rojo concrete worx | custom high end concrete countertops and installs

What is a concrete countertop?
When a person thinks of concrete they usually think of a sidewalk or driveway, never as a countertop. Concrete countertops are the most high end countertops you can find and the possibilities of design are endless. Every concrete countertop is custom. The finish on a concrete countertop is unlike the finish you are familiar with when you think of concrete.

Who would want concrete countertops?
Concrete countertops are the most unique, personal countertop option because they are made from scratch for each client. To determine whether concrete is right for you, think about whether you:
• want something unique and personalized
• want something that looks natural and has character
• appreciate high-quality, hand-crafted items
• think granite is too common
• think synthetic solid surface materials look and feel like plastic
• need a color or visual texture that's not available with other countertop materials

If so, concrete countertops may be right for you.

The advantages and disadvantages of concrete compared to other countertop materials?
Advantages
• Custom: Concrete's biggest advantage is that it is completely custom. Your countertop will be unique to you and highly personalized.
• Versatile: Concrete is extremely versatile. It can enhance any style, from French Country to Contemporary. From Arts and Crafts to Industrial. From Traditional to Modern. The possibilities are endless.
• Practical: Our sealers of choice provide a surface that is extremely stain-resistant and low-maintenance. Common food items will not stain them. The sealer will not degrade, and therefore does not need to be reapplied every year like many other sealers.
• Imperfections: We believe that this is an advantage. Concrete countertops are hand made and hand finished. Since concrete is a heterogeneous mixture of many different ingredients, subtle variations in color, shade, texture and overall appearance should be expected. All concrete is susceptible to harmless hairline cracks. They will sometimes appear months or years after installation, and are generally a result of seasonal movement of the cabinets and the house itself. These should be considered part of the aesthetic charm of concrete, and not a defect. Concrete exhibits natural beauty rather than plastic perfection.
• Green: concrete is a natural, environmental choice. It does not contain plastic or any other synthetic materials.

Disadvantages
• As with any countertop surface, chipping can occur from heavy blows to corners or edges, which can be fixed.
• Scratching: While the sealer we use is very durable, it is possible to scratch it. Also as for any countertop, it is possible to scratch the surface from sliding heavy rough objects over it or by cutting directly on the countertop. For example, in kitchens, you should use cutting boards on concrete countertops. Cutting boards can be integrated into the design.
• Lead time: Concrete countertops are a long lead time item. They take approximately 4 to 6 weeks to fabricate. See the section on lead time for more details.

How much do concrete countertops cost?
Even though it is a completely custom material, concrete is competitive in price with standard countertop materials. The price is competitive with high end granite, ranging from $80 to over $100 per square foot. The exact price depends on the color chosen, style of edging, sink type, finish, etc. We are happy to work with you and your designer to give you an estimate on your project, and we can help you with options to fit your budget.

Where can I use concrete in my home?
• rojo concrete worx makes concrete countertops for kitchens, bathrooms, fireplace mantles/hearths, tables, desks, barbeque surrounds, and anywhere else countertops are required
• Concrete can also be used in vertical applications such as backsplashes, tiles, shower surrounds and fireplace surrounds. For these types of applications, concrete is generally ¾" to 1" thick.
• Horizontal countertops must be at least 1.5" thick. rojo concrete worx can make thicker countertops as well as fabricate front edge returns up to 10" deep.
• Concrete countertops can be straight, curved, notched, multi-level, etc. Unlike granite, which would drastically increase in cost for curved shapes, creating curved concrete shapes simply involves some extra complexity and labor in forming.
• Maximum slab length for standard depth countertops is about 8 feet. Seams are located around sinks and cook tops, or wherever required for structural reasons.
• rojo concrete worx will work with you to design seam placement that is both structurally sound and aesthetically pleasing. Seams are typically 1/16" wide, similar to tile grout lines. However, it is important to realize that concrete countertops are hand made and hand processed; they are not machine cut, so tolerances for seams are more generous than with granite. Seam appearance is minimized by using color-matched acrylic caulk.
• Integral and vessel sinks are possible. See the section on sinks for more information.
• Concrete countertops can be used both indoors and outdoors.

What colors are available?
Almost any color! rojo concrete worx has developed many standard colors to choose from. Each color can be produced in a solid, speckled or variegated pattern. And, you can specify embedded stone, glass, or other objects. You can specify the color, size and density of embedments. Coupled with the many color choices, you have myriad design options.

