Not all concrete countertops are created equal, there are many materials that go into crafting the final product. Concrete countertops have surged in popularity over the past few decades, evolving from a niche choice for industrial and modern spaces to a mainstream option known for its sustainability and versatility. The process of creating these countertops is a blend of craftsmanship and technical precision. If you’re considering a concrete countertop for your kitchen or bathroom, understanding more about the artisan behind the work and how these surfaces are crafted can give you a deeper appreciation for their value and durability.
The Artisan Behind the Concrete
The artisan behind the concrete is one of the most important factors in choosing the right concrete countertop contractor. Is the artisan an alumni of The Concrete Countertop Institute or another technical school ? Do they have the proper background to craft a concrete countertop that will not crack over time? Are they creative and can offer many different patterns and styles? Have they tested the latest and greatest concrete materials available? Have they thoroughly tested the sealer they use and can show you their test data? These are all items that you should consider when speaking with a concrete artisan as there is a wide variance in not only concrete, but also the skills, experience and knowledge of the artisan.
1. Design and Templating
Any concrete project begins with an intended design. Concrete countertops can be customized in numerous ways: color, texture, edge profiles, and integrated features such as sinks or drainboards. The first step involves understanding the client’s vision and necessary specifications. A template is created, typically a physical template that will aid in creating the formwork for the final product. We can also have a digital template created through our distributors and utilize our patent pending process. Most concrete artisans will create a physical template on top of the cabinets that represent the countertop’s final dimensions.
2. Formwork Construction
Formwork refers to the mold or framework that shapes the concrete. A good concrete artisan will have a permanent flat and level casting table that is made from either steel, epoxy coated wood, or some other flat substrate that can be reused over and over. The template is laid upside down on this casting table then the edges are typically constructed are the templating, using melamine, as concrete does not stick to melamine. Using the template to aid in building the mold, ensures that the formwork is precisely built to ensure the final product matches the desired dimensions and shape. This step is crucial because the quality of the formwork impacts the finish and fit of the countertop. The formwork must be level and accurately aligned to prevent any inconsistencies or defects in the final product.
3. Mixing the Concrete
This phase also includes selecting the type of concrete mix, reinforcing materials, and any additives or pigments. Concrete countertops can be made with a fairly large variance in materials but a professional artisan will have a specialized mix that does not come from a big box store. There are also many different types of equipment that may be used to mix the concrete. High Shear mixers are preferred for Glass Fiber Reinforced Concrete. The mix is thoroughly blended to ensure a consistent texture and quality.
4. Spraying and/or Pouring the Concrete
Once the formwork is ready and the concrete mix is prepared, the next step is either spraying and/or pouring the concrete into the molds. This process needs to be done with precision to match not only the client’s aesthetic expectation but also for the highest strength possible. There are a million ways to do concrete and some are better than others. It is not as simple as dumping concrete into a mold, there are careful considerations to be taken to ensure that the product will last a lifetime. This is area of where the experience of the concrete artisan comes into play.
5. Curing
Curing is a critical phase in the concrete countertop process. It involves maintaining adequate moisture and temperature to allow the concrete to reach its full strength and durability. The curing process can vary depending on the mix design but most professional artisans will pour the concrete on day 1 then remove the formwork on day 2, roughly 16 hours later. During this time, the concrete is typically kept covered with plastic sheeting or plastic and blankets, depending on the mix design. The plastic sheeting is to prevent drying out too quickly, which could lead to cracks or weaken the surface. Blankets may be used to trap the heat, some mix designs work better when the heat is trapped in this manner and some do not. (Yet another area of where the experience of the concrete artisan comes into play!)
6. Removing the Formwork
Once the curing period is complete, the formwork is carefully removed. This step and the handling of the concrete at this stage is very important. The concrete has not fully cured and it is in its “baby” state. Concrete must be handled with care to prevent any cracks or breaks as concrete gains its strength over time.
7. Surface Finishing
The finishing process transforms the concrete into a surface that can be sealed. This can involve several steps, and may or may not include acid etching, wet or dry grinding, grouting and any of those steps may be repeated several times until the desired finish is achieved. Concrete is porous but many of the pores can be filled with grouting and sealing.
8. Sealing
Sealing is essential to protect concrete countertops from stains, moisture, and general wear and tear. High-quality sealers will create a protective barrier that also enhances the concrete’s color and shine. The type of sealer used can vary depending on the desired finish—be it matte, satin, or glossy. Different sealers will enhance the concrete’s color at different levels and a skilled artisan will understand the effects of their sealer. There are a lot of sealers available and you should choose an artisan that can show you their own testing of the sealer they use.
9. Installation
With the countertop finished and sealed, it’s time for installation. This involves carefully transporting and positioning the countertop on the cabinets and ensuring a secure fit. Proper handling and installation on a flat and level surface is crucial to avoid issues like cracking and scratching.
10. Final Touches
The final step includes drilling out faucet holes and caulking. Some concrete artisans may opt to have the faucet hole knockouts cast into the formwork, but many will drill the holes on site.
Why Concrete Countertops Are Worth It
Concrete countertops offer unmatched customization and sustainability. They can be tailored to fit any space and design preference, and with proper care, they can last for decades.
By understanding the meticulous process behind crafting concrete countertops, interior designers and homeowners can better appreciate the skill and effort involved. Whether you’re drawn to their industrial charm or their customizable nature, concrete countertops stand out as a testament to both art and engineering in the world of home design.
