Location: Colorado Springs, Colorado USA

Project Lead: Stuart Remodeling

Application: PreCast GFRC Concrete Countertop with Veining

Project Size: 25 sq ft

Products Supplied By: Two Sisters Decorative Concrete Supply

In the gorgeous mountain range of Pikes Peak in Colorado Springs, Colorado a savvy homeowner decided to add to his piece of paradise by adding an Outdoor Kitchen to his home. When contemplating this addition he sought the advice of a professional which could help him decide on the best materials to use so that his Outdoor Kitchen could handle the temperature and weather cycles of Colorado. Tom Stuart of Stuart Remodeling advised the Colorado Springs homeowner to compliment the brick structure of his home and to build the walls of his outdoor kitchen with the same material.

Stuart Remodeling installed the brick wall with true craftsmanship. The time came to decide on an outdoor countertop surface that could match the beauty of the hand placed brick. After researching online the homeowner decided on the organic handcrafted look of concrete countertops. In his research of multiple companies which offer concrete countertop building materials they choose the Xtreme Series Technology of hybrid glass fiber reinforced concrete. To learn more they went to the storefront of Two Sisters Decorative Concrete Supply in Colorado Springs. At this concrete supply center he was educated further on the Hybrid GFRC material and the limitless design and color opportunities that it offered.

They choose to go with a lightweight GFRC concrete countertop that had a 1.5 inch profile edge of “Classic Rail”. With the profile chosen it was time to decide upon the color, texture, and design. Utilizing the SureCrete concrete countertop color chart, they choose Taupe from the 30 standard colors. The “Veining” texture by the Xtreme Series PreCast mix was the desired texture. Finally the concrete countertop for their outdoor kitchen had one last decision, a high gloss or matte finish. The Hi-Gloss sheen was desired and the time came to finally create the one-of-a-kind countertop which had been customized to the homeowner’s specifications.

The concrete countertop was templated, precasted, and sealed off site to ensure that the project site was left in a clean state. Most countertops built with the Xtreme Series Technology have a 5-7 day turnaround from the time of casting. After the sealant reached full hardness, the 25 sq. ft. countertop was taken to the Colorado Springs home and installed on top of the beautiful brick wall system, putting the final touch on this project.

For more information on how concrete countertops are made or the colors, textures, and profiles available feel free to contact Two Sisters Decorative Concrete Supply or Stuart Remodeling.

Xtreme Series Precast Concrete Forming System delivers ease of installation by eliminating the time needed for ripping, screwing, or wasting melamine or other casting surfaces. You will instantly enjoy from the speed and simplicity of the bendable foam rails, as it delivers significant savings in time and labor needed compared to traditional forming methods. The items that make up the system are:

Base Material – Form Rails – PSA Tape – Clear Facing Tape

Base Material

A sacrificial clear sheet of plastic between your casting surface and precast concrete upon which form work begins. This allows multiple uses of your casting deck whether Melamine, Expanded PVC, or other. One side of the base material has a protective film, this side is placed up and the film is removed prior to the pour. Using clean soapy water flood the surface of your casting deck with soapy water, laying the Base material on top. Using a squeegee start from one side and work the water to the opposite end. As you squeegee your goal is to remove any dirt and debris from between the casting deck and the base material. I usually do this 2 times. Starting where you had originally begun lift the corner and flood the surface with clean soapy water again and squeegee in one direction. As you go look for imperfections or dirt caught between the casting matt and your casting deck.

Form Rails

Designed to  simplify the time, material and effort in your precast concrete forming, Xtreme Series Precast Forming System  is available in various thicknesses (3/4”, 1”, 1 ½”, 2”) and come in four foot lengths. The thickness of the form rails will determine the thickness of the precast concrete countertop, fireplace or vanity you will be pouring. One side has a protective film on it, this is the side that is placed facing the center of your mold or the edge in which concrete will be placed.

The precast Concrete form rails can also be bent to form inside and outside radius. When bending it is only possible to bend the form rail “into” the protective film. If you bend away from the film it will break the form rail. When trying to accomplish this type of bend you will need to use Clear Facing Tape. On the opposite side that already has the plastic on it apply a strip of clear facing tape so the form rail can be bent both ways. Once the piece has been bent into the desired shape, remove the tape from the side that would go on the inside of the form and reline with facing tape to leave a smooth surface to cast into.

Clear Facing Tape - is used to line the inside of your mold after bends have distorted the finish of the existing tape or where two form rails come together. Minor radius can be accomplished using this tape as well.

PSA Tape – Pressure Sensitive Adhesive is used to attach the form rails to your casting surface. It is tacky on both sides and eliminates the need for screws. When placing the PSA Tape, apply the tape to the form rails first, then remove the protective coating to expose the other tacky side. It is important to have this tape placed as close to the edge of your inside form rail as possible, this will eliminate the need for caulking because the tape is made from vinyl and will not wick moisture from the concrete.