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Updated: July 8th, 2008 05:26 PM GMT-05:00

Countertops Coast to Coast

Concrete countertops

concrete countertop
Concrete Connexion completed about 40 feet of precast counter­tops throughout a residential home. Jarman chose a subtle counter­top look for a quiet balance with the client’s rich-grained cabinet woodwork. The island and countertops are 2 inches thick with a 6 degree bevel on all the cantilevered leading edges.
concrete countertop
Diamond D Concrete produced five concrete pieces for an outdoor kitchen. The project included an elevated poured-in-place horseshoe bar with a lower sink section.
Nearby is a small counter near the grill with a concrete couch just beyond.
Concrete countertop
Diamond D Concrete produced this limestone-look precast counter for a small office kitchen.
concrete countertop
A challenging element on this traditional kitchen countertop by Concrete Connexion was the homeowner did not want to change her existing cabinets, so Chris Jarman reinforced them with plywood panels. "In between each cabinet we dropped a vertical plywood panel so the vertical grain of the plywood panels would add support," he explains. "We also put a 3/4-inch layer of plywood panel on top of each cabinet to pull them all together to distribute the weight so that not any one plywood panel would take too much weight."

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The stone concrete colored countertop features blue glass aggregate, a number of unique stones and fossils the homeowner wanted Jarman to embed in the countertop, and a built-in drainboard which also includes stainless steel rail trivets. "Those are a good idea for maintenance," Jarman says. "Built-in drainboards are utilitarian and provide a design opportunity."

On the job with Dave Pettigrew
Pettigrew has refined a proprietary mix over the years that allows him complete control over mix color and consistency. He weighs out all ingredients proportionally — rock, sand, water, powder color, fiber reinforcement and so on — so that he knows exactly what is in the mix. This allows him to recreate exactly the samples his clients approved. In order to remain consistent, however, he gives special care in the grinding step. "When you hone down the surface you have so much sand you want exposed compared to rock and cement, and you want to keep that ration of sand/cement/rock uniform so it shows the appropriate amount of material," he explains.

When it comes to finishing, Pettigrew uses the technique and products that best fit the job. "I don't use any one type of sealer, I use what works best for the project and the effect the client wants," he explains. A project with a lot of voids or spaces might be best with an epoxy. "Or if they want a natural concrete feel I use a penetrating sealer and beeswax," he explains.

Pettigrew recently completed an outdoor kitchen project that consisted of five cast-in-place concrete elements. The star piece of the system is an elevated horseshoe bar poured around the metal supports that hold up a gazebo. Below that is a main prep area and sink, and behind is another concrete countertop around a custom stainless steel sink with a prep surface. Off to the side is a concrete tabletop near a grill. All slabs were poured 1.5 to 2 inches thick and reinforced with #3 rebar and 6 gauge galvanized sheets with 2-inch squares. "We cut those out and leave about an inch clear around the border and then reinforcement is poured monolithically in the concrete," Pettigrew says.

The project also included a concrete couch with a curved seat and a concrete back rest. The concrete back rest was made of block, and Pettigrew poured the seat and plastered the back rest to give it a nice texture. A matching concrete bench can be found in an outdoor shower.

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