Our local masonry supply store closed last fall after nearly 50 years of operation (if I recall correctly), victim of the economic blues and a multinational corporate parent bent on trimming away the marginal outlets. It was a sad day. The yard sat empty over the winter, full not with pallets of brick and block, bundles of #4 rebar, and assorted flue tiles, but with drifting snow, scuttling dead leaves, and blank windows. Then I received a postcard in the mail at the very beginning of March, announcing that Shanahan Construction Supply Company of Turner’s Falls, MA was buying the property, expanding the store, and re-opening on March 29th, reincarnating it as a new and improved version of its old self.

Being ever the opportunist, and always on the lookout for a public venue to showcase our craft, I beelined it down to the drab gray concrete block structure surrounded by chain link fence and sure enough, there was lots of activity. I went inside, promptly met the hardworking owner, Ted Whelan of Guilford, VT, congratulated him and made my proposal: “Wouldn’t it be great to have a custom concrete countertop at his checkout desk, for all the builders, and homeowners to ogle?” He agreed (Ted’s a nice guy) but said he was already talking to a bluestone supplier about that very thing. Ted also sells woodstoves and fireplace inserts, in addition to masonry, stone, tools, and landscaping materials,  so I  proffered something about future possibilities and took my leave.

The next day the phone rang. Ted had changed his mind and wanted to talk about taking me up on my idea. I scooted back down, got some quick numbers, and off we went, back to the shop – they were opening in less than three weeks!  The retail counter was a big ell shape, resting on a wood-framed half wall which would be veneered in stone as part of the display. I opined that it might be nice to have his company logo embeded in the top, a suggestion he liked a lot. We decided to work with the logo colors overall – a sage green background  with a dark red logotype. A heavy grind to expose aggregate and a grommet hole for computer cables were also requested. I decided to add some crushed amber glass at the 90 degree turn for sparkle, radius the three exposed corners for comfort, and a little shallow bowl depression for fun. The joint between the two 7 foot sections would be a “z” puzzle seam. It would be sealed with our new high performance reactive lithium sealer, to withstand the wear and tear of a building supply location.

A week and a half later, we carried in the finished countertop. Ted loves it, we love it, and his friends and customers love it. That’s what we like to hear! The new store opened March 29 th and we wish Ted all the best (and hopefully, some business coming our way!).

Pantone, the world-reknowned authority on color, has announced that the color of the year for 2010 is Turquoise, specifically #15-5519 in their coding scheme. What does that mean? Well, it will get a lot of buzz in the fashion and design world, and show up in increasingly large amounts in our current surroundings until a new lucky winner is announced. But for some people, turquoise is already a favorite and the endorsement of a global taste-maker is only icing on the already-baked cake.

We have been working on a custom vanity top with an integral sink for a local client with whom we have had a pleasant collaboration in the past – a garden sculpture/fountain. Expanding on the ideas we explored in that venture, we are now incorporating them into into the new commission. The  four foot wide top is hand-pressed in natural gray concrete (our “Stone” tone) and features a gently rounded, deep oblong basin inspired by an antique  hand-carved wooden bowl. On the edge of the basin is a  terraced soap recess which will hold a special incised leaf tile. The faucet fixture is a wall-mount style, a Waterbridge style in Rustic Nickle finish, from Sonoma Forge. We created a narrow backsplash “shelf ” to house the fixture at the back of the concrete countertop, since the wall partition there was too shallow to accomodate it. The whole is acid-stained in the aforementioned turquoise, with a touch of green and brown, to work into the bathroom’s design scheme. This includes warm Mexican tile on the floor, original natural wood trim and cabinetry, and white fixtures and tub/tile surround with a sprinkle of turquoise blue decorative inserts.  Another wonderful example of artisan concrete’s ability to become whatever one might wish!

We are working on a sweet little project with some neighbors of mine in Wilmington, Vermont (I commute down the mountain to the studio in Brattleboro every morning…). The clients are a great couple I have known for a long time; I actually worked with Matt in my past life as a carpenter in the Deerfield Valley. He and his wonderful wife Angela have a summer cottage on the northeastern shore of Lake Champlain, Vermont’s closest thing to seashore (Vermont is the only New England state without a coastline!). Well, it may be a lake, but it’s a huge one and it has its share of beachcombing treasures. The bartop we are creating for their newly renovated kitchen in Wilmington is incorporating some of the glass treasures they have collected over the years. We are also emulating the undulating shape of a natural shoreline with the outer perimeter of this raised peninsula counter which will serve as an informal eating area overlooking the cooktop.

The crushed glass is only one facet of this accent piece: there will be three bands of color winding across the polished surface. One with the glass; another with exposed aggregate (native gravel), and a wider band with an acid-wash in greens and browns. Several small topographic terraces are sculpted into an edge to suggest natural erosion and the work of the elements that shape our world. Concrete is an excellent medium to showcase all of these design motifs in a single work of functional art which ties together the client, their environment, and the artisan/interpreter.

This is what we do – we love concrete!

