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Decorative Contractors Get Creative with 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 #ConcreteCountertops #DecorativeConcrete #GFRC #PrecastConcrete #ConcreteFinishing #CustomConcrete #ConstructionTechniques #SurfaceTreatments
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