Pre-Cast Concrete
The most popular use for pre-cast concrete has been for kitchen counters. The minimum thickness is 1.5”. Many edge profiles are available from a simple 2.5” edge return to the complicated Bullnose and ogee edges. Other additional items like integral concrete sinks and integral drainboards are also available. Templates are required for production and installation is similar to other stone materials. After templating and fabrication, the counters are sealed in the factory and should be maintained with paste wax every 6 months to help keep the counter from staining.
The most spectacular use for pre-cast concrete is for Fireplace Surrounds. Most of our fireplaces were designed, site measured and installed by Jim Scott Designs. You can email Jim your fireplace questions and request for designs (consultation fee required). In order to get an estimate from us on a fireplace surround, you must submit drawings or photo of a design. Templates are required for production and installation is similar to other stone materials. After templating and fabrication, the fireplace surround are delivered to the jobsite for installation in usually 3-5 weeks. The slabs are sealed in the factory and can be maintained with paste wax every 2-3 years to help keep them looking like new.
Pre-cast concrete is ideal for Bathrooms and can be very versatile in its application including unique accessories from custom integral sinks and shower pans to Tub Surrounds and Tub Panels. The minimum thickness is 1.5”. Many edge profiles are available from a simple 2.5” edge return to the complicated Bullnose and ogee edges. Templates are required for production and installation is similar to other stone materials. After templating and fabrication, the counters are delivered to the jobsite for installation in usually 3-5 weeks. The counters are sealed in the factory and should be maintained with paste wax every 6 months to help keep the counter from staining.
Many objects of all shapes and sizes have been produced for functional outdoors uses including planters, fountains, benches and tables. In order to get an estimate from us on custom furniture, you must submit drawings or photo of a design. Rectilinear designs are more affordable that spherical designs but they usually require new molds to be produced prior to fabrication. Lead time can vary between 4-6 weeks for delivery from order. Volume orders can take longer to produce and the lead-time will be determined by the final quantity ordered. CCD just completed work on the new Westfield Mall in San Francisco.
Pre-cast concrete has many applications outdoors and indoors Tile, Pavers and Pool Coping. The minimum thickness varies from 3/4 “ to 1” to even 1.25” thick depending on the overall size of the tile. The larger the tile, the thicker it has to be. Many edge profiles are available from a simple 2.5” edge return to the complicated Bullnose and ogee edges. Templates are required for production in some cases and installation is similar to other stone materials. Lead time can vary between 3-6 weeks for delivery. Volume orders can take longer to produce and the lead-time will be determined by the final quantity ordered.
CCD has been a vendor for stone fixtures, counters and accessories for many retail stores, restaurants and commercial clients including Origins Estee Lauder, Benihana Restaurants, Pottery Barn,The New Westfield Malls at the San Francisco Centre and in Roseville, Smith & Hawken, neiman Marcus, Stanford University, Mall of America, tommy Bahamas, Hog Island Oyster Bar and Restaurant, Rasellas Jazz Club, O’Melveny and Meyers Law Offices, Macromedia and Mills College.
Installation
CCD Countertop Installation
Cabinets or support structures should be prepped by the millwork subcontractor with a level plywood subtop. Layout each slab in reference to the plan. No extra countertops will be sent for each job.
Although counters are fabricated from full size templates or shop drawings, some trimming of pieces may be required. In most cases, backsplash lengths will need to be adjusted and spaced equally in the field. Please be aware that the concrete is a finished product and all measurement marking with an abrasive such as sand paper. If less than a ¼” adjustment is required, use a 4” diamond cup wheel grinder (medium grade).
Mark the new edge line with low stick tape. Grind into the edge to avoid chipping. If cutting is necessary, a portable bridge saw (dry) or Skil saw with a diamond blade is recommended. Place cut sides towards a wall or seam. Scribe at wall and column conditions. Cut slabs will be left with a ragged edge. Ease the edge with 120 sandpaper or a diamond pad. To align any slab that may not be level with the adjacent slab, use plastic masonry shims underneath. Any holes not indicated on the templates will have to be drilled on site. For holes up to ¾” dia, use a masonry bit. For holes larger that ¾” dia, use a wet diamond core bit. Clamp a wood template to the top of the surface to keep the core bit from wandering. Plunge into the surface ⅛” at a time, rewetting frequently. Drill slowly to avoid spilling. Dry fit each piece before actual installation. Secure the countertops to the plywood subtop by applying construction adhesive to the bottom concrete portion of the slab. Do not apply adhesive to any foam inserts. Apply the adhesive in small pools rather that a continuous bead. Be sure to keep the adhesive away from any overhanging portions of the slab. Caulk between slabs and at protected wall surfaces.
All counters have been factory sealed with lacquer sealer and waxed. After installation, all concrete should be rewaxed. Buff and polish to a low luster. Cover finished counters with plastic sheeting to allow for slow even drying and to acclimate to the jobsite temperature.
Failure to cover can cause warping and curling from uneven drying. Note, do not leave blue tape on the concrete for more than 1 hour. Adhesives will bond to the surface and cause damage to the product. I have read and understand the scope of work involved with installing concrete countertops. Concrete Concepts and Design will not be responsible for extra charges for standard installation work outlined above.
Instructions for Tile Installation
INSTALLATION
A. General: Comply with ANSI Standard Installation Specification A108.1 through A108.7, and Tile Council of America “Handbook for Ceramic Tile Installation”, except if otherwise shown or specified. Maintain minimum temperature limits and installation practices as recommended by mortar and grout manufacturers.
1. Comply with manufacturer’s instructions for mixing and installation of proprietary materials.
2. Neutralize and seal substrates in accordance with mortar manufacturer’s instructions.
B. Thin Set Application (12” x 12” x ¾” tile)
Requirements:
1. Be sure concrete tile is moist before installation.
2. Use thin set additive.
3. Butter the floor and back side of the tile with a notched trowel.
4. Moisten and cover the tile with plastic to allow for a slow and even drying after each day’s work.
C. Placement:
1.Comply with the applicable requirements of ANSI A108.1
2.Set tile ⅛” to ¼” apart to allow for grout.
D. Paving shall be uniformly sloped to provide positive drainage from building(s), and towards drains for exterior paving.
E. Expansion and Control Joints
1. Architect must specify expansion joints and show location details on drawings.
GROUTING
A. Thoroughly remove loose debris from paver joints prior to grouting. Lease use a grout additive for a good bond. Grout joints, forcing grout into all joints to fill entire depth, growth flush edge of paver units.
B. Moisten and cover area with plastic to allow for slow and even drying.
C. Do not force dry.
D. Re-grout cracked grout in 60 to 90 days with a wet slurry to fill shrink cracks.
SEALING
A. All tire are sealed in the shop before installation. Please seal tile and grout with concrete sealer after installation.
