Fast Concrete Countertop Forming
The XS-forming system is the most economical and low labor cost fabrication system on the market. Utilizing 4-foot high-density foam rails, clear facing tapes, and PSA.
How do you Cast an Integral Sink in a Concrete Countertop?
Sink molds are used to create shapes on a concrete surface that become integral sinks within the surface. The sizes, shapes, and variations of each can offer a tremendous library of useful choices and looks for your client. These molds are made to use as A molds only, and the use of GFRC, Hybrid, or in-house made B forms are necessary to form these sinks. The sink molds are made of high strength tooling gel coat that with proper care will offer a lifetime of uses. The walls are five layers of marine grade glass fibers and an integral flange of fiberglass reinforcement is used to keep straight sides, prevent cupping, and give an internal flange to allow it to be pulled from the mold. Blowing the molds out with air may blow out the bottom of the sinks it is a better option to use ice to shrink the mold and pull the sink out with clamps on the internal flanges. By using these materials and entering a market of exacting standards, it is important to understand how to use the tools available through SureCrete to adhere and excel to these standards.
Sinks & Niches: After choosing the sink mold you want to use, you have to fasten it to the surface in some way. Most times just using silicone to adhere the sink edge to the mold surface is sufficient. A plywood insert supplied by the concrete fabricator allows for screws to be used to pull the sink mold down to the mold face; however, silicone is always needed to seal the seam and round the edge. The plywood block may be adhered to the inside of the sink mold return flange with hot glue, so the plywood stays positioned as the screw is fastened into the plywood.
Removal: Using an angle supported by a block of wood you can use c-clamps to put firm pressure on the sink mold. If steady pressure after sitting for 10-15 minutes does not release the mold, you can fill the sink with water and ice cooling the mold until it releases from the concrete. Make sure the block of wood is not on or directly above the sink mold, and the angle is at least 1/8” thick. In the case of A &B molds such as the round vessel mold you can use wood shims on the perimeters to put pressure on the mold parts to separate them from each other. You can also use ice to shrink the molds. Blowing air into the drain flange is a suitable method of separation of vessels only, but be careful to not build up too much pressure if your sink was not properly prepped you may crack the sink.
Care and Use: For a Lifetime of use, clean the mold after each use with a diluted 3 to 1 SCR solution. Make sure to remove build up first with a block of hard wood, while blowing clean and not letting the sand residues scratch the gel coat. When cleaning and wiping use clean sponges and towels so that residual sand will not scratch the surface. Make sure to wax after and before using the sink with Zymol blue car wax and do not refrigerate as directed. Three to four applications will give a slick film suitable to release the sink mold. Scratched sinks can be wet sanded, and the gel coat polished with a regular marine or automotive compound.
It takes a smart person to admit that sometimes you need help to get a job done right. The same principle holds true with concrete casting. You need more than just a wonderfully crafted pre-blended bag of concrete mix (like any of our Xtreme Series lines). No matter which part of the job you need a little help with; we’ve got the accessories to help make your life easier.
For help with the prep-work, we provide easy to use forms, molds and edge profiles so that you can lay out your designs with ease. We also supply some of the strongest and lightest fibers and rods to make sure that your cast mix is the strongest it can be. If you want to get creative with your XS casting products, take a look at our XS Veining, Slurry and Packing Additives.
Wherever you are located, we have a conveniently located distribution center close by for you to pick up any casting accessories you might need to make sure your precast concrete project is a success.