DCC Project Awards 2013

Polished Concrete Over 5,000 SF first place, T.B. Penick & Sons, San Diego, for The Coronado Naval Base. This Hall is part of the Navy’s Homeport Ashore Initiative to improve the quality of life for single sailors. The initial grind to this 25,250 SF area was done wet seven days after the floors were poured. The floors were given a final polish after the walls were placed and painted. Floors were given an exposed aggregate appearance in the community rooms. Judges said this project was the hands-down winner – “About as good as it gets!”

Polished Concrete Over 5,000 SF Second place goes to Creative Construction by Design / Surface Tech, Danville, Illinois, for the lower level of the Blue Line Apartments. This building was originally a trolley barn, built in 1927. The floors had been polished by another contractor who did a poor job and left lots of scratches. The scratches necessitated stepping down to 30 grit metal bonded diamonds and regrinding the entire floor before re-dyeing and repolishing. A shadow edge on the drywall and no base trim caused the edging to be a difficult and infinite task according to the contractor.

Cast-in-Place, Special Finishes. For projects Under 5,000 SF, first place goes to Tom Ralston Concrete, Santa Cruz, California, for Pleasure Point Geo Strata Terraces, also in Santa Cruz. In 2008 when the California Coastal Commission approved the beautification of Pleasure Point Park, they enlisted Tom Ralston Concrete as a consultant. Three years later, when Ralston was awarded the contract, his challenge was in forming vertical surfaces to hold numerous embeds, and, that would strip easily; working during the rainy season; and figuring out how to install a flat whale bone into a tightly curved vertical surface. Judges noted all of the elements encountered by the contractor and the casting of a whale bone into wet concrete.

Cast-in-Place, Special Finishes. For projects Under 5,000 SF Second place went to New England Hardscapes, Acton, Massachusetts, for a patio and kitchen countertop at the Olinger Residence in Portsmouth, Rhode Island. The design called for bluestone and flagstone, which was over the owner’s budget. Despite the architect’s skepticism, the contractor convinced the owner they could duplicate the look in concrete. Challenges included site access and pouring a monolithic slab for areas with two completely different looks. Judges felt the project was executed beautifully.

Cast-in-Place, Special Finishes Over 5,000 SF, there was a tie for first place. This winners is Belarde Company, Woodinville, Washington, for East Bay Public Plaza in Olympia, Washington, which features a plaza-length, interactive stream that utilizes reclaimed water for public interaction and pavement designs replicating Pacific Northwest shorelines. A cutback stream encompassing a sandy beach with tons of locally harvested rocks and pebbles, a wall with seeps and numerous embeds and imprints, and a beach made to represent coarse to fine sands, blend together to form one harmonious environment. The wall is accented with seeps which highlight strategically-placed rocks, bronze wildlife, bird and leaf imprints. Each waterline includes a phrase surrounded by thousands of hand cut and placed glass tiles, glued to a mesh backing and placed by the contractor.

The East Bay Public Plaza by Belarde Company, Woodinville, Washington, also won second place in the Mulitple Applications over 5000 sf category. Three concrete hardscapes are incorporated into this project: a sedimentary cutbank wall and stream, mosaic waterlines and waved gradation paving. Three different integral colors were layered in the wall which required switching trucks during each layered pour.

Cast-in-Place, Special Finishes Over 5000 SF, there was a tie for first place. The second winning project, by T. B. Penick & Sons, San Diego, was Myriad Gardens in downtown Oklahoma City, which received a facelift and added multiple new features. Materials used included local aggregates, white cement, black granite, carbide, and various shades of glass. The local red sand was problematic with the white color selected for most of the flatwork. Other challenges included a winter work schedule and over 200 intrusions in the new glass splashpad. Installed over water-proofing, each flower panel was poured separately. The judges were equally impressed with both winning projects in this category and decided to call it a tie.

Cast-in-Place Stamped. For projects under 5,000 SF, first and second place went to the same company, Salzano Custom Concrete, Centreville, Virginia. First place goes to the backyard living space at the Manassas Residence. The patio features a 13-foot inset “lower tier” area that serves as an eating area. A sitting wall lines a majority of the perimeter of the space. The main challenge was to create the owner’s vision of a dream backyard.

Cast-in-Place Stamped. For projects under 5,000 SF Second place goes to the Centreville residence where Salzano installed a 2700 SF multi-level patio that integrates an over-sized hot tub, an outdoor kitchen and a firepit with sitting wall. The stamp pattern is a natural Pennsylvania bluestone “cut slate” pattern with natural tan grout and mutli-color accent shading.

For Cast-in-Place Stamped projects Over 5,000 SF, first place was awarded to Edwards Concrete Company, Winter Garden, Florida, for the Phillips Toyota exterior paving in Leesburg, Florida. The owner was extremely pleased with the results of the charcoal gray, octagon-shaped pattern selected for their sidewalks and driveways. The judges commented that the project was executed beautifully.

