| Concrete Countertops: Revealing the Mold and Installing the Countertop |
From "Weekend Handyman"
episode WKH-104 |
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Note: Click here for a materials list and complete instructions without images. Time: 2 days -- and extra time for the concrete to cure. Difficulty Rating: It's rated a 3 on a scale of 1 to 5.
Materials for Complete Project: Palm sander or random orbital sander
Screw gun and screws
Buffer
Bolt cutters
Caulk gun and silicone caulk
Five 1-gal. buckets
Magnesium float
Jigsaw
Circular saw
Table saw
Cement mixer
Melamine
100 percent silicone
Denatured alcohol
Kerosene-based release oil
Thick gauge wire mesh (hog fence)
Fiberglass or masonite
Type 1 or 2 cement
Two parts rock (3/8" pea gravel -- a natural lightweight aggregate)
Three parts sand
Water
Water reducer
Pigment
Mask
Goggles
Heavy rubber gloves
2 x 4
150 grit sandpaper
Shop vacuum cleaner
Putty knife
Damp rag
Water-based sealer
3/16" paint roller
Food-safe wax
Tape
2 x 6 Revealing the Mold - Strip the form. Remove the screws and pry the boards (figure A) away carefully because concrete is extremely vulnerable at this stage and can be easily damaged.
Tip: It's very important to know that when you're stripping the countertop from the mold, place the prybar (or whatever you're using as a separation device) between wood and wood, never between wood and the concrete! - Use an orbital sander to smooth the edges before flipping the countertop.
- Flip the top over. Be sure to have help because the countertop can weigh anywhere from 50 to 75 pounds, according to the size.
- Sand the top well with 150-grit paper and palm sander (figure B). This will uncover any holes that need to be filled in.
- Clean off the dust and sand with a shop vacuum.
- Fill any holes with Portland cement and water mixed with dye. Use the same ratio as the initial concrete so the color will match. Take a glob out and fill in the holes by spreading the mixture with your fingers (figure C). Be careful NOT to fill in any "inlay" design (ivy was used for this particular project) you may have used.
Note: Let the filler mixture dry for at least 1-1/2 hours. - Scrape the excess filler off after it dries, and sand again. Remove the dust with a shop vacuum, and wipe with a damp rag.
- Remove the effect (ivy leaf for this project) you used as an inlay, and a great way to make the relief or inlay pop or standout is to trace it lightly (figure D) with a pencil before sealing the countertop.
- Seal concrete with water-based sealer and roll on with paint roller. Let dry for a couple of hours.
Tip: When sealing, it's best to raise the countertop on dowels to seal the sides completely. - Sand again.
- Wax the top of the cement counter with food-safe wax.
Tip: Be sure to wax your new countertop at least once a month to build a protective layer and to maintain the shine. - Buff after wax dries with power buffer (figure E). You can do this by hand, but a power buffer will create a more uniform finish.
- While you're preparing the surface to receive the countertop, it's a good idea to rest the cement top on a 2 x 4 (figure F).
- Tape the edges of the surface that the new countertop will go on, and put a bead of 100-percent silicone along edge (figure G).
- Gently lower countertop onto the cabinets, and then check the overhang alignment.
- Silicone caulk the seam between countertop and cabinet.
RESOURCES :
Concrete Counter Fabrication and Design Concrete Artwork
Product Tips:
- It takes four days to cure the wet concrete in the mold.
- Vibrating the concrete mold helps to lessen the air bubbles.
- Melamine is the best material to use for making a mold.
Concrete Countertops: Design, Form, and Finishes for the New Kitchen and Bath
ISBN: 1561584843
Author: Fu-Tung Cheng
Order this title from Amazon.com.
The Taunton Press Inc.
Website: www.taunton.com
GUESTS :
Andrew Hankee
Concrete Artist
HardArt Studios
2105 Wabash Ave.
St. Paul, MN 55114
Phone: 651-644-8668
Fax: 651-695-1310
E-mail: ahankee@hardartstudios.com
Mike Hancock
Concrete Artist
HardArt Studios
See address, phone/fax above
E-mail: mhancock@hardartstudios.com
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