Modular Concrete Countertops

We are in the process of designing several modular systems that will be sold on our online store. These include concrete bathroom vanities, vessel sinks, furniture, and kitchen countertops.

I would like to hear others opinions on a modular concrete countertop system. Would this be something you may be interested in as an option in your own home? What design features would you look for? What price range would make it feasible? What would be the key factors in your decision process?

A side question for the architects and builders: What dimensions do you find to be most common in the projects that you work on, if you have found such a thing as a common dimension.

Thanks for your input,

Brandon J. Gore
gore design co.
http://www.goredesignco.com

Brandon,

Shame no one's posted an response, so here's one. The idea is a very interesting one, especially since I'm already considering trying to craft some concrete countertops as a DIY project during my kitchen remodel. I wonder though about how feasible it would be to market out of the Phoenix area - shipping would probably price the modules out of consideration as compared to a local design/fabrication shop. Unless you made them comparable to other more common (i.e. boring) solid counter material. To be honest, I haven't started pricing this stuff - afraid I'll scare myself off!

As for dimensions (though I'm not a builder) - I would think a range of single-wide and double-wide units (to match standard base cabinets) along with maybe an ell?

Good luck! I'll keep an eye on your site for product announcements!

Rob

Hello Rob,

FINALLY! A response! :grin: Yes, the modular idea has proved elusive. However, I think we have finally come up with a great modular system. We will probably use GFRC (glass fiber reinforced concrete) as it is much lighter, hence lower shipping costs.

On the note of building your own concrete countertops. We are preparing to roll out a complete line of concrete fabrication products as well as training classes aimed at the DIY'er to the advanced contractor. We have spent a tremendous amount of time developing a fully comprehensive system to form extraordinary countertops. Sink molds (modern designs, not just the typical designs you normally see), drain board molds, faucet knockouts, forming systems, edge molds, rail systems for cutting boards and drain boards, a line of modern integral colors with the admixtures already included, eco-friendly sealers, etc. It is very exciting. We should have the new website with the online store and online registration up within the next 2 weeks. Homeowners will be able to rent our integral molds for their projects, making the process much more simple and cost effective.

I'll attach a pic of a countertop where we used our wave drain board design. Let me know if you have any questions.

Thanks,

Brandon

rental molds-now there's an idea! what will the molds be made of?

so chengwill soon have a competitor, eh?

The molds will be primarily made of rubber. Cheng has no idea what is coming.

That idea of renting molds and selling the supplies is really intriguing.
Have you ever done tests on the GFRC or regular conc. for the support it will need? Say if someone wants a counter that cantilevers out from the cabinet a couple of feet, could it be done? At what point would you need to set a steel beam or rebar into it? How can you check if your existing cabinets or new cabinets that you are ordering can support the weight? I really like the look of concrete countertops, so it will be interesting to see how this develops.

Good questions. The molds are both soft and stiff depending on the design. Some molds need the extra flexibility to be easily removed from the concrete while others do not.

We have used GFRC and wet cast concrete successfully with all of our molds (the attached photo is of a kitchen sink formed with GFRC and one of our rubber molds). The benefit to rubber molds is they can be used indefinitely if taken care of.

Our typical concrete countertop is cast at 2 thick. We reinforce the piece with a combination of carbon fiber grid (C-Grid), and stainless steel bar. The stainless bar is primarily used to keep the C-Grid flat, but it adds structural support as well. We have a civil/structural engineer that has helped us with determining what is a safe cantilever. Using C-Grid is equivalent to 3/8 rebar 12 O/C. We can safely cantilever our countertops 10-12 with no additional supports.

Most existing cabinets can support the weight of concrete. Our countertops generally weigh about 20lbs sqf. Depending on how the cabinets are attached, we may run vertical 2X4's inside the cabinets and build an internal support structure. We also recommend replacing the plastic adjustable legs commonly used on IKEA cabinets with a 2X4 frame.

