Each cast begins with a custom, hand made mold that is tailored to your particular configuration. Custom molds provide plenty of opportunities for creativity, but the craftsmanship requires extreme precision and attention to detail.

THE TEMPLATE
The first step in building the mold is to make a template for the countertop. This template will define and shape the dimensions of the mold and thus of the fished piece. The template is made out of a thin plywood material cut into 3" wide strips. These strips are fastened together with hot-melt glue to conform to the exact size of the finished countertop. This process is done on-site in the area exactly where the finished countertop will rest (on top of the cabinets). This process takes into account any irregularities, such as walls that are not square and complicated intersections.

REINFORCEMENT
The purpose of steel reinforcing is to add tensile strength to concrete, which reduces the risk of the concrete cracking or breaking when placed under a bending or twisting load. For instance, when a houseguest decides to sit on a kitchen countertop's unsupported overhang. In addition to a 3/8' rebar, we also use a carbon fiber screen that is lightweight, yet very strong. During the mixing stage, a fiberglass mesh is added.

THE MOLD
This is what the concrete is poured into to form a completed countertop. The template is taken back to the fabrication shop where the mold is built directly from this template. This is done on specially designed casting tables which are perfectly level and that can dispense the weight of the concrete while it cures. This exacting process ensures that one end of the countertop will not turn out thicker than the other. The result is a level countertop when completely installed.

COLOR/PIGMENTS
Choices range from blacks, browns, sand and other earth tones to reds, blues, greens and other more vivid colors. Obviously choosing the color of a countertop is very important, as well as providing you with a finished product that matches your choice. For this reason, we use Neo-Mix colors, which are pre-mixed according to square foot of countertop to ensure uniform results, reducing the "surprise factor" for our client. We also provide a sample for client approval.

INLAYS
After the mold is finished, before pouring the concrete countertop, additional design options should be taken in to consideration. These include, inlays such as semi- precious stones, found objects, coins, fossils, ceramic mosaic.The choices are only limited to the imagination. Inlays provide a contrast between the concrete and these visual accents on a scale appropriate to the context. Inlays can enhance the subtle colors in the concrete. However, how to use these items is a subjective call. Good design is a matter of restraint, and in this case less is MORE.

FIBERS
Fibers add strength and can reduce the number of small cracks that tend to form in concrete. When cracks do form, the fibers keep them from growing. We use polypropylene fibers exclusively, they are easy to work with and don't effect the surface texture or appearance of the finished concrete.

MIXING/POURING
All ingredients such as fibers, colors, concrete and water are combined in a mixer to ensure that a consistently uniform batch of concrete will result time after time. Insufficiently mixed concrete is difficult to vibrate properly and can end up with dry spots, voids or areas of dull color.

VIBRATING
Concrete will be thoroughly vibrated once it is placed in the mold. Vibrating first, causes the concrete to "liquefy" so that it flows into every crevice and around all the insets, knockouts, rebar and mesh in the mold. The fines in the mix flow around and between the larger aggregates, preventing the formation of voids. Second, vibrating the concrete helps remove any air that might be trapped in the mix; trapped air will form bubbles that create small holes and pits in the surface of the concrete as it sets up.

CURING/FINISHING
Curing refers to the process of controlling the temperature and the moisture content of new concrete to promote hydration. The ideal conditions for curing concrete are high humidity and a concrete temperature between 70 and 75 degrees F for the first 3-7 days after the concrete has been mixed and poured. The strength of the concrete will increase the slower this process is preformed.

FINISHING
After the curing process in completed, if desired grinding or polishing is done. The final step/processes is sealing the porous surface with a penetrating sealer. Next, several coats of food-grade safe wax, are applied with a high-speed buffing wheel resulting in a high-polished/sealed surface.