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There
are several methods of applying and completing an acid stain project,
and this is by no means the only way to complete the task. This
is the method I prefer and use for most applications.
How
Acid Staining Concrete Works
Concrete
acid stain is water based liquid bearing minerals and acid. The
acid mixes with the cement to force a chemical reaction, which changes
the color of the cement similar to a forced rusting. When highlighted
with the proper sealer, this effect gives the natural rock glow
that attracts so many people to acid stained concrete.
Surface
Preparation
Surface
preparation is one of the most important steps of the acid staining
process. The concrete must be free of debris, dirt and oils. For
old concrete, or exposed concrete, be sure the surface of the concrete
is intact, and aggregate is not exposed. Acid stain will only work
on the cement portion of the concrete, and will not stain rocks
and sand. Concrete that has been acid etched or washed with muriatic
acid CANNOT be acid stained.
Often,
surfaces inside an existing house will have dry wall mud, paint,
wood stains, tile adhesives, carpet adhesives, grease, pet stains,
etc on the concrete. Acid stain is not an over coat, it is an opaque
re coloring of the concrete. These spots will show through if not
removed, especially mastic, dry wall mud and paint, as these get
into the pores of the concrete and block the staining process. There
are several products available at a local hardware store such as
adhesive removers and lacquer thinners that can be used to clear
these products from the surface. A fine sanding pad on a floor buffer
can even the surface and re open the pores of a distressed concrete
in this circumstance. These types of distressed floors will nearly
always yield a varied character of finish with a high degree of
color difference area to area across the surface, and the distressed
sections lend character and depth to your floor. Cleaning one of
these floors to a stainable level is a considerable amount of work,
but it is not impossible. If you desire a more even finish, you
should consider an overlay resurfacing, especially on a floor that
has had glued tile or glued plastic carpet.
Using
an organic degreaser (such as DCI Orange, Simple Green, etc) at
a medium concentration, scrub the surface thoroughly with a nylon
brush and rinse with clear water. For an interior project where
water run off is not available, you may use a shop vacuum and mops
or squeegees to contain the water and aid in drying. As a final
step, you may rinse the surface with water and ammonia to fully
neutralize the surface and insure a balanced ph for staining. Be
sure all soap and cleanser residue is removed from concrete before
staining and that the surface is adequately dried.

Applying
the Stain
The
appearance of the finished product is very much influenced by the
manner in which the acid stain is applied. The stain can be sprayed,
mopped, brushed, rubbed, etc. I prefer to spray the stain on using
an all plastic pump sprayer, and brush with an acid brush in even
circular strokes. When the residue dries, spray a second coat on
top of the residue to eliminate any brush strokes in the stain,
unless the strokes are desired in the finish. Brushed acid stain
applies darker and more evenly. For a more diffuse look, you may
wish to spray the stain onto the surface without brushing. Every
slab of concrete is different, and acid staining is an artistic
process, so when available, do small test patches on the surface
in corners or where furniture will be to find the look you like
the best.
Acid
stain can be cut with water to lower the ratio of minerals, thus
making the color lighter in shade. The best option is to test patch
the concrete using straight stain and stain cut two or three parts
water to one part stain. If the water content is too high, the acid
won't facilitate the chemical reaction required to make the color.
This can be corrected by raising the acid content or using stain
extender. Some colors vary more by adding water content and many
factors determine how dark the stain will take such as age of concrete,
cement content and weathering. This is another reason to do as many
pre stain tests as the job site will allow.
As
the acid stain dries and processes, a residue of alkali and minerals
will form on the surface of the concrete. This is natural and part
of the reaction. Different stains need different times to activate
and fully color the concrete, generally from one to eight hours.
Be sure and check your stains activation time before starting the
job to insure full coloring of the surface. If you are going for
the most color from a given stain, spray another coat of stain over
the dried residue. Do not walk on wet residue. When the residue
is wet, before it has been neutralized, the stain is active and
can retain impressions of your feet or other marks from your feet
or tools.

Removing
the Residue
When
the residue has dried and the stain has been given the proper time
to process, the residue should be neutralized and all acidic properties
removed. Properly removing the residue is important for obtaining
the best possible acid stain appearance. Here are the steps I've
found to be most effective in removing the residue and preparing
the floor for sealing.
1)
Prepare a base solution using either baking soda or sodium bicarbonate
at about half a cup of soda per gallon of water. Pour this on the
residue, scrubbing with a mop handled nylon scrub brush and shop
vacuum the residue while it is wet.

2)
Repeat the process, using straight water. After this step, all but
a light residue should have been removed. Let the floor dry and
some lighter coloring may still be visible indicating residue.
3)
Apply a clean, damp mop to the surface, wiping away any remaining
trace of residue. The floor should now be ready to seal.

Sealing
the Surface
"This
is for Direct Colors ac 1315 sealer"
After
the floor has dried from the residue removal, the acid stain must
be sealed with a proper decorative sealer. The sealer may be brushed,
sprayed or rolled on. I prefer spraying for most non textured applications,
but I've included three different methods here for the DCI 1315
sealer.
To
spray the sealer on, use a good all season deck sealant pump sprayer.
These usually come with three different nozzles. For spraying the
sealer straight, use a medium sized nozzle and thoroughly coat the
surface. DCI 1315 sealer dries very smooth and flat to the surface,
so the most important aspect is complete coverage. A thick coating
of sealer can sometimes take 48 hours to cure enough for foot traffic,
depending on humidity, etc. You can decrease the thickness of the
application and the drying time by adding no more than 25% xylene
to the sealer in the sprayer. This product can be obtained at most
paint stores in gallon cans.

To
brush the sealer on, use a good quality brush so the bristles do
not fall loose on the surface as you apply. This is recommended
for very rough surfaces or touch up work. In a sprayed or rolled
surface you can come across areas of a floor that are more porous
and absorb sealer, causing an uneven finish. You can touch these
areas up, feathering the brush strokes without brush marks, as the
sealer cures to the concrete.

Rolling
is a popular method for applying the sealer. Be sure to use a very
short napped roller with no texture, as the texture of the roller
can impress into the sealer. It is much harder to get an even, thick
coating of sealer with a roller and is the method most likely to
have unpredictable finish results. If applied carefully, this is
the easiest of the methods.

You
may also use an oil or water based wax applicator depending on the
type of sealer you are using for perhaps the smoothest, easiest
method of applying the finish. This is the method I most recommend
for home owners or DIY ers. Applying the sealer in two or three
even, thin coats with this method is very, very reliable for achieving
a high quality trouble free application.

To
maintain the gloss of the surface, a good mop on acrylic wax is
a good idea for any acrylic sealed surface, especially surfaces
with high stress from pets or children, etc. These products are
water based and even out the finish after a fresh seal or revitalize
the look of a scratched surface. They can also be buffed for a deeper
glow. This is, in my opinion, the best look for a medium gloss finished
floor, and the look you see most often in commercial applications.

Thank
you for your time and enjoy your new concrete!
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