by Michael Fallarino, Contributing Editor

 

Advances in technology can be harnessed to serve the needs and visions of individual craftsmen. As a result, the exploitation of creativity and artisanship in the building construction industry has never been easier.

As is the case with plaster, the potential for artisans to exploit concrete as a creative and artistic medium can now be accessed in channels that marry accessibility with availability. One of the great pioneers of the contemporary artisan concrete movement is San Francisco-based ceramicist-turned-artisan-concrete-entrepreneur Buddy Rhodes.

 

For three decades, Rhodes has been refining his approach to fabricating all sorts of things with concrete. He now offers two versions of his proprietary blend of artisan concrete, along with all the sundries necessary to accomplish a successful project. His products include concrete pigments, sealers, waxes, additives, and the like.

 

To aid and abet the cause, Buddy has also produced a suite of educational media. Making Concrete Countertops, (144pp, Schiffer Publishing Ltd, 2007) a how-to book replete with photos is a recent collaboration between Buddy and his wife, Susan Andrews, who is a professional educator. Rhodes has also produced a pair of DVDs on the topic of fabrication with artisan concrete. Building Concrete Countertops, and its sequel, Advanced Techniques, guide the prospective concrete artisan though the terrain from raw materials to finished projects.

 

As a finish carpenter, plasterer, and finisher, I was intrigued with Rhodes' vision, accomplishments, and integrated approach to his art. I caught up with him recently at his San Francisco studio to have him school me on his art and craft.

 

Michael Fallarino: Why should we be interested in concrete countertops?

 

Buddy Rhodes: Building concrete countertops puts craftsman to work and creates the opportunity to make something unique for someone's home; a rarity in these days of manufacturing, where it seems that nearly everything is imported by boat. This is a hands-on material that begins with the making of a mold, and in which the end product stands out in a home where nearly everything else is mass-produced. Marble and granite have been over-mined and are now discounted in warehouses.

 

We have a white concrete, which is our normal countertop mix, made with refined dolomite and white cement. It looks very refined and polishes well. We also have a green mix [Buddy's Ultra Green] which has larger, recycled aggregate, and in which a lot of the portland cement has been replaced with fly ash.That's a gray mix.

 

Fallarino: Could a consumer build a concrete countertop?

 

Rhodes: Yes. It's not for everyone, but it's not as hard as you might guess. Our book and DVDs walk you through it. I took my knowledge of ceramics directly into the world of concrete and developed a mix that's very clay-like. The mix trowels well and can be burnished.

 

Fallarino: And craftsmen can take it well beyond the basics, I assume?

 

Rhodes: You can make furniture, tiles, panels, planters, and beyond. You can make shower panels and even spray it out of a hopper gun. Adding glass fibers makes it a lot stronger. You could fabricate four by five foot shower panels at one inch thick and thinset them to the substrate. The material can also be used to make fireplace surrounds. And the panels need not be rectangular. The seams can be curved. At one inch thick, the product weighs about ten pounds per square foot.

 

Fallarino: Can your products be used in exterior applications?

 

Rhodes: Yes they can. You can use it for tiles, countertops, and as long as there is drainage, planters. We use iron oxide pigments, so they are fade resistant and UV-stable.

 

Fallarino: How do you colorize your product?

 

Rhodes: For our white mix, we color the mix water. This homogenizes the color throughout the entire finished product. We also have a signature veining technique where we pack the concrete into a mold and then back-fill the voids the next day with a colored paste and then polish that out. That technique creates a very natural and organic effect. The top surface can also be stained if desired, and these techniques can be combined. We sell sixteen colors, but most concrete pigments can be used. You can also add recycled glass to the mix which then creates another dimension when the product is polished. Recycled glass is available in different sizes and colors.

 

Fallarino: Let's go over the techniques used to fill molds.

 

Rhodes: With the pressed technique we mix the concrete on the dry side and pack it into a mold. That leaves voids that you back fill the next day with colored paste. The troweled approach is done with the material right-side up. You get these hand marks. And you can really take it far by hand polishing it to get an almost Corian-like effect. We did 150 Pottery Barn stores around the country with our troweled finish. We also did a lot of Williams Sonoma, Pottery Barn Kids, and Gap stores.

 

Fallarino: How much do material costs run for your product line, Buddy?

 

Rhodes: About $15 to $18 per square foot.

 

To learn more about Buddy Rhodes Artisan Concrete products, visit them online at www.buddyrhodes.com.

 

Mike Fallarino is a contractor in the Albany, New York, area.
He can be contacted at herbalist@berk.com.

 

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