Despite the simple, rugged nature of the material, concrete counters have become very popular in high-end kitchens and baths. Some homeowners choose this material because it can be produced in any color or texture they want. Others just like the way the product looks: Because they're crafted by hand, no two concrete counters are ever exactly the same.
Cast-in-Place vs. Shop-Fabricated
Concrete counters can be cast in place or fabricated in a shop. Shop methods place a premium on carpentry skill, while casting counters in place requires better concrete-finishing skills. I own a concrete company that specializes in decorative finishes. Since we have many good finishers, we usually pour counters in place.
Shop-fabricated counters are produced off site, then transported to the job and installed in the same manner as granite slabs. They're poured upside down and cured in the form; the shape and texture of the finished surface are largely determined by the form.
Cast-in-place counters are poured right side up, so the shape and texture are heavily influenced by the finisher. First, a continuous plywood top is installed on the cabinets; edges, penetrations, and overhangs are temporarily formed. Reinforcing is then installed, and the concrete is placed. As soon as the concrete starts to set, the edges are stripped and the visible parts of the counter are hand-finished with the same tools and techniques used for other kinds of concrete flatwork. You can float, trowel, grind, or use textured mats to finish the surface.
A matter or taste. Site-cast and shop fabricated counters are similar but not the same. A shop-fabricated counter may be perfectly straight, flat, and smooth. Site-cast counters may be extremely smooth, but they're unlikely to be as flat or uniform as a shop-cast slab.
