How Stencils Work
Three years ago, my dearest friend decided to stencil the floor of her sunroom instead of laying ceramic tiles and asked if I would help her in this project.
Stencils can be any number of commercially produced patterns, as well as custom made stencils which incorporate corner accents, company logos, or family crests, monograms and literally anything the individual wants. However, before you begin, there are several facts you need to know about stenciling. First, stencils can be used on both new concrete and existing concrete. Second, stenciling uses what is known as a blocking technique, allowing for a one-step application of various colors to borders and fields. Third, a very high quality paper stencil is just as suitable for creating decorative effects on concrete as a plastic stencil and lastly, the appropriate applications includes cast-in-place, overlayment, sandblasting, and vertical applications.
When stenciling a new concrete pour, you must take precaution to ensure the stencil is not initially applied too deeply. Another critical issue is the appropriate time to remove the stencil. Removing it too soon when the material is still sticky can result in it not coming out clean and possible breakage of stones whereas, removing it too late can result in a difficult removal.
The following steps should be followed when using stencils on existing concrete:
1.To avoid getting spray on surrounding surfaces, securely tape these areas. 2.Lay out the stencils on concrete. 3.Carefully spray a thin layer of the decorative color coating. 4.After the first coating has dried, or according to the manufacture’s instructions, apply the desired finish to the decorative coating. 5.Carefully remove stencils. 6.Apply sealer
Templates:
For custom templates, the price will vary depending on their design, size and if they are paper or vinyl. Vinyl templates are often a one-time use, whereas paper templates can often be used more than once depending on the pattern and type of sandblasting material and air pressure, which is used in the process.
Templates can be used in either one or two methods. The first method the templates are applied and sandblasted after the floor has been stained and sealed. After the template has been sandblasted and removed, then the design can be left either natural or stained. If the design is to be stained then the floor must be cleaned again.
After the concrete floor has been stained and prior to any sealant being applied, vinyl templates can be are applied to the floor. Then using a gel acid the stain is removed. If the design area is to be stained in another color, then the vinyl templates remains in place as the stain is applied.
Stencil Concrete:
When stenciling concrete, all forms must be set square in order to keep the patterns aligned. After the concrete is poured, its surface is bull floated then edged. The next step is to place stencil borders and adhered them to the surface. The field pattern is then arranged and then placed on the surface. To save time, precut all stencils prior to pouring the concrete. To adhere the stencil to the concrete you can use a speed trowel, stencil roller, or Fresno.
Next, following the manufacture’s instructions, dry shake color hardener over the slab. Generally, it will be necessary to apply two applications to achieve color. It is necessary to use the manufacture’s recommended amount of color in order to achieve proper surface abrasion, and wear resistance as well as the desire color. Using a bull float, float the color into the slab with a trowel.
After the color has been floated into the concrete, the following step is to apply the release agent over the surface. Again, it is vital to follow the manufacturer’s instructions. As soon as the concrete loses its ability to adhere to the stencil, the concrete will simply flake from the stencil when it was lifted. Next, remove the remaining chips by rinsing the slab with water. Muriatic acid is then used to remove the release agent, once this has been accomplished the concrete slab then most be allowed to dry completely before applying at least two coats of sealant.
The only required maintenance is to clean and reseal the surface approximately every 2 to 3 years depending on how heavy the traffic.
How to apply stencils to existing concrete:
Applying stencils to existing concrete can be accomplished in several means, troweled down, spray down, and adhesive stencil. We will take a brief look at each of these methods.
Troweled Down Application:
Once the surface preparation has been completed, a base coat is then troweled or squeegee onto the surface of the concrete, the length and width of the stencil. The stencil will then adhered to the base coat. Repeat this step until the entire stencil has been laid. Once the entire stencil is in place, then a thin topcoat of approximately 1/8? can then be troweled over the stencil.
When applying the release agent there are two very important facts you must keep in mind. First, you cannot get any of the release agent on the base coat, and second you have to keep in pace with the individual troweling on the topcoat be able to texture the material this is due to the quick set time of the top coat.
Carefully remove the stencils, and apply the sealant according to the overlay manufacturer’s instructions.
Spray Application:
With this method, the entire base coast is applied to the surface and allowed to dry completely once the surface preparations have been completed. The stencil is laid with the memory side down, so that the stencil does not roll up. Once you have the first piece of stencil in place on the surface, you can use tape to hold the stencils together. If you need to weight down the stencils further, a thin base coat can be sprayed on these areas. Repeat this process until the entire stencil has been laid down on the surface. Spray the topcoat over the stencil. Once the overlay can chip free from the stencil, remove all of the stencils. The next step is to clean away all the overlay chips, this can to done with the use of a leaf blower. After all the chips have been removed, the overlay can be sealed. Ensure that you follow the manufacture’s instructions for the overlay on how to apply the sealant.
Adhesive Stencil Application:
Properly prepare the concrete surface, then apply the entire base coat and allowed it to dry. Carefully place the adhesive stencils onto the surface. Once all the stencils have been applied to the entire slab, apply the topcoat. Remove the stencils as soon as possible. If you leave them in place too long then they will be difficult to remove. Clean away, all of the overlay chips, and then seal the concrete by following the overlay’s manufacture’s instructions.
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