How MASS concrete is made

MASS is a new generation of concrete.  It offers the character of a sensuous handcrafted finish, combined with high-strength performance from micro-concrete technology.

The surfaces are produced using accurately machined moulds, which are specially made for each casting. The concrete is digitally batched using high performance cements and pozzolanic binders combined with selected clean, fine and well graded sands, pigments and integral admixtures. These help to control the water:cement ratio to the optimum for full hydration, while still producing the flow characteristics of self-compacting concrete.

High strength
This finely tuned mix gives MASS its dense, robust and durable appearance.  Compressive strengths of more than 140MPa are achievable.

Lighter
Keeping the weight down is critical.  MASS does this by combining the micro concrete with its laminating system.  This means surfaces can be made in longer lengths and widths than resin composites – and at a thickness of just 18mm. So weight is kept to an absolute minimum for handling and installation.

This versatility also enables down-stand legs to be moulded to the perimeter of the top surface up to 100mm in depth, to give the appearance of a solid slab.  This means using far less material than conventional concrete for the same finished depth.

Extensive finishing process
Unusually for a concrete product, many MASS surfaces have a hand-crafted character. The secret is an extensive finishing process.  The cast surfaces are water-cured for at least two weeks. Then they are polished using fine, high-grade diamond impregnated discs.  This cutting through the sand grains gives the surfaces their superior cut and abrasion resistance, while maintaining a high quality appearance and sheen.  Finally, a tough stain-resistant sealant is applied.

Cast to order
Cast Advanced Concretes casts all the work to order, with an extensive range of mix designs.  Products come in a range of colours, including the natural greys of concrete as well as whites, creams, browns, blacks and a selection of pastel shades.  Thicknesses are available from 40mm-100mm, seamlessly cast to almost any shape and size.  The standard finish is a silky satin – a contemporary look that complements glass, stainless steel and timber.  Rougher looking raw concrete finishes are also available.

MASS was first developed in 2001.  It has taken off more recently following the takeover of Cast Advanced Concretes by the Edenhall Group.