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Getting Started withConcrete Countertops

Presented by: Jeffrey Girard, P.E.Please hold. The seminar will begin shortly. 2

Getting Started withConcrete Countertops

Presented by: Jeffrey Girard, P.E.

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Introduction

Jeff Girard• President & founder• Instructor• Civil engineer• Started 1999

CCI• Training• Technical information• From-scratch mixes• Founded 2004

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My First Concrete Countertop

Jan 1999

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My First Concrete Countertop

Aug 1999 6

My First Concrete Countertop

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My First Concrete Countertop

July 1999 8

Poll

What’s your experience?

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You want to get to all these steps:• Templating• Forming• Reinforcing• Mixing• Casting• Curing• Stripping the forms• Grinding and polishing• Grouting• Sealing• Installing

• Assuming you’ve decided what project to make.

Your project

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Need:• Space

• Power

• Light

• Water

• Heat

But first: Your workspace

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Garage

Workspace

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Basement

Workspace

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Need:• Personal safety protection

• Equipment

• Materials

Second: Your stuff

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Safety first!

Personal Protection

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Concrete countertops are countertops…

… that just happen to be made of concrete.

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Concrete Countertops

Cast-in-place is done on site, right on top of the kitchen

cabinets.

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Precast is done in your shop,

garage or basement.

Concrete Countertops

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Precast MethodsHand packed

Stiff, zero-slump concrete

Variegated, hand-pressed or solid

Single-sided molds (2D and 3D)

Often all-sand mix concrete

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Precast Methods

Vibration

Single and double-sided molds (for 3D)

Often aggregate based mix concrete

Wet cast

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Major steps in precast concrete countertop manufacturing:

1. Templating

2. Forming

3. Reinforcing

4. Mixing, casting and curing

5. Processing

6. Sealing

7. Installing

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TemplatingAccurately capture important site

information in a physical mock-up.

Good templates ensure an accurate fit. 22

Templating Shape and dimensions of the

countertops

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Templating Location of sink and cooktop openings

Bartop overhangs

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Templating Fixtures: sinks, faucets, cooktops

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Templating Cabinet inspection

Gap, uneven cabinet

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Templating Site conditions

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Templating and Forming

Equipment

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Templating and Forming

Equipment

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Templating and Forming

Equipment

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Templating and Forming

Equipment

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Templating and Forming

Equipment

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Templating

Equipment

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Templating

Materials

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Forming

Forms affect the fit, finish and overall quality.

Accurate forms require accurate templates.

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Forming

Melamine boxes.

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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Forming

Equipment

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Forming

Equipment

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Forming

Materials

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Forming

Materials

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Forming

Equipment

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Caulking

Only use 100% silicone caulking

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Caulking

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Caulking

Wax the form corners first.

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Caulking

Only use 100% silicone caulking

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Caulking

Tool the caulk

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Caulking

Peel off excess after

caulk is cured.

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Curves

Curved edges formed

with foam insulation.

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Embedments

Embedments are glued to form surface.

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Embedments

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Sinks and FaucetsThere’s more to forming than just building

boxes.

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Sinks and FaucetsFaucet and sink layout are critical to function,

looks and long-term satisfaction.

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Good work is noticed once…

Forming

Poor craftsmanship is never forgotten.

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Forming Tips

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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ReinforcingProper reinforcing is critical for success.

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Structural Reinforcement

Most important in Precast (wet cast, hand packed) Pieces are moved, handled and transported

Moderately important in Cast-in-Place Cantilevers still require correct reinforcing

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Reinforcing Rules

Reinforcing is placed close to the tension face.

All countertop slabs are reinforced Bartop overhangs also have cantilever

reinforcing located near the top surface.

Never in the middle of the slab!

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Reinforcing Do not make a concrete countertop like

a driveway or a sidewalk.

It won’t perform the way you expect it to. 58

Countertops are not slabs-on-grade

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.

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Countertops are beams

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.

Weight

BEAM

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Beam Principles

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How concrete countertops work:

Reinforcement and flexural strength are important

HERE. This is where countertops crack.

Countertops don’t

fail by crushing.

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Reinforcing Placement Tips

Flexing creates tensile forces Reinforcing resists tensile forces

Tension forces run in straight lines

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500 lbs of sand8’ x 6” x 1.5” beamNo cracks!

What proper reinforcing can do

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Reinforcing Placement Tips

Cantilevers need reinforcing near the top

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Strong

7 day-old concrete12” bar top overhang960 lbs of sandNo cracks!

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Reinforcement Materials Use structural material that is strong, reliable and

appropriate in size.

9 gauge block ladder wire

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Reinforcing

Tools and Materials

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What NOT to use: Stucco mesh /diamond lathe is

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

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Poor Reinforcing: What not to do

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Mixing, casting and curing

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Mixing and Casting

Materials

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Mixing and Casting: Specialty materials

Materials

Pigments Superplasticizer VCAS

Available from www.concretecountertopinstitute.com 74

Mixing and Casting

Equipment

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Mixing and Casting

Equipment

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Mixing and Casting

Equipment

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Mixing and Casting

Equipment

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Mixing and Casting

Equipment

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Mixing and Casting

Equipment

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Concrete 101Aggregates

Gravel

Sand

Cement

Water

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What makes a good countertop mix?

The right concrete needs to have:

High early strength so you can finish faster.

Good crack resistance.

Low shrinkage potential which minimizes curling.

Consistency for color duplication and long term

performance.

Low cost.

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Why not just use bagged concrete?

