2012 - While the executive lunchroom at Marshall Radio & Telemetry may appear to have a fairly standard concrete countertop, it is, in fact, very unusual.
Using traditional manufacturing techniques this nine-foot long countertop would weigh about 1,000 pounds and require cabinet modification and reinforcement to support the weight. It would also be extremely difficult to install if poured offsite or require an elaborate form if built on site. This one was made using a mold.
There's nothing unusual in using a mold to cast a countertop, however, molds are usually used for shorter runs. A nine-foot countertop manufactured off site would normally be cast in two sections to make transport and installation feasible.
As can be seen in the picture below of the mold immediately prior to applying the concrete, there is no rebar or steel mesh reinforcement. It can also be seen that the form is quite shallow at 1.25 inches with a slightly thicker built-up edge for aesthetic purposes. Normally, a countertop this long and thin without steel reinforcement and cast using traditional concrete would simply not work. It would be highly susceptable to crazing, cracking and breaking, that is, if it could even be successfully de-molded. However, this is not the case with this countertop.
Seemingly defying physics, this countertop is every bit as strong as its 3-inch, steel-reinforced brothers. This light-weight contender weighs in at less than 400 pounds which makes de-molding and installation a relative breeze. The cabinets didn't even require reinforcement! Its secret is the use of lightweight admixtures, specialized compounds, silicas and polyester fibers which are sprayed, not poured, into the mold that contains a sheet of polyester reinforcing mesh. This lightweight concrete allows the incorporation of deep, integral basin, something that is almost impossible to do with traditional concrete.
The magic of this concrete, however, comes at a price; the raw ingredients are about 5 times more expensive than traditional concrete.
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