| It's really two different looks. The subtle irregularities produced by hand finishing give cast-in-place counters a more hand-crafted look.
Finishes aren't the only difference. The forms for a shop-poured counter are built from templates. If the template is off, the counter won't fit. Also, slabs are hard to transport, so large shop-fabricated counters are cast in sections and assembled on site. By contrast, site-cast counters can be monolithic pours, with no seams. Even the backsplash can be formed and poured as an integral part of the top.
Setting Expectations
Most customers have no experience with concrete counters, so it's important to tell them what to expect. We explain that the color may vary slightly across the counter. It's possible the counter will crack - we haven't seen a lot of it, but it does happen. Thick counters are less likely to 'crack than thin ones. Ideally, a counter should beat least 11/2 inches thick at the thinnest spot. On occasion we've gone as thin as 11/4 inches, but we prefer to pour 2-inch counters.
Customers need to understand that concrete may stain over time. They have an easier time accepting this if they know it's coming and have been taught to think of it as the development of patina. Counters can be sealed to prevent staining, but the most effective sealers give the surface a shiny, resin-coated look that some people find objectionable. A less obtrusive sealer may provide less protection. People who want things to look exactly the same five years down the road are poor candidates for concrete counters.
We also warn homeowners not to put red-hot pans directly on concrete: Extreme heat can cause it to spall.
Samples. By the time we get the job, the customers have already seen samples from other projects. They may want a slightly different color or texture, however, so we'll pour three 2-foot--square samples. If they want integral color, we tell them the samples will be close, but not a perfect match to the color of the actual counter. This is because samples are mixed in tiny batches; minor variations in the proportions can affect the results. On the other hand, surface treatments like dust-on color are easier to duplicate.
On the day of the pour, we make additional samples from the same batch of concrete that's going in the counter. We can then experiment with the samples to show the customers what the counter will look like when it's treated with various stains and sealants (see Figure 1). |
