Repairing Damage

One of the most common lines of questioning that I face is: "Why chose concrete over granite?". There are a number of reasons, but one of the less emphasized is "It is repairable".

Much like insurance, it doesn't seem like a big deal until you need it. Recently an equipment failure during the transport/installation of a rather large piece caused a major chip and the piece needed to be repaired.

This is the chip that came out...about 3 inches x 1 inch, ouch!

First step is to fill the hole. I make sure to mix up a VERY large batch, about 2-3 Gallons worth. The closer that you can recreate the conditions of the original pour, the closer the color match will be.

It gets covered with plastic to help prevent shrinkage and cracking.

When it cures, it looks pretty obvious (and ugly).

A good bit of grinding and polishing reveals the sand and blends the color.

Pinholes get filled in just like the original piece and then the finish goes on. Complete, it blends almost perfectly. You can tell but only if you really know what to look for. Otherwise it just seems to be a natural variation of the piece. Not as easy with granite or marble.

Still beating Icestone

Recently I had a designer contact me about a small vanity that they were doing for a client. The client had seen a sample of Icestone's "Sky Pearl" and fell in love. Unfortunately, since Icestone sells by the slab and ships out of New York City(that ain't no Pace Picante), the cost of a small vanity was astronomical.

The designer asked if I could relicate the look. Even with the upcharge for developing a custom mix (yes, if you want something unusual, I do have to charge you for my time), the estimate was lower than the "yankee" option. Also, I had to assure the client and designer that if I wasnt able to come close to the sample they wanted, then I wouldnt charge them for it.

Top Left: Original

Rounds: Initial trials

Bottom Right: Final Product

At first, I tried with the glass I had around the shop, which was more of a dark Cobalt and took a stab at the proportions based on counting the individual bits of glass and Mother of pearl in the sample that was give me. Pretty far off the mark, but it created a sample that I have since grown to really like.

In the meantime I ordered some additional glass samples, one was still a little dark but another was a perfect match.

Then the most challenging, getting the proportions right of the clear glass sizes. The key, as it turned out was a "back to basics" approach. The mix designers at Icestone use a fairly standard aggregate size distribution. a couple of tweaks and boom.....Perfect.

The clinet then made the request to see more blue and mother of pearl and to add a slight gray cast.

These were easy to accomodate and now the client has a beautiful countertop at a reasonable price and it is 100% uniquely theirs!

PS. New Camera is friggin' awesome, Mr. Bigglesworth!!

I Love a Parade

This year I was lucky enough to have pieces in 2 homes on the HBA Parade of Homes.....One was even unexpected!

The downside to one of these parade homes is that you have a hard end date for having the home complete. We finally got the dimensions for the countertop about a week before the parade was due to open. I suppose that when the framer or insulation contractor is installing their part of the home and they get delayed by a couple of days, they get hassled for taking too long, but it doesnt seem like the end of the world. But it just means that the concrete countertop guy doesnt get to have those days to do his job. And those days add up, one after the other.

Hence, when you show up to install your countertop and there are 3 additional trades and a TV news crew all invading the master bathroom where you are supposed to install the 4" thick tops, life really goes to a step more towards tense. This of course happens after everyone concerned with the job has called you many times to make sure you will be on time.

But despite nerves that were tighter than a guitar string, the install went well and we produced a product that we were proud of.

The installation consisted of a 9 foot charcoal colored dual vanity, with 2 elevated sections for the custom cast ramp sinks. the whole thing was made of my latest Eco-Lite Concrete (80% recycled content and half the weight of traditional concrete). Both ramp sinks included slot style drains.

The great thing is that i got to spend some time manning the room during the tour and I would estimate that 80% of the people stopped, looked closer and turned on the faucet....just to see the sinks do their job. That was very gratifying.

Also, we installed 2 custom COMBI benchs in that home. To my surprise, next door Threshold Interiors had teamed up with the Micheal Hsu Design Office and placed another COMBI bench on their porch!!!