MarbleCrete Mix, Inc. - Use Instructions/Recommendations

Application:

            There are several ways to expose the natural beauty of the MarbleCrete in your project: 

1. Grinding and Polishing with diamond wheels will give a smooth and glossy finish.  This is not recommended for exterior floor applications because of the potential of slippage and physical harm.
2. Surface Retardants are applied to forms or lightly sprayed on the surface to affect the curing capability of the cement, only on the surface.  The surface is then scrubbed with water and a firm bristled brush the day after pouring to reveal the beautiful marble.
3. Sand Blasting is done after the MarbleCrete has initially cured.

The above applications should be sealed with MarbleCrete Mix – Diamond Seal or Diamond Coat to optimize the natural beauty and alleviate staining, discoloration and oil penetration.  Sealers can not be used in areas being submerged in water (i.e., pools or water features). 
           
            MarbleCrete Mix achieves its high-strength because of several reasons.  None the least of which is the fact it’s naturally cementitious.  When mixed with water and cement the marble chemically reacts, binding itself and producing the strongest natural (no additives) concrete matrix.
           
            Because of the high-strength of MarbleCrete Mix, your project can be constructed and/or manufactured with less thickness and MarbleCrete material.  This will decrease the cost of production, labor required for installation and stress on supporting fixtures or foundations.

            Depending on the application, we recommend using reinforcement (rebar, wire mesh).  Because of the high-strength, in most applications there’s no need for additional strength additives.

            MarbleCrete Mix achieves an overnight (24 hour) 2,500+ psi compressive strength.  MarbleCrete Mix is regularly poured in the afternoon and de-moulded the following morning.  This allows for early de-moulding and increased production capabilities.  

Each Unit consists of multiple Parts: 

            A – Water:  2 to 3 quarts per Unit (Not Supplied)
            B – High Strength Sand/Aggregate Mix
            C – Premium White Cement
            D – Specialty Fleck(s) (Optional)
            E – Pigment(s) (Optional)

Mixing:

            Start with the minimum specified amount of Part A (water), then add/mix-in the full amount of Parts B (mix) and C (cement).  Part D (fleck) can be added accordingly to achieve desired aesthetic results.  Thoroughly mix by hand in a wheel barrow, or the equivalent of 280 revolutions with a concrete mixer.  Add and maintain the minimum amount of water needed for your particular use.  Determining factors include desired slump, cream and finish, type of application and climate/temperature/weather conditions.  Increased water can produce decreased strength, improper curing, shrinkage, voids, cracking and material segregation.

Note:  Contact MarbleCrete Mix, Inc. for proper methods when using these products in excessive hot or cold conditions, or for exterior applications in areas where freezing conditions occur.    

Follow individual instructions when adding pigments.  Each pigment type requires different use and preparation.  For instance some dry pigments require mixing with water prior to adding to the concrete mix.  Liquid pigments can be added directly to the mixing concrete.

Pouring:

            Use MarbleCrete Mix in the same manor as common concrete. Vibrate the freshly poured material to consolidate the MarbleCrete and eliminate trapped air voids.

Note:  Although you may not see voids on the surface, they may be visible after grinding, without proper vibration or screed/finishing of the surface/project.  

             Because this material is naturally cementitious its chemical reaction is faster and hotter than common concrete.  Keep this in mind and pour/finish accordingly.  Increased temperatures or direct sunlight will only speed up the chemical reaction. 

We recommended that projects be covered with poly type tarps to retain moisture while curing.  This will maintain uniformity and decrease the possibility of internal stress, surface cracking and warping.

Curing/De-moulding:

            As previously stated MarbleCrete Mix achieves high-strength overnight and can regularly be de-moulded the following morning after being poured.  Temperature can affect cure time, proceed accordingly.

Grinding/Polishing:

            We recommend allowing your project to cure 2 days before grinding/polishing.  The amount of exposure of the larger material will be determined by the depth of your grinding.  A solid ‘Cup’ type diamond wheel is best suited for aggressive initial grinding.  Continue with a pad type polishing wheel, or start with a pad when a shallow grind is desired.  It’s best to start with 50 grit and continue successively finer to achieve your desired finish.  Pads are available from 50 to 10,000 grit.  Polishing compound can achieve an even finer finish. 

Note:  When using MarbleCrete Mix – Diamond Seal or Diamond Coat it’s not necessary to polish beyond 300 to 500 grit.   

