Mastering Surface Quality: How Fiber Loading and Mix Design Shape Every Concrete Project

Most of us got into this trade for freedom - to build with our hands, chase an idea, and create something that’ll outlast us. But somewhere along the way, that freedom can slip through our fingers, traded for long nights, wasted hours, and frustration over mix issues that steal our flow.

In this week’s episode of The Concrete Podcast, Brandon and Jon sit down after hosting another powerful Ramm-Crete Workshop to talk about what really matters - time, balance, and the pursuit of mastery. They unpack a recent tech call that revealed how fiber type and loading directly shape flowability and surface quality (and how a small change can solve problems most of us face in our own shops).

You’ll also hear about Kodiak Pro’s Yeti Holiday Giveaway, upcoming Concrete Design School workshops for early 2026, and an honest take on how working smarter - not longer - creates more space for life beyond the shop.

If you’re chasing better surfaces, smoother systems, and a more intentional rhythm between work and living - this one’s for you.


#TheConcretePodcast #ConcreteDesign #KodiakPro #ArtisanMindset #MakerLife #ConcreteCountertops #GFRC #GrowthMindset #CreativeFreedom #rammedearth 

Photo from Vince Cathcart of his real life results with Kodiak Pro:

Real life results of Maker Mix bagged concrete GFRC mix

A photo of Maker Mix (left) compared to a competitors mix (right). This photo was sent to us by a customer:

A comparison of surface quality of GFRC concrete bagged mixes

Photos from the Ramm-Crete Workshop we held last weekend. If you'd like to register for the next class, visit www.ConcreteDesignSchool.com:

Ramm-Crete rammed earth cladding and furniture
A concrete maker mixing Maker Mix GFRC UHPC mix
Concrete Design School workshop attendees at a training class for DIY and Pro concrete countertops
A photo of Ramm-Crete, thin section rammed earth that can be used for cladding, tile, and furniture

TRANSCRIPT HIGHLIGHTS:

[00:20] Opening and Upcoming Workshops
Brandon: Hello, Jon Schuler. Bringing the energy this morning.
Jon: That is right.
Brandon: We have a lot to cover. First, we just completed the Ramm-Crete Workshop this weekend at Concrete Design School.
Jon: I was there. Great time.
Brandon: People are already asking when the next Ramm-Crete workshop is. It is scheduled for January 24–25, 2026 in Goddard, Kansas. Register at ConcreteDesignSchool.com.
We also opened registration for Fundamentals (The Basics) on February 21–22, 2026 in Goddard, Kansas. That beginner workshop is the best first step for makers who want professional results with DIY concrete, GFRC, concrete sinks, and concrete countertops. Details at ConcreteDesignSchool.com.

[01:20] Yeti Holiday Giveaway, Why Quality Merch Matters
Brandon: Two days ago, around 3 p.m., you called with a holiday promo idea.
Jon: Something fun, something people would actually use.
Brandon: We had done diamond pad giveaways before, but I said I love Yeti gear because it lasts. I am looking at my original Kodiak Pro Yeti tumbler from five years ago. It still looks new. We tried RTIC at one point to save money. The powder coat chipped, especially around the engraving. The Yeti finish still looks great, even after nightly dishwashing. Quality matters.

Brandon: A customized 30 oz Yeti tumbler is about $55. I used to buy $10 tumblers. They chipped and looked rough after a few months. Our Yeti cups have held up for five years. This is the kind of thing customers keep, which is the point.

YETI giveaway promotion for Kodiak Pro

[03:23] Tiered Yeti Rewards, November and December
Brandon: Here is the Yeti Holiday Giveaway for orders placed in November and December. It is tiered by your total cumulative spend.

  • $2,500–$4,999: Yeti can cooler or 14 oz ceramic-lined mug

  • $5,000–$7,499: Half-gallon jug, shot glass set, or 30 oz tumbler

  • $7,500–$9,999: Beverage bucket or 1-gallon jug

  • $10,000+: Custom Yeti Tundra 35 hard cooler

Brandon: I have owned that exact Tundra 35 cooler for nearly 20 years. It is still phenomenal. This promo is our way to say thanks. We would rather invest profit into customers than send forgettable swag.

Jon: When you receive something well made, you feel appreciated. That does not happen often in retail. Thoughtful, durable merch creates real connection.

[07:41] Ramm-Crete Workshop Recap, What We Built
Brandon: Quick recap of the Ramm-Crete Workshop. You flew into Wichita. Attendees included Sean Albright, Kevin McDonald, Henry Kaldenbaugh, Mike Sheehan, and Zachary Wolf. Everyone had real experience with concrete countertops, concrete sinks, GFRC, and DIY concrete projects.
Jon: Working with experienced artisans raises the level of conversation. We dig into materials, techniques, and the realities of this industry.

Brandon: We built a Ramm-Crete wall and cast an SCC-GFRC countertop to sit on it. You demonstrated ICT Protect Fusion application. The wall turned out great, the countertop was clean and dense, and the sealer process was simple and repeatable. For a day-and-a-half workshop, we transferred a lot of practical knowledge makers can use immediately.

Jon: And it is good to connect shoulder to shoulder. Not just talking on the phone or social. Mixing, placing, finishing. The human part matters.

