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Getting Started withConcrete Countertops
Presented by: Jeffrey Girard, P.E.Please hold. The seminar will begin shortly. 2
Getting Started withConcrete Countertops
Presented by: Jeffrey Girard, P.E.
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Introduction
Jeff Girard• President & founder• Instructor• Civil engineer• Started 1999
CCI• Training• Technical information• From-scratch mixes• Founded 2004
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My First Concrete Countertop
Jan 1999
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My First Concrete Countertop
Aug 1999 6
My First Concrete Countertop
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My First Concrete Countertop
July 1999 8
Poll
What’s your experience?
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You want to get to all these steps:• Templating• Forming• Reinforcing• Mixing• Casting• Curing• Stripping the forms• Grinding and polishing• Grouting• Sealing• Installing
• Assuming you’ve decided what project to make.
Your project
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Need:• Space
• Power
• Light
• Water
• Heat
But first: Your workspace
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Garage
Workspace
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Basement
Workspace
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Need:• Personal safety protection
• Equipment
• Materials
Second: Your stuff
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Safety first!
Personal Protection
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Concrete countertops are countertops…
… that just happen to be made of concrete.
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Concrete Countertops
Cast-in-place is done on site, right on top of the kitchen
cabinets.
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Precast is done in your shop,
garage or basement.
Concrete Countertops
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Precast MethodsHand packed
Stiff, zero-slump concrete
Variegated, hand-pressed or solid
Single-sided molds (2D and 3D)
Often all-sand mix concrete
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Precast Methods
Vibration
Single and double-sided molds (for 3D)
Often aggregate based mix concrete
Wet cast
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Major steps in precast concrete countertop manufacturing:
1. Templating
2. Forming
3. Reinforcing
4. Mixing, casting and curing
5. Processing
6. Sealing
7. Installing
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TemplatingAccurately capture important site
information in a physical mock-up.
Good templates ensure an accurate fit. 22
Templating Shape and dimensions of the
countertops
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Templating Location of sink and cooktop openings
Bartop overhangs
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Templating Fixtures: sinks, faucets, cooktops
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Templating Cabinet inspection
Gap, uneven cabinet
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Templating Site conditions
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating and Forming
Equipment
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Templating
Equipment
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Templating
Materials
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Forming
Forms affect the fit, finish and overall quality.
Accurate forms require accurate templates.
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Forming
Melamine boxes.
Foam sink knockout has silicone caulking.
Glass embedment is glued to form with silicone. Drainboard form is adhered with carpet tape.
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Forming
Equipment
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Forming
Equipment
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Forming
Materials
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Forming
Materials
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Forming
Equipment
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Caulking
Only use 100% silicone caulking
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Caulking
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Caulking
Wax the form corners first.
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Caulking
Only use 100% silicone caulking
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Caulking
Tool the caulk
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Caulking
Peel off excess after
caulk is cured.
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Curves
Curved edges formed
with foam insulation.
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Embedments
Embedments are glued to form surface.
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Embedments
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Sinks and FaucetsThere’s more to forming than just building
boxes.
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Sinks and FaucetsFaucet and sink layout are critical to function,
looks and long-term satisfaction.
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Good work is noticed once…
Forming
Poor craftsmanship is never forgotten.
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Forming Tips
The forms must fit the templates exactly.
You’re working upside down.
Check, double-check and triple-check your forms against the templates!
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ReinforcingProper reinforcing is critical for success.
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Structural Reinforcement
Most important in Precast (wet cast, hand packed) Pieces are moved, handled and transported
Moderately important in Cast-in-Place Cantilevers still require correct reinforcing
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Reinforcing Rules
Reinforcing is placed close to the tension face.
All countertop slabs are reinforced Bartop overhangs also have cantilever
reinforcing located near the top surface.
Never in the middle of the slab!
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Reinforcing Do not make a concrete countertop like
a driveway or a sidewalk.
It won’t perform the way you expect it to. 58
Countertops are not slabs-on-grade
Slabs depend on well-compacted subgrade fill to completely support the concrete.
Floor slabs cannot span soft spots or open spaces.
Slabs usually have only secondary reinforcing for shrinkage and temperature.
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Countertops are beams
Beams are structures that span open spaces and are internally self-supporting.
Beams contain primary reinforcing to resist all tensile forces developed during service life.
Weight
BEAM
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Beam Principles
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How concrete countertops work:
Reinforcement and flexural strength are important
HERE. This is where countertops crack.
Countertops don’t
fail by crushing.