Thin overlays under 5000 SF, first place Salzano Custom Concrete for the pool deck at The Haverhill Apartments, Manassas Park, Virginia. Two layers of cementitious overlay were applied to the existing concrete deck. The stone pattern was created by applying stenciling tape one piece at a time, to achieve the most natural look possible. Judges commented on the fact that the color was applied by individually hand rubbing each stone.

For Countertops first place went to Hyde Concrete, Annapolis, Maryland, for the Schutt Residence in Alexandria, Virginia. This project included concept development, design, fabrication, and installation of a complete outdoor kitchen. The cabinets were fabricated out of decorative Glass Fiber Reinforced Concrete panels with a custom finish, giving the appearance of large slabs of stone. Pre-fabbed concrete countertops top the cabinets. Pre-fabrication reduced installation time and the weight of the pieces was significantly less.

Second place for countertops went to Brooks Construction Services, Sioux Falls, South Dakota, for a project entitled “Dining With the Stars”, also in Sioux Falls. This outdoor living area sports Brooks’ glow-in-the-dark Casper stone, which soaks up light during the day and shines for over 12 hours at night. The countertop consists of two levels and incorporates stainless steel joints and carbon fiber mesh. The concrete was polished from 50 to 500 grit to expose the Casper stone.

For Multiple Applications, projects under 5,000 SF, first place went to Cornerstone Decorative Concrete, Fennville, Michigan, for the Hudsonville Winery / Pike 51 Brewery in Hudsonville, Michigan. After conversation with Cornerstone, the owner essentially gave them free rein on project design. Three concrete slabs with vastly different ages were addressed with a micro-topping consisting of multiple layers, integrally dyed. Hand-carved rocks, a hand-carved logo, a custom design for the wall behind the bar, and a bartop with turned-down edge were all completed within two weeks.

Second place for Multiple Applications, projects under 5,000 SF went to Artistic Concrete Surfaces, Olathe, Kansas, for an outdoor retreat at a residence in Overland Park, Kansas. The project consisted of a colored, exposed aggregate pool deck; a Gunite pool with waterslide, waterfall and elevated spa; a swim-up pool bar with stone countertop that includes convection-cooled cup holders; a pool house; outdoor kitchen and fireplace; 3D entertainment center and sound system throughout. All of these elements within a tight area made for a challenging project.

First place for Multiple Applications over 5,000 SF went to T. B. Penick & Sons, San Diego, for Reunion Trails, a 17-acre recreational facility in Henderson, Nevada. Reunion Trails incorporates sculptures and artistic embellishments based on the work of famed graphic artist M C Escher. Ten, thirteen-foot long lizards grace the picnic area. These were taxing to install as one skewed hexagon would have disrupted all other elements. “Attic windows” were created in the concrete using reactive coloration and sawcutting. Sedimentary walls incorporate two halves of a ½”-thick steel lizard embed. Precision was key to ensuring that the two pieces came together as one lizard. A meditative plaza features a labyrinth with a Lithocrete pixie dust finish.

For Concrete Artistry, projects Under 5,000 SF, first place went to the Olinger Residence, where New England Hardscapes was asked to blend modern and rustic design for this oceanfront home. The contractor textured the concrete and used a buff-colored integral pigment, then used several, hand-applied concrete stains. The pattern was hand-cut, paying careful attention to replicate the size and shape of real flagstone.

Second place for Artistry under 5,000 SF went to Concrete Mystique Engraving for the pool deck at the Hite Residence in Springfield, Tennessee. The contractor had to pave a new deck that aligned with a badly done homeowner pour. The design is based on wrought iron decoration on the property. The wrought iron theme allowed the contractor to create an asymmetrical design around the unusually curved pool. The design was colored using a heavily diluted black stain

For Stained Concrete, First place for Projects Under 5,000 SF went to Hyde Concrete for Spice 6, an Indian restaurant in Hyattsville, Maryland. The project scope consisted of a highly decorative stained and stenciled floor and a precast panel in front of the serving line. In the area to receive the stencil, the concrete was stained to provide the hued color ranging from red to umber. Once the stencil was in place the interior was stained antique black with gold. Everything was coated with an epoxy primer, with a polyaspartic sealer as the topcoat. The judges called this an awesome use of stains.

In the Graphics category there was one first place winner for projects Under 5,000 SF. It was Hyde Concrete for Spice 6, which also won a first place for stained concrete. Once the floor slab was stained, Hyde placed a 35-foot long stencil onto the floor. To accomplish this they had to ensure the accurate placement of over 14 separate stencil patterns for the centerpiece. This was repeated for 80 LF to create the border of the restaurant.

