Everybody I know- especially the boys from iNViDiA Design- is familiar with my currently crazed obsession, over the latest popular leisure activity for American youths; that's right, you guessed it- pouring concrete. Ken and Aaron's endeavors with iNViDiA Design, aren't just some specialized outsider trade, or what have you, they're riding a tsunami sized trend, that is sweeping the United States quicker and fiercer than the Nazi's in Warsaw! Was that in poor taste? Anyhow, concrete pouring fever is the hippest trend to hit young folks since drugs came around. I've heard some kids refer to the action itself, as "dropping mortar,"or, "hitting the cement," and in common slang for the newly popular raw material, it is referred to as "the hard powder," or "the green alternative." No matter what you call it, I'm hooked like a fish!
So obviously, when Ken and Aaron told me I'd be spending my weekend in boulder junction with them, to pour some of "the hard stuff" for an enormous outdoor bar/patio job- I tried my best to conceal my feelings of elation. I apparently hid my happiness well, since I was told several times by Aaron, "quit complaining, its only one weekend, your grandma will make it till Monday I'm sure." Ken was also quite supportive, in reminding me that "… there's a whole 'nother weekend coming up next week, how many freaking' weekends do you need!?" As usual, the guys were completely right, and after Ken reminded me that in "his" day, there was only one weekend a month- I realized I was acting a bit selfishly. I immediately called the church to tell them to get bent, and that I had more important things to do than "feed the needy," and then I phoned my grandmother and asked her to try her best to make it until I returned on Monday. In retrospect, I guess I didn't need to tell the church to get bent, but who are they to tell me what Jesus wants me doing- he was, after all, a carpenter wasn't he? I figured he would understand if nobody else would.
Finally, I was ready for the trip up north, and the massive pouring and installation of the extravagant outdoor kitchen, that was to be installed in order to make the Diedrichs' luscious summer cabin complete. Oh joy!
The layout of the kitchen seemed deceptively simple to me when judging by the many small manageable molds we were hauling, and though there were a few large pieces that would be a burden to carry, I figured it wasn't anything we couldn't handle after pulling that Braun job off.
I was right in my bestowed confidence of our small 3 man crew being able to handle it all, but I was dead wrong in my estimation of how simple, quick, and manageable I thought the job was going to be. Slowly but surely, we all fell prey to a much deserved mood of frustration, but mind you, when I say that our frustration was deserved, I don't mean it lightly- we were working away, grinding and slurrying, till damn near 5 in the morning! By then, with weary eyes and flat beers, we had been pouring for fourteen hours straight, and it was time to make the drive into town and hop into a motel bed for a few hours so we could be back on site the next day by noon, to do the finishing work, and installation. We grabbed some greasy McBreakfast, checked into the hotel around 6 a.m., and I was out like a light the second I hit the cot- I didn't even bother to wash the concrete dust out of my hair, and luckily for me, sweat didn't set the mortar that I feared could permanently style it as the raggedy tangle it was. I rested contently in my own filth, and even had the audacity to wake up refreshed and ready to work the next day. I made sure to shower first of course.
We worked hard to get everything where it needed to be, and in our very last efforts, we were informed that the entire kitchen, as well as the entire patio, was called off because of zoning ordinances. Amazingly, the small detail of "how close you are legally allowed to build a patio, to the waterfront," was completely overlooked by the general contractor! It goes to show you how important it is to know your zoning laws, before constructing a highly elaborate outdoor extension to your home. Who'd a thunk it?!
Well, I guess that's no excuse for me to not share all the great process photos with you, right? Right. So without further ado, here's a nice little photographic summary of all the hard work that went into the project anyhow. I've even been so good as to insert my smart-ass remarks along with 'em, since I'm sure you all don't have enough television to rot your brain with in your free-time already. Enjoy!
Here's the rig we had prepared for the voyage; it was necessary to carry all the molds, and the tools we needed, as well as any of the "extras" that might come in handy when you least expect it. When you have a job as far from the work space as this was, it is essential to have everything you do need, as well as anything else you could need. Whatever small amount of room there is for error, must be compensated with all the tools to properly fix that error. The only thing more amazing then the fact that we made it all the way to boulder junction with our beloved company truck- that is on its last limbs to say the least; is the fully stocked bar and lounge that Aaron and Ken built into the trailer. For those guys, there is absolutely NO room for error in a good dry martini- especially since we only had enough room to carry one frightened whimpering bartender... Don't look at me like that, we fed him. 