Concrete is a lot of fun, and given the proper instruction and tools anyone can create a beautiful, sculptural, extremely functional concrete countertop. It is my personal feeling that the concrete countertop industry has tried to hide behind a veil of secrecy. Companies don't want others to learn how to create pieces in fear that they may lose business. I believe in proliferating knowledge. We want to teach others everything we know, and help others push the design envelope. We want to provide all of the components necessary so that anyone, from the weekend warrior to the professional can more effectively and economically produce cutting edge designs. We have learned that we are not losing business by teaching homeowners how to build their own pieces, they would have done it regardless, but we are helping them create an exceptional piece with increased functionality.

Brandon,

Glad to see I sparked a thread! The idea of the molds is WAY cool... that especially gives you an edge in the ability to deal with out of area clients, if (hopefully) you're willing to rent/ship the molds out of your immediate area?

We've got that other well known concrete fabricator in my area (SF Bay), and I know that they actually do address the DIY market, but not to this extent - I applaud you for the concept.

Rob

Thanks for the compliment Rob. Yes, we are planning to rent the molds nationwide.

In regards to the other fabricator, I consider him a friend and a great concrete artist. I learned the basics from him, and have even taught a seminar for his company.

We are taking the training seminars and product line to the next level. It is our goal to offer the most comprehensive, sculptural, easy to use product system in the industry.

Hey Brandon, I started reading this thread and was thinking how expensive to ship a countertop! But after reading further, I was really excited about your idea to have molds for rent. Fantastic idea. I'm about to start a project in my bathroom, building a small rectangular vessel on a wood and steel frame and I'm completely enamored by the vessel pic you published. I'll definitely keep checking your site and progress on these. Great design work listed on your site as well.

regards, Matt

Regarding sinks used in bathrooms, basins generally have an overflow drain at the top edge - is this a convenience feature or is it some sort of code requirement? Same goes for bath tubs. If it is a requirement, how would you incorporate it into the design of a concrete basin? While I'd be willing to take the risk of having a basin with out the overflow drain, I'd hate to put one in and find out later that one was required.
Thanks for any imput.

Hello Pablorey,

In general we don't incorporate overflow drains into our sinks unless a customer spec's it. It is an extremely easy feature to add, which we will show hands on in our classes. The process is essentially to take a piece of flexible foam, insert it into the middle of the sink wall as your forming the sink starting it at the top of the sink where you want the drain to start and ending it at the undersink drain hook-up. After the sink has cured pour acetone (or anything else that will melt styrofoam) through the drain. Let me know if you have any further questions.

Best Regards,

Brandon

I have wondered why no one was making concrete countertop forms. Have you made any more progress with the sink molds? I looked at your web site, but I didn't see any mention of it. Thanks.

_kirk

Hello Kirk,

Yes, we have completed our initial line of sink molds. Our current website will be scrapped when we launch our new site. As usual, the new site has taken much longer than anticipated. The development firm assures me it will be ready any day now. The new website will feature an online store, online class registration and a Find a Contractor section that will allow contractors to place a free listing. It is our hope that more small artisan firms will place a listing, allowing homeowners all around the US to locate a company that fits their style. If you like, drop me an email at brandon@goredesignco.com with your email address and I will notify you when the new website launches.

Brandon:

This is exciting because I was beginning to get discouraged. We have friends who recently remodeled their kitchen with concrete countertops (two years ago...) I was considering that material but became dismayed because all I could find regarding the material on the web seemed to indicate that it was difficult to work with and when factoring in a contractor, was not a cost savings at all.

I found this thread doing a web search for alternative countertop materials, and I'm glad I did.

Keep those ideas coming!

Tony

The first DIY'er class held in our studio was an overwhelming success! The class created extremely artistic pieces with an integral sink, drain board and soap dish! They wanted to be adventurous, so they created a glass mosaic as well as two-tone countertops (please see the photo to the right. This is the actual countertop made by the class). Needless to say, these weekend warriors were creating countertops that are at the very pinnacle of the design envelope.