What is the process for custom colors?
rojo concrete worx specializes in custom color development. We offer custom colors other than our standard colors. An up charge of 15-20% will be applied to all projects containing custom colors. Premium colors such as blue, purple, dark greens, bright reds, etc will carry an up charge of 30 - 50%+. We can customize existing colors or match the color of an item such as a paint chip or fabric. The custom color matching process takes about 3 weeks. Samples are then submitted to customer for approval. Additional samples can be produced for an additional cost of $ 150.00 for two 9" x 9" samples.

What embedments can be inlayed into the countertop?
Any object that will not deteriorate. Fossils, coins, glass, geodes, old skeleton keys, tiles, copper shavings, glass, and company logos or family crests are just some of the possibilities that can be inlayed in the countertop.

What features are available?
There are many features that are available with concrete countertops. Integral drain boards, removable integrated cutting board, removable integral strainer, heat trivets, integrated fruit basket, and FIBER OPTICS. FIBER OPTICS are not visible until they are turned on. Once you turn on the FIBER OPTICS your countertop will sparkle like the stars in the sky. FIBER OPTICS are a great way to add some pizzazz to your indoor, or outdoor kitchen.

Can I choose the embedments that are cast into the countertop?
Some of our clients enjoy placing inlays into their countertops including bits of interesting stone, stainless steel, drain boards, fossils, etc. embedments offer a fantastic opportunity to tie the countertop into the overall design of your room. We can provide embedments for you or direct you to supplier that sells them.

Options
There are many options that are available with concrete countertops that are not possible with any other type of material, creating a truly one-of-a-kind piece. Each piece is as individual as your fingerprint.
• Embedments/Inlays are a great way to personalize your countertop. Any object that will not deteriorate can be embedded. Embedments/Inlays can vary from semi-precious stones, fossils, tiles, glass, old skeleton keys, coins collected from foreign travels, metal shavings, geodes, and company logos or family crests are just some of the possibilities that can be inlayed in the countertop.
• Edging is also a great way to customize your countertop. There are basic eased edges, ¾ radius, pencil edge, ogee, to detailed edges that only concrete can create.
• Glass embedment in the countertop also makes an attractive "terrazzo" look to the countertop. Glass can be seeded into specific locations in your countertop or be randomly scattered. Many sizes and colors are available.
• Pressed/ veined finish is a unique finish that is available. The concrete countertop is cast in its mold and using our "pressed" method, causing voids to appear in the finished surface. These voids are then filled with a contrasting color or similar color and create unique one of a kind finish.
• A removable integrated cutting board is a great way to incorporate a cutting board into your concrete countertop making the cutting board aesthetically pleasing and fully functional.
• Integrated drain boards can also be cast into your countertop.
• Heat trivets to sit hot pots and pans on.
• Integrated fruit basket to add some character and charm to your countertop.
• Fiber- Optics. Imagine your countertop sparkling like stars in the sky at night. This awesome feature will have everyone envious of your countertop. The colors of the fiber-optics can range from basic white specs of light to a colorful display of lights. The fiber-optics are invisible to the eye until they are turned on. This great feature will "WOW" you and your guest in your kitchen or outdoor kitchen area as the night begins to fall and you turn on your countertop and let the "stars" shine.

Finishes
There are 6 finishes that rojo concrete worx offers.
1. Fine/light grind. This finish shows very fine aggregates in the countertop giving a more uniform finish.
2. Medium grind. This finish shows more of both fine and coarse aggregates.
3. Heavy grind. This finish will show a great amount of both fine and coarse aggregate giving a more "terrazzo" finish.
4. Pressed/Veined finish. This finish consists of a primary color for the countertop and a second or third color to fill the voids in the countertop. The second or third colors can match the color of the primary color of the countertop or be a contrasting color to create a mottled effect.
5. Glazing/Distressed is unique finish in itself. This finish provides an old world look.
6. Acid staining is another unique finish. After the countertop is finished being processed it then acid stained. This finish creates a unique mottled effect that is truly one of a kind.

All of the finishes listed above are one-of-a-kind finishes. No two countertops are exactly alike, just like your fingerprints.

How much color variation can occur?
Concrete is a natural, handmade material. Many factors such as humidity, sand lot and cement lot can affect the final appearance of the concrete. All of our color formulas record the type of sand, type of cement, and exact measurements of pigments to 1/10th of a gram, and we use specially developed software to calculate mix design. However, colors can still vary because of the aforementioned factors.