[13:44] Main Topic: Fiber Choice, Loading, Flowability, and Surface Quality
Brandon: A recent tech support issue started on Facebook. Someone had air pockets with Maker Mix. We asked for the mix design and got photos and videos. The core problem came down to fiber type and fiber loading, which directly affect flowability and surface quality for GFRC and SCC-style mixes.

I personally use one AR glass fiber type at the recommended dosage on our site. I do not deviate, because repeatabilityis everything for me. Same fiber, same loading, same temperature targets for concrete countertops and concrete sinks. I understand why others vary fibers for different effects. Jon, break down what was happening.

Jon: Documentation was excellent, which removed guesswork. He was casting tall verticals and wanted SCC-like flow. Here is a simple framework makers can save:

  • Small fibers like PVA 15s and 3 mm AR glass increase viscosity. Heavy small-fiber loading will choke the mix.

  • Large fibers like PVA 100s or PVA 400s, or AR glass bundles such as 82 tex or 135 tex at half to three-quarters inch, support flow when loaded correctly.

  • If you want toughness without killing flow, keep 3 mm AR glass around 0.1% as secondary reinforcement. Carry the main fiber load with large fibers.

In this case the total small-fiber load was around 0.5%, which predictably produced a clay-like mix that barely flowed, even with extra plasticizer. Buckets took 15 to 20 minutes to empty when it should have taken 3 to 5 minutes.
For true SCC behavior in GFRC using Maker Mix, use only large PVA fibers at about 0.8–1.0%, and keep plasticizer in the 70–75 g range. Pushing plasticizer to 85–90 g will not fix over-loaded small fibers.

Jon: The end result looked beautiful with a natural, stratified movement. That is a useful, repeatable aesthetic. If you want a uniform, dense SCC-GFRC surface for concrete countertops or concrete sinks, remove the PVA 15s, keep the 3 mm AR glass at ~0.1% if desired, and carry the load with PVA 100s or 400s or AR bundles.

Brandon: My advice is to make a sample of that stratified look and keep it in the showroom. Many clients love visible concrete movement on vertical faces and aprons. Now you can offer it intentionally, with notes on how to achieve it.

[28:58] Fire Tables, Thermal Shock, and AR Glass Selection
Jon: Fire features can crack from thermal shock, especially when wind pushes the flame across the surface. Best practices:

  • Keep space between the burner pan and concrete.

  • Use glass wind guards.

  • Consider section thickness and, where appropriate, insulation or lightweight aggregate strategies.

On fibers for GFRC around fire:

  • Traditional GFRC specs often land at 2–3% AR glass bundle loading. At 3% you lose flow, so most aim for about 2.25–2.5% to balance strength and workability.

  • 82 tex vs 135 tex: 82 tex gives more bundles per pound. Think higher thread count in fabric. At similar flow, 82 tex can improve shock resistance and stealth. Many makers have moved to 82 tex for that reason.

Brandon: That is great context for DIY concrete makers who build fire tables alongside concrete countertops. Use the right fiber and the right load for durability.

[39:21] Sales Flow: Human, Simple, Repeatable
Brandon: On our Kodiak Pro Facebook group Concrete Confidential, there was a thread on sales flow. Jon, what is your process?
Jon: Most of my work is local. A referral calls, I visit the space, look at cabinets and finishes, make suggestions, then fabricate concrete sinks, vanities, or concrete countertops. I do not install. Simple and personal.

Brandon: Most of my projects are not local. People find me via Gore Design Co. or Hard Goods. I mail color samplesand a simple brochure, then finalize details and move forward. I prefer a human process over chatbots. A handcrafted product deserves a direct conversation with the maker.

Brandon: Pricing tip. Do not over-itemize quotes. A clear lump-sum price for custom concrete countertops or concrete sinks feels better than a list of nickel-and-dime add-ons. If the total is fair, most clients say yes.

[47:20] Work-Life Balance, Profitability, and Better Materials
Brandon: We posted “Stop wasting nights at the shop.” Someone said it did not resonate. Years ago, I worked until 2 a.m. constantly. Materials and processes were rough. I recast pieces multiple times. In 2025, with Kodiak Pro Maker Mix, ICT Protect, repeatable GFRC techniques, and tight processes, I leave by 3 p.m. most days. That is good business.
Jon: Efficiency is not laziness. It is discipline. Time is more valuable than materials.
Brandon: Exactly. Saving $10 per bag is not savings if it costs you days of labor, lost opportunities, and stress. For DIY concrete or pro shops, materials that reduce rework and eliminate slurrying pinholes can change your profit profile on concrete countertops and concrete sinks.

[54:32] Growth, Ego, and What Really Matters
Brandon: Early on, many of us try to prove we can suffer more. The 20-foot one-piece countertop, the all-nighters. It feels like commitment. With time you realize that profitability, process, and peace are better goals. You do not need to prove anything to anyone. Deliver quality, on time, and live a life you are proud of.
Jon: If you crave discomfort, let it be the discomfort of free time. Go hike. Train. Be with family. Let the shop run smart, not hard.

[57:47] Wrap
Brandon: Case just walked into the shop, so I am going to get to work. Let’s reconnect in two weeks.
Jon: Sounds good. Good talking with you.
Brandon: Adios, amigo.
Jon: Adios.