Sax Point Terrazzo Floor
With abalone, recycled glass, and limestone aggregates.
This West Coast contemporary home showcases charcoal polished concrete floors. Only resin diamonds were utilized for a “cream polish”, as the homeowner wanted the floor to be as dark and rich as possible. It was poured on a plywood t&g base at 2″ thick and had minimal cracking. The slab was placed with integral charcoal pigment and power troweled incredibly smooth. By starting with the right diamonds, the patina and colour was retained, and small imperfections removed.
Conventional underfloor heating systems use either electrical resistance elements (electric systems) or liquid flowing in pipes (hydronic systems) to heat the floor. Both types can be installed as primary heating systems or as localized floor heating for thermal comfort. Polished concrete can be integrated with both hydronic and electric heating systems.
With over 20 years experience with SD Concrete as both a designer and floor installer, I have been involved in over 300 residential concrete floor installations. I have seen many installation methods, some with better results than others.
Hydronic systems and the complex heating systems that work with them are usually installed in new construction. They are generally not a good choice for renovations.
Renovations of kitchens and bathrooms are usually to refresh and renew, they do not typically include heating system overhauls. This is why electric heating systems have been so popular with renovation contractors and home owners in the past ten years.
There is a big difference in overall floor thickness with each system. Typically hydronic systems utilize conventional concrete at an average thickness of 1.5” – 6” whereas electric systems use self levelling concrete mixes, and have a total thickness (including heating) of 3/4” – 1”.
There is no ‘one fits all’ solution. When choosing heated concrete flooring systems, one needs to consider: insulation and performance, energy efficiency, weight of materials, and overall costs of both the floor finish and heating system.
Hydronic heating is ideal for homeowners that do not like forced air heating, and want to keep their home at a consistent, comfortable temperature. Hydronic systems can use a single source or combination of energy sources to help manage energy costs. Heat pumps or solar panels can be integrated into these systems to help save energy costs. Excluding the cost of the concrete (which is a necessity of the in-floor heating system), polished concrete typically ranges from $5 – $10 per sq/ft.
Conventional concrete is typically poured at a 4″-6” thickness for hydronic applications. The concrete can be poured as a monolithic pour, or done as two separate slabs, one to encapsulate the heating system, the other as the finished flooring. Both methods have their advantages and disadvantages, consideration to construction process and schedule will likely determine the best process for your project.
White or grey portland concrete can be utilized for the cement base color. White portland cement only comes in bags in the pacific northwest, and can double or triple the cost of the finished product. Titanium Dioxide can also be used to lighten the color of the concrete, it too is quite costly. Integrally coloring concrete to a darker or warm shade is quite simple, Davis Colors , or Interstar, both have great color charts and cost effective products.
Freshly placed concrete can be seeded with glass, stones, steel fillings or pretty much any hard material. They seeded materials are then floated into the surface and revealed through the grinding and polishing process.
Topical coloring can be done after the slab has cured and during the polishing process. These dyes penetrate into the concrete pores and are further protected with densifiers. This is not a process that wears off with time.
If you want to heat a small zoned space like a single bedroom or bathroom, electric in-floor heating can be a great choice. These heated floors are powered by electric cables or mattes of electrically conductive plastic built in to the floor. Electric mattes or cables integrate well with homes that use forced air heating. When going over top of plywood sub floors, membranes are essential to control cracking in the polished concrete overlay.
There is very little information available related to concrete overlays and electric heating systems. Search terms such as: heated concrete overlays, self levelling heated floors, embedding electric heating in polished concrete overlays, and thin heated concrete floors yield pretty much useless information to date (currently Feb 2017).
Calls to the large manufacturers: Mapei, Rapid Set, and Ardex didn’t produce any useful information. Using self levelling concrete to cover heating cables is far from a new concept, using it as a finished polished concrete floor with electric matt systems is where there is a lack of information. To date, Stone Design has completed 8 projects of various types and sizes that integrate electric heating systems and polished concrete overlays. These have been some of our most stunning and near perfect floors to date.
Heated polished concrete floors tend to fit aesthetically with most natural materials. The base ingredients (cement, sand, and aggregate), are found in nature and do well surrounded by similar materials. This means that modern homes, and their simplistic minimalist design are often complimented by polished concrete. Most engineered self- levelling concrete products contain very little aggregate, so grinding further into the slab does not mean larger aggregate. Polished self-levelling floors are usually more consistent and uniform when compared to conventional concrete. A cream finish aesthetic, without the busy look of sand and aggregate is much easier to achieve with self levelling products. Many customers ask about white or cream colored floors, achieving these aesthetics are completely possible with concrete overlays.
Stone Design was given totally artistic freedom on this dallas road reno. The client wanted a modern and bright space that would showcase their art collection. Stone design proposed an idea that utilized two different base colours of self leveling concrete and a theoretical process of placing the concrete. The cream and white self leveling materials were batched separately, and placed on the floor strategically to create a marble aesthetic. Once the self leveling overlay was cured, the floor was polished to 800 grit and sealed. The results are a seamless creamy white polished concrete floor that looks like one solid piece of marble from a quarry on Vancouver Island.
A couple pictures of a gorgeous project we finished a year ago. Clients are all moved in now and provided these pictures.
The Uplands Walk Supportive Housing project is a 33 unit 25,000 square foot LEED Gold building designed by Chow Low Hammond Architects Inc. This complex will provide supportive housing to the homeless or those at risk of homelessness and is scheduled for completion fall 2014. Stone Design seeded 3 floors with amber and clear glass, it was ground to a terrazzo when cured and polished to 800 grit.
Windley Construction from Nanaimo, BC is the general contractor. Stone Design is excited to forge this new relationship.