Concrete countertops epitomize customization – and that’s the truth. No other material can be manipulated and personalized to the same degree. It’s the almost-magical phase change from liquid to solid that enables this opportunity; the artisan can work with and through the material to accomplish their design goals, be they straightforward or fantastical. Add to that the endless combinations of particular aspects such as color, shape, texture, dimension, amalgamation and the possibilities become limitless.

One example of the chameleon properties of artisan concrete countertops is the ability to coax several surface appearances from the same base. When concrete is turned out of the form, it has a solid, somewhat homogenous appearnance characterized by pigmented “cream”, the pure binder paste of cement and fines that line the face of the mold upon compaction in the pouring process. Lurking just below the surface are the aggregates that lend their strength to the matrix: first the sand grains and then the coarser particles, such as crushed stone or glass. The fabricator artist can reveal these at will, by varying the amount of grinding and polishing on the various faces of the piece. We have had a run lately (instigated by my friends in Putney) of what we term a light sand finish on the working countertop face, contrasted with a heavy grind on the vertical front edges. The subtle mottling and sparkle of the filled and polished worktop is set off by the multi-colored diamond ground profile of the counter’s edge, accented by a thin bevel where they meet. No other material can match this striking combination. Which is why we love what we do…

Just this morning, we flipped out a concrete countertop sink run cast in our “Slate” color which includes an integrated drainboard, as do many of our kitchens. New England residents love drainboards - maybe it is a hearkening back to our collective childhood, sitting in a grandparent’s kitchen with the big , old slate or soapstone farm sink and the wide pitched planes to each side where the dishes were set to air dry.  They are eminently practical and a perfect showcase for the three-dimensional versatility of artisan concrete. Each one is different from the previous, some subtly and some dramatically.

This drainboard uses an elemental reference to flowing water by incising ripples into the drain plane,  which is set to the right and slightly back from the undermounted sink aperture. This introduces a pleasing touch of assymmetry to the composition (any Slave to Rhythm would agree…). Immediately outside the New Hampshire window in front of which this concrete countertop will repose are the client’s lush perennial gardens; they are symbolized as well using the movement and vining shapes of the rippling grooves. Another reference wrapped into the design is the heavy roundover on the cabinet doors and their round wooden pulls.

Once installed atop the natural wood cabinets in the owner’s home, it will be apparent that this particular example of functional art was fully intended to be exactly there and nowhere else. Now, that’s integration!

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.

Not every project we undertake is a concrete countertop… Recently we created 15 cast concrete windowsills for a client’s residence in Westmoreland, New Hampshire. The client returned a little while ago and asked about creating a matching concrete hearth for a brick fireplace in the home: the same integral  terra-cotta color and the same molded profile on the lower edge. This was to be 3 inches thick with a gently arcing leading edge and a ”tongue” locking into the firebox area. We decided to block out part of the underside to reduce weight and make handling a little easier for all concerned. By doing so, we reduced the weight by about 25 %, down to 200 pounds of wetcast standard weight concrete. Every little bit (less) helps!

We are nearly ready to ship out the latest concrete countertop project from our casting tables and one of our most ambitious yet: a total of five sections of 2″ thick pure white concrete, destined for an inhouse restaurant at ABC Home and Carpet, on Broadway in Manhattan. Two of these pieces weigh over 600 pounds and are 10 feet long. They will form the bartops in a newly renovated restaurant at this prestigious New York retailer of interior furnishings – everyone knows of ABC in the design world!  Now a bit (or a lot) of Vermont craftsmanship will help the shoppers to satisfy their hunger for excellent cuisine and the best in architectural concrete surfaces. The bar was designed by Eric Slayton of  Brooklyn (go to http://www.ericslayton.com/) who has his custom furniture pieces on the showroom floor there. His work in steel, concrete, and wood emphasizes the material surface in a clean, straightforward manner, honest and functional.

A little revisit to a recent concrete countertop project helps to demonstrate the rationale and inspiration behind some of the design decisions that we make when contemplating an upcoming project.  Always a collaboration, of course, between artisan and client – the concrete results incorporate the designer, the owners and their respective environment, be it a home or business.

In this particular case, we knew that the kitchen remodel included a multi-colored slate tile backsplash and the existing natural cherry custom cabinetry. The situation required a little thought about the proper means of tying this together. we opted for a subtle gray/green sage base color for the countertop, with some black sand (recycled coal slag!) added for texture, and a series of one inch square glass mosaic tiles, backpainted in tones to coordinate with the slate’s amazing range of color. These were arranged in a fourquare pattern and embedded at three different locations in the tops. Seen in context, it all makes perfect sense. And that’s why we love what we do – reasons to be cheerful.

The concrete countertop we cast in our “Terra” shade was installed last week in its final home, atop a natural birch cabinet vanity. The colors worked together as intended, with the warm orangey wood and the tan/beige marble baseboard tile bringing out the concrete base color as well as the circular ”Caramel” inserts. A little sprinkle of amber glass echoes the sink orb and contemporary faucet geometry, and lends a little motion to the vignette.  All in all, a fun project! The kitchen will be next…