This is the tale of my adventures pouring a concrete counter top. Given the length it came to, I somewhat arbitrarily broke it up in 3 parts. Here in part 1, I’ll just go over some terms and background; in part 2 I’ll cover some details on forms and the actual concrete pour, and in part 3 go over the staining and sealing. Disclaimer – I am not an expert. I don’t do this for a living. Everything here was learn as you go and I make no claims as to whether any of it is correct, let alone the best way to do any one thing. Caveat emptor.
Concrete counter tops can be beautiful and come at a fraction of the cost of higher end counter tops. By way of quantifying that last item, the pour I’ll describe here cost me roughly $300 for material, including polishing pads but neglecting more ‘durable’ goods, e.g. powered grinder/polisher, and various floats and trowels. This is in contrast to, depending on the exact granite selected, something like $2000 installed for this size of countertop. Let’s ignore the labor; and since I enjoy the creative process, it’s not really time lost.
So before proceeding, you have to decide what type of pour you are going to do: Cast-in-place (CIP) vs pre-cast (PC). CIP is, as the name suggests the assembly of the form, pouring, and finishing the counter top at its final location. PC is built, poured, and finished “off-site” and moved into place after it’s completed. Each has its pros and cons.
The main difference in the pours is of course where you build the counter top; in addition, PC is the lager of concrete counter tops and CIP the ale. A PC counter top is (generally) poured upside down with the final counter top being at the bottom of the form whereas a CIP is poured “face-up” – your finished surface is visible from the start of the process.
A CIP pour has the advantage of there being no need to move the counter top after the process is complete. That can be a major advantage for large pours or more complicated shapes. Except for a very small pieces, a PC pour is just not in the cards for a 1-2 person job and if you have a large angled piece, moving it without damage is a challenge. I don’t think I’d DIY a large PC pour. Of course the disadvantage is that you are going to make a somewhat of a mess; careful preparation can mitigate that, but you will inevitably have a lot of clean-up to do. In addition, since the pour is in place, you will remove that area from use during the build – for something like a kitchen where you use it day in and day out, that can be a significant issue.
A PC pour has the advantage that all the mess can be restricted to a place where a mess is less of an issue – garage, back-yard, warehouse, etc. Additionally, you don’t put the area you are installing it to out of circulation during the build. Since the final surface is usually face down, you don’t see it during the build. This can be a pro or a con – on the pro side, you can get a close to finished surface if you prep the bottom of your form (top of the counter) well and pour carefully. On the con side, you won’t see any issues until the concrete is set and you flip your project. Of course I don’t see any reason you couldn’t do a PC face-up, but it seems that in most cases it’s done face down. I’ve also found that you can get a pretty nice finish just from the pour and troweling in a CIP, so on this front, there’s probably little difference. On the other hand, with PC, you better have lots of help, and be very careful, and be able to get around corners etc, or there’s a decent chance you will ruin your work (or PC in pieces and ‘merge’ them place).
I prefer the CIP and this is a CIP build and all the following is specific to a CIP pour – some steps and materials may not be necessary for a PC and vice versa. In either case, I strongly suggest that you do a test pour before proceeding to you project. This applies to both pour methods. This is my fourth pour: utility sink in the garage (PC), vanity for the bathroom (CIP, but poured outside, vanity moved after the fact), small utility cabinet (CIP, but poured outside, cabinet moved after), and this job (CIP). For each one, I still did a small test pour. It can be as simple as just pouring a 2×2 slab and going through the full process to make sure you can get the result you are looking for and that you like it. For this pour, I did a small garden bench.
Equipment
To tackle this project, you’ll need some equipment:
- Cabinet/base – we’ll assume you already have those and won’t trouble you with the details for this build.
- Cement board substrate – This goes down on the counter tops before you pour the concrete.
- Concrete – This is self explanatory. Some detail below (but probably best to avoid any rapid set!)
- Edge form (contain concrete, removed after is sets)
- Mesh/rebar – Re-enforce/strengthen the concrete and minimize chance of cracking in the final product.
- Polishers – Bring the countertop surface to your final desired smoothness. This can be done by hand or with a powered polisher and can be done wet or dry. I used all combinations.
- Stain and sealers – If you want the finish color to be whatever your concrete color is (e.g. you can add dies directly at mix time – I did this on my PC pour and didn’t care for the result), you don’t need the stain. You will want to seal the counter top though since concrete is a porous material and will absorb whatever you put on it. I had both from previous projects – if, as is likely, you don’t, add $150 to the cost quoted above
- Misc – plastic (to cover things), rollers, paint pans, small quart measuring ‘pails’, lots of tape – I’m partial to the 3M No Residue Duct Tape
Here’s my base prior to any prep for the pour.