Pre-bagged home center concrete:

Made for sidewalks, footings

Aggregate-rich, cement-lean

Needs excess water for workability

28 days to gain rated strength

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Level 1 Mix

Based on local raw ingredients

High strength

Gray or white cement-based concrete

Low cost: $1.90/sf @ 1.5” thick

5000+ psi in 3 days

7500+ psi in 7 days

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Level 1 Mix Formula

53 lbs pea gravel

53 lbs of sand

30 lbs of Type 1 Portland cement

5 lbs of VCAS (pozzolan)

10.5 to 14 lbs of water

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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Professional Mix

Fully from-scratch

Allows for total customization and control

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

Low cost: $1.90/sf @ 1.5” thick

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VCAS

VCAS is a pozzolan Ultra-finely ground recycled glass

Enhances workability

Boosts long term strength

Eliminates efflorescence

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WaterAn important ingredient that must be dosed carefully.

It is not used like salt and pepper are to “season” the concrete to “taste”. 88

Why Not Just Add Water?

It’s easier…

It’s cheaper…

It’s faster…

But is it the right thing to do?

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The Role of Water

Grape Kool-Aid®

Too much water dilutes strength, color90

Simply Adding Water:

Reduces strength

Increases porosity

Increases shrinkage

Alters coloration

Decreases freeze-thaw resistance

More chance of cracks

Produces poorer quality concrete

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Improving workabilitywithout adding water

Superplasticizer

Use less water to make better concrete

Add workability without losing strength

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Improving workabilitywithout adding water

Video

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Precision is essential for quality and consistency

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Casting Concrete

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Wet Casting

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Wet Casting

Pour adjacent pieces from the same batch for consistency

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Wet Casting

Wet cast mixes are usually fluid and pourable. Castings are sometimes vibrated for improved surface quality. 98

Wet Casting

Complex shapes require complex forms.

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Wet Casting

Wet cast concrete has unique surface texture.

Wet cast concrete has fine detail and great precision.

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Curing

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Curing

Tomato Seed Needs water to grow

Dies if dries out

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Curing

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.

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Processing Consists of Grinding, Honing, Grouting,

Polishing

Depends on Ground versus As-Cast

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Ground versus As-Cast

This choice of finish affects many of the steps:

Forming

Mix design and casting

Processing

Sealing

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Processing Step 1: Flatten

Flattening the back, smoothing the underside.

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Processing Step 2: Grind(Optional)

Rough grinding, initial honing

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Grinding

Heavy milling with turbo cups

Rough, aggressive. Used to expose aggregate.

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Grinding

Equipment

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Processing Step 3: Hone

Fine finishing, honing

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Honing

Light material and scratch removal

50 grit – 200 grit

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Honing

Equipment

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Honing

Equipment

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Light Hand Sanding

Equipment

400 – 800 grit wet/dry sandpaper114

Light Hand Sanding

Crème Finish

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Light Hand Sanding

Crème Finish

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Processing Step 4: Grout

Filling pinholes and voids. Minimal for as-cast finish.

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Grouting

May need to be done more than once for a ground finish.

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Grouting

Supplies

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Grouting

Grout = Cement + VCAS + Pigments + Polymer 120

Processing Step 5: Polishing(Optional)

Polishing:

Sheen development

400 grit – 3000 grit

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Why seal concrete?

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Concrete Sealer

Protects the concrete from food, stains, oil

Enhances the concrete’s appearance

Should be effective

Should be easy to use

Should be repairable if necessary

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Sealer Philosophy

Two schools-of-thought:

“Natural concrete” using penetrating treatments

Topical coatings

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Sealer Philosophy

“Natural concrete” finish using penetrating treatments - No physical barrier between concrete and

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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Sealer Philosophy

I recommend high performance coatings

Coatings + Physical barrier between concrete and

environment

+ Greatest stain resistance, least maintenance

- Can scratch

- Large variety of products, great variability

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Some sealers have great stain and acid resistance:

Two different urethane coatings.

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Many do not:

“Natural concrete” finishes: hardeners, wax, diluted acrylic.128

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

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Microfiber Cloth

Application Equipment

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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

Application Process

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Priming

Application Process

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Sealing• Undiluted TK6

• Wipe on very thin, streak-free film

• Let dry 1-2 hours between applications• Apply minimum 6 coats

Application Process

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Sealing

Application Process

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Choose a sealer that: Offers countertop-quality performance

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

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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Test to verify

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Extensive, free sealer information:

Sealer articles and videos on the CCI website at:

www.ConcreteCountertopInstitute.com/Sealers

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Installation

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InstallationSimilar to granite countertops

Transportation

Handling

Mounting

Small sink installation

Plumbing fixtures

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Transportation

Getting there is half the fun

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Installation

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InstallationDifferent from granite countertops:

Undermount kitchen sinks

Seaming

Caulking

Anchors/drilling

Repair

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Installation

Tools and Materials

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Installation

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Installation: Seams

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SeamsConcrete:

Sanded acrylic tile caulk

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Major steps in precast concrete countertop manufacturing:

1. Templating

2. Forming

3. Reinforcing

4. Mixing, casting and curing

5. Processing

6. Sealing

7. Installing

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Questions & Resources

What next? Level 1 Getting Started

• 65-page step by step instruction manual

• More sealer options

• Detailed shopping list for materials and equipment

• Priced at $99.

• SALE! $49 3 days only

Type this into your browser: bit.ly/Level1Sale

You will receive a link in a later email to access the free recording of this webinar.

Contact: info@concretecountertopinstitute.com or 888-386-7711

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© The Concrete Countertop Institute, LLC 2013