Our Process
Pre-Production and Design
Our process begins with the raw drawings that the client's architectural and design team provides. Typically, they provide a building drawing that may or may not have sufficient detail. If not, our design team jumps in to fill in the gaps. Depending on where the project is in the building process, we may go to the job site to take our own measurements. When we have all the dimensions and information we need, we create our plans and submit them for approval. Then we are ready for the production phase.
Fabrication
The first step of fabrication is to craft the formwork. This step in the process has to be perfect because the concrete will pick up any detail in the formwork. There are many different ways to go about this. We typically make a reusable form out of wood, steel, rubber, or plastic, depending on the desired shape and design of your piece, whether it is a countertop, hearth, vanity, or stair tread. We prep it for the concrete, ensuring it is absolutely watertight so the concrete will set well.
The concrete mixture we prefer to use is based on CSA, calcium sulfoaluminate. We avoid Portland cement when possible. CSA is both more environmentally friendly and cures faster, so it is better for everyone involved. When the formwork is perfect, we start casting the concrete. Depending on the situation, it will take anywhere from a couple of hours to a few days before the piece is ready to be removed from the formwork. At this point, we process your product to the desired finish. Finally, we do any polishing, acid washing, or sandblasting requested by the client. Now it is time to seal and crate them for shipment to the job site.
Delivery & Installation
Every job is different, but they all boil down to similar steps. We carefully package and ship your products anywhere in the United States. For installation projects, we take the pieces to the job site, set them in place, ensuring they are straight, level, and properly aligned, and secure them using adhesive or bolts as appropriate. For larger pieces, we use specialized equipment to ensure safe and efficient installation.
Once the job is completed, we send you a care guide for your concrete products. Whether it is a countertop, hearth, vanity, or stair tread, they can all be cared for using the same methods as concrete floors.