DIY Network

Concrete Countertop: Making Template From "Rock Solid" episode DROC-107

Concrete continues to make a statement in kitchens and baths and all around the home. In this episode of Rock Solid, stone masons Dean Marsico and Derek Stearns are in Paradise Valley, Arizona to take on the construction of a concrete kitchen countertop. Lucky for them, they will have some help from concrete specialist Hannah Black.

The project begins with a template.

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	Dean and Derek are in sunny Arizona...
	to add the "wow" factor to kitchen countertops.
	The duo meet up with concrete specialist Hannah Black.
	Together, they create concrete countertops that...
	are sure to impress!

Materials:

Making Template

Strips of thin veneer wood such as lauan or doorskin
Glue gun
Tape measure
Permanent marker
Utility knife
Square
Hand stapler

Creating Countertop Mold

Countertop templates
3/4 inch melamine
Large work table
Pencil
Table saw (with sharp new blade)
Screw gun with 1/8 inch drill bit
Screws
Blue painter's tape
100% silicone caulk
Caulk gun
Clean rags
Denatured alcohol or acetone
Protective gloves

Pouring Mold

Quikrete Non-Shrink Precision Grout
Concrete color (optional)
Concrete mixer (can be rented)
Measuring buckets
5 gal. buckets
2 in. spatula
Steel mesh or 3/4 in. rebar
Steel wire
Bolt cutters
Steel wool
Acetone
Screws (can be same used for fastening mold)
Trowels
Rubber mallet
Concrete vibrator or vibrating sander
Safety glasses
Dust mask
Protective clothing

Finishing Up

5 in 1 tool
Hammer
Plastic bucket
Muriatic acid
Sponge
Hand squeegee
Sander
Sandpaper (starting at 120 grit through 220 grit sandpaper)
Clean rags
Penetrating sealer
Beeswax
100% silicone caulk
Caulk gun
Siliconized latex caulk (sanded variety)
Blue painter's tape
Safety glasses
Dust mask
Protective gloves

Making Template

1. There are two ways to create a countertop: the first is to pour the concrete directly on top of the cabinets and hand trowel the surface; the second is to build molds for the countertops and pour the countertops off site. Dean, Derek and their expert Hannah Black suggest pouring countertops into a mold, as this method will ensure a smooth surface, a cleaner kitchen and easy application.

2. This process of pouring concrete countertops involves creating very accurate templates of the existing space. From these templates, the molds for the countertops will be made. However, before you get ready to build your countertop, talk to your carpenter or cabinet maker to make sure that your cabinets will support the weight of concrete countertops. Concrete countertops tend to weigh between twelve and twenty-two pounds per square foot when they're poured at a thickness of two inches. If necessary, add extra support to the cabinets.

3. There are two ways to create a template: trace the countertop base on an oversized piece of wood veneer or create a template by connecting strips of wood veneer (figure A). The template that you create should be the exact size of the countertop base or cabinet top – not the size of the countertop that will go on it. Using wood veneer strips, secure the strips to the surface of the cabinet top with the hand stapler. On corners, use a diagonal piece for extra support secured using the hot glue gun (figure B). If the template is particularly long or wide, add strips for cross supports. Score and snap off ends with the utility knife and square.

Figure A

Figure B

4. The template process is also the time to decide on a couple of design features such as control seams and countertop overhangs. If countertops are made in sections larger than about 8 feet, they are prone to cracking and can be difficult to move. You can reduce the chances for cracking by incorporating joints or seams in your countertop.

5. Countertop overhangs – the countertop lip that extends beyond the face of the countertop – will add dimension between the face of the concrete and the face of the cabinet as well as prevent things from dripping onto the face of the cabinet. Overhangs for standard cabinets are usually 1/2 inch; for flush cabinets, 3/4 of an inch might be better.

6. Mark the locations for the seams as well as the edge that will have an overhang added to the mold on your template with your permanent marker (figure C). You should also measure your countertop base again and write these measurements on the template for particularly accurate measurements (figure D). Remove the template from the countertop and move it to where you'll be making your countertop mold. You can build your mold and pour your countertop in a garage or workroom, but avoid places that are exposed to the weather and have drastic temperature changes.

Figure C

Figure D

RESOURCES :

Architectural Concrete Specialties, Inc.
Hannah Black, President
Phone: 602-955-2396
Fax: 602-955-3001
Factory Phone (Phoenix): 602-275-3908
E-mail: acsconcretestudio@cox.net
Website: www.acsconcrete.com

Spaces Indoors and Out
Barbara Kaufman
Phone: 480-767-7636
Fax: 480-767-7635
Mobile: 602-549-9863
E-mail: spacesforyou@cox.net
Website: www.spacesindoorsandout.com