This project was recently featured on Houzz.com and was designed by Narofsky Architecture & ways2design.
See the whole project <HERE>
Professional interior shots by: Phillip Ennis
This Long Island home sits perched above the water with a beautiful and relaxing view. The style and design of the home was a perfect match for all of the concrete work throughout the space. The floating concrete sink was designed by New York Design Firm ways2design. The sink was fabricated and installed by Trueform Concrete. Brackets were sent ahead of time to the be installed prior to the sink installation. This allowed the continuation of the work in the room during the time of the concrete fabrication. The sink color was Storm in the Classic Finish and the sink style was the Vallum Sink (ramp sink).
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We recently completed a concrete countertop and integral concrete sink project for BKC of Westfield in Westfield, NJ. One of the challenges for this project was that because this display was for a real working kitchen to be used for events and cooking demonstrations, the Board of Health required there to be 3 separate sinks. Rather than doing undermount sinks, BKC decided that concrete would be a great solution to fit 3 sinks into the space and serve as an interesting design element for their newly renovated showroom.
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Trueform Concrete has created a concrete sink that answers the need for stylish ADA compliant sinks for designers, architects and homeowners. Most ADA sinks are unattractive and not simple to deal with. Keep in mind that this unit can be used in a setting where ADA compliance does not apply. This sink meets the ADA requirements in leg clearances, accessibility, and finished height but remain stylish and user-friendly. This sink unit is extremely light and simple to assemble. The concrete sink is a precast GFRC sink and the base is constructed of blackened plate steel.
A side note about GFRC: This means that the sink will be a fraction of the weight of a traditional concrete sink, and will have a very high flexural strength to it. GFRC is being used in many areas of residential and commercial projects. The reason is that GFRC can be cast in larger and lighter pieces. This allows the projects to become more complex and still be manageable for the end user as well as the manufacturer. Crating, shipping, unloading, and installing all becomes easier. For these reasons, most of the concrete industry is turning to GFRC products.
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Trueform Concrete has created a beautiful 10′ x 4′ concrete dining table top and base. The concrete table was a solid 1.5″ thick with an eased edge profile. The color was Graphite from our Classic Color Palette. The table base was constructed of reclaimed lumber with a wire brushed texture. This was constructed as an 8 person dining table, but it would have no problem fitting 10 people comfortably. Overall, we really liked the way this project came out. It had a nice clean look that fit well with the client’s existing decor.
We recently completed a beautiful outdoor concrete kitchen. This custom contemporary home was situated on a bay front property in Bridgehampton, NY. The outdoor living area was designed with concrete in mind. The project had several challenges that made this project both difficult and exciting. The kitchen featured two waterfall legs, an integral concrete sink, cast-in stainless steel piers for an upper bar top, and rabbeted panels surrounding the two peninsulas. The architect chose the color Taupe in our Classic Concrete Finish. By casting the concrete countertops in GFRC we were able to reduce weight and keep a heavy 2″ edge profile. The concrete sink was cast directly into the countertops to create a seamless working surface. Prefabricated stainless steel piers were fabricated and cast into the concrete to create the support system for the upper bar top. Unfortunately this was not in place when we snapped some photos. The Rabbeted concrete wall panels were a really slick touch. We had a 3/8 x 3/8 rabbet that followed all the panel perimeters. Small details like that really turn a great project into an exceptional one.
The “Big Idea” -
Just when we thought that we were already making large scale concrete tables and islands, the past monsters were dwarfed by this incredible 12′ x 5′ concrete conference room table. A marketing company located in Westchester county, NY, asked Trueform Concrete to create this 60 sqft table top for their main conference room. The existing table that they had made them feel crammed and unorganized with wires everywhere. It’s not every day clients come to us with projects of this scale so the challenges that this table posed pushed our team to tweak process and stretch our abilities.
