Here’s a couple candid shots (by a real pro – the client) of a recent installation in nearby Putney, Vermont. The set of concrete countertops were cast in “Thunder” with a light polish but the real challenge was the lack of wiggle room once they were set in in their final resting place. In this particular project (designed by the client as well!), there were to be no backsplashes and no overhangs on the countertops – flush to the wall and the cabinetry. To add to the demand, the seams of the main ell, over ten feet long in both directions were a mortise-and-tenon style puzzle feature; this detail was extrapolated from the notched drawer pulls in the hand-crafted cherry fronts. All in all, this meant there was no room for adjustment in any direction – it HAD to fit, first try.

We were a little nervous but we took our time – easy does it -  the sections were carefully set and slid into each other… voila!  Ah yes, easy peasy, lemon squeezy.

We have just stripped and flipped the last and most intricate piece of the puzzle-seamed kitchen we are creating for a nearby new home in Putney, Vermont. The concrete countertops include an integral sink and drainboard with stainless steel inserts, “mortise and tenon” seams, a ground and bevelled edge, a zero-overhang and no backsplashes (wall scribed). All-in-all, a very exacting challenge which is a fitting component of the owner-designed residence, meticulously hand-crafted with incredible attention to detail. We are honored to be a part of this project!

The images show the features of the piece during the wet-curing process, gaining strength and nearly ready for processing, just prior to installation in its final position atop gorgeous cherry cabinetry hand-made by another part of the puzzle, Claude Blazej of Avalon Woodworking. Look for finished shots coming soon by a photographer much more skilled than I – the owner (these guys are a hard act to follow…).

So, how do you make a concrete countertop? A little more process discussion…

After a template is made by recreating the exact  layout and dimensions of the cabinetry where the finished tops will be installed (using thin strips of lauan plywood and hot melt glue), the transferred shape is duplicated in the shop in the form-building process. Outside dimensions are matched with edge forms on a base sheet; cutouts for appliances or fixtures are located precisely and blocked out (concrete is unforgiving after the fact).

The completed form is moved to the casting table, the concrete is batched and mixed to a very strict formula and then placed carefully so nothing is disturbed. Vibration is applied to consolidate the fluid mix and drive air bubbles to the surface, strengthening and densifying the material. Then the wet slab is lightly floated with a trowel to smooth the under-surface (since this is reverse casting) and wrapped up to retain moisture overnight.

The pictures accompanying this post, from a current project, show a freestanding island cabinet in the cabinetmaker’s shop while being templated (no overhang on this piece) and the resultant form (with cooktop blockout) immediately after placing and vibrating the piece on the casting table in our own shop.