a spiritual quest for beige.

We get to make a lot of really cool stuff.

 I mean, there are much easier ways to make enough money to feed one's family than slogging it out in the Texas summer heat, crawling around with a saw cutting patterns into floors or making concrete the hard way (buckets of sand, bags of cement and our trusty little Imer mixer) only to have to bear the highest level of "hand-holding" in all of the construction trades and the most brutally competitive market for decorative concrete in the world.  (Texas was referred to in Concrete Decor Magazine as  "the starvation market").  I don't remember the last time my work day didn't end with me smelling like a homeless man.  My big, pointy nose gets filled with concrete dust regularly, my joints hurt most mornings, and we risk tens of thousands of dollars every day.  Good news is, I really don't think I could be happier!

How rad is it to make a living making stuff you think is great with guys you like for awesome people?  God bless America, eh?  But enough about all that - I bet you are not reading this because you care about how I smell or how my nose feels for that matter.

What I hope to share here is a reminder that while edgy concrete wall panels and ornate medallions in floors look cool in our portfolio, what it is really about is the day to day consistency.  I haven't written here too much recently because I have been maniacally focused on building systems that make the day to day work of the artisans of element7concrete better and more consistent.  And to that end, we are maniacs for beige.

"There is no beige acid stain" - Brandon Adamson at my 2nd day of training at Engrave-a-crete in Florida.  It's early 2006, and I have committed to going into the decorative concrete business, but I am still working my union job, and taking every seminar in the nation I can before moving to TX to take over the company I have ran for the last 5 years.  Brandon went on - "Sealer should be re-applied once a year or maybe once every two years."

This all sounded like crap to me.  I lived in Las Vegas at the time, and most things were beige.  Re-sealing annually?  Sounded like a white elephant for sale to me.  I knew my own concrete driveway at home hadn't been touched for at least 4 years and while it was grey and totally unremarkable, it was not something I had to deal with.  There had to be a better way.

The project photographed above was just finished this morning. It was about a year and a half old, ugly grey, and covered with oil stains and tire tracks when we started.    We used nothing other than Kemiko acid stains, lots of little tricks, an amazing penetrating sealer that will go at least 10 years before needing anything- there is no paint, "dye", or anything else questionable used. If that is not beige, I don't know what to call it.  Most important to me,  I will bet that when my little kids are out of collage, this thing is a good cleaning away from looking a lot like it did today.

Note: Engrave-a-crete makes great tools and is a really positive force in our industry.  I mean no disrespect to Brandon, his family, or their company.  I just know that if you tell a stubborn old Kraut like me crap like that, I will find a better way.

Show me a picture, and I'll cut it into your floor.

Custom home builders love us because of how we improve the experience for their customers.  One way we do that is by cutting a medallion in the foyer based on anything they already have and like (contrasted with selecting from catalogs or samples at a store).

It's less permanent than a tattoo, but we still careful to pick something that translates well to concrete and is timeless.  The floor we recently finished for Dave and Vicki Shurman in a home by Reven Builders is typical,
This one was based on a coat rack.  They had owned this coat rack for years and just always seemed to feel better after looking at it.  I think a swirling sun is about as primal as you can get, and the engraving process is not wholly unlike the petroglyphs of the Native American tribes of the Southwest. Vicki gave Todd (awesome guy on our team since 2006) this photo as something they liked and would like a medallion of:

This picture was passed onto me on the second day of the project (winter 2010 I think), and I knew that it would be best to translate this on a finished floor after the sealer had really cured out.  So, we finished the floor and let the other monkeys ply their trades, planning to put it down when we came back for the final polish. 

Now in July, the house is about done and it was time to do the final polish and install this medallion.  Putting a Ermator S26 vacuum on the tools, and having an great team cleaning up on my heals made working in a finished home a breeze. I dug the hand made look of the coat rack, and wanted that to translate to the floor with little deviation in the swirl, but better rays.   Rather than sandblasting or using a needle scaler, this one was cut free-hand with a 4" grinder so the texture of the engraving accentuates the design.

The best part, though was Vicki saying "That is exactly what I hoped for".  I thought to myself "You saying that is exactly what I hoped for!"   

 I am really thankful to be able to feed my family making stuff I think is cool for people I like.  Thank you David and Vicki Shurman, Larry and Randy Reven (I don't know Mrs. Reven, but she must be a saint).  

All's well that ends well - Correcting Construction Errors Episode 5

We did it!  It was a long day of grinding, scrubbing, head-scratching, re-staining, and rinsing, but we did it.  The floor described earlier in "Avoiding Construction Errors" now looks pretty sweet.  Like so many before it, the floor is actually better now than if everything would've gone as we hoped it would have.

Because of a mishap with my iPhone, and the SD card for my camera doubling as a vehicle for an audiobook I wanted our interns to hear, I have no pictures of the corrected floor to share here now.  Photos of floors in homes without proper walls or trim stink anyhow.  I know it sounds like I am trying show the bright side of "the dog eating my homework" and I might be.  I will try to get some proper pictures when we do the final polish and will post them to http://www.facebook.com/pages/Element7-concrete-design/105210402870801
(please click "like" there if you haven't already) and put them on twitter as well.  You can follow us there @element_7.

What we did to fix it is hone the floor with bonded-diamond-abrasives (blocks of metal and resin with little bits of diamond in them), re-stain it, rinse it, densify (apply a chemical that makes the concrete hard and dust-proof), and then come back the following day and finish it out with a stone oil/paste wax.  The stamping done outside by the concrete contractor is not the best I've seen, so it's not likely that'll make it into our portfolio, but the interior floor is first-class.  The low spots of the floor kept a bit more of the dark walnut stain from before, and the overall texture is buttery smooth now.  There is good color movement and the finish is refined, yet rustic.  Like much of work when it's right on, it looks brand new and 100 years old at the same time.  Sorry if that seems a bit self-promoting, but after all the blood and sweat poured into this one, I am really stoked with the finished floor.  

Avoiding construction errors.

They say an ounce of prevention is worth a pound of cure.  Today we find ourselves doling out that pound with our HTC machines and a lot of power and diamond tooling.

The builder following this little link on our website could have saved today and tomorrow's work for us.

http://www.element7concrete.com/builder_awareness.html

Behold the culprit:

This was one of three drinks we found on the framing when we started the project.  Who knows how many more were in the house and spilled on the floor so far?  I would guess about 5 or 6 based on the spots on the slab.  If you zoom in, you can see one in the room behind the can.

The point is unprocessed concrete is like a big hard sponge, and chemical staining is like that black light they use in scary evening "news" shows (Dateline, 20/20, etc.) that shows all the gnarly stuff on the bedding of a hotel room.  If the concrete is to be stained without a lot of grinding, stuff like spilled sodas is going to show up.  Now, if you root through the insights given on element7concrete.com, you'll read about how much we like leaving the cream of the concrete intact, but sometimes you gotta do what you gotta do.  So we are slogging it out in the Texas heat, grinding a floor that should've been protected a bit better.

Now to be fair, the builder on this project is a good one.  He and I have worked together many times before and I don't blame him entirely for the mistakes.  Concrete flooring is a great way to create value when building, but it's frankly a pain for the GC to have to protect the floor as much as the have to.  Most importantly, the communication has to be better.  The link given will soon have an easy to print sign in PDF format that can be hung around jobsites where stained concrete is specified.  Until then, please contact us for a copy of this so we can all build efficiently and keep moving forward.

How to fix our schools (?)

I really hope this is a bit of a snowball that grows with input from others.  There is a serious problem in our country, and it won't be solved by one person with a plan or by us ignoring it.  So for goodness sake, please consider this idea, and either promote it, rip it apart, or just tacitly pass it along.  If we don't discuss it, our education system will continue to deteriorate and our country will decline and ultimately crash.  We have nothing to lose by trying to fix this.  Who knows, maybe we can find legitimate hope and make something better for once.

