How are concrete countertops made?

All of the slabs are pre-cast in our shop and fully finished and sealed prior to installation. When it comes to concrete countertops, there are two basic processes: cast-in-place and pre-cast. Cast-in-place involves building forms and pouring concrete in place, directly on the cabinets. While this avoids the hassles of transporting heavy slabs, it does tie up the site for many days (or weeks), and it involves a messy process. In addition, cast (or pour) in place provides fewer options and less control over the finished product. Generally the only finish available is a troweled surface, which is either acid stained or colored with pigments. The quality of the concrete, the finished appearance and ultimate performance of the countertop are all hampered by the fact that it's all being done on site under a rushed time schedule. Pre-cast concrete countertops, on the other hand, move all of the procedures off site into a controlled environment. In the structural engineering community, it ...  more

When it comes to concrete countertops, there are two basic processes: cast in place and precast. Some contractors do one or the other; some do both. Neither is superior to the other, but there are some differences in the final product. Cast in place concrete countertops are done right on the cabinets or millwork. The forms are built on the cabinets and the concrete poured in the forms. The countertop surface is troweled until smooth and free of pinholes. Many coloring effects are possible, including integral colors and acid stains, and talented craftsmen can do amazing things with stencils or other techniques. Achieving a fine finish with cast in place countertops requires a high degree of skill with a trowel, and cast in place countertops often have more of a handmade or rough look. The process for precast concrete countertops is just like granite, as far as the general contractor or homeowner is concerned. You may be more familiar with and comfortable with this process. Your ...  more

Many homeowners are taking advantage of concrete?s flexibility and its ability to incorporate other functional features such as integral sinks, drain boards and butcher blocks. Camelot Concrete also provides backsplashes and wet walls in complementary colors and textures. Countertops are pre-cast in shop. We like to pour in the shop where conditions are controlled. Special casting tables are used and we have the countertop in our possession while it is curing and until it can be adequately sealed. Countertops are made of cement, lightweight aggregates and a combination of additives. Additives such as fiber reinforcement, silica fume pozzolan and acrylic are often used. Some types of reinforcement are used such as structural steel, wire mesh, fiberglass and/or fibers. Sometimes more than one type of reinforcement is used. Countertops are often ground. Camelot Concrete, for example, grinds off the surface ?skin? with progressively finer diamond polishing stones. This achieves two ...  more