Sealing/Finish:

            To achieve and maintain optimum appearance, quality and value, your MarbleCrete Mix project should be properly sealed.  MarbleCrete Mix offers the finest quality sealers and associated products available:

MarbleCrete Mix – Diamond Seal
MarbleCrete Mix – Diamond Coat
MarbleCrete Mix – Stripper
MarbleCrete Mix – Clean’Brite
MarbleCrete Mix – Reducer

Please Refer to:  Sealers and Applicators - Surface Preparation & Reducers

Thin-set Overlay System 

Preparation:

• Proper preparation is extremely important to alleviate possible delamination and cracking.
• Any oil or contamination of the existing surface will require proper remediation prior to the Overlay application.
• A smooth or machine trouled surface will require grinding or shot-blasting to rough-up the surface, to achieve proper adhesion.
• The concrete surface should be cleaned with a high-pressure washer.  The surface should be scrubbed with a course bristled shop-type broom and Muriatic Acid.  The acid should be neutralized with vinegar and the surface re-washed with the high-pressure washer.  Vacuum the excess solution and dispose of properly.
• Active cracks in the substrate will produce cracks in the overlay.  Proper crack repair and an epoxy coat with sand applied to the surface during the epoxy application (for Overlay adhesion) will decrease the possibility of minor cracks surfacing through the overlay.  Existing control joints should be marked and re-cut within 24 hours after applying the overlay. 

* Note:  An epoxy coat will seal the surface and could create moisture and/or vapor - pressure issues. 

Application:

Best result can be achieved with a consistent, warm temperature (though not excessive).  Direct sunlight is not recommended before, during, or for at least 12 hours after Overlay application.
*Note:  It may be necessary to prepare the surface and apply the Overlay in the late afternoon or evening.

1. Thoroughly soak the concrete surface to be applied with water (preferably for several hours prior to application).
2. After proper surface preparation, mix MarbleCrete Mix – Bonding Agent to a ‘Pancake Batter’ consistency.  Apply to a wet surface, though with NO standing water.  Squeegee the Bonding Agent uniformly and apply Overlay immediately thereafter.
3. Mix MarbleCrete Mix – Thin-set Overlay material with water (4-5 Quarts per Unit).  Start with the minimum and add to desired consistency.  (Less water equates to more strength)
4. Apply to the desired thickness (1/4" interior, 3/8" exterior) using a ‘Gauge Rake’.  Troul and/or Float the Overlay material while applying, to achieve properl consolidation.  The more uniform the surface - the easier the grinding/polishing.
   *Note:  Proper consolidation is necessary to alleviate ‘bug holes’ and voids from being exposed when polishing or exposing the surface. 
   

Curing

Cement will continue to cure forever.  Moisture is what causes the cement to react.  The most critical time for cementitious overlays is the first 12 hours.  The overlay should not be allowed to dry out.  Misting with water may be necessary.  Carefully covering with a sheet of plastic, or burlap which is kept moist may be necessary.
*Note:  Pre-existing control joints should be marked and re-cut within 24 hours after applying the overlay.  

Interior – Polished

      Allow a minimum of 48-72 hours cure time before grinding and polishing.  Warmer temperatures will cause the cement to react faster and decrease the required cure time.  Start with the least aggressive diamond grit as possible.  The less cure time, the finer the starting grit (48 hours – 60-80 grit).  Check for possible ‘Pulling’ of the course aggregate.  If Pulling occurs, change to a finer grit.  Continue polishing in increments up-to 400 grit.  Apply the densifier and continue working into the surface for 45 minutes with a shop-type broom.  Continue polishing with 400 grit.  A greater luster can be achieved by finer grit polishing pads.  Depending on the application, we recommend polishing to a high-luster with 3,000 grit.         

Exterior – Exposed

1. Allow the overlay to dry until the surface water has disappeared (approximately 1 hour after finishing).  Apply the surface retardant in a mist.  Cover the entire surface with a sheet of plastic, letting the plastic lay directly against the surface.
2. Allow the surface retardant to work for 6-8 hours (depending on temperature).  Remove the plastic and wash the surface with water or high pressure washer, and a course bristle brush or broom.  Wash and remove the excess material.  Dispose of excess material properly.
3. Allow to cure as previously referenced in the curing instructions.
4. Seal the surface with a clear high-quality, UV resistant sealer, such as MarbleCrete Mix – Diamond Seal to avoid staining and discoloration.  
   

In the event you have any questions, please don’t hesitate to contact us.

Educational Courses:

The above is a brief summary for an exacting science.  MarbleCrete Mix, Inc. is pleased to announce the availability of hands-on Educational Courses provided by Instructors with the experience and passion for the industry to jump-start you into a successful and highly profitable business venture.

Craftsmen and contractors in the Specialty Concrete industries are more in demand than ever before.  MarbleCrete Mix products and systems provide the highest value and profit margins in the industry. 

MarbleCrete Mix Certified Contractors have the advantage of:
     -Marketing and geographical project referrals
     -Product Discounts
     -Continual Technical Support and Instruction
     -Proprietary MarbleCrete Mix information and Specialty Products     

Take advantage of these AWESOME opportunities!

Certification Courses offered for instruction of:

MarbleCrete Mix Countertops (Precast – Cast in Place)
MarbleCrete Mix Floor Overlay Systems (Exterior and Polished)
MarbleCrete Mix Vertical Surfacing Systems
MarbleCrete Mix Pool Surfacing Systems 

Classes are forming!  Contact us for more information, dates and Course locations.