Our proprietary concrete recipe is the essence of our quality
products. Through several years of research we have refined
our custom mix into a high-density, ultra strong concrete.
Fresh cement, washed and dried aggregate, iron oxide pigments,
high solids acrylic, and special add mixtures are all combined
to give us a PSI 300-400% greater than what a typical house
foundation would have.
Production Method
CONCAST
STUDIOS uses a production method that varies from most precast
concrete manufacturers called Glass Fiber Reinforced
Concrete (GFRC). This method gives us a big advantage in the
quality of the products we offer. GFRC has been used in applications
such as concrete columns and tilt up concrete walls, but we
are one of the few companies that has adapted it to countertops.
Other countertop manufacturers pour their countertops a minimum
of 1-½” thick and can’t usually produce
larger than 8 foot pieces. The advanced masonry of GFRC allows
CONCAST STUDIOS to make products a mere ¾” thick
and create monolithic pieces (up to 16 feet long and 5-½ feet
wide) with no seams, allowing for a much cleaner appearance.
If a seam is necessary we try to make it as unnoticeable as
possible. We use color-matched epoxy to bond our seams and
they are no larger than 1/16” wide. The other great advantage
of the GFRC production method is its resistance to cracking.
Hairline cracking may still occur around fragile areas like
kitchen sinks where the countertop is generally only 3 to 5
inches wide, but with thousands of glass fibers interwoven
into the concrete the crack will not open and will remain hairline.
Our secret production method also enables us to produce up to 175 square feet
of concrete all from one batch of material. The result is that we can make
countertops, floor tiles, and a fireplace without any color variance between
pieces.
CONCAST STUDIOS is also able to create products with a finish that is as smooth
and flat as granite without any voids. Holes on a countertop surface are breeding
grounds for bacteria and while they add character they have no business in
the kitchen or bath. However, if you desire such a look, we can suggest the
70/30 or Roccioso finish. CONCAST STUDIOS has taken the concrete medium to a refined level that was previously
experienced only by high quality marble and granite fabricators. We do not
produce the style of concrete countertops that could be mistaken for a section
of sidewalk (unless, of course, that’s how you request it to look).
The Precast Advantage
There are two ways to produce concrete countertops, precast
and
pour-in-place. Pour-in-place countertops are produced at the
job site. A mold is set up on top of your cabinets and then
filled with concrete. The disadvantages of this process are
numerous. To begin with the contractor that will do this job
for you generally does all facets of concrete work and does
not specialize in countertops. Integral sinks, drain boards,
and backsplashes are not part of their ‘bag of tricks’.
Those beautiful cabinets you just paid thousands of dollars
for may very well be damaged from the labor-intensive work
that goes into making concrete countertops. The countertops will only be as flat and smooth as a trowelled finish. The
sanding that is necessary to polish the countertops is a toxic
mess. In short, your house is not the controlled environment
necessary to produce refined custom concrete countertops.
CONCAST STUDIOS generally spends a total of 1½ days on your job site;
half a day to template and one day to install. This leaves more time for other
trades to work on your house while we’re producing your countertops.
Our installation is very noninvasive, and while minor trimming may be necessary,
each piece is produced ready to be set-in-place to achieve the tightest fit.
Unlimited
Design
What
separates concrete from natural stone is its creative flexibility.
Concrete can be formed into shapes and designs that would be
impossible or outrageously expensive to produce in other materials.
A 1-½” edge is standard for countertops but any
size edge can be produced to give an illusion of girth. We
can also integrate sinks, drain boards, and soap dishes into
solid countertops. Artistic elements such as inlayed metal,
minerals, logos, tile, glass, shell, and various impressions
(i.e. leaves) can all be integrated into our concrete products.
Care
and Maintenance
All of CONCAST STUDIOS’ products leave our facility
sealed and ready for use. We use a penetrating sealer followed by a topical
wax to help keep food, oil, and water from staining the concrete’s surface.
Regular care consists of cleaning the concrete with a mild soap such as dishwashing
soap or Simple Green. The wax will have to be occasionally reapplied to the
concrete every three to four months depending on use.
Warranty
CONCAST
STUDIOS will give technical advice and assistance
for the duration of our products. Our products are designed
for a lifetime of enjoyment and provide a surface that will
withstand normal kitchen and household usage. CONCAST
STUDIOS has a five year limited structural warranty.
We will repair or replace the product if it fails to maintain
functional structural integrity for the intended purpose.
However, we are not responsible for damage to our products
due to gross negligence, the failure of supporting members
(e.g. cabinets, walls, floors), or acts of nature.
