The Concrete Network

Red Tile

Steve Eyler is so fascinated by concrete's design potential that he finds himself envisioning an endless array of shapes, patterns, colors, and materials at all hours of the day and night. And Eyler is also finding new ways to make concrete stronger, less permeable, and cure quicker.

Eyler, owner of Eycon Surfacing in Myersville, Maryland, has a 20-year foundation in the concrete business, but the decorative side of the business won him over about four years ago.

"I dream about this stuff all night long," he said.

Terrazzo

Eycon primarily serves the Maryland, Pennsylvania, and Virginia areas, but also caters to the rest of the Northeastern United States. The company specializes in countertops, acid stains, spray decks, and overlayments.

Eyler said making the move to decorative concrete was the best thing he ever did. He loves being able to use his mind more to produce an ongoing stream of one-of-a-kind concrete design projects, rather than relying on just his body, as he did in his earlier years.

"I was intrigued with the results ... It's a lot more artistic and you tend to appreciate the work more — plus it's not as hard on your body," he said. "I can really experiment and put myself into my work."

Eyler works on both residential and commercial projects. He is seeing an increasing demand for countertops on the residential side, and more requests for acid-stained floors on the commercial side.

"The countertops are a big West Coast thing right now, but they're slowly making their way across the country," he said.

He can create unique countertops in colors ranging from classic bone to striking graphite, rich plum to slate blue, and classic terrazzo to vivid red tile. Eyler offers custom samples made to the client's specifications with every order taken. Eycon boasts a variety of edge styles, unique to concrete countertops, and can create just about whatever an architect, designer or homeowner comes up with.

And now Eycon has come up with a process to ease the concerns some may have with pursuing concrete for projects like countertops and sinks: One of the company's greatest strength lies in Eyler's pioneering use of glass fiber reinforced concrete (GFRC) for countertops.

Eyler knew that GFRC had been used for years, primarily in buildings and concrete statues. With his research and experimentation mode switched into full gear, he was soon on his way to developing a mix that eliminates structural cracking, resists stains because the surface is less permeable, maintains consistent coloring, and allows for unlimited mold shaping and finishes.

The mix is made up of the usual sand, cement, aggregates and water. But Eycon adds a water reducer, silica Fume and alkaline resistant glass at a ratio that creates a web-like matrix that literally doubles the strength of the end product.

A typical concrete countertop requires seven days to cure before the polishing and grinding process can begin and the countertop ships in about 28 days. With GFRC, it takes just 16-24 hours of waiting until polishing and grinding, then the countertop can be shipped in seven days.

Eycon uses a two-part water-based epoxy and a water-based urethane to seal the counters. They have tested everything from acrylics to solvent base products and have found this combination to be the most-stain resistant and durable, and it's environmental friendly. It comes in three finishes: flat, satin (matte) and gloss.

Alkaline resistant glass (ARG), a high-zirconia alkali-resistant glass fiber, developed for reinforcing cement or concrete, is a key material in GFRC. Eyler uses ARG from Nippon Electric Glass, which offers the glassfiber with the highest zirconia content available — 19 percent.

"There are a lot of fibers used that can withstand time — they don't break down ... I can't believe people aren't using this more," he said.

With GFRC the concrete can be poured less thick and still have all the strength.

Eyler also loves the fact that the new concoction opens up a whole new world of molding possibilities, including round and cuffed molds. Eyler has created arched and curved entrances, even circular bars.

"I like to do a lot of geometry. With concrete you can use a different material that produces an old-world look — or you can make it high-tech," said Eyler.

One of Eyler's favorite projects is one he's finishing up for a bakery. The store owners wanted concrete for the counter where customers order and look at the baked goods. Eyler was given free reign on the project and his imagination ran wild.

"I started thinking about glass," Eyler said. "So, I went to the stained glass store and then made a bunch of samples."

The concrete counter is a brick, taupe-brownish color; Eyler then integrated orange glass into the mix. Eyler loved the results, and his clients were equally thrilled. The counter is as scrumptious as the goodies that reside within it.

Eyler also works in concrete floor overlayments, a cement-based resurfacing product with a polymer additive that can be applied at a thickness of ½ inch to as little as 1/16th of an inch thick. It can be applied using a texture sprayer, to create patterns, stenciling and other affects. It can be squeegee and troweled on to create a base for stamping and acid staining. The end product yields low maintenance, and a high-sheen, durable surface that will last a lifetime.

Next on the plate for Eyler is the possibility of working with a Manhattan company on a condominium project in the prestigious East Hamptons. Eyler is in the process of meeting with builders to discuss creating 115 kitchenette countertops.

In the meantime, Eyler will continue experimenting, making samples, creating new marbleized looks, mixing exciting new colors, and his favorite endeavor — trying out various combinations of concrete, glass, and inlays and then watching the magic that transpires as the light dances across the surface and catches the sparkles of glass and concrete aggregates.

Eyler also has plans to experiment with lighting inlays. Using the GFRC to his full advantage, his designs are more flexible than ever, the end product is stronger, the concrete cures twice as fast, and there aren't any adverse environmental consequences, he said.

"I like to stay ahead of the game," Eyler said.

And he has his illustrious — not to mention stronger, less permeable — work to prove it.

Eycon Surfacing
Steve Eyler
9700 Baltimore National Pike
Myersville, MD 21773
(301) 293-3457
(301) 293-1354 FAX
Send Mail Now - Click Here
www.eycon.us

Michele Dawson writes each week on one of the contractor members of The Concrete Network (www.concretenetwork.com). She has written about the home building industry for several years and was on the public affairs staff of the California Building Industry Association.

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