Latest counters, install, and revelations.

Hey Folks!
Slab-Fab-Studio has done it again!
Our friends Kevin and Rachel Mitchell needed a new look for their kitchen.
They were very tired of their faux butcher block formica and decided to go with Slab-Fab-Studio for concrete replacements.
Kevin and Rachel did their own prepping of the kitchen space… Wall painting, trim etc.
Why not have a fresh look all around if you are going to go to the expense of new counters?
They chose a nice “spicy” ochre color for the walls and a suitable off white for their 1927 interior trims.
Kevin and Rachel had existing custom oak cabinets, but were worried that they were tired looking.
I recommended that they replace the hardware (an inexpensive change), and that we gear the concrete colors to compliment the existing cabinets.
We would take a wait and see approach to changes in cabinetry (likely possible painting) after the counters were finished.
Nowadays everyone is wanting to make the most of their living space.
Yet budget is playing a determinant role in spending decisions because the endless housing appreciation funny money of seems to be over for now. (come back!).
In these times, you have to get creative.
Kevin and Rachel had paid handsomely for a Anthracite over mount kitchen sink when they bought the house.
They really were not in the position to replace it… after all they liked it, but they wanted to have their sink undermounted in their new counters.
The sink was too large to fit inside the cabinet cavity as it was… we would need to trim off it’s overmount flanges in order to fit it in.
Anthracite is some cross between a cultured acrylic and marble cast, hard and brittle.
I had to warn Kevin, I could try to cut it down, but may destroy it in the process.
With disclaimers in place, I bought a small carbide circular saw blade, set it up on my table saw and gingerly made the cuts.
I successfully trimmed down the sink…. at the total destruction of the blade.
We were in business for undermounting their sink.

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