Custom Copper Counter Top Design & Fabrication Page

 Updated 8 / 2022

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Experience?
Our specialty has been to design and fabricate exterior rain management products, but we have been asked to do some of this type of interior work as well.

This refined interior work is not something I want to push, as it will not be perfect at close inspection, as with anything custom hand-made, such as this. Clients are used to seeing most store bought products that were mass-produced and expect a flawless appearance, or it will be returned to the store.

Finish Quality?
To be frank, these kind of projects may have minor scratches and dents, because we do not have access to perfectly polished copper sheets to use for projects like this, so I cannot guarantee your satisfaction with the new copper finish that you may expect. You are then welcome to have it polished as much as you want by those who specialize in metal polishing work. After it has developed a patina you may not notice these imperfections nearly as much. Some clients love the rustic hammered copper look, which would help to hide any future dents or scratches that may occur.

Advantage of Copper?
Beside the unique look of copper, the main preferred advantage of copper over stainless steel is largely for it's anti-microbial properties. Very little cleaning is needed, since the main advantage of raw copper over stainless steel or any other counter surface material is how copper is much more anti-microbial, which naturally kills germs on contact. As explained from this link below. Stainless steel may look cleaner than tarnished copper, but looks can be deceiving.

I hear some hospitals outside the USA have impliments more copper shelving and such to cut the staff infection rate quite a bit.

It also has a character you cannot find with any other type of surface; with it's ever changing appearance as it develops it's patina over time, which does not stain or rubs off on other things.

Strength?  
Most of these projects are made with a thick 32oz copper, which is about 4 times as sturdy as the more common 16oz copper used by most sheet metal shop to save on their material cost. That is if they are willing to work with copper at all. This 32oz copper sheet stock is not found at most other sheet metal shops at any price. This is just twice as thick as the 16oz copper, but much stronger to help be more scratch and dent resistant for many years of service. Why use a life-time metal like copper if it is so thin and frail?

Heat Issues:
Copper can handle a lot more heat than the wood base, but be advised that the heat from a pot of food set directly on the counter top could expand the copper momentarily and pop the glue loose, so using trivets should solve this issue.

Feel?
The copper sheet is bonded to the wood base with an expanding polyurethane glue, so it has a good solid feel. To do this I have to rough sand the underside of the copper sheet before slathering on the glue to both surfaces. Then quickly place a sheet of plywood over the copper with heavy weights on top with some clamps while the glue sets.

The copper is rough sanded underneath to grip better to the expanding polyurethane glue, which bonds the copper to the wood surface for a nice solid feel. Less tinny that way. The copper is carefully sealed at the corners to be water tight.

Examples?
Th
ese first photos are of a bathroom set I had done for a local Client up on Council Crest named Jeff Whitol in 2015, whom we had already done some copper gutter work for previously. This was the finest compliment to be asked to do more work for them such as this.

Customized?
When you need CBD to build the wood counter top as well I use hardwood plywood for more dent resistance and a better screw attachment than ordinary plywood or cheap particle board commonly used.

We do our best to make these as seamless as possible, by wrapping around the front edge of the counter tops and bending an upward back-splash to keep any spills on top. The edges are sanded smooth, so there are no exposed sharp metal edges. We cannot guarantee to make these flawless, such as any custom hand made products, but we do our best. Many even appreciate the rustic hand made aspect of our work.

Below is a few more photos this client had shared with us after 10 years in service:

Cost?
These sort of project typically run $100 per square foot for these covered with 32oz custom copper formed, soldered, sanded, glued, and fine sanded. It can have a hammered texture or patina added for and extra $20 sq'. If you need us to build the wood foundation it usually runs $20 sq' plus solid framework boards underneath that may be necessary to have a thicker outer rim.

If you are not local to the Portland, OR area then a custom wood crate, padding, and freight charges would apply.

I can use a thinner 20oz or 24oz copper, but that would only save you about $5 square foot. Given how most of what you're paying for is design, labor, and in some cases freight, using a thinner copper is not very practical in the long run. My aim is not to up-sell you. It is just focusing on your 'long term satisfaction'.

Textured?
If you want a more rustic hammered copper look that adds $20 per sq' to these projects.

Bold industrial looking rivets can also be added around the edges for a rustic decorative element for $3 each.

To antique the copper would add another $20 sq' to these costs. I do not recommend having us do that, since I cannot guarantee it will turn out just the way you want, and I am not able to keep redoing this multible times to your satisfaction at that cost. I host links on my Site Map to web site that go into how you can patina the copper to get the look you want. If it does not turn out the way you like it can be polished again to start over with different chemicals. It could be quite a lengthy process to get just the look you're after, or just let it tarnish naturally:
http://copper-by-design.com/links.htm#resources

Keep in mind the only way to keep this new penny look seen here requires a clear lacquer coating, which would ruin the benefitial anti-fungal properties of copper, and eventually become scratched up and peal after a while, which would look terrible. Keep in mind how any product is only as good as it weakest link. It could always be stripped off again and resealed, but that is not a simple process. Most Clients just let the raw copper age naturally, or have it polished from time to time.

Below is an example of the 2 layers of 3/4" marine grade hardwood plywood top for this vanity we covered with copper to work with this cute drop in sink.

Below is an example of hardwood plywood coffee table top covered with a thinner 20oz copper and a set of curved copper pipes for adjustable legs. As you can see the thinner copper does not lay as flat. You can see all 28 photos of this project on Facebook by clicking on this photo.

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Helpful Roofing Information
For some valuable advice with regards to roofing and rain management issues check out our:

(a) Gutter Installation
(b) Gutter Debris Protection Options
(c) Roofing Quality Standards
(d) Chimney Flashing

(e) Moss Control & Treatment

web pages for answers and solutions that could save you thousands of $ and a great deal of anguish.

If you do find this information very helpful, feel free to send us a $ tip for the assistance we so freely have published on the web here for your benefit, like you might tip a waitress.  Heck, send us a gift certificate for a candle lit dinner for two.

 

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Below is a photo of our
Better Business Bureau's
NW Business Integrity Award
for the year 1998

1999 Better Business Award

We were also a 1997 finalist for this same award. See our referral web page to see how we managed to be honored with this special award

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Company
Profile
Roof Caps Chimney
Caps
Scuppers Gutters Shipping

Contact Info

custom sheet metal fabrication

 

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

custom sheet metal fabrication

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