Wednesday, December 10, 2008

The outrageous sink

In one of the longest running projects to date, we have finalized our work on a very intricate bathroom, with an extremely complicated sink. The key features include:
  • 9 inch thickness
  • Cast in place sink with a drain that is actually housed within the wall
  • Integrated towel bar
  • Over 11 feet in length as a single casting
  • Concealed attachment to the wall
  • 50% recycled content
  • Bright white color

I am now looking forward to some professional photography so that I can get this on my website!!





The Form


Once removed from the form, its time to polish and shape the edges.



Finished product in place.




No visible plumbing...the drain is contained within the concrete and the P-trap is inside the wall. Gives that magical 'floating' look.


Thursday, November 20, 2008

Overcomming Adversity - The big sink


Sometimes that which should be easy.....isn't.


This was the case when our client made a last-minute decision to use this extra-big italian ceramic sink. Oops!




However, the cabinet vendor, Kitchen Craft, Responded to the situation quickly and working hand-in-hand with them, the cabinet was trimmed just enough to avoid what would have been a very costly rebuild. Its very common for us to collaborate with other trades to promote quick and positive results.


Just barely fit!!







Sunday, November 2, 2008

Better Than IceStone!!




Although we have done many projects that featured recycled glass filled concrete, this is by far the most extensive application performed by Newbold Stone.
This product competes with a product made in New York, called IceStone, which is touted for its eco-freindly benefits. Our product is superior in 3 ways:
1. The product is made locally, of local components. Portland cement, from San Antonio, Crushed Glass from Dallas (or from the Austin Recycling center for multi-colored glass), local water and various additives. This eliminates the transport energy that is expended from shipping the sheet product from New York. It also reduces turnaround time and keeps the money in the local economy.
2. The product is formed in the shape that it will be installed. All sheet materials like IceStone (or granite or Silestone) is shipped in sheets and then cut to size locally. What happens to the extra material on the cuttingroom floor....landfill.....Texas landfill in our case.
3. The thickness that looks best for you. Sheet materials are available in a single thickness (or sometimes 2 or 3 if you pick the right one). Local artisans can customize a 4" curved surface, if that is what you want......now that is keeping ahead of the Jones's.




Sunday, October 12, 2008

1/2" Thick Concrete







My favorite thing about the GFRC techonology is that it opens up the range of what i can do with concrete. Although it has become commonplace to pour concrete countertops as thin as 1-1/2" thick with traditional methods, Use of the homogeneous glass reinforcement has enabled me to break out of this range. I knew I could make it 3/4" thick, and I had become fairly confident with 1/2" thick backsplashes, but I wasnt sure if it would work as a countertop. Wow, what a surprise. It is strong, stable, and fantastic. In this particular case, we added an integral sink as well.

Wednesday, September 24, 2008

Cantilevered Glass Sink


This small guest bath was a surprisingly challenging space. The client was looking for a WOW factor in a rather small and standard powder bath layout. After countless exchanges and redesigns, they happened to find this Kohler Antilia Wading Pool Sink and fell in love with it.

The challenge then became finding a way to fit the huge 17" x 28" glass sink into the small space without having everything feel cramped.

It turned out that less was more and by cantelevering the sink in a frame of concrete, the semi-transparency of the sink was usefull in de-emphasizing its overall size and resulting in a very clean, very cool installation that you could see right through!!


Thursday, August 30, 2007

Up...Up...in the air





Another instance of having the right tool for the job came this week during the installation of an excessively heavy piece (340lb) At a client's 2nd floor Master Bath. Since this was a new construction project, we were able to take advantage of a lofted hallway before the railing had been installed. Renting a highlift turned out to be just the trick!



We love creative solutions to difficult problems.

Monday, August 27, 2007

Concrete sealant technology

The number one question posed to me at the home show was regarding sealants. everyone wants to know if concrete is porous. It is very obvious that the silestone people have been doing a great job playing up the porosity of other materials and trying to make them sound unsafe.

Raw concrete, without a sealant, is inherantly porous. But just like granite, it is just a matter of the sealant that you use. Many different methods seal the surface. We use a newer hybrid technology and there are some critical reasons why.

Absorbtion is the first thing that must be sealed against. Raw concrete can absorb moisture by the fact that there are small pores on the surface. Filling these pores is critical, and once it happens, the health concerns which have been beaten into our heads by the ad campaigns of artificial surface manufaturers are no longer valid. This has been done many ways in the past, most notibly by the use of acrylic based sealers, many of which can be found on the sehlf at home depot (price $10-$60/gallon). however, these sealers have a tendancy to wear off and require re-sealing at regular intervals (one or twice per year). if you get too much of these sealers on the piece, then they can actually form a chaulky colored shell that can be chipped off.

Acrylics also dont protect against the second issue that plagues concrete and natural stone....ACID. acids are found in a lot of the more fun things in life...like lemons, wine, vinegar, etc. This is historically where waxes come in. People that dont like the acrylics, love wax. It protects briefly against the acids by acting as a sacrificial layer. the acid eats it before it gets to the concrete. but it gives you just enough time to clean the offending material off before it gets to the surface below. hence, wax needs to be replaced fairly often. its a good thing that they are less expensive. However, you have to get a food-safe version of these waxes...car wax has petroleum in it.

But the question is, what are the acids attacking? concrete is based upon a crystaline structure of Calcium Silicate Hydrate (CSH) between pieces of natural crystaline stone. the acids primarily attack a byproduct of the cement hydration process, namely Calcium Hydroxide. This byproduct is basic (similar to baking soda) and reacts quickly with acids. As soon as acids react with this chemical, it leaves the surface free to be stained. There are two ways to combat this reaction. One is to protect the Calcium Hydroxide, which is what the waxes do, and one is to remove it.

The sealer that we typically use is based upon Lithium Silicate. Lithium Silicate prrovides a ready source of silicate Ions, which react with the Calcuim Hydroxide to form more of our favorite crystal, CSH. The beauty of this reaction is threefold:

First, it removes the calcium hydrate from the surface, eliminating the targets for these acids.
Secondly, The additional crystals means additional strength and sealing of pores.
Thirdly, it continues to react for years. in fact, forever. Concrete is a curing reaction, which slows over time but never stops, which means that the production of Calcium Hydroxide never stops. those free silicate Ions remain, constantly forming more CSH.

If you dont get all the chemistry, then dont worry about it. Just know that it pays to have a guy with a chemical engineering degree building and sealing your concrete.