Many factors go into a concrete project to ensure it will last. At Rockborn we design each project to specific needs and ensure each step of the way is done to exacting specifications using the best materials available. Or more simply, we build our product to last. 

Below are the simplified steps to a proper concrete installation and the work that goes into ensuring your project is done right.

1. Excavation: Excavation depth depends on a couple of factors; what kind of traffic your concrete will experience (pedestrian, vehicular, etc.) and the specifics of your soil (sandy, clay, shale, etc.) will determine how much base material is sufficient for your project and thus the necessary excavation depth. In Canada, we have a harsher climate and projects require deeper excavation and a thicker base than most other places.

2. Geotextile: For some projects certain geotextile materials are necessary due to unforeseen subsoil conditions, excessive water saturation, or other conditional factors. Geotextile materials are often used to decouple the base material from the sub-soil or to reinforce the base material in layers to make it more able to withstand concentrated pressures. Our team can tell you more regarding your specific project's needs.

3. Gravel: The base on which the concrete is poured is one of the most important aspects of your concrete installation. The type of materials used as well as the number of distinct material layers depends on the purpose and specific design of your project. We always use large, angular stone aggregates which lock tightly together, never cheaper round gravels, small limestone screenings, or dirt. Ask us more about this, we're always happy to discuss how our materials differ from the competition.

4. Compaction: Base material needs to be laid and compacted in 'lifts' to ensure strength and proper consolidation; Thin layers of material are put down, flattened, tamped, and repeated until achieving final required thickness. Some other companies often rush this step or cut corners because it requires a large amount of time, but we know through experience that it is absolutely necessary to ensure a lasting product.

5. Forming: Creating the concrete forms can either be a simple process or a complex foray into carpentry depending on the specifics of the project. Borders, curbs, curves, separate pours, changing heights, water runoff, and grades are all factors to take into consideration. A lot of time and care is taken when building the forms because they have to withstand the extreme weight and pressure of the concrete as well as accurately layout both the heights and the shapes of the concrete project. 

6. Reinforcement: Some concrete installations require reinforcement of mesh, rebar, fibre, or extra elements to ensure they can withstand the forces exerted upon them. These elements are calculated and engineered to ensure a concrete project meets specifications.

7. Pouring: Depending on the access and size of the concrete pour, various machinery, line pumps, and overhead boom pumps are utilized to ensure a smooth placement of product in a timely manner. Pouring concrete is a race against the clock as there is a short window available to manipulate the material, so it's all hands on deck.

8. Finishing: Finally, experienced concrete finishers get to work at exact intervals of moisture content and plasticity required for each type of finish. We offer a multitude of different finishes depending on the application and design you are looking for, so reach out to ask us about the endless possibilities.
   
   

Every installation is different, but this gives you a general idea of the process and the steps involved. We are passionate about our work and are always happy to discuss any part of our process and how we differentiate ourselves from our competition. Feel free to reach out to us at any time with any questions or projects you have in mind.

Since concrete is so versatile, we offer many options to alter both the function and the form of your patio, walkway, or driveway installation: