There are multiple steps involved in bringing your concrete project to life. We hope you find the following information helpful in understanding the process of creating concrete objects and the approximate timeline for each step to be completed.
The process of pouring concrete begins by creating templates of the existing space where you plan to place your future concrete object(s) (e.g. countertop, sink, etc.). The molds for the concrete will be made from these templates. The template-making process is the time to decide on design features such as countertop overhangs.
On a pre-scheduled date, Stone Soup Concrete artisans will arrive at the project site to create a template of the future concrete object(s). At this time all of the cabinetry and appliances must be installed and sinks and faucets be present on site for countertops. At the time of templating, you may make changes to the design. However, you should note that these changes may affect the final pricing.
Once the template is made, it will be brought back to the shop where a form for the future concrete object(s) will be constructed. Forms are built with PETG (polyethylene terephthalate), a thermoplastic material.
The forming process takes anywhere from 2 days to 2 weeks depending on the complexity of the job. During forming, any special features such as decorative inlays will be completed. You may choose a border of shells to your concrete countertop or choose colored glass for added visual interest. The options are limitless as each piece is custom made.
Pouring and Deforming
Once the form has been completed, concrete is poured into the form and your concrete object begins to take shape. This is also the time when the color formula is completed.
Concrete will be poured into the form and deformed (i.e. taken out of the form) in 2 to 3 days. The objects will then cure outside the form for another week.
Slurry and Sealing
Concrete slurry is used as a glue to bind the old concrete to new concrete during the “touch-up” process. Slurry is also used to smooth the top of the concrete surface.
Once the concrete has cured for a week, touch-ups are completed to fill tiny holes where the concrete may not have completed settled. The object will then be sealed, touched up and sealed again, with several curing times in between. After curing for 5 or more days after the last coat of sealant was applied, the object will be ready for delivery and installation.