Child TV Star Now Makes Concrete Countertops

The article presents five distinct examples of decorative concrete countertops, highlighting the versatility and customization possible with concrete in various applications. Each project showcases unique challenges and innovative solutions employed by concrete specialists. The first project, by Tom Fischer of Fishstone Studio, involved creating a large, custom-colored Glass Fiber Reinforced Concrete (GFRC) countertop for an outdoor restaurant bar. This 85-square-foot countertop was precast in five sections to accommodate four existing roof support columns, requiring custom metal supports for reinforcement despite the GFRC's lightweight nature. The fabrication process involved templating, molding using steel tables and melamine boards, and mixing custom integral yellow and red iron oxide pigments with white portland-based cement. Fischer applied a GFRC mist coat, followed by a hand-placed backer coat to achieve a 3/4-inch thickness with a 4 1/2-inch apron front. The finishing involved wet polishing to a 400 grit using specialized tools, followed by hand-sanding the corners, and finally, applying a UV-resistant topical sealer with an HVLP sprayer for outdoor durability. The pieces were then caulked at the seams during installation. Carl DeSouge of Cade Construction developed a 1 1/2-inch-thick precast concrete countertop featuring a unique blend of integral yellow color, colored glass, and yellow serpentine rocks. Before pouring, he incorporated Solomon Colors' yellow pigment along with yellow, white, amber, and beach glass and shells into the concrete mix. Serpentine rocks were strategically placed in the forms to define the edges and corners, ensuring continuity across seams. Reinforcement was achieved with fine fiber mesh in the mix and aluminum corrugated tile wire mesh in the forms. After pouring and vibrating to eliminate air, a hard trowel finish was applied. The polishing process progressed from 100-grit to 3,000-grit pads, with a densifier applied after the 150-grit stage and slurrying to fill voids. The edges were routed to create a waterfall finish on the serpentine rock. A sealer was applied, followed by buffing with a diamond twister pad and a final coat of beeswax. Bayard Fox of Cement Elegance created a residential concrete countertop with a distinctive leather texture and a custom-matched color. The project encompassed a 55-square-foot, 2-inch-thick upper and lower bar, both featuring a radius, with the upper bar also having a chiseled edge. Achieving the leather texture was the main challenge, solved by attaching a vinyl-like material to the forms, which was tight and wrinkle-free but releasable. Fox used GFRC spray-applied in multiple layers, each containing integral pigments to ensure consistent color throughout the countertop, especially important for visible undersides. Post-curing, a fine sandblasting method and fine sanding preserved the leather texture during detailing. A water-based epoxy sealer was spray-applied in three custom layers in a dedicated finishing room. Tony Tyner of Custom Concrete Countertops of Oklahoma executed a kitchen countertop project totaling 113 square feet, including an L-shaped counter, a two-piece stove counter, and a bar countertop. The objective was to harmonize the countertop color with the existing backsplash, stained floor, and antiqued cabinets. The process involved installing 3/4-inch plywood over lower cabinets, building forms with 2-inch Plexiglas for the sides, and reinforcing with wire mesh and 3/8-inch rebar. enCounter's countertop mix was poured, followed by a hard trowel finish. After curing, the countertops were acid-stained with a blend of tan and black, applied simultaneously for color variation. After a day for the stain to blush, it was neutralized with water and ammonia. A thick coat of Stamp Store acrylic sealer was applied with a paintbrush, followed by a self-leveling epoxy coating for durability, ease of cleaning, and color enhancement. A heat gun removed air bubbles from the epoxy, and a thin coat of polyaspartic was brushed and wiped on to increase the epoxy's hardness. J&M Lifestyles LLC, specializing in decorative precast concrete, developed a countertop for an old Pennsylvania farmhouse kitchen, earning a Cheng Circle of Distinction Award. The homeowner desired to retain existing cabinets while adding character. The result was a precast concrete countertop with a wood decorative finish and bespoke edging. The design, molding, casting, finishing, and installation took two weeks, accommodating a copper farm sink and integrating seams purposefully with hand-hammered iron plates for a decorative appeal. A 3 1/2-inch-thick radius free-form island countertop featured a texture resembling flamed blue stone, with hand-forged iron nails embedded for detail. The island was acid-stained to match the home's stone fireplace. #ConcreteCountertops #DecorativeConcrete #GFRC #PrecastConcrete #ConcreteFinishing #CustomConcrete #ConstructionTechniques #SurfaceTreatments

