Getting Started with Getting Started with Concrete Countertops Concrete Countertops
Presented by: Jeffrey Girard, P.E. Presented by: Jeffrey Girard, P.E. Please hold. The seminar will begin shortly. 1 2
Introduction My First Concrete Countertop
Jeff Girard CCI • President & founder • Training • Instructor • Technical information • Civil engineer • From-scratch mixes • Started 1999 • Founded 2004
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My First Concrete Countertop My First Concrete Countertop
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1 My First Concrete Countertop What’s your experience?
Poll
July 1999 7 8
Your project But first: Your workspace
You want to get to all these steps: Need: • Templating • Forming • Space • Reinforcing • Mixing • Power • Casting • Light • Curing • Stripping the forms • Water • Grinding and polishing • Heat • Grouting • Sealing • Installing
• Assuming you’ve decided what project to make.
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Workspace Workspace
Garage Basement
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2 Second: Your stuff Personal Protection
Need: Safety first! • Personal safety protection • Equipment • Materials
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Concrete countertops are countertops… Concrete Countertops Cast-in-place is done on site, right on top of the kitchen cabinets.
… that just happen to be made of concrete.
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Concrete Countertops Precast Methods Hand packed Precast is done in your shop, garage or basement.
Stiff, zero-slump concrete Variegated, hand-pressed or solid Single-sided molds (2D and 3D) Often all-sand mix concrete
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3 Major steps in precast concrete Precast Methods countertop manufacturing: Wet cast 1. Templating 2. Forming 3. Reinforcing 4. Mixing, casting and curing
Vibration 5. Processing Single and double-sided molds (for 3D) 6. Sealing Often aggregate based mix concrete 7. Installing
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Templating Templating
Accurately capture important site Shape and dimensions of the information in a physical mock-up. countertops
Good templates ensure an accurate fit.
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Templating Templating
Location of sink and cooktop openings Fixtures: sinks, faucets, cooktops Bartop overhangs
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4 Templating Templating
Cabinet inspection Site conditions
Gap, uneven cabinet
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Equipment Equipment
Templating and Forming Templating and Forming
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Equipment Equipment
Templating and Forming Templating and Forming
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5 Equipment Equipment
Templating and Forming Templating
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Materials Forming Forms affect the fit, finish and overall quality. Templating
Accurate forms require accurate templates. 33 34
Forming Equipment
Melamine boxes. Forming Foam sink knockout has silicone caulking. Glass embedment is glued to form with silicone. Drainboard form is adhered with carpet tape.
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6 Equipment Materials
Forming Forming
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Materials Equipment
Forming Forming
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Caulking Caulking
Only use 100% silicone caulking
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7 Caulking Caulking
Wax the form corners first. Only use 100% silicone caulking
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Caulking Caulking
Peel off excess after Tool the caulk caulk is cured. 45 46
Curves Embedments
Curved edges formed with foam insulation. Embedments are glued to form surface.
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8 Embedments Sinks and Faucets There’s more to forming than just building boxes.
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Sinks and Faucets Forming Faucet and sink layout are critical to function, Good work is noticed once… looks and long-term satisfaction.
Poor craftsmanship is never forgotten.
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Forming Tips Reinforcing Proper reinforcing is critical for success.
The forms must fit the templates exactly. You’re working upside down. Check, double-check and triple-check your forms against the templates!
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9 Structural Reinforcement Reinforcing Rules
Most important in Precast (wet cast, hand Reinforcing is placed close to the packed) tension face. Pieces are moved, handled and transported
All countertop slabs are reinforced Moderately important in Cast-in-Place Bartop overhangs also have cantilever Cantilevers still require correct reinforcing reinforcing located near the top surface.
Never in the middle of the slab!
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Reinforcing Countertops are not slabs-on-grade
Do not make a concrete countertop like a driveway or a sidewalk.
