Instructions / Assembly

INSTRUCTIONS Paper Stencils
IS32241 11/16
4430 Gibsonia Rd. • Gibsonia, PA 15044 • USA • 800-444-7060 • www.bonway.com
APPLICATION:
Stenciled concrete offers a selection of patterns and finishing techniques
to create the appearance of natural brick or stone in newly poured
concrete or concrete overlays. Use BonWay™ True Color Hardener and
Release Agent to achieve the desired color. Texture rollers or concrete
brooms
may be used to add realistic texture.
NOTE: Paper Stencils should be applied with the shiny
side facing up and the matte side on the concrete.
LAY-OUT AND DESIGN:
Consider the stencil pattern to be used when you are preparing the job.
For rectangular or square patterns, such as Running Bond Brick, make
sure the form work is square. If forms are not perfectly square, partial
bricks or stones at the sides and ends of the pour will not be evenly sized.
Expansion joints should be placed with consideration of the pattern, so
that joints will occur on a mortar joint rather than cut through the center of
a brick or stone. If there is only one expansion joint, it should be placed
halfway between the two sides, measuring to make sure that it is parallel
to the sides.
CONCRETE MIX DESIGN AND PLACEMENT:
Concrete slurry should have a slump of 4 to 5 inches, contain no calcium
chloride and no more than 6% entrained air. It is preferable to keep
entrained air below 3%. All fine and coarse aggregates must be totally
non-reactive (free of deleterious particles.)
Stencils can also be used with BonWay™ resurfacing overlayment.
Place concrete, screed and float in a normal fashion. If you are going to
apply Bon True Color, use only a wood or magnesium float at this point
so that the surface will remain open to receive the color broadcast.
PLACING AND EMBEDDING STENCILS:
Cut stencils into lengths approximately two feet longer than the formwork
(end to end) of the slab. Strike a center line for reference, equi-distance
from the ends and sides . While the concrete is still wet (surface should
have a moist sheen), begin laying the lengths of stencils on the surface
starting at one of the expansion joints or at either side.
Do this by having two people hold the stencil by the leading edges about
12 to 18 inches above the surface, while slowly letting the trailing ends
lower
onto the concrete. The long mortar joint at the trailing edge of the
stencil should lie in the expansion joint or the form at the side if there is
no expansion joint. The short mortar joints (those running perpendicular
to the stencil pattern) should lie on the center line. If the trailing mortar
joint does not land properly, pick up the stencil and repeat this step. Do
not attempt the pull the stencil sideways to line it up with the center line or
expansion joint as this will create wrinkles and distortion. Once the
trailing edge of the stencil is properly placed, gently lower the leading
edge
onto the concrete, making sure that the short mortar joints land on
the center line. Repeat these steps working outward to the sides and
overlapping the mortar joint on the leading edge of the previous section
of stencil. To tack down or embed the stencil into the concrete, use a
BonWay™ stencil embedding roller (#22-151) or trowel over the stencil
with a bull float or hand trowel. Do not embed the stencil too deeply or
there will be cracking of the edges of the “stones or bricks” upon
removal.
COLORING THE CONCRETE:
When the stencils have been placed, embedded and all the bleed water is
dispersed, the first application of BonWay™ True Color Hardener can be
broadcast onto the slab surface. Apply the color hardener according to
the directions on the pail. For more contrast in color, you can also use an
application of BonWay True Color Release Agent. For all applications
options see BonWay Color Chart. The grout lines created by stencils will
remain uncolored. For a more realistic appearance, use a texture roller
over the surface.
Five easy steps to
change ordinary
concrete into
something
“extraordinary”
1. Place stencils
2. Embed stencil with roller
3. Add True Color
™
Hardener and float
concrete
4. Add True Color
™
Release and texture
with roller
5. Remove stencils and seal
STENCIL REMOVAL:
Remove the stencils when the concrete has stiffened sufficiently to allow clean
edges
on the bricks or stones. You can test this by lifting out a small portion of
stencil along the end. In general, the stencils should be removed when
pressing your finger on the surface no longer leaves an impression. Blow off
loose particles and chips with a mechanical blower. Finish the surface by
spraying on a light coat of BonWay™ Boss Gloss or Boss Matte Clear
Enhancer. Dismantle forms.
FINISHING EDGES:
If the edges of the slab will be exposed after landscaping, you can finish the
edges as follows: Brush on a thick viscous mixture of BonWay™ True Color
Hardener and water; using a BonWay™ touch up tool or detail chisel, mark
the edge where the mortar joints should be located. Do this within 24 hours of
the pour.
NOTE: These are very general instructions for a simple rectangular slab.
For more detailed instructions on particular situations, please call our technical staff
or visit our knowledge center at www.bonway.com