Precast Concrete Countertop Mixes: Stiff versus Fluid, part 1 of 2

There are several considerations to make when choosing a concrete countertop mix consistency. Some factors include the appearance of the finished piece, the forming and casting methods, and the complexity of the mold geometry.

Other factors that are not so obvious also drive the selection process. These can include the type of mixer that will be used, how the forms are assembled, the shrinkage tendency of the concrete and subsequent vulnerability or resistance to curling and hairline shrinkage cracks.

This article outlines the basic differences between two mix styles, stiff and fluid, in design, look and technique.

There are two basic types of mix consistencies: stiff and fluid.

A stiff mix is a versatile, all-purpose mix that can beadapted to a wide variety of looks, from a “solid” appearance, to a variegated/veined, or a terrazzo look. A stiff mix is typically made using only sand as an aggregate, and it has zero slump.

zero slump concrete countertop mix

A fluid mix is a high slump mix that is more conventional in its ingredients, since it uses both fine and coarse aggregates. While coarse-aggregate based mixes are easy to make fluid, it’s vital that the fluidity is achieved by using superplasticizers and not by adding water. Concrete countertops require high quality concrete for aesthetic and long term performance, and using water to enhance workability instead of superplasticizers results in weak concrete that is prone to shrinkage, curling and cracking. Of course being disciplined with mix water applies to all types of concrete, but fluid concrete is more susceptible to water abuse.

flowable concrete countertop mix

 

Difference #1: The Look

Stiff Mixes

Stiff concrete mixes will always have voids in the cast surface. This is because the cement paste (and the mix as a whole) is so stiff that the entrapped air bubbles cannot escape. Often larger voids are irregularly shaped, and this tends to lend a more organic, stone-like look to the concrete.

pressed concrete stool

small round sink in concrete countertop

copper embedded in concrete countertop

variegated integral sink concrete countertop

The fact that the concrete is stiff and will always have air pockets can be exploited by purposefully introducing voids and patterned fissures. The resulting look resembles the veins in natural stone. Sometimes the voids are left open, but more often they are filled with contrasting cement grout. This highlights the voids and reinforces the resemblance to natural stone.

Fluid Mixes

Fluid concrete creates castings with very high surface quality. Edges are crisp and precise. Surface color and visual texture is smooth and even.

fluid mix pinholes

ramp sink in concrete countertop

Fluid concrete mixes can sometimes have a few small pinholes, or if the casting is done carefully, no pinholes at all. Concrete can be made fluid by using an appropriate mix design and superplasticizer, or astiff mix can be made fluid by vibration. Either way the cast surface will very closely reflect the surface characteristics of the mold. If the concrete was cast against smooth, glossy plastic then the virgin cast surface will be shiny and almost glass-smooth.

Difference #2: Casting Techniques

Stiff Mixes

Stiff concrete is placed by hand, often in small handfuls.The stiff nature of the mix allows the concrete to be packed onto vertical forms and place in thin layers.

hand packing sink form

hand packing in form

Fissured concrete, sometimes called variegated or hand-pressed concrete, is placed so that air gaps between areas of concrete result in fissures once the concrete is demolded.

variegated round table

Fluid Mixes

Fluid concrete is often poured into forms, but it can also be placed by hand.

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casting fluid concrete countertop mix

 

The next article will explore three more differences between stiff and fluid concrete countertop mixes.

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