Kimberley Robles, a specialty contractor based in the Bay Area, specializes in decorative concrete, offering solutions for both residential and commercial projects. Her company, Robles Concrete Design, focuses primarily on polished concrete and various toppings, transforming existing concrete slabs into aesthetically pleasing and durable floors. Robles emphasizes that decorative concrete, particularly polished concrete, is a sustainable flooring option as it utilizes the existing building material. She highlights its longevity and modern appeal, aligning with contemporary design preferences in areas like San Francisco. The process of polishing concrete involves a scientific approach, starting with rough grit diamonds and progressively moving to finer grits to achieve the desired reflectivity. Robles notes that a truly polished floor requires reaching at least 800 grit to prevent it from wearing off quickly. She cautions against the misconception that concrete floors require no upkeep, explaining that acidic spills must be cleaned promptly to avoid surface damage. Part of her work involves educating clients on the proper maintenance required to preserve the look and integrity of their polished concrete floors. Robles' journey into decorative concrete began through an apprenticeship with a union, initially in carpentry before transitioning to cement masonry. She describes concrete work as one of the hardest trades due to its physically demanding nature and the artistic skill required, especially in residential applications. Her interest in decorative concrete led her to attend numerous classes and workshops, recognizing the limitations of informal learning sources like YouTube for mastering the craft. After gaining significant experience, she took the entrepreneurial leap to establish her own company. Running her own business, Robles faces the challenge of managing various aspects beyond the technical work, including administrative tasks and business growth. She stresses the importance of building a competent team and delegating responsibilities to avoid burnout. Currently, she is pursuing project management certifications to enable her company to bid on larger public projects, which often require such credentials. She is also actively involved with the American Society of Concrete Contractors (ASCC) and its Concrete Polishing Council, advocating for greater awareness among architects and the public about the intricacies and potential of concrete polishing. Robles also shares her experiences as a woman and a woman of color in the trades, noting the significant changes in workplace awareness and diversity efforts since she started in the early 1990s. She views the construction industry as an untapped market for women, emphasizing that it offers lucrative career paths without necessarily requiring a college degree. She champions education and continuous learning as crucial for success in the concrete trade, recommending industry events like World of Concrete and manufacturer-led training sessions to stay updated on new products and techniques. Regarding current trends, Robles observes a preference for matte finishes over high-gloss surfaces in the Bay Area, where clients desire a natural, clean, and modern aesthetic. She frequently works on refinishing concrete floors in Joseph Eichler homes, known for their midcentury modern design and often featuring heated concrete slabs. She also touches upon the history of discriminatory housing policies in San Francisco, linking it to the displacement of communities of color and the subsequent gentrification of neighborhoods like the Fillmore, which impacted her own family. This historical context underscores the broader social implications intertwined with urban development and housing. #DecorativeConcrete #ConcretePolishing #ConstructionTrades #WomenInConstruction #BayAreaDesign #SustainableFlooring #Apprenticeship #SmallBusiness

The article highlights Steve Perfect's dedication to polished concrete, focusing on a specific project for Clarke Environmental, a company that wanted a sustainable flooring solution for its new 20,000-square-foot headquarters in Roselle, Illinois. Initially, the company planned to install carpet throughout the building. Perfect, owner of Perfect CC Midwest, Inc., based in Batavia, Illinois, successfully advocated for polished concrete as a more sustainable alternative. He convinced the owners by performing 12 mock-ups to demonstrate the aesthetic appeal and consistency of polished concrete, ultimately securing the contract to polish 11,000 square feet of concrete. Perfect CC Midwest exclusively uses the Husqvarna HiPERFLOOR Concrete Polishing System. Perfect emphasizes that adhering to a specific system's specifications ensures quality craftsmanship and transparency in the bidding process, preventing shortcuts that could compromise durability. He notes that while he initially learned the craft by 'skipping steps,' he later realized the importance of following a strict specification for a long-lasting finish, including proper grout coats, crack fills, joint fills, and densification. The only customizable aspect for clients is the gloss level, as all other steps are crucial for the floor's longevity. A significant challenge on the Clarke Environmental project was the demolition and floor preparation. Perfect and his team preferred to handle the demolition themselves to minimize damage to the concrete substrate. They recycled 23,000 square feet of carpet, preventing 8,120 pounds of material from ending up in landfills. The concrete itself presented difficulties due to its excessive hardness and an irregular level of aggregate exposure. Achieving a full stone exposure required extensive grinding, using 11 different diamond grits, starting with five sets of Husqvarna 16-grit Soft Softs' before transitioning to 30-grit. The uneven distribution of aggregate meant that full stone exposure could be achieved at varying depths, from a quarter inch to over three-quarters of an inch, making it one of their most challenging exposed aggregate projects. Perfect's team also faced the