Small Custom Decorative Concrete Solution Resolves Big Problem

Posted on February 14, 2025 in Blog

Award: 2025 Project of the Year

SUNDEK of Washington crews resolved a critical issue for the MacMillan Aqueduct site’s remodel, using a SunSplash coating to match nearby pavers in a spot where the pavers would make a custom door unusable.

Gilbane, one of the nation’s largest general contractors, spent about three years transforming the former McMillan Aqueduct site into a premier multiuse center. Just minutes from the Capitol, this ambitious project includes high-end finishes throughout, including a sprawling outdoor plaza. However, in the middle of the project, a critical issue arose that threatened to delay the project’s completion. That’s when Ruppert, the site’s landscape contractor, called Bob Miller, vice president of SUNDEK of Washington, for help.

Bob was directed to a problematic area at the center of the plaza where high-end decorative pavers had been installed. The issue was a miscalculation in the design of the surface inlay depth for the custom horizontal metal emergency entry doors that led to pump rooms below. These doors were designed with a specified two-inch paver inlay to accommodate the adjacent pavers seamlessly.

Unfortunately, the custom-made metal emergency doors were delivered out of spec, with only a one-inch inlay. This was only discovered months after installation in the cast-in-place concrete. Removal and shipment of replacement doors would take several months and reconstruction to retrofit. After numerous attempts to get custom cut one-inch pavers from the paver manufacturer, it ended up that this was not an option they could provide.

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With time running out, Ruppert trusted Bob and SUNDEK to provide a quick, yet high-quality solution. Understanding the urgency and aesthetic demands of the project, SUNDEK proposed installing a custom hand-applied overlay to provide a precise match to the color and design of the adjacent pavers.

For the overlay, Bob and SUNDEK suggested SunSplash, a coating that protects the surface against weather, salts, and environmental pollutants. It’s easy to maintain and also provides a slip-resistant surface.

SUNDEK provided several mockups for approval, and once the color was approved, they set out to install SunSplash on the 200-square-foot space.

The completed section of overlay before SUNDEK of Washington added the final color.

Thanks to SUNDEK’s expertise and efficiency, the issue was resolved without compromising the aesthetics or functionality of the plaza. The Reservoir District’s grand outdoor space was able to move forward as planned, ready to welcome visitors to one of Washington, DC’s most exciting new destinations.

Contractors Who Help with Surface Solutions

At SUNDEK of Washington, we resurface concrete in the major metros in the area, including Arlington, Alexandria, Fairfax, and Reston, Virginia; Bethesda, Frederick, Gaithersburg, and Hagerstown, Maryland; Washington D.C.; and beyond.

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