OK.  So here is the first proposition.  From what I gather, the state pays some $10,000/year/student for education.  Merit-based-pay sounds good on paper, but it's problematic in reality.  What do you suppose would happen if we took the $60,000-$120,000/year that could be spent in a traditional school, and allowed parents to pay that to a certified "home schooler" (with the same or more rigorous standards teachers are held to now).  Of course there would be oversight, but don't we have administrators already?  Wouldn't that kind of income and freedom to really help kids grow attract great teachers (or maybe realistically keep the great ones from burning out and leaving)?  How well does the feedback system of the amazon.com, zappos.com, the app store, etc. work compared to the current ways we evaluate teachers ?  This might be great or it might be dumb.  Please share your thoughts and push the snowball.  At the risk of sounding dramatic, the stakes here are pretty high.  Your input, from a completely different plan, to a simple post on Facebook to attract attention to the issue is the only way we can fix this.  There is no knight to ride in and save us.  Let's get busy!

Correcting Construction Errors - Episode 4

Regretfully, I still don't have photo's back from the Rick Burleson Job alluded to in a previous episode, so here I will share a recent adventure at Double Horn Brewing
http://www.doublehornbrewing.com/
This whole project was correction of construction errors, as the building was originally a laundromat, had probably half a dozen cold joints, plumbing trenches, and holes and was a generally haggard 50-some-year old slab.  It was the Keith Richards of concrete floors.  The worst part was a combination of slabs in the floor with about a 2" ridge.  More on that later: let's start at the front door.

Months after the interior floor was finished, I got a call from the builder about an issue with the front door.  Apparently, the doors couldn't open right, and the ridges between the three slabs in 5 feet ahead of the front door (just past where we finished our work) was flagged by the inspector for not being wheelchair accessible.  Now, grinding an inch of concrete off is no small task.  It usually doesn't look too great, either.  So to deal with all of that, I cut a leafy, barley-inspired (It's a brewery after all, and the idea struck me about three beers into a night of celebrating April 2011 as the best month in our company's history).  I acid stained it green, then installed a thin, stamped overlay to mitigate the ridges and half covered the leaves with the brown polymer-modified mortar and distressed it back for a good gradient of colors.  Really representational art generally looks cartoon-ish to me on a floor, so I try to keep it a little abstract and variegated.  I sealed it with a solvent based acrylic sealer and took the photo above moments later.  It should mellow a bit over time.    

Details vs. Altitude

If you ask my team what 90% right is, they know to answer "wrong!".  In our work, the details are actually pretty big.  The problem this causes an entrepreneur is that there are potentially infinite details to consider.
Attention to detail in the technical work is easy to get in the habit of and set standards for.  After all, when you are done, it's there to look at.  Things get trickier when you start considering creating customer experience, establishing stewardships for you people, creating a brand, and manifesting a social change.  The magnifying glass that made you the the great studier-of/wrathful-god-of the anthill gives you a very distorted view of your dog.  The elephant is incomprehensible through it.
  
Altitude is clearly the answer.  Backing up, zooming out, getting the Google Earth view, that is clearly paramount to orientating ourselves to lead.  But we know broad strokes alone will never do.  Some areas clearly need to be cut in with the smallest brush and detailed.  Challenge is, we have about 17 waking hours today (tops), families that need us, bills to pay, and obligations to meet.  We can't possibly do it all.

The answer is simple and brutal.  The only thing to do is to blueprint the day and then stick to the plan.  This means there are many things we will have to say "no" to if we are to say "yes" to things that are truly more important.  The three options you have are:
1.)Take the time to make a list of all the things that could possibly be done, grouping them ala David Allen's GTD, and then have the discipline to stick to our commitments of working in uninterrupted blocks of time to knock it out.
2.) Lower your standard and quit caring
3.) Go insane.
Now, go. (not insane - choose #1 for goodness' sake)