were used at varying degrees of dilution. Once the coloring was complete, the surface was cleaned and neutralized, and dry, multiple applications of siloxane modified methyl methacrylate clear sealer were applied.

6721 Columbia Gateway

rzuellig — Fri, 01 Jan 2021 19:19:00 GMT

2021 DCC Award Winner
6721 Columbia Gateway, Hyde Concrete

First Place: Polished Concrete & Overlays, Under 5,000 SF

6721 Columbia Gateway is a renovated, vibrant, multi-tenant office offering versatile social spaces. The 3,800 SF first floor features areas for conferencing, lounging, and gaming, and a community kitchen. The space required a durable, high-end finish to accommodate heavy foot traffic, without sacrificing design. The architects knew the existing concrete slab was not in the best condition, so they specified a polished concrete overlay. Hyde's scope of work included the first-floor main corridor, amenity space, lounge, and library.

The main challenges were installing the divider strip pattern and achieving the appropriate overlay aesthetics. The floor was divided down the middle in a flowing pattern with two finishes using PVC divider strips. The client wanted one overlay finish to look as though it had salt and pepper aggregate exposure, while the other needed a heavy aggregate exposure. This required sourcing a unique aggregate mixture with the correct stone size and color. The aggregate was incorporated into the overlay material to replicate the aesthetic of heavy aggregate exposure.

The second challenge was delaying the setting time of the concrete without compromising the water/cement ratio. To achieve this, citric acid was used to increase the initial fluidity of the concrete, giving finishers enough time to properly manipulate the concrete for consistent aggregate distribution. A steady hand and careful attention was necessary throughout the overlay finishing process.

Skyline Community College

rzuellig — Fri, 01 Jan 2021 19:13:00 GMT

2021 DCC Award Winner
Skyline Community College, Floor Seal Technology

First Place: Polished Concrete & Overlays, Over 5,000 SF

Skyline College wanted to create a state-of-the-art innovative science event center on a cliff overlooking the Pacific Ocean outside of San Francisco. DES Architects and XL Construction designed and constructed a 30,000 SF building which took almost two years to complete. DES designed a highly decorative overlay floor in their main conference area, atrium lobby and in the corridors utilizing a Tekflor System. The desired color was black. Floor Seal Technology began producing mockups utilizing 3/8" overlayment self-leveling topping coupled with colorful glass and mirror aggregates. After 15-20 samples, the chancellor chose a mockup with over 18,000 lbs. of red, gold, and black, different sized glass, and small chip mirror, broadcast with no separation. Sitting on a bed of radiant heat the 3/8" overlay aggregate installation took one day with over 15 installers and was finished with a Mirrorcrete polishing system, exposing an array of impressive color and shine surrounding "The Compass Rose' marble centerpiece. Prefabricated riser and poured-in place treads for the grand staircase required the same high level of detail.

Red-Tailed Hawk Inclusive Playground

rzuellig — Fri, 01 Jan 2021 19:10:00 GMT

2021 DCC Award Winner
Red-Tailed Hawk Inclusive Playground, Colorado Hardscapes

First Place: Multiple Applications, Under 5,000 SF

At the end of 2017, seven-year-old Ashaun made a wish for an all-inclusive park. Designed by Urban Play Studio, the 8,000 SF playground suits all kids, no matter their physical capabilities. Colorado Hardscapes' contribution to the site features a sensory wall composed of a tactile composition of shapes, textures, and colors, a wavy walk that undulates like a roller coaster, and swings, spinners, and slides of several sorts. Micro-Top XT was used to make the sensory wall pop with color, while an imprint texture mat added a high-touch surface to the rising wall. Con-Color stain was used to add swooshes of whimsical flair to flatwork surfaces. This project called upon Colorado Hardscapes' artistic capacities as there was only a sketch to start with. The team was able to be creative in conceptualizing the parts and pieces of this one-of-a-kind sensory wall.

