There are some things in this country that we as consumers will pay a lot to have, just because they are different. There is also some prestige in being the first to have something NEW, but with that there is also inherent risk. I still try not to buy a first model year car, as my dad always said “Girl, let them work out the bugs first!” Concrete or cement countertops are not really a new anything else, but they are still in the high-cost range of counter tops.
So questions remain: what were the initial “mistakes” as the product was developed? Have they been resolved satisfactorily? And: is the surface area really worth the extra expense when completing a kitchen remodel?
When I was building a house in 2000, a lifetime ago, concrete countertops were the latest in old-fashioned technology, so to speak. My home builder was offering it as an upgrade, but the project managers were very discouraging, offering advice that I recall sounded pretty logical at the time: concrete countertops may be great in an established structure, but their weight in a house that is newly built can cause dramatic settlements putting the top at risk of cracking. Well, certainly based on that information, and facing all the other decisions I needed to make, I quickly abandoned the thought; there was no way I wanted to trip over that “I told you so” guy.
Keep in mind that concrete is awfully heavy, I discovered this first hand on a DIY field trip to a local fabricator; cap handling is strenuous and laborious. Concrete weighs about the same as granite, but is typically poured thicker than the typical 1 1/4″ used for stone countertops. The heavier visual weight is more luxurious and gives the top a more substantial presence.
As it is, concrete is a mixture of natural aggregates, activated by water; therefore, it is potentially susceptible to cracking, primarily through a few different but manageable conditions. Air bubbles in the mix weaken the material, so it is essential to loosen and release the bubbles when you first pour the top. This is difficult to do by hand, commercial fabricators, like the one I recently visited in Rockaway, NJ, use giant automated shake tables to get the desired result right. Factors that can contribute to cracking over time are shrinkage of the material due to continued drying over time, which is why professional fabricators store caps in a humid, temperature-controlled environment after pouring. Finally, concerns about handling and installation, the weight and size of the caps make it difficult to transport and install. The right equipment, shim material, and epoxies ensure that all the hard work that went into making them won’t go to waste if they break or get damaged just as you’re about to complete your entire project!
All of these factors lead me to believe a few things:
- The guys who built my house may have just not wanted to deal with the material: the weight, the temperament, and the service issues.
- the countertops we fall in love with in magazines and trade shows aren’t made in an hour or two
- making concrete counters is not for the typical DIYer
- like all great art, there has to be passion for the subject
I was fortunate to have the help of the true professionals in the industry when I made my concrete countertops (one vanity top, one for a dry bar), Bill Gockeler, a recognized expert in the decorative concrete manufacturing industry and owner from “Artisan in Concrete” the facility I visited in Hackettstown, NJ. We needed strength and skill to make the forms, the molds had to be precisely mitered, the center lines of the faucets and sinks were taken into account, and then we caulked and sealed everything in place, and headed to the mixing room. Following strict recipes for mixes to create our chosen specific colors and finishes, we formed a line of buckets and passed full and empty buckets back and forth until both mixes were blended to the right consistency. Pouring, shaking, smoothing the lids and cleaning took the rest of the day.
We left the shop tired, after a solid seven hours, and the covers weren’t done yet. In the days that followed, they were troweled many more times, then polished and glazed. The final colors and textures on the tops are absolutely beautiful and unlike any other surface you could choose from.
Some of the benefits include:
- heat resistant (not heat resistant)
- smudge resistant (not smudge proof)
- impact tolerant
- natural look
- Environmentally friendly
- sustainable
- moldable
- available in an unlimited color palette
- many varied textures and finishing effects
- unlimited style and design options
When tackling any kitchen design remodeling project today, I naturally offer my clients sustainable “green” design options throughout the process. Concrete is a natural offering in this category, it is a renewable, durable material and can be expected to last a long time, and it is a product that is manufactured in a closed environment with no harmful contaminants. Additionally, truly “green” concrete can be made using silica fume and fly ash; These are by-products from silicone metal manufacturing and the coal burning industry. Using these materials as a direct substitute for Portland cement makes use of a material that otherwise goes directly to landfills.
When I asked Bill what he thought was the biggest misconception about concrete as a countertop surface, he replied, “Because of the relatively high cost per square foot, there are a lot of masons, contractors, and homeowners who think ‘hey, I can do this.’ – most of the time with poor or even disastrous results. When a concrete countertop is poorly made, the initial perception is that the concrete stinks: they (consumers) blame the material, not the manufacturer. This situation can give the concrete a bad reputation as it is innately dependent on proper manufacturing.High quality decorative concrete is worlds apart from ‘side walk’ concrete.”
My original question, is it worth the extra investment when remodeling your kitchen? My Answer: YES, if you’re in love with the look, they’re worth it, I’d definitely recommend saving up and spending the extra money to have them professionally made and installed, after all, you don’t want a countertop that looks like a sidewalk, do you? If your idea is to personalize the top with familiar handprints, inlaid embellishments, crystals, basically anything you can dream of, your maker will help you with that. This is a truly custom item to add to a kitchen or bathroom remodel.