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The process by which concrete products are produced may be fairly standard however our approach and our level of quality truly makes us different.
While there are four steps to creating any concrete piece, there are two we think are particularly crucial which we’d like to focus on. (Read below for an in-depth explanation of the entire process).
The two key areas that have the highest potential to negatively impact the integrity of a piece are cracking, which is impacted during the processing stage, and sealing. At Surface Studios, we utilize a mix and reinforcement design that has proven dependable. In the four years we have been in business we are happy to say that we have had no calls or complaints regarding cracks. We have worked with experts in the field and have done our own testing in order to determine what type of mix and what style of reinforcement perform best.
Sealing is another area that is tricky to master, but we are confident we have done exactly that. There are a variety of sealing options available and we have tested a great majority. The particular system we use has proven most effective and is considered revolutionary and industry-changing. We use an Ultra Violet light curing system which has been rated #1 by the Concrete Countertop Institute for staining and abrasion. When you shop around, you’ll find we’re the only concrete studio in the state which utilizes this technology. The reason others haven’t been so quick to adopt the process is that there is an investment required in purchasing the necessary equipment and a learning curve involved in mastering the process. We recognize the value of these two things and feel that our clients are worth it!
Four steps to creating any concrete piece.
- Templating
- Forming
- Processing
- Sealing
Templating – Every job requires that a template of the area be made so that we have the exact dimensions for the piece that is being produced. This is the first and very key step in the process in that if the template is not accurate, the entire job will be incorrect and all the time and energy spent in the steps following templating will be in vain.
We template every job and every sink. The reason for this is that we cannot depend on the accuracy of architectural drawings in that walls may be off slightly. While sink dimensions are often provided in a product description, this information can vary as well so we always require the client provide the exact sink and faucets being used so that we can template according to those dimensions.
Forming – Another key step in the process, forming requires precision, a keen eye for detail, and extensive experience with woodworking. Forms are built from wood which include knock-outs for particular areas indicated on the template, for example faucets, sinks, etc. This part of the process also includes producing any molds needed for sinks or other items that will be integrated into the final product.
Much like the templating, this step requires exactness. If anything is off in this process, the entire job typically will need to be scrapped.
Processing – This is where the piece begins to come to life for the customer. They choose their color, how they want the piece to be finished as far as a polished look which is a solid color surface, lightly ground which reveals small amounts of aggregate, or heavily ground which shows greater amounts of aggregate and rock. Additionally, they can choose the appearance of the edges – whether a continual look of the top or cut to expose the aggregate.
At this stage the customer can actually touch and begin to see their concrete product in a roughly-finished state. Again great skill is required in this step as well in order to achieve a consistent look and feel throughout the piece(s).
Sealing – This is the final step prior to installation. We utilize a new process that virtually eliminates any potential issues with sealing. With the use of a Ultra Violet light, we are able to apply and cure the sealer in minutes. This essentially means we can install a product the day we seal it, which is a big benefit over other sealing options.
Like all the other steps in the process, this too is an art. The sealing process we use not only requires the highest level of safety precaution, but also demands an eye for fine details. This entire process takes place in a room designated solely for sealing. I allows us to minimize any foreign debris and to maintain the integrity of the sealer.
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