Once we create templates for a project on-site, we bring them back to the studio and translate the measurements, layouts, and notes into a three dimensional form to receive the concrete. The resultant countertop castings will follow the form details exactly – it is a literal translation of positive and negative. The result is completely dependent on the care invested in the preparation. This is a lesson you learn early in your concrete countertop career. Take your time, do it right: you only get one chance. It’s  an iteration of the old-school computing truism – GIGO “Garbage In, Garbage Out”. This is where forethought and planning, not to mention manual dexterity, come into strong play. Will that sink form’s shape release cleanly? Will the faucet handle clear the backsplash when actuated? Are the users right-handed or left-handed?

We do most of our wetcasting on sheets of 3/4 inch melamine coated particle-board. Nesting the required sections on the backer, placing the sink and faucet holes where they need to be – we do everything upside-down and backwards. This is a mind-bending exercise sometimes; there are moments when it is best to step back and take a deep breath, because the effort to re-do a mix-up is considerable at this point. Record-keeping and communication come into play here too: assumptions are a killer. This is why we require that all sinks and hardware be in our physical possession at the time of forming. Manufacturer’s specifications are usually reliable, but cannot be counted at all times. Products are revised, OEM vendors change, industry standards evolve. In the end, everything matters. Don’t Think, Know!

Yesterday we hopped in the van and ran up I91 to Hanover, NH for a consultation and templating appointment with a new client, a doctor in this beautiful university town with a world-class medical facility. Meaning Dartmouth  and Dartmouth Hitchcock, specifically… Rolling hills along the Connecticut River, venerable brick edifices and striking modern architecture denote this regional center of commerce and higher learning.

The good doctor is redesigning and renovating an apartment above his practice; one of the initiatives is a relocated and higher-functioning kitchen. Still very compact, the layout includes a raised eating bar, a dishwasher, an undermount sink, undercounter refrigerator and freezer drawers, and a slide-in gas range. Initially it was thought to  include a cast concrete farm sink, but in the interest of budget and size constraints, it was decided to go with a stainless steel zero-radius sink. The color decided upon is our “Cayenne”, a very warm (naturally!) bricky red with specks of black sand. The other colors in the kitchen will be built around this lead; the site-built cabinetry will have a painted finish and the walls and floor will follow suit.

Once a few of these “detail” decisions are made, it’s time to start the actual creation of the concrete countertops for the project. The first concrete (sorry) step is to pull templates from the site, in order to reproduce in our formwork the exact dimensions and relationships  for a perfect fit at installation. All of our castings are 100% formed; there is no machining other than polishing of the surfaces. It is a creative, additive process – not one of removing stock from a given slab and merely locating holes and edges. This is the thrill of the craft – envisioning something from nothing, or rather, from everything. We play the Creator, re-enacting Genesis in our small way.

Our templates are created using the old-school method: thin 3 inch strips of lauan plywood (a grade known euphemistically as “door skins”) are hot-glued together atop the installed base cabinets and/or half walls, following the walls and overhangs so a s to cretae a physical pattern that can be transported and used as a reference back in the studio. All pertinent information is noted directly on the templates such as finished edges, backsplashes, sink base restrictions, cantilevers, and the project name and date. Then they are carefully removed and placed in the van for the trip back to the shop, where we begin the steps to transform the two dimensional record into three dimensional sculpted sections. Here’s where a critical bit of process creeps in: remember to flip the template when building the matching molds! We perform what is known as reverse wet-casting (typically) and whereas the templates are made face-up, on the cabinets, the concrete is cast upside-down and backwards ( a running joke) and if this protocol is missed, all is in vain. Keeps you on your (steel) toes…

Yesterday we installed the Lake Champlain-inspired bartop in its intended home in Wilmington, Vermont; it “fit like a clock”, as a friend used to say, and the installation process went  quite smoothly and with dispatch. The thoughts behind the design elements incorporated in this highly figured piece were apparent once it was resting in the surroundings; all the colors, shapes, and features worked together to form an ensemble or collage that “belonged” in the owner’s beautiful new kitchen. And there’s the magic: it is all about the client, the environment, and the artisan’s interpretation of it all through the medium of concrete. Functional art: You have to see it to comprehend it.

The “Lake Champlain Shoreline” project we are currently working upon has taken on another manifestation: after several days of wet-curing, the piece was unwrapped and partially diamond ground to expose the native aggregate and the crushed beach glass hidden below the cast surface. The bands of color are striking in their many hues and shapes, wandering across the bartop suggesting eddies of water and an undulating coastline. The solid color band at the arched edge will be acid-stained after final processing and add its own characteristic mottled patina to the composition. Small terraced topographical indentations add to the freeform shape and lend contrast to the adjacent smooth surface.

The lake interpreted in customized concrete: Art-formed by Concrete Detail.

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!

The postman has nothing over us; we deliver in rain and snow also… Last month we transported and installed a new set of concrete countertops for a beautifully remodelled home in Putney, Vermont - just 10 miles north of our studio. With an eye toward the future and realizing her lifestyle was going to change, the client had Evergreen Homebuilders do a wide-ranging makeover of her residence. The accommodations in the kitchen include a universal-access stainless steel undermount sink and a dropped (lowered) eating bar. More typically, a kitchen layout might incorporate a raised breakfast bar section but this was a client- and site-specific adaptation – much as custom concrete tops are by nature.

The kitchen was cast in our deep red “Cayenne” base color, with black sand added for character and texture in a lightly polished finish. Maple cabinets, stainless steel appliances and range exhaust hood, a beautiful bamboo floor, and warmly painted walls…

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!

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…).

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.