challenge of working around other trades. They decided to outpace other contractors, such as drywall installers, to mitigate contamination and reduce the need for extensive hand grinding along future walls. Despite their efforts, other trades caused some surface stains from mud work and paint overspray, which the 30-grit metals were able to remove. Hand grinding the edges with Metabo angle hand grinders was still necessary to ensure an even and consistent finish. Environmental consciousness extended to concrete dust disposal. Given the architect's concern about dust entering the ventilation system, Perfect's crew dedicated an hour daily to vacuuming recently ground areas. Dry concrete dust is costly to dispose of due to its weight and is not accepted by concrete facilities in that form. Perfect implemented a recycling process learned from a previous job, converting the dry dust into a slurry by mixing it with water in dedicated slurry dumpsters. This slurry was then transported to a concrete plant for use as filler in future concrete orders. On this project, 41,840 pounds of concrete slurry were recycled, demonstrating an environmentally responsible approach to waste management. Perfect plans to implement this recycling process on all future jobs, storing dust from smaller projects until a full slurry dumpster can be filled for recycling. Perfect expresses pride in this project, particularly because it's in his hometown. He views it as one of the most prestigious and challenging floors he has ever installed, serving as a valuable example for prospective clients. His success is attributed to extensive job experience, networking, and a steadfast commitment to a specific polishing system, which consistently delivers high-quality results. He routinely visits his completed floors to ensure their durability, a commitment he learned from Husqvarna, emphasizing the importance of a proven brand name and a visible track record of quality work. #PolishedConcrete #ConcreteFlooring #SustainableConstruction #HusqvarnaHiPERFLOOR #ConcreteRecycling #EnvironmentalResponsibility #ConstructionChallenges #DecorativeConcrete #ConcreteGrinding

Seven years ago, Brian Sieffert embarked on his journey into decorative concrete by creating his first countertop. Since then, he has honed his skills through extensive training with industry leaders such as Buddy Rhodes and Fu Tung Cheng, culminating in the establishment of his own company, Concrete Zen. Based in Pittsburgh, Concrete Zen offers a comprehensive range of decorative concrete services, including custom countertops, sinks, and both vertical and horizontal overlays. While primarily serving Ohio, West Virginia, and western Pennsylvania, Sieffert has also collaborated with artists in New York and holds a license in West Palm Beach County, Florida. Before founding Concrete Zen in 2009, Sieffert owned and operated Take Pride Construction and Design, LLC (T.P.C.D.), a full-service renovation company. He continues to manage both businesses, completing approximately six residential and commercial renovations annually, frequently integrating concrete elements into these projects. Sieffert observed that although commercial building and new construction had experienced a downturn, the remodeling sector saw some improvement. This shift led to increased competition in remodeling, driving down prices. Concrete Zen, however, carved out a unique niche by focusing on sustainable design, utilizing locally sourced materials, and emphasizing a return to fundamental construction principles. Beyond T.P.C.D.'s remodeling endeavors, Concrete Zen extends its services to architects, who often specify the company's work and collaborate on innovative design solutions. Sieffert and his team maintain a high level of enthusiasm for their craft, which he attributes to their clients' shared passion. A key differentiator for Concrete Zen is its versatility, encompassing expertise in overlays, Glass Fiber Reinforced Concrete (GFRC), various molding techniques, and training in both Cheng and Buddy Rhodes styles. The team's collaboration with an engineer and a master mason further expands their capabilities, enabling them to tackle diverse projects and overcome engineering challenges posed by creative design elements. A notable recent project in Upper Saint Clair, Pennsylvania, involved a comprehensive restoration by Sieffert through T.P.C.D. This project included installing a concrete topping, overlay, island countertop, additional countertops, and a sink. The overlay was colored using an H&C; Concrete Espresso water-based stain and an H&C; Concrete Potter's Wheel reactive stain. Additionally, a Modello Designs stencil was incorporated into the foyer, and a fleur-de-lis stencil marked the transitions between different color sections. Sieffert detailed how a concrete topping leveler and overlay were applied over existing porcelain tile floors in the foyer, hallway, kitchen, laundry room, and bathroom, with water-based and reactive stains creating a natural, organic transition between the kitchen and laundry room. Looking to the future, Sieffert has ambitions to further develop the decorative concrete industry in Pittsburgh, where he notes its current limitations despite the presence of talented individuals. Inspired by the broader national activity within the decorative concrete sector, he aims for Concrete Zen to play a significant role in shaping new architectural and design trends in Pittsburgh. His goal is to integrate concrete styles with sustainable building practices to create impactful and enjoyable projects. The article concludes with a summary of Concrete Zen's services, key products, and equipment, highlighting their use of training and supplies from industry experts like Cheng Concrete and Buddy Rhodes, as well as products from companies such as Ball Consulting Limited, Brickform, H&C; Staining, Engrave a Crete, Artemis Environmental, and Solomon Colors, alongside various Makita, Dewalt, and ADT tools and Surface 519 sealers. #DecorativeConcrete #ConcreteCountertops #ConcreteSinks #ConcreteOverlays #SustainableDesign #ArchitecturalConcrete #ConstructionRenovation #PittsburghContractor #GFRC

