Concrete countertops are manufactured either top up or top down. With a top up technique, where the finished countertop surface is troweled, whether cast in place or cast in the shop, the formwork—or molds—do not have to be so perfect, since the surface you are casting against will seldom be seen. The exception to this is the edges, which often are made with a molded edge form, available from a variety of sources or make your own rubber edge forms. Molded edges can be rough like broken stone or smooth and rounded. Concrete countertop molds are made by a variety of countertop mold manufacturers each offering a unique benefit.
Top down casting, on the other hand, means that the countertop surface will be the face that was cast against the mold. For that concrete to look as good as possible, the quality of the mold is essential—it must be perfectly smooth and perfectly sealed. Melamine, a plastic coated fiberboard, is the standard material used to mold the countertop surface. Melamine will only last for one or two castings but since most countertops are custom, that's seldom an issue.
Many materials, including melamine and Plexiglas, will release from the concrete without an added release agent. Other materials, including steel and rubber, require a release agent to be applied prior to pouring. With concrete, water content is an important factor in appearance. So if the mold leaks, or absorbs water, the concrete in that area will have a lower water content and therefore a different color. Molds need to be watertight.
Types of Molds:
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- rubber
- fiberglass
- composite
- melamine / wood
- styrofoam
Casting Surfaces:
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Related Articles:
- urethane rubbers
- silicon rubbers
- mold release
- melamine
