When we initially went to scope out the framework and cabinetry for the Jacobus' enormous residential counter-top job, I could have easily been fooled into thinking iNViDiA was about to be featured on one of "MTV's" obnoxious hit reality T.V. shows, like "Cribz," which in layman terms to our elderly audience, is a show titled in reference to the owners "pimped out" houses. When young folks say that a house is pimped out, it of course, means that the home reflects an owners highly eloquent sense of taste, and the sub-text, arguably refers to the manifestation of the home as being a result of social or financial affluence. A pimped out crib, is a model for the newest trends in high design, and is furnished with only the finest of decor, along with, of course, being healthily stocked with select wines, and the plushest of toilet paper available for ones butt. It should also be noted, that the "z" in Cribz, is purely accidental. How that spelling error got past the executives at MTV, I'll never know.
So now that I've relinquished any possible linguistic differences, and we're all on the same page, I'll continue in saying that this was an absolutely gorgeous home, with a most spectacular view of Lake Michigan right in the back yard. As this was one of the first on-site jobs I had the pleasure of being a part of, I hadn't fully appreciated yet, the fact that this lovely scenery would be our temporary work space!
The tentative kitchen re-modeling- a stretch to say within itself, considering that a whole new kitchen was created- so, more aptly put: the tentative kitchen design (much better), called for custom counter space in the entire kitchen, which was composed of: a long, several piece counter-top that fit their stove, and integrated numerous custom design elements, including raised stainless steel strips to elevate hot pots and pans (found conveniently on both left and right sides of the stove); another substantially sized single-piece counter, fit precisely for the island sink, that included the inlay for a custom made cutting board; an enormous (as in the largest piece we have ever poured!) island bar/counter-top that fit to overlook the sink island; as well as a smaller wine-nook counter-top that featured some interesting coins and trinkets that were inlayed into the surface at the Jacobus' request. This job, from the very beginning, was recognized as a wonderful opportunity for iNViDiA DESIGN to flex its creative muscles, while still demonstrating the punch of Aaron and Ken's quick, efficient, highly personable, and labor-intensive business principals.
So, as the molds were being produced, we all took the opportunity to familiarize ourselves with the layout of the kitchen, and the placement and over-all implementation of the extra design elements that had been cleverly sewn into the enormous counter-top's we were preparing to pour...
Here, we see Ken walking into what is being transformed into the new kitchen and dining room. It seems to be a potentially glamorous addition to the already beautiful home. That is, if all goes according to plan....
This what we we're working with in the very beginning. Not quite what you would call pimped out right? Not yet at least... keep a mental picture of this one here, so you can feel the fully charged blast of "holey-crap-what-an-amazing-transition," that is going to take place right before your very eyes, compliments of the iNViDiA team! 
Another dramatic "before" shot, depicting Aaron discussing the full details of the project, with the general contractor. Maybe Aaron is quizzing him to make sure he knows his zoning laws, but more than likely, he's asking where a good place to get a sandwich is around here. 
A potential problem on iNViDiA's end, is always the possibility of other contractors work not lining up with the plans, or our installation needs being overlooked. For good measure, it is always crucial to check everything over, to make sure that the numbers and measurements are where we need them to be. More often then not, a few half an inches fall through the cracks somehow, and alterations are necessary. 
Matt, Aaron, and Ken begin mixing one of many bags of cement for this enormous counter top piece. Because of the sheer enormity of this counter top in particular, we ended up having to pour it outside the Jacobus' house to save ourselves from having to carry and transport the despicably heavy object an extra time. 
With pieces as extraordinarily large as this one, or in other instances, overtly complex- the importance of securing your pour, and the procedure behind it, becomes more and more of a focus. In this situation, the weight of the counter top without full support, can potentially crack itself in the drying. Because of this, the huge mold was kept on the trailer for the entire pour, and through the entire next night, so we could be absolutely sure that the next time we took the risk of moving it, it would be the de-molding, and installation. Keeping it on the trailer gave it full support in comparison to the way the horses might unevenly distribute the weight, and it also saved us from having to lift the beast from the ground, onto the horses, for the grinding and slurrying process. 
The biggest issue when dealing with a mold of this size, is the fact that it literally cannot be moved with a team as small as our pour team. When Ken and Aaron finish the super-strength robotic bodies they are working on in the shop, they might not have the same problem, but until then, we have Carl to help us. 