Here's the raw construction of the outdoor kitchen when we got there. We weren't all that thrilled with it in general, but we figured it was still in its first stages of construction, and of course, everybody knows how much an iNViDiA counter top will enhance the over-all aesthetic of it. I was wondering how the drywall would withstand the weather, and Aaron was good enough to give me a quick sit down- young grasshopper style- and explain to me the general properties/characteristics of "cement board," the material being used here. I would share it with you, but it's one of those secrets handed down generation by generation among the most elite of Jedi, ninja, and contractor circles. Sorry... I'll share my grahm crackers with you if you want though? Their animal shapes, and you can even make the lion one's eat the giraffes! 
Ken and Aaron set up and evaluate our work space, making sure we safely cover the giant hop-scotch court- I think that's what it is at least... I was naively assured by the guys, that if I behaved the whole time, I would be allowed to play on it after the work was done. Of course, I wasn't allowed to, and as I bawled the whole 4 hour car ride home, Ken collected almost a whole jar of my tears! Ken cooks with it, and he says its the secret to his youthful livelihood- I'm glad to help the guys however I can, and I guess its better then them beating it out of me with that awful sack of rotten oranges... Sometimes you gotta take one for the team, right? 
In order to properly prepare the molds, it is important to wipe any of the dust, dirt, or wood shavings out before hand, as well as applying a filler to any gaps that could potentially cause a crack upon de-molding the piece. Pouring concrete might appear to be all fun and games, but allot more work goes into it than what you might think. The hollywood depiction of the concrete pouring lifestyle, is much more romantic then the real deal, however, I will admit, the girls go nuts for it- concrete groupies, or "croupies," are no joke! 
Here, we see the template for the sink, being laid into the mold. This way, when we pull the fitted pink-foam piece out of the concrete, there is a perfect void in place for the sink to fit into. You didn't think we just stuck slabs of concrete on top, and cut the shapes out afterwords, did you?! Silly people, we're much smarter then we look- that would be quite wasteful! 
A standard 50 lb bag of mortar sits on top of the sink template, while the silicone adhesive dries- that nifty little blue circle there, works the same way as the sink template knockout, and allows a perfectly fit void for the plumbing to fit into. Because of this, everything looks completely factory-flush-fit, as if it were all manufactured as one! Sometimes it's necessary to just sit back and appreciate how good we are... Join us in a brief moment of egotistical bliss! 
Ken and Aaron get to mixing their special blend of concrete for this job, I stand there with a camera. "My arms are tired from holding the camera guys, can I sit down?" As you can see, we are working- by request of course- with the same charcoal colored tint that has been a solid Milwaukee trend ever since we unveiled it for the infamous Braun job. Just wait and see, we'll be building mansions with the stuff soon, and by then, we will be pouring pure gold for our counter tops! By request of course... 
The mix is blending wonderfully thanks to Aaron and Ken's patent techniques, and of course, the obvious grace and finesse they apply. Legend has it, that they learned their savvy techniques from a seventy-six year old Mongolian dance instructor, with obsessive compulsive disorder, and a notable weight problem. The story tells that he turned to concrete at the age of twelve, because through enlightened meditational practices, a diet of fried chicken, and prayer, Buddha instructed him to build a temple in tibet. His name is Fred, and if you too, wish to learn the sacred way, you can usually find him pan-handling in front of Pueblo Foods in Riverwest. Enlightenment in general, is a commodity found where you least expect it- just ask Fred! 
Since the surface of each one of these little molds should be absolutely perfect, they are in many ways, much more of a pain to pour than the larger pieces. That's not to say that they don't require the same amount of attention of course, but at least with the large ones, you have only one surface to treat under the time limitation of the setting cement. 
Ken works carefully to preserve all the screws from the molds he is taking apart, because after the concrete pieces are carefully removed from the mold bottoms, they must be meticulously re-constructed in their original form, to be used for a second pouring. So many individual molds being used twice, saves on material, and cost, but complicates this particular job because of the importance of their exact replication; as well as the fact that there are then two separate pours, and thus forth, two separate drying times that tremendously lengthen the amount of time I have to be stuck in the north woods with Aaron and Ken... Did I say that right, my apologies, I meant: the amount of time I have the privelage, of being stuck in the north woods with Aaron and Ken. Much better. 