SoFi Stadium

rzuellig — Fri, 01 Jan 2021 19:06:00 GMT

2021 DCC Award Winner
SoFi Stadium, Trademark Concrete Systems

First Place: Multiple Applications, Over 5,000 SF

The sheer size of this project is unique; nothing this large having ever been developed in the Los Angeles decorative concrete market. As with the over 720,000 SF of decorative paving, everything on this project was on a whole other scale. Trademark truly learned what they were capable of, stretching decorative concrete flatwork placements to 300 CY, a day, back-to-back, while maintaining consistent surface retarder finishes. The stadium roof structure anchors to the ground at three locations around the site, called abutments. At each abutment is a unique 14' wall with batters ranging from 11-39 degrees and consisting of a surface retarder finish. Most of the vertical elements did not have of a 90-degree vertical face; most walls utilized custom cut foam to achieve custom batters and radiuses. The 6" planter curbs transitioned using foam to an 18" tall battered seatwall while maintaining a surface retarder finish. Every vertical wall on the site had a surface retarder finish, meaning every wall had to be stripped and hand finished to achieve the design teams intent. Trademark detailers spent over 2,400 hours {300 Days) detailing every single site element to support the field with this project. All survey and layout was based off shop drawings. This project pushed our team to new heights and we all really enjoyed the challenge, this once in a lifetime project will be missed.

Brandon Beier Residence

rzuellig — Fri, 01 Jan 2021 19:02:00 GMT

2021 DCC Award Winner
Brandon Beier Residence, Knox Concrete, LLC

First Place: Decorative Resinous Coatings, Under 5,000 SF

This project included a SunMetal application to an approximately 2400 SF full basement and a three-bay garage slab-on-grade for a $2 M+ custom home. Knox Concrete shotblast, prepped and applied an MVB primer and a custom metallic "antiqued marble" design to fit the homeowner's Tuscan theme. Most difficult was coordination with other trades to not contaminate the area. The homeowner had interesting color suggestions, including a white base with off-white accents, silver veining and Himalayan salt pink for the light accents. Knox was worried about the pink, however it added a nice complimenting color. All in all a remarkably successful project with a very satisfied owner.

Happy Basset Barrel House

rzuellig — Fri, 01 Jan 2021 18:59:00 GMT

2021 DCC Award Winner
Happy Basset Barrel House, Lamberson Construction Concrete by Design

First Place: Countertops/Furniture/Firepits

Lamberson Construction created and executed this 63' long bar top for a local brewery to mimic hand carved rock with a "river'' down the middle. The countertop is all concrete and covered with an epoxy coating. A custom scratch coat mix was used for the base, and a Kirtbag carving mix for the outside texture coat. 128 lineal feet of multi-color fiber optic lighting was embedded into the "river". The river and bar top were filled with Simiron casting epoxy with Simiron polyaspartic sealer as a topcoat. Work was completed in a little over six days.

Kalkaska Trout Inlay

rzuellig — Fri, 01 Jan 2021 18:56:00 GMT

2021 DCC Award Winner
Kalkaska Trout Inlay, Fisher Companies

First Place: Concrete Artistry, Under 5,000 SF

Fischer Companies was presented a unique opportunity to work with Grand Travers Construction Co. to complete a decorative trout mosaic inlay for a newly constructed clock tower in the trout capital of Michigan.

During the initial meeting Grand Travers wanted to place the tile into the concrete on the day of the pour. After much thought Fisher suggested a plan to precast the six-foot by six-foot concrete tile two inches thick.

A Trinic GFRC mix was used to gain 10,000 PSI and pretensioned stainless steel cables were embedded for transportation and installation. Each tile was hand cut and placed on lexon plastic to achieve a smooth, uniform tile.

A mirrored template was adhered to the underside of the clear lexon to place each piece of tile in the proper location. Once the tiles were secured, the concrete was poured into the form.