For Stained Concrete Under 5000 SF, second place went to TODDRose Decorative Concrete, Lincoln, Nebraska, for Defy Gravity, a trampoline / dodge ball facility in Papillion, Nebraska. The owner asked for something flashy and different to attract their younger clientele. They wanted to replicate an irregular flowing appearance using a black on tan color scheme. The contractor found that by lightly spraying their water-based color on 2-mil plastic, they could then transfer the second stain coat to the concrete using a simple roller frame with pad and walking in spike shoes. After pulling up the plastic they were left with a flowing nebulous pattern caused by the air trapped under the plastic.

Thin overlays under 5000 SF, second place Concrete Mystique Engraving, for the Lance Residence Pool Deck. The homeowner wanted to feel as if he lived in the desert. Three separate concrete pours followed by applications of acid and water-based stains were used to create the exact colors of the design elements. The judges commented on the intricacy of the design.

Vertical Application, first place for projects Under 5000 SF went to LAVADA, Brooklyn, New York for the bar cladding at Robusta Espresso Bar in New York City. The contractor’s challenge was to make a bold impression with few dollars at a building with three sides of floor-to-ceiling glass, a rare occurrence in Manhattan. After considering metal and wood, the architect agreed that concrete offered a customizable, lightweight, economical and modular cladding. A range of finishes was used so the panels would not look mass-produced. The panels were painted to appear red from one angle and gray from another. Judges particularly liked the abstract use of concrete in this application.

For Vertical Application Over 5,000 SF, first place went to Gerner Kronick Valcarcel, Architects, PC for TEN23. Both the architect and the project are in New York City. The façade of TEN23 is translucent glass set within architectural cast-in-place concrete. Designed around the number 10, the relief pattern was formed by layering adjacent decagons. Over 7000 cubic yards of 5000 psi concrete was used for the building. Exterior columns and shear walls were made of a special mix using 3/8-inch stone. A higher slump for the architectural mix allowed for an exceptional finish. Custom form liners, weighing over 600 lbs. each, were used for exterior columns, shear walls and slab edges. The aesthetic of the building is based on contrast between the coarse texture and patterns of paved concrete juxtaposed against the smooth aluminum and glass.

Thin Overlays over 5000 SF, first place Honestone, Tuggerah, New South Wales, Australia, for St. Barnabas Church in Broadway, Sydney. The contractor installed 600 square metres of flooring and 280 square metres of walls. After several weeks of preparation, Honestone used a cost-effective method of filling a 50mm setdown with rapid cure engineered cement screed, and then applied a seamless 6mm thin coat overlay. This was all done under demanding circumstances including adverse weather, a very rough concrete substrate, and working alongside other trades. The judges admired the seamless transitions.

Vertical Application over 5000 SF, first place Honestone, Tuggerah, New South Wales, Australia, for St. Barnabas Church in Broadway, Sydney, The vertical work here involved many intricate and demanding processes such as blending wall products to the flooring, working with curved walls that disappeared behind the ceiling, and technical details including lining up corners and leveling non-symmetric planes. The contractor designed a counter-leveled mobile scaffold that supported the side stretches of the curved walls. Honestone believes there is no other project like this one in Australia.

Overlays ¼” – 2” under 5,000 SF. First place Concrete Mystique Engraving for the Bullard Residence, a home dating to the turn of the century with a brick floor over 50 years old. The contractor elected to go with a 3/8” self-leveling overlay over the brick. The overlay was then given a large wood pattern to match the floor in another room of the house.

Overlays ¼” – 2” under 5,000 SF. Second place goes to Sundek of Illinois, Rolling Meadows, Illinois, for an outdoor path from the house to pool at the Mooncotch Residence in St. Charles, Illinois. Sundek was able to capture the owner’s vision of a jungle oasis in the Chicago suburbs with an overlay and a variety of water-based stains. The result is a rock formation carved into the hillside that appears to have been there for many years.

Overlays ¼” – 2” Over 5000 SF, first place goes to Sundek of Washington, Chantilly, Virginia, for the Cameron Grove Resort & Retirement Center in Upper Marlboro, Maryland. The contractor was challenged with providing a cost-effective, slip-resistant entryway to match an existing masonry stone pattern. When management saw the result they thought it was real stone and the project scope was extended to add retaining walls, steps and pool deck. Judges commented on the amount of detail work on both horizontal and neutral surfaces.

Polished Concrete. First Place, for projects Under 5,000 SF goes to Rosebud Concrete, Myerstown, Pennsylvania for the Susquehanna River Lodge in Dauphin, Pennsylvania. The design concept was to lay river rock in the main entranceway to resemble a dry river bed.

There were numerous challenges at the Susquehanna River Lodge: the main polishing challenge being a mix with a high fly ash content. The judges called this project “spectacular” and the polishing “stunning”.

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