Expressions LTD- Concrete and Unique Decor products: Concrete Sink Mold, Vessel Bowl

Product Description:

The 'Vessel Bowl' Sink Mold for concrete sink fabrication.

Two part mold- Inner Bowl Mold, and Outer Vessel Shell Mold.

Inner bowl can be used alone to make integral sinks. If you already have our Bowl sink mold, you can just order the outer shell mold and you'll be able to make the vessel bowl.

Small style drain for bathroom/lavatory size drains.

Dura-BLU fiberglass Molds are reusable indefinitely with proper care.

Dura-BLU molds have a highly polished Industrial Gelcoat finish.

Dura-BLU Molds are made using the strongest commercial-grade resin, NOT out of GP (General Purpose fiberglass resin).

Each Dura-BLU Mold has an Internal Flange:

Inner Flange further strengthens and braces the Mold.
Creates a platform to screw into; securing the Mold to the form.
Allows clamps to be used to lift stuck Molds out of cured concrete.
Each Mold comes with one disposable foam drain hole knockout. Additional Foam Knockouts available here. Reusable Rubber Faucet Knockouts (Large size) can also be used for drain holes.

Product Specifications:
Sink Mold Measurements: Inner- 15 3/8" Diameter x 5 1/4"D**. Outer- 18 1/2" Diameter, 6 3/4"D**.
*Depth can be adjusted by trimming/sanding down the Mold to your desired depth, but you may lose the Internal Flange that is in the Dura-BLU Molds if you trim very much.
Sides to Dura-BLU Molds have at least a 5° slope to ensure Mold removal from concrete.

Mold Setup:

This is a two part mold. Silicone the inner bowl to a form (melamine, glass, etc.). Place outer Vessel Mold over the inner mold, and silicone the outer mold in place. The outer bowl also has a 1.5" flange so it can be secured in place with screws. Concrete is poured through hole in the top of the outer shell.
Apply 2-3 coats of a Mold Release Wax (sold separately).
Apply small amounts of silicone to the Mold's rim, and set in place in your form. Allow silicone to dry.
Screws can be used to secure the Mold if necessary. Using screws of the appropriate length, screw through the bottom of the form, up into the Internal Flange of the Sink Mold.
Run a smooth silicone bead around perimeter of the Sink Mold, where it meets the form base. Silicone Disposable Foam Drain Knockout (supplied with Mold), or Reusable Rubber Knockout, on to Mold. Allow silicone to dry.
Apply a thin coat of Fiberglass Safe Form Release (sold separately) to the Mold just prior to casting the concrete piece.
Various methods can be used to cast the concrete piece:
GFRC: Cement and fiberglass is sprayed on and hand packed into the form and around the Mold.
Wetcast: Oatmeal consistency concrete is placed in form and around the Mold and vibrated. A simple box should be built around the Sink Mold, to contain the concrete during this process.
Hand Packed: A drier concrete mix is hand packed into the form and around the Mold. A second step after de-molding will fill the voids with cement slurry, usually of a different coloring.
More information available on our Fabrication Tutorials Page.
Any voids in the concrete can be filled using a cement slurry. Add Cenospheres to portland cement to reduce shrinkage and make filling voids easier.

Mold Removal:

If Mold Release Wax and Liquid Release were used prior to casting the concrete, most Molds will usually pull out of the concrete with little effort.
If the mold is difficult to remove:

Adding cold water and ice to the inside of the mold for 10 minutes will shrink the mold just enough that removal is easier.
Compressed air shot around the Mold rim will break the suction holding the Mold in the concrete.
Using a few blocks of foam against the concrete, place a 2x4 across the Mold, and pry the Mold out using some large C-clamps, or wood working clamps.
Most Molds can be pushed out of the concrete by removing the drain plug, and pushing the Mold out through the drain hole.

Warranty and Mold Care:

Each Dura-BLU mold has a Lifetime Guarantee against defect. This Guarantee does not cover misuse of the Molds (Dropping the Mold, Prying the Mold out using a screwdriver... etc.).
Liability Policy: Expressions LTD will not be held liable for any damage, misuse, or collateral damages resulting from use of any of our products. If there is a flaw or defect with a product, we will fix or replace the product.
Clean Mold with a sponge after each use. Waxing and buffing the Mold after use is recommended to maintain the Mold in top condition.
Any damage can be repaired using 2-Part epoxy (Available for a few dollars at any hardware store- comes in a double syringe). Mix the epoxy, apply to the damaged area, and sand smooth when dry. Wet sanding the Mold will return the damaged area to a high gloss if desired.