Aaron carefully uses the hammer to tap the sides of the mold, allowing the vibrations to free the laminate coated wood surface from the hot moisture of the dried concrete. This can be a trickier task with pieces so small, since the strong bond formed from the heated concrete and resulting condensation can be great enough to snap a piece if you aren't careful enough, or if you don't have wire mesh laid into the cement pieces. Ken, wearing his rain boots in a far grasp for avant garde fashion, puts all the molds back together as Aaron takes them apart.
The ghost of Ken, haunts Aaron as he tries to figure out some measurements for one of the larger molds. All work and no play, can make Aaron a dull boy- nothing a few warm Leineinkugels in the North Woods cant take care of though! At least while our bartender mixes those cocktails up in the trailer... 
No matter how you cut it, and no matter how precisely you configure your work out on paper, there are always a few measurements that come into question and cause re-calculations, and re-measuring to take place. I'm usually blamed for it all somehow, but I just cant help using the projections for coloring- there's all those perfect lines and shapes, and none of it is colored in yet! What would you do?! 
As it got dark out, we had to grab some lights, and some extensions, and get ready for a long night. When your last pour is already in the dark, you can count on it being a while for the last molds to dry, before you can eventually begin the grinding and slurrying process to them. The good part is, you can already start the grind/slurry process on the first molds that are already dry! Are you as excited as I am by that? I highly doubt it. 
One of the last contractors that was there working at the cabin, saw that we had lots of work left to do, and he apparently sensed that our convictions were strong enough to keep us there working hard late into the night, since he helped us out by lending us a few extra lights. It would have been a much nicer gesture of him, if he hadn't accidentally stepped on, and broke one of the pieces while hooking the lights up though. We appreciate the gesture of kindness anyhow, and since the guy told Ken and Aaron that I did it, I was told to balance the broken concrete pieces on my head for the rest of the night, and everything turned out O.K. for him. 
Aaron looks wearily into the night at the last few pieces we have left to slurry. At this point, sleeplessness and exertion have made slurry of our brains, and everyone is maniacally attuned to their tasks with one goal in mind, finish slurrying, so we can get to bed! 
Slurry, in case you haven't already been over this with me, is a pasty material made with similar ingredients as the concrete itself. It is used in a repetitive patching process, in order to fill all the small "bug holes" that can be seen in the pours of the cements surface. By tinting the slurry with variations of darker charcoal tone, a pattern can be achieved as you fill in all the holes with the darker slurry, and then eventually, grind away the excess paste from the surface to clean it up completely. 
The patches you can see on the surface of this cement piece, are the final coat of slurry we applied the night before. After the water intensive grinding process removes the patchy quality it currently shows, you will have a completely smooth, polished, charcoal-colored surface, that has an organic constellation of smaller, freckle-like, patterns that are obtained by using the slightly darker tinted slurry. The overall effect, is what that rich chick from the movie Titanic, would call breathtaking. 
In this lovely little detail shot, you can really get a sense of how broad the range of possibilities is when working with concrete. Aaron took a few stones that the outdoor patio was being lain with, and set them into select corners and spots of the mold, so when he removed the thin layer of cement, it exposed the stones, and created a gorgeous effect. Kinda like when Han Solo was encased in carbonate during "The Empire Strikes Back," and then exposed again in the beginning of "Return of The Jedi." Even as a Star Wars nerd, I feel I can safely say that this is even cooler than that! Maybe I've turned to the dark side, and I'm even more of a concrete nerd by now though... 
The view sure is lovely here, it would be unfortunate if something were to halt the entire project, like maybe... ZONING LAWS!!! C'mon now, check into a detail of such enormity before you decide to hire the whole county for a job! Obviously this mass-take wasn't on Ken and Aaron, as this wouldn't be the job of anyone subcontracted- but an important duty of the "general contractor," or GC, is to know all the zoning ordinances, and paperwork like the back of their hands. It just so happens that in this particular job, the GC managed to overlook the zoning ordinance that proclaim just how close a patio is allowed to be to the waters edge. Whoops. 
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