Another factor that contributes to perceived variation is simply the size of samples. A 3" x 3" sample, or even a 6" x 6" sample, will look different than a whole countertop simply because the small sample does not capture all of the natural, random variations that will occur over a large surface. The color in a 3" x 3" sample may appear completely uniform, but a whole countertop in that exact same color will not appear as uniform. The same situation occurs with other natural materials such as granite. If you are looking for perfect uniformity, solid surface might be a better countertop option for you.

What edges are available?
For concrete, edging is formed and cast rather than cut like granite or solid surface. Therefore, edge choices depend on the availability of appropriate trim molding. For example, rojo concrete worx can do pencil, beveled, concave and reverse cove edging, and many other profiles are available. Edging may be placed on top or bottom of the countertop. Diamond edging is also available to reveal aggregates or glass embedded into the countertops to reveal an exposed edge of glass and/or aggregate.

What kind of sinks and fixtures can be used with concrete countertops?
rojo concrete worx concrete countertops can accommodate all types of sinks and fixtures including drop-in, under mount and apron front. The minimum lip of concrete around all sides of sinks is 3". Concrete can also accommodate drop-in cook tops. The minimum lip of concrete in the front of a cook top is 3"; we recommend 3" for the back.

rojo concrete worx can make integral concrete sinks of almost any shape or size. Bathroom vanities are an excellent application of integral concrete sinks. We do not recommend integral concrete kitchen sinks for engineering reasons. Kitchen sinks have angles that would put large stresses on the concrete and have high potential for cracking. Concrete kitchen sinks also develop a patina overtime that may be, to some beautiful and not as pleasant to others. We can fabricate a concrete kitchen sinks with the approval of the client and the client being informed of the possibilities that may occur with this type of sink.

Concrete vessel sinks are also possible, and concrete's versatility means that the sink can be any color and shape.

What about backsplashes?
Backsplashes are cast and finished separately and deck mounted after the countertops are installed. Backsplashes are nominally 1 inch thick and can be from 3 inches high to full height. Outlet openings are cast-in, not cut on site.

Will concrete countertops stain?
Not under normal usage. Typical spills should usually be wiped and not left for long periods of time. rojo concrete worx has uses a high-performance sealer that is exceptionally durable and provides excellent resistance to incidental contact with staining agents such as red wine, lemon juice and olive oil. This high performance sealer is more than a sealer. Sealers usually refer to a topically applied surface protectant sealer. The sealer we use is more of a treatment. This is a two part treatment that reacts with the concrete and permanently bonds to the concrete. This treatment leaves the concrete with a very smooth satin finish that enhances the true color of the concrete and also does not compromise the texture for the people who want to "feel" the beauty of the concrete. This is a treatment process that actually changes the characteristics of the molecular structure of the surface. It also has very good stain resistance to the above mentioned solutions. This stain resistant treatment was chosen for their proven track record in the industry, being the best products for high performance concrete uses.

Will they scratch?
rojo concrete worx high-performance sealer is durable, but it can scratch if cut with a knife or subjected to heavy, sharp objects dragged across the surface. Cutting on the concrete may compromise the integrity of the sealer and allow stains to permeate the concrete matrix. As for rojo concrete worx treatment process, it will not scratch, but you can scratch the concrete itself. Cutting on the concrete will also ruin knives, requiring a professional re-sharpening to reshape the damaged edge or even complete replacement. Remember, concrete is made with stone; the same thing used to sharpen knives and will therefore dull them just as easily.

Can I put hot pots on the countertops?
As with almost all types of countertop surfaces, it is best to use trivets. Concrete can micro cracks if exposed to high heat, and for rojo concrete worx high performance sealer; is not elastic enough to "absorb" these micro cracks. The surface will appear "crazed". However, it can be touched up to minimize the appearance of these micro cracks. rojo concrete worx treatment process has very good resistance to heat. As a safe rule of thumb, do not put hot pots or pans onto countertops that are of a temperature higher than 450 degrees. Each stain resistance option has been tested at 450 degrees with no adverse affects.

Hairline Cracks
Non-structural hairline cracks are possible and are considered an inherent part of the product, not a manufacturing defect. Hairline cracks can occur at any time during the life of the countertop, but are usually not a common occurrence. Hairline cracks are defined as cracks, which are generally the width of a hair, that do not threaten the integrity or stability of the slab nor prevent the continued and normal use of the countertop. These are just a characteristic of concrete and its natural beauty not a defect or reason for rejection.

