Testimonials | Surface Masters

Trucks and backhoes have been visiting Kerry Court this month, digging up a lot of dirt to install "exposed aggregate concrete".

Last week they completed the driveway pour: today they make expansion cuts and next week comes the acrylic sealer. We took a long time to select this material after visiting many flawed alternatives based on coloured asphalt or patterned concrete. Our initial Village theme was red brick herringbone walk and driveways but our house ruined the cul de sac with ugly cheap black asphalt. After 24 years of frost heave and weeds taking their toll it was time to re-consider. White concrete doesn't look in keeping with the 1840's theme of Heritage Village and stamped concrete wears badly.

The exposed aggregate technique is relatively rare in this area. We visited one large country driveway in Virgil, and a couple of suburban driveways in Font Hill before contracting with Rick Danyliw of Surface Masters, St. Catharines. The concrete is made with pea gravel rather than crushed limestone. After smoothing out the wet cement, it is sprayed with a chemical retardant that prevents the top millimeter surface from hardening. Then after one day of hardening a high-power water wash is used to remove the top layer, to partially expose the pea gravel. The result is a pleasing pebble-texture that is safer for seniors to walk on than glossy stamped concrete and has greater resistance to salt damage, compared white concrete.

The project had it's rough moments - especially when the excavation crew tried to short-change us with only 6 " of gravel base. The prime contractor caught them - and made them re-do the excavation. We contracted for an 18" excavation depth to allow 12" of gravel and 6" of concrete (industry standard is 5"). The walk way got 5" compared to industry standard 4 ". If you want a solid concrete driveway that lasts 25+ years, the extra inches matter, to prevent ground heave, cracks and allow drainage.

Fluorescent paint on water main in the centre of our driveway didn't stop the back-hoe operator from breaking the valve. That required a visit from town engineers and a new excavation (by hand) for a hole 5 feet deep, to attach a new valve. They repacked the hole with gravel and, at my request, added rebar supports in the overlying cement. Fortunately, the fix was not on my bill.

The crew got better as the work shifted to the surface finishing. Like artists on a canvas, they worked the trowels until just right. Once the power wash removed the white crust, the wet aggregate "glittered" in bright sun, and my faith in their talents was restored. Care was taken during the cut and seal. The weather cooperated - just wet and cool enough to help cure - not freezing - then a dry spell for application of the penetrating sealant. The final look will require a semi-gloss surface sealant to be applied next fall.

Drawbacks to this method are the month of cure time and the big mess it makes when the top layer is removed. Make sure they clean up the solids and power-wash to the sewer. I had to scoop up two wheelbarrows full of fine sticky mud - and power wash the neighbour's drive to make things right. A contract hold-back would have been wise (like my wife told me!). I thank our neighbours who endured the mess - and loaned us car parking spots.