Stencilpave is our trademarked system for the horizontal installation of stencilled concrete and can be installed with freshly laid concrete; ’Wet Cast’ System or applied to a suitable existing concrete base; ’Spray On’ System.
The area to be constructed is excavated to a depth of 200 millimetres. A 100mm layer of stone is installed and compacted to provide a suitable base for the concrete. Ready mixed concrete is then poured on the stone sub base and levelled to the required surface profile.
2) The chosen stencil pattern is laid on top of the freshly installed concrete surface; beginning with the header (border) patterns and feature designs, followed by the main area pattern. It is important to carefully match up the stencil patterns when laying the stencil to ensure a uniform pattern throughout the entire area.
3) When the stencils have been placed onto the concrete, they are gently rolled further into the concrete surface using a roller. This ensures the stencil is secure and when the stencil is later peeled away, it reveals a clean and well-defined joint.
4) Colour Surface Hardeners (in powder form) are then cast over the wet concrete surface. The colour surface hardeners are then floated into the surface of the concrete. The floating action (trowelling) helps the colour surface hardener penetrate and colour the concrete surface. A second coat of surface hardener is then applied to the concrete surface in the same way.
5) As the concrete cures, various surface finishes can be applied to the surface; ranging from textured to smooth. The textured finish has excellent anti-slip characteristics while smooth finishes are easily cleaned and give an engineering brick look, although provides less of an anti-slip surface.
6) When the surface of the concrete is beginning to cure, the stencil is peeled off revealing the chosen pattern/s.
7) Once the stencil has been lifted, the surface is cleaned to remove any excess colour surface hardener that is left as a result of the peeling operation. When the surface is cured and dry, a microporous concrete sealer is sprayed evenly over the area. This sealer protects the finished StencilPave surface from diesel, petrol and oil spillages and help prevent colour fade; tests reveal only a 5% fade occurred over a ten-year period.
The ’Spray On’ System is used when StencilPave is applied to an existing suitable concrete surface.
Before Application
After Application
1) Original Existing Concrete Surface
The surface is washed, acid cleaned and thoroughly dried to ensure that all dirt and detritus materials are removed.
2) After the area is prepared, a base coat is applied to the surface. The base coat provides a uniform colour for the area and will ensure that the finished ‘grout lines’ will be the same colour.
3) When the base coat is dry, the stencil patterns can be laid, beginning with the header (border) patterns and feature patterns.
4) The main area stencil patterns can then be laid. It is important to carefully match the pattern to ensure a uniform pattern throughout the whole area. It is also important to ensure that the stencil patterns are secure on the surface to achieve a clean and even pattern.
5) When the stencil is secure, the colour surface hardener mix can be evenly sprayed onto the surface. Once the first coat is completely set, a second coat is applied.
6) After the required time (different on each job, depending on weather conditions and temperature) the stencil can be lifted off, starting with the area that was first sprayed.
7) The surface is cleaned and the area is then sealed using a microporous concrete sealer. The sealer protects the surface against diesel and petrol spillages and contains a UV filter that prevents the surface colour from fading.
8) After the first layer has dried, then another coat of the sealer is applied to the surface to further protect the StencilPave surface.
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