After taking the on site measurements of the Parker Outlet store facade, it was time to throw Google SketchUp at the design project.
This is, after much design head scratching, what the Slab Fab Studio awning solution might look like.

Amy and her brother Jeff Parker (co-owners of Parker Hosiery), were excited, and gave the go ahead for the actual building of their Outlet awning.

I designed the awning in several bolt together pieces.
The vertical supports to be through bolted into the brick wall.
The horizontal roof support bolted to the vertical support.
The Outlet lettering, cut out of 1/8″ steel, 12 inches tall by Laser Precision Cutting were welded to a flat bar arc, and bolted to the vertical supports.
The galvanized 14 gauge steel “wave” roof was bent up by B and H Environmental and Sheet Metal of Asheville. It also bolted up to the awning horizontal supports.
The multiple pieces made the awning more difficult to fabricate initially. But it made the installation much easier… the brick facade was very uneven and ten feet off the ground.
Here is a picture of the awning in my shop prior to painting.

Here is a picture of the awning after finish painting and installation.

And another to accentuate the “wave” roof…

Tino Procida and Anoop Krishnan (Mela Restaurant) have opened a new restaurant on Lexington St. in Asheville called Boca.
They contacted Slab Fab Studio for color consultation, some specialty paint finishing, and some concrete elements at the beginning of the project remodel. The space was a clothing store previously.
The floor to ceiling brick columns in the space the interior had been painted over many times… Their last incarnation being a bubble gum purple color. We decided to bring the brick back to a charming and easy on the eye “brick” color, that would give that cozy lived in but not abused feel. Here is a picture of the previously painted brick with a coat of “brickish” tinted primer base on it.

Here is a picture of the same column with a variety of glaze colors and a faux mortar joint color… I think the brick, now looks and feels like…. brick!

We wanted to have the restaurant feel historic, jazzy , but comforting in all light.
In the end, we wound up with a “old school room” feel to the interior space.
A charcoal ceiling, school bus muted walls, natural pine trims on the huge windows and darkly stained tables and chairs. The whole place feels muted, friendly and unpretentious.

The outdoor dining/courtyard area, is a lovely fresh air dining space. David Earl (Tomlinson) of Dynamic Metal Work, did all of the steel railing work, and the water fountain for the courtyard.
Slab Fab Studio did the concrete cap elements for the railings through out.

The food at Boca is fantastic! One of the best huevos rancheros breakfasts in town!

Last but not least…
Google SketchUp continues to amaze my brain…
I designed this stairway for studio access to this upper balcony… SketchUp made building the set of stairs much easier… because the pieces were already put together (virtually).

Google SketchUp actually helps you visualize constructing the project, while you make the project drawing.
Because you can view the drawing in 360 degrees, you can view all aspects of the project’s anatomy. SketchUp is very helpful for creating cohesive, well organized and visually compelling drawings for the fabricator and the client.
Here is the finished product in place.

Here is a drawing of a metal platform bed that also happens to be our bed at home.

You’ve probably seen the finished project before but….

Here is a square concrete, steel ,and wire glass coffee table that will soon be produced.

I am working on some concrete casting experiments on textured board.
I was searching for a way to create a weathered, historic, or rustic looks.
The possibilities are endless with concrete, it seems to really be up to one’s imagination.
I will be creating a full scale project using one of these filled textures… I’ll keep you posted.

Here are some lovely linen colored concrete end tables and coffee table.

The “Bar Console” ( 26″x14″x36″H) is a Briwaxed 3/16″ plate steel and a ground and clear lacquered steel rod configuration.
I wanted the shelving space to be dynamic looking, but retain some practical storage. I came up with this, encroaching overhang design, while thinking about skeletal skyscrapers under construction…

The above coffee table was an experiment.
I welded up a cage of 3/8″ square bar steel.
Then placed the cage in a concrete mold and poured in a moss colored concrete.
I then polished the concrete flush with the steel bar.
After a clear finish and “Craftsmanesque” style detail to the welded steel base.
In the right home this could be very elegant and unusual.

