The Process of Concrete Fabrication

Concrete is one of the world’s oldest building materials, and is still widely used today. Because concrete is a liquid, it lends itself easily to organic shapes. This allows for endless opportunity to create imaginative designs. While each piece is unique and designed to customer specifications, the basic process for fabrication remains the same:

Build the mold and add the inlay.

  • The mold is built upside down, which means the bottom of the mold will be surface of the piece. This makes it easy to add inlay work and creates an extremely smooth surface right out of the mold.

Once the mold is complete and the inlay designs have been set, the concrete is ready to be poured.

  • The desired color is obtained by adding special concrete dyes during the mixing process.
  • After the pour, the concrete will cure in the mold for 30 days. This will ensure the strength of the concrete and reduce hairline fractures.

Release the piece from the mold and finish.

After the piece is out of the mold, the surface will be polished to the desired finish.

  • It can be ground heavily to expose the aggregate, or simply wet polished up to 3000 grit with diamond pads for an extreme high polished look.
  • The polished concrete is treated with a sealant to protect the surface. It can also be waxed for a glossy look.
  • Some surface imperfections are expected and often times encouraged. These imperfections add to the finished appearance and make concrete an extremely unique medium.

The slideshow below illustrates some of the works in progress.