Q1: What is D-FRC?
Decorative Fiber Reinforced Concrete, or D-FRC, consists of high strength fibers embedded in a cementitious matrix. In general, fibers are the principal load-carrying members, while the surrounding matrix keeps them in the desired locations and orientation, acting as a load transfer medium between them.

Q2: What are the benefits of D-FRC countertops?
The D-FRC method reduces material consumption by using 1/3 less material with no steel needed. D-FRC countertops are lighter and stronger allowing for larger, seamless castings. Integral sinks can be cast without a back form. Time savings is key—projects can be de-molded 12 hours after casting. An entire project can be turned around from template to installation in less than 72 hours.

D-FRC v. WET CAST METHOD

Q3: How much does a D-FRC countertop weigh compared to a standard "wet cast" countertop?
A D-FRC countertop with a 2" edge face will weigh 7 lbs./s.f. By comparison, a standard 2" thick "wet cast" countertop will weigh approximately 23 lbs./sf.

Q4: What is the minimum thickness of a D-FRC 8' length countertop?
1/2" thick.

Q5: How long can I cast a countertop out of D-FRC without a seam?
The longest runs have been up to 20 feet.

Q6: What is the difference in mix design between D-FRC and a traditional wet cast method?
Traditional wet cast concrete has lots of large aggregate blended with sand and cement to create the structure of the concrete. D-FRC is a blend of advanced technology fibers, cement and fine sand. By replacing the aggregates in traditional wet cast concrete with the advanced fiber blend in D-FRC we are able to make the concrete much thinner and lighter while maintaining the same structural performance of the concrete.

Q7: What is a typical D-FRC project turnaround time?
A standard 8'-0"L x 3'-0"W x 1-1/2"T project can be turned around in less than 72 hours from template to install if needed.

Q8: What surface finish techniques can be achieved with D-FRC?
Marbled, polished, acid stain, sand blasted and exposed aggregate surface finish textures can be achieved.

Q9: How is D-FRC countertop installation different from wet cast countertops?
You don't need muscle men on the install crew.

Q10: Are D-FRC countertops easier to maintain than standard wet cast countertops?
When sealed with the CHENG Concrete Countertop Sealer, the maintenance will be the same as for a "wet cast" countertop.

Q11: Are there "green" benefits of D-FRC?
Yes, saving on materials and supplies are what contribute to the green benefit of the D-FRC method with 3/4 less material used than standard wet cast countertops. Also, no steel reinforcing is required.

MATERIALS, TOOLS + PRODUCTS

Q12: What materials do I need to make a D-FRC countertop?
NeoMix D-FRC is an easy to use suite of advanced technology products, making it possible to create flawless D-FRC projects with consistent professional results. NeoMix D-FRC Suite of products consist of CastingBlend, SprayBlend, BackingBlend, SlurryBlend and Activator.

Q13: What CHENG Concrete Countertop Products can I use?
NeoMix Color, Acrylic Slurry, Sealer, Wax, Sink Knockouts, Base Pigments, and any of the related forming supplies like Pro-Form and trivet strips.

Q14: What tools and equipment will I need? Where can I find them?
In addition to standard wet cast tools and equipment, you will need a stand mixer, hopper gun and air compressor.

Q15: What mix designs will I use?
With NeoMix D-FRC Products there are no mix designs to wrestle with. Simply dilute the NeoMix D-FRC Activator in water and mix with 1 bag of NeoMix CastingBlend, SprayBlend or Backing Blend.

THE BOTTOM LINE

Q16: What is the cost investment to start doing D-FRC in my shop?
If you are already making concrete countertops, the additional investment will be somewhere between $1000 and $2500 for a stand mixer, hopper gun and air compressor.

Q17: What is the suggested retail price of a finished D-FRC countertop?
Pricing per s.f. could range $85 - $110 depending on varying local or regional markets.

Q18: What are my material costs for an average D-FRC countertop?
Depending on the market location, material costs tend to fluctuate between $6.50 and $9.50 per s.f. for a typical countertop.

Q19: What D-FRC applications/possibilities exist beyond countertops?
Fireplaces, BBQs, window and door trims, window sills, showers, tubs, columns, signage, wall cladding, floor tiles, hoods, tables, planters, benches, sculptures and displays.

Q20: Who are recommended participants for the 2-day Professional D-FRC Training?
Concrete countertop contractors, skilled craftsmen, carpenters, tilesetters, stone fabricators, sculptors, artisans, concrete masons, and any building or landscape professional interested in working with and understanding D-FRC applications.

Q21: What are prerequisites for the 2-day Professional D-FRC Training?
Previous concrete experience, basic carpentry or mold-making skills is required for successful participation in the training.