DIY Network

Timeless Traditional (3 of 4): Creating Concrete Countertops From "Kitchen Renovations" episode DKTN-207

	In this week 's episode of Kitchen Renovations, host Paul Ryan starts a four-part project with homeowners Cathy and Dan Zielske to convert this stuck-in-the-'70s kitchen ...
	with serious design problems ...
	that the homeowners wanted to change.
	Even the adjoining family room suffered from the design flaws in the kitchen.
	But step-by-step the kitchen was renovated into this beautiful, ...
	timeless traditional kitchen and family room that will bring the home into the 21st Century.

In this segment host Paul Ryan and the homeowners create concrete countertops.

Materials and Tools:

For Installing Cabinets --

Cabinets
Gil lift
Power drill
Level
Ruler
Nail gun

For Concrete Countertops --

Luan
Utility knife
Straight edge
Hot glue gun
Table saw with guide
Wheelbarrow
Shovel
Palm sander
Melamine
Nail gun
Steel mesh
Concrete mix and pigment
Water
Magnesium float
Edger tool
Steel trowel
Foam brush
Sealer
Silicone
Beeswax
Soft cloth

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	Figure A
	Figure B
	Figure C
	Figure D

Note: Concrete countertops are becoming more and more popular, and mainly because natural stone (yes, concrete is considered a natural stone because it's mined from the earth) is durable.

Creating Concrete Countertops

1. Make a template of the counter using 1/4" sheets of luan (figure A).

2. Once you get the right shape, you can trim the luan with a utility knife and a straight edge.

3. Once they're cut, carefully glue the pieces together with hot glue, and write notes on the template to indicate the walls and finished edges.

4. Cut the forms out of a piece of 3/4" Melamine (figure B) and screw them together. Lay steel mesh into the form to add strength to the concrete.

   Note: Melamine is made from plastic resin, which gets heated to form a tough, impervious surface similar to laminate. This smooth surface will release the concrete easily.

5. Pour a bag of the concrete mix into a wheelbarrow.

6. To mix the color, pour a half gallon of water into a bucket along with a pint of the color, then add one gallon of water and stir.

7. Add the color mix (figure C -- ash was used for this particular project) to the dry powder a little at a time.

8. When the mix is ready, add it into the form. Smooth it out with your hands and be sure to work out any large air bubbles.

9. Clips the wires of the form and then begin "screeding" (a smoothing process) the mixture, by sawing a board back and forth over the top (figure D).

10. Take a palm sander and vibrate the sides of the mold to get rid of air bubbles.

11. Take a magnesium float and go across the top of the mold to seal it and get rid of any bumps.

12. Let the mold sit for 45 minutes to an hour for it to harden.

Note: It takes a full 28 days for concrete countertops to cure.

In the final segment of Pt. 3 of our "Timeless Traditional" kitchen renovation, the countertop installation begins.

RESOURCES :

Skil
Robert Bosch Tool Corp.
Website: www.skiltools.com

Stanley Tools Information
Stanley Tools/Works
Website: www.stanleyworks.com

Fiskars (Bucket Boss Division)
Fiskars Bucket Boss Division
Website: www.bucketboss.com

3M Painter's Masking Tape and Sanding Pad
The 3M Company
Website: www.3m.com

Gil-Lift (Cabinet Lift)
Telpro Inc.
7251 South 42nd St.
Grand Forks, ND 58201
Toll-free: 800-441-0551
Website: www.telproinc.com

Cabinets (KraftMaid)
Brand name: KraftMaid Cabinetry
Model #: ML
Color: Solid maple slab door style in natural finish
Where available: Visit the KraftMaid Cabinetry site, link below.
Kraftmaid Cabinetry
Website: www.kraftmaid.com

Concrete Countertop and Backsplash
Where available: Visit www.stampedinstone.com

Concrete Countertop Materials

Concrete Mix: CCM101 (bag)
Ash Color: ASH011 (Quart)
Mesh: CWM050 (Sheet)
Edge Forms: REF051 (Lengths)
Penetrating Sealer: PSG060 (Gallon)
Satin Seal: SSG065 (Gallon)
Wax: CCW070 (Jar)
Where available: Visit the Buddy Rhodes Studios website, link below.
Buddy Rhodes Studios
2130 Oakdale Ave.
San Francisco, CA 94124
Toll-free: 877-706-5303
Website: www.buddyrhodes.com

Undermount Apron Front Sink and Faucet
Sink brand name: Elkay
Sink model #: ELUHF3320
Sink color: Stainless steel

Faucet brand name: Elkay Allure
Faucet model number: LK6360
Faucet color: Brushed nickel Where available for sink and faucet: Visit the Elkay website, link below.
Elkay
2222 Camden Ct.
Oak Brook, IL 60529
Phone: 630-574-8484
Fax: 630-574-5012
Website: www.elkayusa.com

GUESTS :

Mike Verlennich
Owner and Installer
Verlennich Masonry & Concrete
1406 Prairie Ave., Unit D
Staples, MN 56479
Phone: 218-894-0074