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CARVE SURFACEWORKS
Atlanta, Ga. & Wilmington, N.C.
www.carveconcrete.com

Carve Surfaceworks out of Atlanta, Ga., and Wilmington, N.C., specializes in precast concrete countertops, sinks, furniture, architectural elements and acid stain floors. Owners John Jarvis and Hal Griffin created this countertop system for a home on Figure Eight Island, an elite community outside Wilmington, N.C. Carve Surfaceworks used Quikrete's Countertop Mix on this 2-in.-thick countertop system which includes a 1,500-lb. island cast in two slabs along with a 300-lb. slab and 200-lb. backsplash for a sunken sink, a 1,200-lb. length of countertop that houses a stove top, and a small 150-lb. slab for a wine bar area. Carve used 3⁄8-in. rebar and diamond mesh for reinforcement, framing the rim of the undermount sink with the rebar. They utilized an integral color from Cheng Design Products.

Carve Surfaceworks used a 12-cu.-ft. mixer to make 3 cu. ft. of mix. They dry mix all materials first, and add water in very small amounts. "Because of the water reducers, you need to be very aware of the amount of water you use," Jarvis says. "Even a tiny bit of water - 1 cup - can weaken the mix."

Carve has a custom casting table made out of I-joists and marine-grade plywood on metal horse stands. Jarvis says the table is strong enough to support around 6,000 lbs., but it's designed so that workers can shake the table, which Jarvis says is important for initial consolidation. Table-mounted vibrators were used for full consolidation of the countertop. "With this mix you don't have to vibrate as much," he says. "A lot of times we have to slurry to fill voids, but with this mix we didn't have to slurry so much."

Griffin used a water-fed diamond grinder to a 3,000 grit. He says the density of the mix and the color-hardeners allowed him to achieve a mirror-like finish; the density also reduces porosity for a more stain-resistant countertop.

CUTTING EDGE DECORATIVE CONCRETE
Richfield, Ohio
www.cuttingedgedecorativeconcrete.com