In the coffee table photos above…
I wanted to get away from my usual square tube steel table base design.
I opted for some 3/16th” plate steel and have “leg” areas CNC plasma cut out by Bryan at Powdertek here in Asheville.
I love the squatty/clunky feel of the coffee table base.
I am certain that I will be including more welded plate steel base designs into my work.
I’d also love to try out Powdertek’s powder coating services when a appropriate project comes up…
My mind is reeling with the color possibilities!
I’ll let you know!

Here are some projects that we have produced, that may inspire you.

We produced a concrete fireplace surround with a delicately curved mantle and hearth.
The curved surround elements allude to the soft geometry of the gas “logs” within the fireplace.
The “gas logs” are concrete and ceramic “fire shapes” made by Rasmussen Gas Logs and Grills.
The fire shapes appealed to us because they weren’t trying to imitate anything else (wood).
You can peruse the many different gas log alternatives using the Rasmussen link here.

Slab-Fab-Studio has begun an association with Landis Reed Homes of Charlotte North Carolina.
Landis Reed Homes approached us feeling that our product, in their unique model homes, would further separate them from their competitor’s cookie cutter offerings.
Slab-Fab-Studio’s unique concrete countertop solutions are now being offered to Landis Reed Home buyers as kitchen and bath upgrade options.
Needless to say… Were excited about the possibilities.
We are glad that Landis Reed Homes had the vision to roll with us!
Above is a Landis Reed Home model master bathroom vanity under construction.
Pardon the dusty cabinets!

As an aside…
For the first time in my self-employed life, I have purchased magnetic door signs for my truck.
I designed the sign online at www.buildasign.com.
I made a quick Photoshop logo up for the occasion, chose colors, supplied text, then click, my part was done.
Submitted for her logo design approval…Slab Fab-Studio friend Jennifer Losch, a Digital Marketing whiz/guru (here in Asheville) gave me a C+ on the logo… (I think she was just being nice) Check out her services if you want professional marketing help.
For a quicky thing… I am happy for now.
BuildASign.Com did a great job for me, at an affordable price.
I was proud to finally hang my shingle out (on my truck).
After showing the new truck signs to my hard working brother in law, Brian Friel, professional plumber, and owner of Gutter Helmet here in Asheville, asked… “Why did you put your phone number on your truck? …..People might call you for work!”

You may, or may not recall, an experimental two pour inset countertop (work in progress) I mentioned in my last blog.
Here is a picture of the finished 1 1/2″ x 22″ x 36″ two tone top.
I’m am interested in the possibilities that this piece inspires…. the inset could be just about any shape that you could come up with, and definitely any variety of color combination. Hmmmmmmm……pretty cool.

Slab-Fab-Studio has been producing some welded steel furniture too.
Here are a couple of steel bedside stands with a “Antler” colored concrete slab as the tops.
These stands will eventually have a muted maple wood drawer installed under the top, to add storage, and add another contrasting material texture.
These side stands could just as easily live just as you see them here.

Lastly,
Slab-Fab-Studio got it’s hands on a chunky 2″ x 42″x 74″ rustic wood slab dining table top from Chris McMillan at Dwellings in Biltmore Village.
We welded up a simple 1 1/2″ tube steel support frame with 4″x 4″ steel leg “sleeves” attached.
We then mortised rustic 4×4 stained wood posts into the steel sleeves.
We secured the wooden table legs to the steel sleeves with macho lag bolts, and voila!… one super beefy/rustic dinner table fit for you chic, urban primitives.
The table is currently at Dwellings.
It will likely be in their April Warehouse sale, along with other Slab-Fab-Studio furniture.
Go to the Dwellings website for warehouse sale details… because spring is coming….soon. (but not soon enough!)

Contact us if we can help you with your nest building!
Billy@slab-fab-studio.com

I just finished a remake of my Slab-Fab-Studio website.
I used a template design, then tweaked it to get just what I needed.
I wanted simplicity, user friendly navigation (good organization) and lots of pictures.
You can peruse the new website by clicking here.

Slab-Fab-Studio recently installed a retail counter for Chris McMillan’s new Dwellings store in Biltmore Park.
Shane Martin produced the counter carcasses. Slab-Fab-Studio did the ebony stained trim work, acid etched galvanized panels, and of course the concrete counter tops.