Using the pretensioned cables, the tile was secured to the transportation skid and the concrete was sealed. The 6 foot by 6 foot piece was set in place using the embedded cables.

3rd Street Improvements, Phase 2

rzuellig — Fri, 01 Jan 2021 18:43:00 GMT

2021 DCC Award Winner
3rd Street Improvements, Phase 2, T.B. Penick & Sons, Inc.

First Place: Concrete Artistry, Over 5,000 SF

T.B. Penick & Sons had the pleasure of collaborating with Las Vegas Paving and Southwick Landscape Architects on this project to achieve the city's design-intent. The paving patterns colors, and materials were identified early on as a main design element. The street was being narrowed and the sidewalks widened to promote a more walkable space and enhance aesthetics. This portion of 3rd Street is adjacent to the Arts District, with a theater in the middle of the project, so color and pattern were encouraged on every element of design.

Penick achieved all the project's design elements including a green glass band that meanders throughout the project, fine mirror glass embedded on the surface, decorative saw cuts, stain superimposed on the surface to simulate a leopard pattern, and large bands of quarried stone finish.

Self's Reclaimed Basement

rzuellig — Fri, 01 Jan 2021 17:08:00 GMT

2021 DCC Award Winner
Self's Reclaimed Basement, Captivating Concrete

First Place: Cementitious Overlays, Under 5,000 SF

The client was struggling to find a contractor that could give her a basement floor that matched the rest of her house; most of which was reclaimed finishes. A giant ship's wheel is a chandelier and 100- year-old hardwood floors, hand hewn beams and galvanized metal create a look that only Father Time and Mother Nature could design. After discussion and several pictures the plan became a 3/8" overlay stamped in various sized reclaimed timber pattern. The overlay was poured using the control joints for start and stop points. Three days later coloring began and the result was exactly what the client wanted.

Zhuhai ChimeLong Hengqin Island Theater

rzuellig — Fri, 01 Jan 2021 17:05:00 GMT

2021 DCC Award Winner
Zhuhai ChimeLong Hengqin Island Theater, Beijing Orangestone Hardscape Co., Ltd.

First Place: Cementitious Overlays, Over 5,000 SF

With 8,000 seats, Zhuhai ChimeLong Hengqin Island Theater is the world's largest acrobatics and performance theater. The design concept follows the history of the ChimeLong Circus and creates their very own "Avenue of Stars". The floor is dotted with the logos of the International Circus Federation and the ChimeLong Group, and photos of classic horse dramas.

A contrasting selection of decorative concrete products and finishes were used in combination, including blue alloy aggregates, sand wash areas, five-pointed stars, concrete mosaics, as well as painted areas, etc. The supporting flower bases and stools were finished in complimenting patterns and finishes to further highlight the theme atmosphere.

The five-pointed star on the red ribbon in the Avenue of Stars is made of copper alloy aggregate which reflects sunlight with a high intensity and shine. The center of the five pointed star uses metal inlays to introduce the history of the five-generation innovative development of the circus.

National Harbor Showcase Intersection

rzuellig — Fri, 01 Jan 2021 16:55:00 GMT

2021 DCC Award Winner
National Harbor Showcase Intersection, Salzano Custom Concrete

First Place: Cast-in-Place Stamped, Under 5,000 SF

National Harbor is a waterfront resort facility in the Washington DC area situated at the foot of the Woodrow Wilson bridge on the Maryland side of the Potomac River.

Salzano Custom Concrete was brought in to work through details for a stamped concrete layout for one of the central intersections in the shopping and restaurant district, where two primary roads meet, both with many shops, restaurants, and office space. This area also overlooks the Capitol Wheel observation ride, and features life-like statues of service men and women from the five military branches.

The customer decided on medium gray color London cobblestone pattern as they felt it blended in nicely with the colors and textures in the surrounding spaces.