We have received a lot of interest from individuals interested in taking the class, but scheduling has been the primary issue. To make the class more convenient, it is now scheduled for the following 4 weekends:

10.15.05-10.16.05
10.22.05-10.23.05
11.12.05-11.13.05
12.10.05-12.11.05

If you are interested in taking the class please drop me an email at brandon@goredesignco.com and I will email you a class registration form.

The following is a list of the classes we currently offer:

W.W.1 - Weekend Warrior / Level 1
Cost: $700 per person, $600 per each additional person in group
Duration: 2 days, Approximately 8 hours per day
Included: Light Refreshments, Lunch
Prerequisites: None
Class Dates: 10.15.05-10.16.05, 10.22.05-10.23.05, 11.12.05-11.13.05, 12.10.05-12.11.05

Weekend Warriors rejoice! We have heard your requests for a condensed class targeting basic concrete countertop fabrication and developed this course specifically for you. You will learn how to create a beautiful, functional concrete countertop with an integral sink and drain board using readily available materials and tools.

C.S.1 - Contractor Series / Level 1
Cost: $1100 per person, $1000 per each additional person in group
Duration: 3 days, Approximately 8 hours per day
Included: Light Refreshments, Lunch
Prerequisites: None
Class Dates: 10.28.05-10.30.05, 11.14.05-11.16.05

This 3-day class was designed specifically for persons interested in learning the skills required to capitalize on the increasing demand for high quality concrete countertops. You will learn how to create a professional industry-leading countertop with an emphasis on integral components. In addition, topics ranging from sales and marketing to pricing will be covered. This is the class you should take if you are considering entering the concrete countertop industry as a profession. This class is also beneficial to existing concrete countertop fabricators who are interested in learning new techniques for forming as well as sales and marketing.

C.S.2 – Contractor Series / Level 2
Cost: $1700 per person, $1550 per each additional person in group
Duration: 3 days, Approximately 8 hours per day
Included: Light Refreshments, Lunch
Prerequisites: C.S.1 Member
Class Dates: 11.04.05-11.06.06, 11.17.05-11.19.05

This is the premiere advanced class for individuals who want to stand apart from the crowd and create works of art. Building on the techniques taught in C.S.1, you will learn advanced techniques to form complex countertops. Emphasis will be placed on curved seams, drop down edges and glass infused countertops. We will cover workshop design/theory and you will learn the secret to gore design co.’s glass like surface. Sign up now to learn the skills needed to offer what everyone wants and no one else has.

G.F.R.C. – Glass Fiber Reinforced Concrete Class / Level 1
Cost: $535 per person, $485 per each additional person in group
Duration: 1 days, Approximately 8 hours per day
Included: Light Refreshments, Lunch
Prerequisites: C.S.2 Member
Class Dates: 11.20.05

AoCC offers training that is not found anywhere else. Individuals who complete our C.S.2 class are eligible to enroll in our G.F.R.C class (glass fiber reinforced concrete). This exciting program will show you how to create amazing pieces by “shooting” concrete. These pieces
are lighter, require no additional reinforcement, and the turnaround time is much quicker. Learn the skills needed to offer designs that would be cost prohibitive or impossible to produce using wet cast. Enroll today to set yourself apart from your competition

Specials
We are currently offering the following training specials:

Gold Contractor Package
Cost: $2500
Save $300 by signing up for C.S.1 and C.S.2 at the same time! You will learn all facets of wet cast concrete countertop fabrication, from basic skills to advanced techniques. You will also learn invaluable sales and marketing skills and workshop design/theory. This is the package for individuals who want a turnkey training program for concrete countertops.

Platinum Contractor Package
Cost $2985
Save $350 by signing up for C.S.1, C.S.2 and G.F.R.C. at the same time! In addition to learning wet cast, you will be one of the few contractors with the knowledge to offer GFRC! You will learn to create complex pieces much easier and increase your profits by attending our GFRC class.

In regards to our product line, as some of you have noticed, the new website is up. However, many of the features are not yet functional. Online class registration and credit card payment should be done by the end of the week as well as the online store (hopefully ).

Should anyone have any questions at all, please feel free to contact me directly at brandon@goredesignco.com.