1- The 4 basic zinc options available to you as a consumer. $70-$700
1- The 4 basic zinc options available to you as a consumer. $70-$700
A challenge facing the zinc countertop industry is simply understanding the difference between the four basic fabrication methods; their limitations, their strengths, how they differ from one another, and, ultimately, why their pricing differs. All zinc products are not created equally!
It seems that every technique is trying to mimic another, so what are you to believe? Here, I break down the basics of these 4 techniques: Sheet Metal, Cold Cast/Artisan Cast, Slip Cast/Deposition, and French Foundry Cast.
Sheet Metal:
The most common and economical method is sheet metal. Small shops use metal brakes to bend sheet around a substrate of plywood, which is usually built up to 1.5” thickness.
Sometimes the two are bonded together with adhesive, and sometimes not. Decorative nails can be used to hold the sheet in place or add visual interest, but because sheet metal can only be extruded in a straight run or laid flat to create a curve in plan, complex geometries can be difficult to achieve with this conventional fabrication method.
Break form sheet metal severely limits design options to basic extrusions or square profiles that make up curves. Most customers think that all metal countertops are made this way, but you can not achieve compound, complex curves from brake form sheet metal.
It may appear to be the most affordable option, but it is the most dissimilar from the three other methods I’m going to discuss. If you receive a sheet sample with rectangular corners, know what this sample is trying to say.
It cannot transform into something it is not. Sheet is great for square edge tables, and basic profiles, but even then, other methods may outshine this basic technique.
If a curve is executed in plan and an entire edge has to be soldered, know that once this detail goes through the patination process, the edge will look much different from the surrounding metal. It is an imperfect and rustic look that sometimes suits a project perfectly.
I’ll also quickly note to be aware of galvanized sheet steel, which is a huge no-no for food safety, and I’ll be talking more about this in a later post.
Cold Cast/Artisan Cast:
A fabrication method that has gained popularity in the last six years is a process called “cold casting”. Sometimes referred to as “artisan cast” or by other names, this method was developed as a less-expensive alternative to “slip cast”, which I’ll discuss in a minute.
This rather deceptive description leads you to believe that this involves some two part mold broken directly from the core of the planet Krypton, but just like the early frost brewing ads from the 1990s, it leaves the user disappointed in the end.
Alas, it is just an epoxy resin with metal flake mixed in, sprayed onto the surface of a substrate or core. It doesn’t react like real true genuine metal, but more like plastic, and if you set a hot object on this material, which has a heat deflection temperature of 120 degrees Fahrenheit, you will be disappointed.
It should not be used for everyday surfaces, but has a place in decorative accents. Once you touch this material, you can feel that something disingenuous is going on. I do not recommend this for counter surfaces, so if you receive a sample that looks too good to be true, ask about the qualities I’ve just listed.
Slip Cast/Deposition:
Other metallizing deposition methods popularized in the past decade, sometimes referred to as “cast” or “slipcast”, fail to take full advantage of the strengths of this technology, which is emulating the original products from France that we will talk about shortly.
This tremendous process currently uses a substrate made of plywood and other hardwoods built into a form, then gradually layered with thin deposits of metal to achieve a desired thickness. So there is no casting into a mould or two-part process involved. This is the most expensive of the current American manufacturing techniques, but it is also the most versatile.
In future posts I will discuss this method further, but of all 4 methods discussed here, this one has the most promise.
French Foundry Cast:
The last method is the technique from the 1880s that produced the original bistro tops in France. By truly casting small sections of real pewter trim in dangerous foundry work moulds, cooled pieces are joined to larger sheets laid over a wooden substrate, then soldered together in a labor-intensive process.
If a new trim is desired, you must create a new mold. Often these beautiful projects are smaller or require two to three times the amount of lead time to receive, if at all possible.
In general, the technical requirements for modern bar tops and the lead time and overseas coordination with French manufacturers make this option less unobtainable for customers needing support and responsive turnaround times.
It’s less flexible, in terms of design possibilities, than metallizing deposition, but some enjoy the charm of this original technique.
The French produce gorgeous tops, which has led to a Renaissance of metalworking ideas in the United States. These tops are the most expensive, but they only come in one metal, Pewter, which is very soft.
When talking about zinc counters, understand the fabrication method and the limitations and strengths associated with it. Each is very different from the next, and clearly understanding that 4 different products are available to the market will help you ask the right questions when it comes to specifying a product, eliminating inferior methods, and ultimately decoding pricing.