The new stamped concrete area is about 3,200 SF and included the main intersection as well as four crosswalks. The cobblestone pattern was used throughout, and turning the orientation of the stamp pattern in the walkways as an enhanced decorative element.

El Paso Zoo Chihuahuan Desert Exhibit

rzuellig — Fri, 01 Jan 2021 15:58:00 GMT

2021 DCC Award Winner
El Paso Zoo Chihuahuan Desert Exhibit, Bomanite Artistic Concrete

First Place: Cast-in-Place Stamped, Over 5,000 SF

The Chihuahuan Desert Exhibit at the El Paso Zoo showcases North America's most diverse desert that encompasses the El Paso and Northern Mexico regions. The exhibit tells the story of the Chihuahuan Desert; not only the land, but the peccaries, wild turkeys, jack rabbits; Mexican grey wolves, mountain lions, and jaguars; birds including sand hill cranes, and barn owls; reptiles such as the bolson tortoise and coach whip snake; and arachnids such as scorpions, tarantulas, and black widow spiders that live there.

With plans in place and everyone working towards the same design goals, Bomanite Artistic Concrete worked with PGAV Destinations and the zoo on the decorative concrete surfaces that consisted of three styles of implementation. To achieve the desert landscape with the natural ecosystem of plants and animals, natural stone patterns and aggregates were chosen.

As visitors enter the exhibit they come through a recreated arroyo. The Garden Stone pattern, with natural English slate texture, consists of varying sizes of stones ranging from½" x 1" to 15" x 21", providing a realistic approach to replicating the desert rock riverbed landscape from boulders to small pebbles. A total of 15,000 square feet of imprinted concrete was installed using sand integral color for the base and varying color hardeners of autumn brown and forrest brown. A clear sealer was applied for protection.

Walking paths invite visitors to pass beneath two abandoned bridges that allow jaguars to cross between the mountain and their exhibit spaces. The native desert trail of 850 SF is a natural exposed aggregate concrete finish that winds its way in and out of the area. The 6" random boardwalk pattern was used with autumn brown color hardener and walnut brown release agent. To give it a worn, aged look, accents in forest brown were added, then the 717 SF of textured and imprinted concrete was given a final seal.

St. Louis Aquarium at Union Station

rzuellig — Fri, 01 Jan 2021 15:54:00 GMT

2021 DCC Award Winner

St. Louis Aquarium at Union Station, Musselman & Hall
First Place: Cast-in-Place Special Finishes, Under 5,000 SF

St. Louis Union Station, an amazing collective adventure of a giant ferris wheel, fire and light shows, delicious dining, an old-time carousel, 18-hole mini golf, and a ropes course, recently opened a grand aquarium featuring one-of-a-kind exhibits and marine environments.

The building is 120,000-sq-ft, and two-stories built inside the footprint of a nearly 500,000-sq-ft, 19th century iron umbrella train shed designated a National Historic Landmark.

PGAV Destinations, known for their design work on 50 fantastical aquariums around the world, had been searching for the right finish for the "River Pavement" for the exterior plaza feature. After discovering their original design of epoxy terrazzo was not recommended for exterior use, the search ended when the designer attended a lunch and learn presented by our company. Pictures and samples were shared of the revealed decorative concrete system and the decision was made. Musselman & Hall's proposal to install an architectural concrete with varying exposure depths, using decorative aggregates with advanced application procedures to produce a finished product that showcases the seeded aggregate was selected.

Forms designed to emulate the confluence of the Mississippi and Missouri Rivers were set, followed by blackouts for the "railroad bridges" to be installed later with pavers. A plain concrete base slab held down ½" from the finish elevation was poured first. Once the base was placed, the Revealed was mixed on site, adding the selected blue integral concrete color, a combination of three different colors of blue glass aggregates and clear glass aggregate. This mixture was applied at a½" thickness directly over the primed base concrete for a monolithic bond. Engraving the river names completed the work.