Slabs depend on well-compacted subgrade fill to completely support the concrete. Floor slabs cannot span soft spots or open spaces. Slabs usually have only secondary reinforcing for shrinkage and temperature. It won’t perform the way you expect it to. 57 58
Countertops are beams Beam Principles
Weight
BEAM
Beams are structures that span open spaces and are internally self-supporting. Beams contain primary reinforcing to resist all
tensile forces developed during service life. 59 60
10 How concrete countertops Reinforcing Placement Tips work:
Countertops don’t Flexing creates tensile forces fail by crushing. Reinforcing resists tensile forces
Reinforcement and flexural strength are important HERE. This is where countertops crack. Tension forces run in straight lines
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What proper reinforcing can do Reinforcing Placement Tips
Cantilevers need reinforcing near the top
500 lbs of sand 8’ x 6” x 1.5” beam No cracks!
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Strong Reinforcement Materials
Use structural material that is strong, reliable and appropriate in size. 7 day-old concrete 12” bar top overhang 960 lbs of sand No cracks!
9 gauge block ladder wire 65 66
11 Tools and Materials What NOT to use: Stucco mesh /diamond lathe is Reinforcing not appropriate structural reinforcement.
Chicken wire and fencing are woefully inadequate .
#3 rebar is too large for 1.5” thick slabs.
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Poor Reinforcing: What not to do Poor Reinforcing: What not to do
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Mixing, casting and curing Materials
Mixing and Casting
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12 Materials Equipment
Mixing and Casting: Specialty materials Mixing and Casting
Pigments Superplasticizer VCAS
Available from www.concretecountertopinstitute.com73 74
Equipment Equipment
Mixing and Casting Mixing and Casting
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Equipment Equipment
Mixing and Casting Mixing and Casting
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13 Equipment Concrete 101
Mixing and Casting Aggregates Gravel Sand Cement Water
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Why not just use bagged concrete? What makes a good countertop mix?
The right concrete needs to have: Pre-bagged home center concrete:
High early strength so you can finish faster. Made for sidewalks, footings
Good crack resistance. Aggregate-rich, cement-lean
Low shrinkage potential which minimizes curling. Needs excess water for workability
Consistency for color duplication and long term 28 days to gain rated strength performance.
Low cost.
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Level 1 Mix Level 1 Mix Formula
Based on local raw ingredients 53 lbs pea gravel
High strength 53 lbs of sand
Gray or white cement-based concrete 30 lbs of Type 1 Portland cement
Low cost: $1.90/sf @ 1.5” thick 5 lbs of VCAS (pozzolan)
10.5 to 14 lbs of water
5000+ psi in 3 days
7500+ psi in 7 days Makes about 1 cubic foot of concrete
8 sq ft @ 1.5” thick; $1.90/sq ft
6 sq ft @ 2” thick; $2.55/sq ft
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14 Professional Mix VCAS
Fully from-scratch VCAS is a pozzolan Allows for total customization and control Ultra-finely ground recycled glass Can make pure-white concrete
Based on same materials as Level 1 mix
Total control yields consistency and repeatability
Requires more precise tools
High strength, good performance Enhances workability Low cost: $1.90/sf @ 1.5” thick Boosts long term strength Eliminates efflorescence 85 86
Water Why Not Just Add Water? An important ingredient that must be dosed carefully. It’s easier… It’s cheaper… It’s faster…
It is not used like salt and pepper are to “season” the But is it the right thing to do? concrete to “taste”. 87 88
The Role of Water Simply Adding Water:
Reduces strength Grape Kool-Aid® Increases porosity Increases shrinkage Alters coloration Decreases freeze-thaw resistance More chance of cracks
Produces poorer quality concrete Too much water dilutes strength, color 89 90
15 Improving workability Improving workability without adding water without adding water
Superplasticizer
Video
Use less water to make better concrete Add workability without losing strength
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Precision is essential for quality and consistency Casting Concrete
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Wet Casting Wet Casting
Pour adjacent pieces from the same batch for consistency 95 96
16 Wet Casting Wet Casting
Complex shapes require complex forms. Wet cast mixes are usually fluid and pourable. Castings are sometimes vibrated for improved surface quality. 97 98
Wet Casting Curing
Wet cast concrete has fine detail and great precision.
Wet cast concrete has unique surface texture.