Our good friend , Ben Schlaefer, found an antique door he wanted to turn into a head board for his bed.
Ben did the nasty job of stripping off many layers of paint . Slab-Fab-Studio cut the door to size. Then welded up a bracket and bracing to tie the new head board to Ben’s existing bed frame.
This looks even better attached to the bed.

Slab-Fab-Studio is getting a bit experimental (for us) with a new “inset” slab design.
The idea is to pour a perimeter of concrete, then inset another contrasting pour of concrete after the perimeter has cured enough. Here is a picture of the perimeter with the wire lathe showing, that will integrate the two slabs when both are poured. I polished the perimeter frame and exposed the aggregates. I plan to leave the interior, while a different color, unpolished , for further surface contrast.
I’ll let you know how the experiment works out.

Finally, I made up a logo for the biz. It’s not real deep, but it’s graphic enough to get the job done I think.
I needed something to ad to the magnetic signs I’ve ordered for my truck. Here’s what I came up with…
All you logo whiz’s might have some feedback for me. I’m not long term married to the graphic… just eloped on the quick.

Slab-Fab-Studio has been at it again!
This time it is in a charming 1920′s-30′s cottage in West Asheville, NC.
Our client Anne Dupree Rodgers is an out doorsy type and avid kayaker.
With her fondness for the river, we wanted AD’s concrete counters to have a earthy, organic, river stone kind of feel.
We (Jim Ojamaa and I ) made up some concrete samples, trying to pick up a twinge of walnut color of AD’s newly refinished dark walnut floor.
We lightly honed all the concrete countertop slab surfaces with a 400 grit diamond pad, by hand, to bring out some delicate sand texture.
This makes the slabs feel more smooth stone like, as if they were honed by thousands of years of the river lapping at them.

Slab-Fab-Studio also installed the subway tile back splashes to compliment the concrete counters.
Anne Dupree chose a matte antique subway tile to integrate the antique charm of her house back into her stainless appliances, concrete counters, and undermount stainless sink.
Anne Dupree had Shane Martin, our local Asheville cabinet maker wunderkind, create her cabinetry.
She chose a simple shaker design, and had Shane paint them with a mildly antique off white acrylic lacquer.
It is great to have a fantastic start to a kitchen project, like Shane’s excellent cabinetry work, to help make Slab-Fab-Studio’s concrete counters look even better!

Kevin and Rachel had chosen a darkish charcoal base for their concrete tops.
We opted for cibola granite, amber glass, black glass, mirror glass, and white granite aggregate seedings to accent the charcoal base.
The seeding aggregates are cast (artfully) into the bottom of the concrete molds, which will end up as the top face of the cast.
One of the beauties of concrete is that you can get very refined in your color tones and color matchings.
The aggregates you might choose ( if you are polishing to expose them) all add to the flavor of the slabs.
Think of it like cooking, in that the accent aggregates are the spicings, that give the slabs visual zing you have control of.
These controls can tie into all sorts of other color concerns etc. that you have in your existing environment.
Design control is good!
Concrete color options are almost limitless!
For a new minor esthetic change, Slab-Fab-Studio made 1 inch thick back splashes for the counters (ordinarily 1 1/2 inches like the slabs themselves).
The elegance of their appearance seemed to overcome any structural worries about them being 33% thinnner.
They turned out beautifully (flat,straight, and strong) and will become the new standard back splash issue.
The sink area was a real test of craftsmanship.
The relationship between the countertop and the sink is very focal… the fitment a make or break in terms of quality craftmanship or not.
As the sink was never meant to be undermounted, the cutout, or rather knockout ( a foam template that occupies a space in the cast for some future object… say a sink or faucet) in the concrete had to be traced freehand inside the sink itself (trickier than it sounds) (thank you art school!).
With much head scratching I managed to make a mold knockout that seemed to function, and crossed my fingers that it had remained faithful to the grace of the existing sink interior detail.
I wouldn’t know until we installed the sink… but all turned out well in the end.