How are concrete countertops made?
All of the slabs are pre-cast in our shop and fully finished and sealed prior to installation.

When it comes to concrete countertops, there are two basic processes: cast-in-place and pre-cast. Cast-in-place involves building forms and pouring concrete in place, directly on the cabinets. While this avoids the hassles of transporting heavy slabs, it does tie up the site for many days (or weeks), and it involves a messy process. In addition, cast (or pour) in place provides fewer options and less control over the finished product. Generally the only finish available is a troweled surface, which is either acid stained or colored with pigments. The quality of the concrete, the finished appearance and ultimate performance of the countertop are all hampered by the fact that it's all being done on site under a rushed time schedule.

Pre-cast concrete countertops, on the other hand, move all of the procedures off site into a controlled environment. In the structural engineering community, it is well known that pre-cast concrete is superior to cast in place concrete, mainly because tighter quality control can be exercised. Curing, which is a critical step that is commonly misunderstood and overlooked, can be closely monitored. Moving the process to a shop allows greater flexibility in terms of the look of the concrete. Glass, stone and other objects can now be embedded; these require extensive wet grinding with diamond power tools to reveal the embedded objects and hone and smooth the resulting surface.

Lead time
Approximately 4-6 weeks. We begin by coming to your site and making a detailed template. Then, an exact mold of your counter is fabricated and prepared for the concrete pour. Once the mold is filled, the countertop is carefully cured for. This time is crucial for the success and durability of the product. During that period, the concrete is ground and polished many times until it becomes the desired smoothness. There is a tremendous amount of time and labor spent with your countertop to produce a product that will truly be a sculptural centerpiece.

Although countertops are one of the last items to be installed, concrete countertops should be selected as early as possible. Here is an outline of the process:
1. Color selection. rojo concrete worx produces custom color matching and submits samples for your approval. Allow about 3 weeks for this process. See the section on custom colors for more information.
2. Templating is done from finished and installed cabinetry, and it takes less than one day. Any adjustments needed to cabinetry need to be done prior to installation of the countertop.
3. Fabrication. The typical time required to fabricate most concrete countertops, depending on their size and complexity, is 4-6 weeks. Note that the fabrication process may not start immediately after templating depending on how full our production schedule is. A good guideline is to contact rojo concrete worx at the beginning of the project, or at the latest one month before cabinetry is scheduled to be installed, both to allow time for custom color samples and to secure a spot on rojo concrete worx production schedule.
4. Installation. Because rojo concrete worx concrete countertops are pre-cast and pre-finished, installation generally takes less than one day.

In the case of a residential project such as a complete kitchen remodel, homeowners are usually willing to wait longer for their custom-made, handcrafted concrete countertops. However, temporary countertops can be a way to minimize inconvenience. We can provide temporary countertops at an additional cost.

What is the template process?
Concrete countertops are templated just like granite. Templating is done after any existing countertops are removed, or after new cabinets are fully installed. Almost all concrete countertops require physical templates from the finished and installed cabinetry.

In some cases, such as small or freestanding pieces, we can fabricate from CAD drawings or scaled renderings instead of physical templates. We will advise on templating requirements for your project, and we provide your contractor with a templating checklist to help him prepare. All fixtures that penetrate the concrete, such as sinks and faucets, must be available at the time of templating.

How are the countertops installed?
Concrete countertops are handled and installed just like granite. Seams are caulked with a color-matched acrylic caulk. Your contractor needs to arrange for plumbing and electrical hookup no earlier than 24 hours after the countertop installation.

Are there any special structural considerations?
A square foot of 1.5" thick concrete weighs about 17.5 lbs; a square foot of 3 cm granite weighs about 16.5 lbs. no plywood is required for extra support. rojo countertops are engineered to be self supporting. Typically, no special considerations are necessary for standard kitchen or bathroom vanity countertops. Cantilevered slabs, bar tops on knee walls and similar situations sometimes require brackets or other structural supports for the countertops. concrete worx can advise on support requirements.

Do you offer a warranty?
Yes. rojo concrete worx warrantees the structural integrity of the concrete for one year after installation. The countertops will of course last a lot longer than a year, but if any problems were to occur, they would occur in the first year. We subject the concrete to much larger stresses while handling it than clients ever could once it is installed.