cast concrete counter tops

[csgray]

Does anybody know firsthand the process for pouring and installing cast concrete counter tops? Are they poured in place or lifted into place after pouring? (Sounds heavy to me!) And can a whole kitchen be poured in one piece or does it go in sections? How do prices compare with other counter top materials? Last, but not least, is there anyone on this side of the Island who has remodeled with these who can recommend someone to pour and install cast concrete counter tops?
Mahalo,

Carol

[jade]

I have checked into this as well. You can look online type in concrete counters and you should get a lot of response. You tube has videos. I am contemplating doing this myself. I don't know of anyone that has them or has done them here on the rock. I might try and do it myself. I see that they do this both ways. There are companies that do them off site or some come in and do them. I am interrested if anyone else respondes to this topic.

[Rob Tucker]

Our Punaweb member, John the Architect, has done them nicely. If he doesn't notice this right away you could try to email him.

All those I have seen were poured in place and finished with various applications.

[Peter Epperson]

I have made several ferrocement counter tops. This type of construction is better than poured-in-place as it is lighter and less likely to crack. It also allows you to make seamless backsplashes and other custom features.
Structural demands for a counter top aren't too great, a section of ferrocement 1/2" to 3/4" thick with two layers of steel mesh is plenty strong. Ferrocement is highly reinforced concrete that has a very thin cross section. Sheets of fine steel mesh are laminated between thin mortar layers to create concrete that won't crack. Our company has been building ferrocement water tanks here in Hawaii for a long time. More ferro info is here: www.pacificgunite.com
I don't build counter tops anymore but my son can help you. He does beautiful work. If you want to hire someone, call Tyson at 982-7899. If you want some free guidance on how to do it yourself you can call me at 968-6059.

[David M]

We did DIY pour in place counters here at the house. Not a professional, but willing to share any info.

David

Ninole Resident

[mr. bill]

Poured on site yes. Poured in place no. Been watching this trade develop and refine for 8 years. Can't imagin what a buggered-up mess a (poured in place) counter could be, unless your aiming for something really rustic like a fish cleaning table on a public pier. Concrete countertops are poured inverted in molds (usually of Melamine) sometimes on site to reduce the chance of dammage in transport.
Try www.concreteexchange.com

Give me liberty and give me BAIT

[Carey]

There are a number of ways of casting concrete counters, and poured in place is used as one type (see the first video link for a number of different counter finish techniques.

I have only done a few 'research pours' & have found that a very smooth surface for the base of the mold for an upside down poured slab, along with a vibrating table provides an almost polished stone surface that has withstood outside weathering for the last 3 years.... without any polishing

The smoothest surfaces we have found are polycarb & glass.... (glass can break & polycarb sheets can be $$$.... but we were using castoffs for both) We found that formica gives a rougher finish that must be ground down & polished for the polished stone look

One of the hardest things to do in the counters is to adequately vibrate - you can use a 'stick' vibrator, but it was a bit of a pain on the smaller area of a countertop, esp in counters & such.... a vibrating table works best (we borrowed time on one....). If you are pouring in place, creating the molds for any cutouts & the finish troweling are the most important steps.... If you have voids, they are easy to patch & can create a very interesting finish (see the first video for some very interesting void concrete work...)

Anyhow, hope these links help:
Concrete Networks link:
http://www.concretenetwork.com/concrete/...s-diy.html

Videos:
http://www.youtube.com/watch?v=imppzBYinp8
http://www.youtube.com/watch?v=m3-U_zMfIEc
http://video.google.com/videoplay?docid=...2162861273#

Glossy counter form building using polycarb & a solution to break down water adhesion:
http://www.youtube.com/watch?v=d5gK_CcGOCs&feature=related

you can also spend time following many of the youtube links that are on each of the video sidebars
Enjoy!

[Kapohocat]

if you have vibrate the underside of the form with a palm sander it works really well.

[csgray]

Thanks for all the info, everyone.

Does anyone have an idea of cost here in Hawaii. Everything I find on prices is from the mainland. I know the current counters have to go, I just need a quality affordable replacement and I am willing to think outside the box on materials. We have an area that is an open U, with a 5 foot leg, a 12 foot middle with the sink, and a 3 foot leg, measured at the back, and I would ideally want a one piece counter without seams and cast in drainboards.

Carol

[pslamont]

There is an incredible designer/builder here named Dan Wentworth. I have seen his work on cement flooring and countertops up close and personal and was astounded at the quality he produces. I hope he doesn't mind my putting him out there. Call 808 965 8396. He is not cheap and neither is the work you get. Really, his work in incredible.