Two issues that have been at the top of my concrete countertop craft mind… have been sealer and slurry.
Effective sealing has it’s obvious place, but it’s more important than that… An effective (durable, stain resistant, easy enough to apply) sealer is really the holy grail of finishes… we have been searching for some time now.
All the while “effective” has to include esthetically pleasing to the eyes and touch… that complicates the criteria!
We’ve been experimenting, and have come up with a very good solution…
Wear, tear ,and time will tell if we are onto something.
I will let you know.
Lastly, and I should have known this as a former painting contractor…
Surface preparation really, really, matters….REALLY!
“Slurrying”, the filling of air voids and “bug holes” inherent in the concrete casting process with a portland cement based paste, has been somewhat under exercised at Slab-fab-Studio… I am embarassed to say… we just didn’t get it!
We have recognized the error of our ways and now understand the sublime importance of solid, smooth (as babie’s bottoms) surfaces.
The trees, and the forest! The forest, and the trees.
Perfection… is a road that has no end..
We are enjoying the drive…

As always many thanks to Jim Ojamaa. And a thanks to Robert Rhyndress for hands, back, brains, and spiritual guidance

We decided to do an unusual concrete mix, where the aggregate content of mix (ordinarily gravel) would be replaced by broken safety glass cubes.
We thought this would create a modern/slick looking set of counters for the showroom she was designing for Cowan Tire’s brand new Rutherfordton, NC location.
Hunt and Sallie Cowan’s new tire store and car service, is a slick, multi-bay, ultra outfitted concern, seemingly more at home pitting Indy cars than changing the oil in Uncle Joe’s clunker.
But Sallie and Hunt are down to earth, with a real interest in recycling, an intense passion for vintage car racing, (and a keen sense of good BBQ!).
They even have a space heater that keeps their entire shop toasty in winter, that runs off used motor oil, with almost no emissions.
The shop may be the slickest thing on highway 221, but I’m sure the service will be very down home friendly.

The concrete counters were going to be big on colored and clear glass, with mirror and stainless steel parts thrown in, all polished to a baby smooth feel.
We were looking for wow factor, to quote Sallie, she wanted “more cowbell” that you can’t often find in straight up polished concrete.
I ended up making 260 pounds of recycled shower and sliding door safety glass for our aggregate content courtesy of Habit for Humanity. I broke the glass windows with a steel petanque ball sometimes having to throw the ball hard, many times before it shattered… safety glass is tough stuff!

We also added 50 pounds of cobalt blue glass made from crushing blue wine bottles with a 8 pound tamper.
No, I did not drink all of this German Liebfraumilch…
We found out that the recycling centers here in Asheville do not recycle blue glass.
Apparently it “poisons” the clear, brown, and green glass colors, and has to be hand separated out.

Sallie and I labored over the seeding process as the call was always “more cowbell”.
We cut cobalt blue glass and canary yellow panes found at a local stained glass supply shop into dramatic larger shards.
We added hidden treasures, coins and surprises.
Hunt provided us with stainless steel bits and bobs from his car spare part inventory, to further spice up the tops, sprockets, washers, and bearing races.
There were twenty four man hours in the mold seeding alone.
Many elements of the seeding had to be glued onto the mold one by one.
Here is what the seeded forms looked like prior to pouring the concrete.

Here is a picture of the molds poured with concrete.
We used white portland cement, white sand, and titanium white colorant to get… white concrete!
The curved leading edge of the mold was a nice challenge.
Multiple laminations of thin plywood provided the flexibility to follow the curve, and the strength to contain several hundred pounds of concrete.
The counters were basically two mirroring “wing” shapes in four sections, all totaling about 750 pounds of concrete.

Here is a picture of a slab section after polishing… aggregate exposed.
I’ve been looking for a way to describe the effect of glass aggregate replacing the stone/gravel.
I guess the assumption is that concrete usually looks heavy and clunky.
The white portland cement base and transparent aggregates, make these slabs have a inorganic/synthetic feel without being fake, cold, or plasticky.
The largeness and drama of the glass shards put distance between this concrete and a “terrazzo” look.
I keep coming back to “modern” in a “space age” kind of way.
The photos do not adequately convey this feel.

Here are pictures of the final product, installed at the construction site.
I will be taking more pictures when the showroom is completed… to give you the full impact of the tops in context.

Please check the Slab-Fab-Studio Flickr gallery to the right of this page for larger images.