Julio Hallack, owner of Concrete Innovations by Hallack in Turlock, California, transformed a layoff from a construction supervisor role in 1986 into a successful career in decorative concrete. Initially, he started a landscaping business in California to support his family, quickly realizing his preference for outdoor work and hands-on projects. Hallack emphasized strong business practices from the outset, including consistent branding on company vehicles and employee uniforms. His company diversified into colored concrete after a few years, a move that significantly strengthened its market position. By 1998, Hallack shifted his company's focus entirely to decorative concrete work, discontinuing the landscaping services. Today, Concrete Innovations by Hallack specializes in concrete restoration, decorative countertops, pool decks, stamping, staining, and intricate artwork. The company employs nine individuals and generates nearly $1 million in annual sales, with commercial projects accounting for 70% of the business and residential work making up the remaining 30%. Hallack's success stems from his commitment to staying current with industry trends, continuously seeking new ideas from his travels, and experimenting with products at his 3-acre estate, which includes an 8,000-square-foot showroom and testing facility. He is known for pushing product limits and developing unique applications, such as decorative shower stalls that offer an aesthetic alternative to traditional tiles. Hallack places a high value on education and training, not only for himself but also for his employees. He maintains a low employee turnover rate by offering competitive wages, paid holidays, and performance-based bonuses, which fosters a sense of collective responsibility among his crew. He enforces strict professionalism on job sites, including policies against smoking and alcohol, mandatory drug tests, and requirements for covering tattoos and removing piercings. Recognizing the significant Hispanic workforce in the industry, Hallack has collaborated with L.M. Scofield to translate educational materials into Spanish and has conducted numerous Spanish-language training courses across California. He also served as a translator during demonstrations at the World of Concrete, aiming to mass-educate workers and promote industry growth and pride in workmanship. Over two decades, Hallack has completed notable projects, including the restoration of the historic State Theater in Modesto, California, and the creation of intricate labyrinths. His business continues to expand, with plans to hire more staff and explore new markets internationally, including consulting opportunities in Hawaii and potential training initiatives in Mexico and Central America. Hallack foresees significant growth in the decorative concrete market and a strong future for the concrete industry, particularly in restoration, which he views as a multi-billion-dollar sector. He is committed to securing high-quality contracts and delivering exceptional work. A prime example of Hallack's expertise is his work on nine Save Mart Supermarkets in central California, where his team completes 40,000-square-foot stained concrete floor projects within a strict one-week deadline. These large commercial jobs require extensive pre-preparation, including understanding floor conditions, chemicals applied by concrete contractors, and collaborating with general contractors to recommend suitable water-based curing compounds. Hallack conducts mock-ups on-site weeks in advance to test processes like prepping, staining, stripping, and sealing. Upon taking over a job site, his crew dedicates up to two days to meticulously clean construction debris and address specific challenges like tire marks, utilizing high-quality cleaning equipment to prevent issues such as delamination of stain and sealers. The artistic elements, such as elaborate windmills and greetings, are executed by his most artistic employees, taking several days to complete with multiple layers of stain. Hallack developed an efficient system for staining large areas, adapting 25-gallon farming sprayers for chemical stains to reduce labor and time. He also successfully navigates challenging conditions, such as applying stains in cold weather by extending drying times and using heaters. Neutralizing the floors after staining is a critical and meticulous step, involving repeated scrubbing and rinsing until wash water is clear, followed by a tape test to ensure no contamination remains before applying sealers. He typically applies two basecoats and several finishing coats of sealer, filling expansion joints with colored tile grout to add definition and meet aesthetic requirements, demonstrating his thorough approach to delivering high-quality decorative concrete finishes. #ConcreteInnovations #DecorativeConcrete #ConcreteRestoration #JulioHallack #ConstructionIndustry #VocationalTraining #CommercialProjects #StainedConcrete #Entrepreneurship