1 1 Getting Started with Concrete Countertops Presented by: Jeffrey Girard, P.E. Please hold. The seminar will begin shortly. 2 Getting Started with Concrete Countertops Presented by: Jeffrey Girard, P.E. 3 Introduction Jeff Girard • President & founder • Instructor • Civil engineer • Started 1999 CCI • Training • Technical information • From-scratch mixes • Founded 2004 4 My First Concrete Countertop Jan 1999 5 My First Concrete Countertop Aug 1999 6 My First Concrete Countertop
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Introduction My First Concrete Countertop€¦ · Concrete Countertops Cast-in-place is done on site, right on top of the kitchen cabinets. 17 Precast is done in your shop, garage
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1
Getting Started withConcrete Countertops
Presented by: Jeffrey Girard, P.E.Please hold. The seminar will begin shortly. 2
Getting Started withConcrete Countertops
Presented by: Jeffrey Girard, P.E.
3
Introduction
Jeff Girard• President & founder• Instructor• Civil engineer• Started 1999
CCI• Training• Technical information• From-scratch mixes• Founded 2004
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My First Concrete Countertop
Jan 1999
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My First Concrete Countertop
Aug 1999 6
My First Concrete Countertop
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My First Concrete Countertop
July 1999 8
Poll
What’s your experience?
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You want to get to all these steps:• Templating• Forming• Reinforcing• Mixing• Casting• Curing• Stripping the forms• Grinding and polishing• Grouting• Sealing• Installing
• Assuming you’ve decided what project to make.
Your project
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Need:• Space
• Power
• Light
• Water
• Heat
But first: Your workspace
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Garage
Workspace
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Basement
Workspace
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Need:• Personal safety protection
• Equipment
• Materials
Second: Your stuff
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Safety first!
Personal Protection
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Concrete countertops are countertops…
… that just happen to be made of concrete.
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Concrete Countertops
Cast-in-place is done on site, right on top of the kitchen
cabinets.
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Precast is done in your shop,
garage or basement.
Concrete Countertops
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Precast MethodsHand packed
Stiff, zero-slump concrete
Variegated, hand-pressed or solid
Single-sided molds (2D and 3D)
Often all-sand mix concrete
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Precast Methods
Vibration
Single and double-sided molds (for 3D)
Often aggregate based mix concrete
Wet cast
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Major steps in precast concrete countertop manufacturing:
1. Templating
2. Forming
3. Reinforcing
4. Mixing, casting and curing
5. Processing
6. Sealing
7. Installing
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TemplatingAccurately capture important site
information in a physical mock-up.
Good templates ensure an accurate fit. 22
Templating Shape and dimensions of the
countertops
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Templating Location of sink and cooktop openings
Bartop overhangs
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Templating Fixtures: sinks, faucets, cooktops
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Templating Cabinet inspection
Gap, uneven cabinet
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Templating Site conditions
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating
Equipment
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Templating
Materials
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Forming
Forms affect the fit, finish and overall quality.
Accurate forms require accurate templates.
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Forming
Melamine boxes.
Foam sink knockout has silicone caulking.
Glass embedment is glued to form with silicone. Drainboard form is adhered with carpet tape.
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Forming
Equipment
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Forming
Equipment
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Forming
Materials
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Forming
Materials
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Forming
Equipment
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Caulking
Only use 100% silicone caulking
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Caulking
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Caulking
Wax the form corners first.
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Caulking
Only use 100% silicone caulking
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Caulking
Tool the caulk
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Caulking
Peel off excess after
caulk is cured.
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Curves
Curved edges formed
with foam insulation.
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Embedments
Embedments are glued to form surface.
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Embedments
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Sinks and FaucetsThere’s more to forming than just building
boxes.
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Sinks and FaucetsFaucet and sink layout are critical to function,
looks and long-term satisfaction.
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Good work is noticed once…
Forming
Poor craftsmanship is never forgotten.
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Forming Tips
The forms must fit the templates exactly.
You’re working upside down.
Check, double-check and triple-check your forms against the templates!
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ReinforcingProper reinforcing is critical for success.
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Structural Reinforcement
Most important in Precast (wet cast, hand packed) Pieces are moved, handled and transported
Moderately important in Cast-in-Place Cantilevers still require correct reinforcing
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Reinforcing Rules
Reinforcing is placed close to the tension face.
All countertop slabs are reinforced Bartop overhangs also have cantilever
reinforcing located near the top surface.
Never in the middle of the slab!
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Reinforcing Do not make a concrete countertop like
a driveway or a sidewalk.
It won’t perform the way you expect it to. 58
Countertops are not slabs-on-grade
Slabs depend on well-compacted subgrade fill to completely support the concrete.
Floor slabs cannot span soft spots or open spaces.
Slabs usually have only secondary reinforcing for shrinkage and temperature.
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Countertops are beams
Beams are structures that span open spaces and are internally self-supporting.
Beams contain primary reinforcing to resist all tensile forces developed during service life.
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