Building the concrete mold -
One of our initial challenges was actually finding the correct surface to cast this project on. Keep in mind that concrete is cast on water resistant surfaces, and finding a surface in one piece that is 60 sqft is a challenge in itself. Once we secured our casting surface it became clear that we needed to create a cart that would support and allow us to cast this table top flat and level. We were able to manipulate an existing 10′ x 4′ casting cart to handle this project by adding some steel runners and supports. Precast concrete is typically cast upside-down in the mold and flipped over the following day to expose the finished surface. As we thought this project out, the third challenge surfaced about how to flip this large concrete table top safely for the piece and for the staff. We decided to place two casting sheets on top of each other and then separate them with wood strips every 10″ the whole length on the mold. The idea was to elevate our casting surface and allow us to place our nylon slings under the concrete table top before we started casting. Because of the high and early strengths of our concrete mixes, we can typically de-mold and flip pieces the morning after we pour. With a project of this scale it was better to have everything setup before hand and reduce the risk of stressing the table while flipping it over.
Casting the concrete table –
This project required about 800 lbs of raw casting material so all the separate mixes were prepared before we began. Because of the large size of this concrete table, we created a pulley system with a bungee cord support for our GFRC spray equipment. The pulley was constructed to handle the weight of the concrete in the GFRC gun. It also allowed us to spray this table with two men, one on each long side of the mold. The spraying portion of this project took about a solid 40 minutes of continuous spraying. Several layers of fiber mesh were placed into this table to create support and strength. The casting process continued for about another 2 hours leaving us with a monster to face the next day.
Flipping the table –
Before flipping the table over, it was ground and sanded smooth on all of the undersides because people’s knees, hands, and legs, would interact with the bottom of this table on a regular basis. Once the table was clean and smooth, we used a chain fall hoist and strapped it into the pre-placed slings. We were able to flip this table right over and back onto the cart it was cast on. The table sat on that cart for another two weeks and went though our standard process to receive the desired finish and look the client had requested.
Delivery and Installation –
The table was much too large to fit in our truck, so we got a 16’ trailer and mounted our A-frame on it. With all of the pieces loaded, strapped, and in place, we were off to our destination. The table was transferred to a sheetrock A-frame and rolled into the conference room to be set on its base. It was a 4 man operation getting this table top to set onto the steel base.
The project also included a countertops along built-in cabinets and a floating side table with a waterfall leg. The tables and the countertops all had our signature finish and a thickness of 2.5”.
We recently cast two floating concrete sinks for a bathroom in south Jersey. Because of our extensive color library, we were able to use an older color sample from a past job and match it up to the client’s tile perfectly. Color matching is one of those unique specialties that concrete has and at any given time we are creating custom color samples for clients. At the client meeting in our showroom, we provided our client with two steel sink brackets as well as mounting instructions for the contractor. Once the brackets were in the wall, construction could continue right around the brackets. For the concrete sinks, the client chose model B3 20″ x 12″ x 5″ rectangle sink. When we came for installation, the brackets were protruding out of finished tile wall completely level and spaced properly, which made our job easy. We used adhesive caulk to adhere the concrete sinks to the wall and brackets. To finish it off we ran a clean bead of caulk around the perimeter of the sink to prevent water from dripping behind the sink. The final product was two beautiful floating concrete sinks.
Trueform Concrete recently completed concrete sinks for a NYC Office Building. Because they were for a commercial application we were to make sure that the countertops met ADA compliance. The concrete color chosen for this project was a custom dark brown. The concrete sink featured a six inch apron drop edge with an undermount porcelain sink. The vanity had an integral backsplash cast into the concrete. The concrete was supported by wall cleats on one side wall and the back wall, while the other side of the concrete was supported by the integral waterfall leg. The faucet and the soap dispenser were both automatic sensor activated. Functional and unique, concrete once again proves to be a great solution for commercial applications. Being able to cast everything as one solid unit decreases the amount of time it would take to install every part separately. Because it is cast as one sink unit it is also seam free, which clients love.