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Reinforcing Placement Tips
Flexing creates tensile forces Reinforcing resists tensile forces
Tension forces run in straight lines
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500 lbs of sand8’ x 6” x 1.5” beamNo cracks!
What proper reinforcing can do
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Reinforcing Placement Tips
Cantilevers need reinforcing near the top
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Strong
7 day-old concrete12” bar top overhang960 lbs of sandNo cracks!
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Reinforcement Materials Use structural material that is strong, reliable and
appropriate in size.
9 gauge block ladder wire
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Reinforcing
Tools and Materials
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What NOT to use: Stucco mesh /diamond lathe is
not appropriate structural reinforcement.
Chicken wire and fencing are woefully inadequate.
#3 rebar is too large for 1.5” thick slabs.
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Poor Reinforcing: What not to do
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Poor Reinforcing: What not to do
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Mixing, casting and curing
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Mixing and Casting
Materials
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Mixing and Casting: Specialty materials
Materials
Pigments Superplasticizer VCAS
Available from www.concretecountertopinstitute.com 74
Mixing and Casting
Equipment
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Mixing and Casting
Equipment
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Mixing and Casting
Equipment
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Mixing and Casting
Equipment
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Mixing and Casting
Equipment
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Mixing and Casting
Equipment
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Concrete 101Aggregates
Gravel
Sand
Cement
Water
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What makes a good countertop mix?
The right concrete needs to have:
High early strength so you can finish faster.
Good crack resistance.
Low shrinkage potential which minimizes curling.
Consistency for color duplication and long term
performance.
Low cost.
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Why not just use bagged concrete?
Pre-bagged home center concrete:
Made for sidewalks, footings
Aggregate-rich, cement-lean
Needs excess water for workability
28 days to gain rated strength
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Level 1 Mix
Based on local raw ingredients
High strength
Gray or white cement-based concrete
Low cost: $1.90/sf @ 1.5” thick
5000+ psi in 3 days
7500+ psi in 7 days
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Level 1 Mix Formula
53 lbs pea gravel
53 lbs of sand
30 lbs of Type 1 Portland cement
5 lbs of VCAS (pozzolan)
10.5 to 14 lbs of water
Makes about 1 cubic foot of concrete
8 sq ft @ 1.5” thick; $1.90/sq ft
6 sq ft @ 2” thick; $2.55/sq ft
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Professional Mix
Fully from-scratch
Allows for total customization and control
Can make pure-white concrete
Based on same materials as Level 1 mix
Total control yields consistency and repeatability
Requires more precise tools
High strength, good performance
Low cost: $1.90/sf @ 1.5” thick
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VCAS
VCAS is a pozzolan Ultra-finely ground recycled glass
Enhances workability
Boosts long term strength
Eliminates efflorescence
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WaterAn important ingredient that must be dosed carefully.
It is not used like salt and pepper are to “season” the concrete to “taste”. 88
Why Not Just Add Water?
It’s easier…
It’s cheaper…
It’s faster…
But is it the right thing to do?
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The Role of Water
Grape Kool-Aid®
Too much water dilutes strength, color90
Simply Adding Water:
Reduces strength
Increases porosity
Increases shrinkage
Alters coloration
Decreases freeze-thaw resistance
More chance of cracks
Produces poorer quality concrete
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Improving workabilitywithout adding water
Superplasticizer
Use less water to make better concrete
Add workability without losing strength
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Improving workabilitywithout adding water
Video
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Precision is essential for quality and consistency
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Casting Concrete
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Wet Casting
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Wet Casting
Pour adjacent pieces from the same batch for consistency
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Wet Casting
Wet cast mixes are usually fluid and pourable. Castings are sometimes vibrated for improved surface quality. 98
Wet Casting
Complex shapes require complex forms.
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Wet Casting
Wet cast concrete has unique surface texture.
Wet cast concrete has fine detail and great precision.
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Curing
101
Curing
Tomato Seed Needs water to grow
Dies if dries out
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Curing
Drying is NOT curing.
Curing enables the concrete to gain strength.
Cure for 2-3 days before stripping.
Wetting the concrete keeps the moisture inside the concrete from evaporating.
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Processing Consists of Grinding, Honing, Grouting,
Polishing
Depends on Ground versus As-Cast
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Ground versus As-Cast
This choice of finish affects many of the steps:
Forming
Mix design and casting
Processing
Sealing
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Processing Step 1: Flatten
Flattening the back, smoothing the underside.
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Processing Step 2: Grind(Optional)
Rough grinding, initial honing
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Grinding
Heavy milling with turbo cups
Rough, aggressive. Used to expose aggregate.