Once all 9 bags of cement mix are poured, everyone works quickly to smooth out any surface imperfections. When the mixing is done, it can be a particularly tense moment in the process, and one where everyone needs to really be on their toes (and their hands and knees), to make sure this last precious time is used to make the form as clean, smooth, and flawless as possible. Any humps, or imperfections that are left, are taken out with an angle grinder, and since this takes 3 times as long, it is essential to make major changes when the cement is still partially malleable. 
When you pour as many as 9 bags in one mold, it is done in 3 sequential batches, and it becomes essential to prevent the first 3 bags from being hardened before the final batch. A cost effective way to make this happen, is to invest a few extra bucks in drying retardants. By using the drying retardants in the first two batches of the pour, you can actually chemically alter the drying times, so that all 9 bags are coming into their final stages of setting, at the same time! When you pour a piece this large, you have to look at the cost of labor and materials over all, and to ensure that the piece turns out without any flaws, it is worth it to spend the few extra dollars on retardants, to literally, buy you some extra time to perfect the form. 
Another difficult aspect of this mold- contributing to its overwhelming weight, and the difficulty of the overall form- is the 3 inch drip ledge that you can see is being cleaned up in its final stages. Aesthetically, the drip ledge makes the counter appear that it is even more massive than it already really is, and the sheer weight, visually, comes off with a wonderfully grandiose feeling of permanence. These overhangs, although elegant, make it much more difficult to pour since you have to spend so much time meticulously filling them; also, they are nothing but a burden to the mold maker. They also make a form particularly difficult to level out exactly, since you cannot use a board as a skim, to make sure the surface is perfect. I'll stop complaining soon though, I swear. 
Ahh yes, the good 'ole laying of the templates- always a procedure involving debate, second guessing, and re-measuring. This is not anyone's fault, and there is no real remedy except for everyone taking a solid ten minutes to overlook everything, and make sure that the right move is about to be made. It would seem simple enough, but the problem is that mold making in general, involves a very back words way of thinking, since most often, you are actually working on the piece upside down, and considering the way it would sit, if it were right side up. It pains me to even try explaining it... 
A unique aspect of Aaron and Kens green friendly, no waste approach, is that most of the time they pour, there is an extra mold waiting to be filled in case they mix more than needed. Such was the case with our big boy, and luckily for us, we had a sink mold just waiting to be poured! 
Here, we see Aaron grinding away anything that might be uneven. Notice that with this monster piece, it stays exactly where it was the day before, on the trailer- even if it might be easier to grind it on the horse, you only move a counter top of this weight, when you absolutely must. Carl stands nearby casually, making sure that the work is done right. Every time someone screws up, they get punched in the face by Carl. Call it tough love, call it dedication to quality, call it physical abuse, or even assault and battery- no matter what, you can't deny that these guys are dedicated to getting the job done right.
Ken puts the first coats of sealant on one of the pieces, as Carl observes, once again. Since its such good weather for a beating, we all work tirelessly under Carl's massive shadow. 
Ken applies a few coats of the sealant, and checks it over thoroughly to make sure that Carl won't find any imperfections. Once this final coat dries, a second solution is applied to give the surface a perfect sheen, and protect it from spills. The various sealants that are used, work to protect it from stains, and general ware and tear. No matter what though, a simple extent of maintenance, and caution is necessary to keep the surface as beautiful as it is once finished. 
Flipping the piece, and de-molding it, is a particularly difficult task with a counter top as heavy as this. It must be handled with a surprising amount of care to the distribution of the weight on all ends, and no matter what, allot of pink foam is necessary in keeping edges from chipping, and surfaces from cracking. Also needed to flip a piece this heavy, is a Carl. 
Normally, a large piece might not be as heavy as this one was, but as the surface area increases, it is necessary to make it thicker, so, asides from the 3 inch overhangs, the full piece is a solid 2 inches all the way through. ONLY considering the dried concrete used for this piece, it is still a whopping 540 pounds! Thats not even including the countless gallons of water that are added to the mix.
Here, we can see that the bug-holes in this piece are fairly large. They will, of course, be filled with slurry in the end, and although this might not be necessarily desired, they will be a beautiful effect aesthetically- after we all spend hours filling them that is! 
Here you can see the sink layout, as it is carefully placed on the nearby horses for finishing and slurrying. There is a knock-out template for the sink to fit into, and next to it, is a shallow inlay designed to hold the custom cutting board being created. Because of the shallow inlay in this piece, it is important to be especially careful when handling it, so it doesn't crack. 
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