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Curing Curing
Tomato Seed Needs water to grow Dies if dries out
Drying is NOT curing. Curing enables the concrete to gain strength. Cure for 2-3 days before stripping. Wetting the concrete keeps the moisture inside the concrete from evaporating. 101 102
17 Processing Ground versus As-Cast
Consists of Grinding, Honing, Grouting, Polishing This choice of finish affects many of the steps: Forming Depends on Ground versus As-Cast Mix design and casting Processing Sealing
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Processing Step 2: Grind Processing Step 1: Flatten (Optional)
Rough grinding, initial honing
Flattening the back, smoothing the underside.
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Grinding Equipment
Heavy milling with turbo cups Grinding Rough, aggressive. Used to expose aggregate.
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18 Processing Step 3: Hone Honing
Light material and scratch removal 50 grit – 200 grit
Fine finishing, honing
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Equipment Equipment
Honing Honing
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Equipment Crème Finish
Light Hand Sanding Light Hand Sanding
400 – 800 grit wet/dry sandpaper 113 114
19 Crème Finish Processing Step 4: Grout
Light Hand Sanding
Filling pinholes and voids. Minimal for as-cast finish. 115 116
Grouting Supplies
Grouting
May need to be done more than once for a ground finish.
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Processing Step 5: Polishing Grouting (Optional)
Polishing: Sheen development 400 grit – 3000 grit
Grout = Cement + VCAS + Pigments + Polymer
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20 Concrete Sealer
Protects the concrete from food, stains, oil Enhances the concrete’s appearance
Should be effective Should be easy to use Why seal concrete? Should be repairable if necessary
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Sealer Philosophy Sealer Philosophy
Two schools-of-thought: “Natural concrete” finish using penetrating treatments “Natural concrete” using penetrating treatments - No physical barrier between concrete and Topical coatings staining agents - Relies on care and constant diligence in cleaning and maintenance - Vulnerable to acid and some stains
Traditional stone and tile “sealers”
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Some sealers have great stain Sealer Philosophy and acid resistance:
I recommend high performance coatings
Coatings + Physical barrier between concrete and environment + Greatest stain resistance, least maintenance
- Can scratch Two different - Large variety of products, great variability urethane coatings.
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21 Many do not: Recommended Sealer: TK6
One part, water-based coating. No mixing, no fumes Gloss or Extra Low gloss Interior or exterior use, UV safe Wipe on application Resists: Lemon juice Vinegar Mustard Coffee Oil Red wine Buy from VSeal.com
127 128 “Natural concrete” finishes: hardeners, wax, diluted acrylic.
Application Equipment Application Process
Microfiber Cloth Priming • Dilute TK6 with water • Add 1 part water to 10 parts TK6
• Wipe on generously to soak into concrete • Wipe off thoroughly before it dries
• Let dry 30-60 minutes • Repeat, let final primer dry for 1 hour
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Application Process Application Process
Priming Sealing • Undiluted TK6
• Wipe on very thin, streak-free film
• Let dry 1-2 hours between applications • Apply minimum 6 coats
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22 Application Process Choose a sealer that:
Offers countertop-quality performance Sealing Achieves the look and feel desired Is reliable Is available from reliable and dependable supplier Comes with effective and detailed instructions You are comfortable using Is cost effective
Consult the manufacturer, practice and test before using any sealer.
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Common problem: Staining, etching and sealer failure Test to verify
Sealer used improperly, insufficient coats, over dilution (trying to turn a coating into a penetrating sealer) Wrong sealer type used for environment. Acidic materials attack cement paste, leading to etching, dulling and pitting Improper assumption that polished concrete offers stain resistance Incorrectly set expectations; poor client education
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Extensive, free sealer information: Installation Sealer articles and videos on the CCI website at:
www.ConcreteCountertopInstitute.com/Sealers
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23 Installation Transportation Similar to granite countertops Transportation Handling Mounting Small sink installation Plumbing fixtures
Getting there is half the fun 139 140
Installation
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Installation Tools and Materials Different from granite countertops: Installation Undermount kitchen sinks Seaming Caulking Anchors/drilling Repair
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24 Installation
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Installation: Seams
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Major steps in precast concrete Seams countertop manufacturing: Concrete: Sanded acrylic 1. Templating tile caulk 2. Forming 3. Reinforcing 4. Mixing, casting and curing 5. Processing 6. Sealing 7. Installing
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25 Questions & Resources
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© The Concrete Countertop Institute, LLC 2013 152
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