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Grinding
Equipment
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Processing Step 3: Hone
Fine finishing, honing
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Honing
Light material and scratch removal
50 grit – 200 grit
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Honing
Equipment
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Honing
Equipment
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Light Hand Sanding
Equipment
400 – 800 grit wet/dry sandpaper114
Light Hand Sanding
Crème Finish
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Light Hand Sanding
Crème Finish
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Processing Step 4: Grout
Filling pinholes and voids. Minimal for as-cast finish.
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Grouting
May need to be done more than once for a ground finish.
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Grouting
Supplies
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Grouting
Grout = Cement + VCAS + Pigments + Polymer 120
Processing Step 5: Polishing(Optional)
Polishing:
Sheen development
400 grit – 3000 grit
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Why seal concrete?
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Concrete Sealer
Protects the concrete from food, stains, oil
Enhances the concrete’s appearance
Should be effective
Should be easy to use
Should be repairable if necessary
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Sealer Philosophy
Two schools-of-thought:
“Natural concrete” using penetrating treatments
Topical coatings
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Sealer Philosophy
“Natural concrete” finish using penetrating treatments - No physical barrier between concrete and
staining agents
- Relies on care and constant diligence in cleaning and maintenance
- Vulnerable to acid and some stains
Traditional stone and tile “sealers”
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Sealer Philosophy
I recommend high performance coatings
Coatings + Physical barrier between concrete and
environment
+ Greatest stain resistance, least maintenance
- Can scratch
- Large variety of products, great variability
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Some sealers have great stain and acid resistance:
Two different urethane coatings.
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Many do not:
“Natural concrete” finishes: hardeners, wax, diluted acrylic.128
Recommended Sealer: TK6 One part, water-based coating. No mixing, no fumes
Gloss or Extra Low gloss
Interior or exterior use, UV safe
Wipe on application
Resists: Lemon juice
Vinegar
Mustard
Coffee
Oil
Red wine
Buy from VSeal.com
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Microfiber Cloth
Application Equipment
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Priming• Dilute TK6 with water
• Add 1 part water to 10 parts TK6
• Wipe on generously to soak into concrete• Wipe off thoroughly before it dries
• Let dry 30-60 minutes• Repeat, let final primer dry for 1 hour
Application Process
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Priming
Application Process
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Sealing• Undiluted TK6
• Wipe on very thin, streak-free film
• Let dry 1-2 hours between applications• Apply minimum 6 coats
Application Process
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Sealing
Application Process
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Choose a sealer that: Offers countertop-quality performance
Achieves the look and feel desired
Is reliable
Is available from reliable and dependable supplier
Comes with effective and detailed instructions
You are comfortable using
Is cost effective
Consult the manufacturer, practice and test before using any sealer.
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Common problem: Staining, etching and sealer failure
Sealer used improperly, insufficient coats, over dilution (trying to turn a coating into a penetrating sealer)
Wrong sealer type used for environment.
Acidic materials attack cement paste, leading to etching, dulling and pitting
Improper assumption that polished concrete offers stain resistance
Incorrectly set expectations; poor client education
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Test to verify
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Extensive, free sealer information:
Sealer articles and videos on the CCI website at:
www.ConcreteCountertopInstitute.com/Sealers
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Installation
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139
InstallationSimilar to granite countertops
Transportation
Handling
Mounting
Small sink installation
Plumbing fixtures
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Transportation
Getting there is half the fun
141 142
Installation
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InstallationDifferent from granite countertops:
Undermount kitchen sinks
Seaming
Caulking
Anchors/drilling
Repair
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Installation
Tools and Materials
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Installation
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Installation: Seams
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SeamsConcrete:
Sanded acrylic tile caulk
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Major steps in precast concrete countertop manufacturing:
1. Templating
2. Forming
3. Reinforcing
4. Mixing, casting and curing
5. Processing
6. Sealing
7. Installing
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Questions & Resources
What next? Level 1 Getting Started
• 65-page step by step instruction manual
• More sealer options
• Detailed shopping list for materials and equipment
• Priced at $99.
• SALE! $49 3 days only
Type this into your browser: bit.ly/Level1Sale
You will receive a link in a later email to access the free recording of this webinar.
Contact: [email protected] or 888-386-7711
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Copyright Materials
This presentation is protected by US and International copyright laws. Reproduction, distribution, display and use of the presentation without permission of the speaker is prohibited.
© The Concrete Countertop Institute, LLC 2013