Preparation
Given the base cabinets, the first step is to place base layer. I used Hardie Backer. In my case, given the large span over the beer fridge, I put down 1/2″ MDF. This raised the counter top surface and resulted in more exposure of an unfinished surface below the form (see “Form” section). In retrospect, should have put steel braces in instead of the MDF – 1/2″ changes feel of the height more than one would think and there was additional work to cover the exposed edge. Don’t (or do) screw the concrete board down to the cabinets. I initially did, but removed the screws and filled the holes with caulk. If you ever want to tear out the counter top, it’s going to be much harder to do that if you’ve screwed your base down into the cabinets. I just tacked it down with some caulk – the weight of the top should be plenty to hold it in place, and now I can just pull the whole counter top up/break it up without damaging the cabinets should I ever want to do something different.
HardieBacker substrate installed. On the right, you can see the screw holes I initially put in. I removed them an filled with caulk. The gap between the two pieces of cement board were also caulked as was the gap against the wall.
In the next Episode, we’ll talk about building the concrete form and pouring the concrete.
No one knows what it’s like…to be the First man…the bad man…behind the First.
The next stanza better fits a False Firster like you.
I could have used you 30 years ago, PM, though maybe cement hadn’t been invented yet. Very interesting idea. Looking forward to the next two episodes.
I thought of the stone tops, whatever they are but way too expensive for me.
“Choose Your Own Adventure” – good choice of category.
LOL yeah, this is an adventure I do not choose. I know myself.
+1 on both the article and category.
I chose the same category on my 3D printing series.
Seemed appropriate there as well as here.
Wish I could claim clever credit, but I think I left it blank; whoever edited gets credit for being clever.
On a different note, the evening slot is a bit awkward time wise for me, so I’ll be scarce. I’ll check in later tonight and in the morning to answer any specific questions; though this part is long on background, short on operations, so not much to say.
From what I recall the default is “I am lame”.
Now I just want you to decorate your dining room like Beetlejuice.
Goddammit they are all smoking.
They can replace the cigarettes with radios in the anniversary release.
Thank you, PM.
I am hoping to pour a counter top this winter.
I think polished black concrete is gorgeous.
I know Quikrete says “Just add water”, but I use chicken broth for more flavor.
Fiber! Good for the digestion.
Is it okay if I use vegetable stock?
We need to replace our crappy kitchen counter. Looking forward to this.
Question: What music did you listen to while doing this project?
Follow-up question: Will you come to my house and do this to my kitchen cabinets? I’ll supply some beer and better work music.
Generally speaking some mindless drivel like AC/DC – easy to fade into the background and ignore.
If you can offer something actually good like, oh say some Canadian power trio perhaps, maybe we can deal.
Actually I usually have a podcast in the background – Lindsay’s New Discourses works well as I find him a bit repetitive so I can miss little bits during power tool usage, excursions to the garage for a tool I forgot to bring with me, etc without really missing the gist.
Who else? Duh!
Lol. I thought you were going to drop Steely Dan on MikeS.
I was nervous, but trusted that GT wouldn’t be so evil.
Wrong material.
…and I’m perfectly capable of being that evil.
I suppose Stone Temple Pilots might have been close.
Or that Joni Mitchell song where they paved paradise and put up a countertop.
Excellently apropos.
Side note; I don’t hate that song as much as I used to.
/side eyes Mikes.
Concrete Blond was one of my faves back in the eighties.
https://www.youtube.com/watch?v=7AjwOK8A4X4
https://www.youtube.com/watch?v=aNZpkimAZSI
https://www.youtube.com/watch?v=axnCMV-on9Q
This should be one of the Glibs theme songs.
Can’t… stop… self…
Must… punk…
https://m.youtube.com/watch?v=ndjCXG_c9kk
not…clicking…
You’ll be fine. It’s the live version.
Watching the print is hypnotic…
It’s gotten up to the shoulder sockets.
It is, isn’t it? Strangely relaxing.
This is one of the manliest articles I have read.
Whoever said the F2 race was truly nuts wasn’t kidding.
Just watched both back wheels come off a car.
Given the length it came to, I somewhat arbitrarily broke it up in 3 parts.
🧐
Looking forward to next episode where we get some concrete details on this project. So far, I think it will work in aggregate. How to really cement the puns? Something to really seal the deal for Switzy.
Adsfor Nissan Ariya where they’re driving it around in the middle of nowhere, far from any charger. Wtf?
Nor pictured generator in bed of IC Nissan truck
Not pictured
Zactly. I see those charging stations when I’m on the road, with people milling around like a gypsy camp. Sad. How much time, the one irreplaceable item, is wasted on that crap? Bring back Harvey Houses and at least some decent food.
It ONLY takes like 45 minutes per 250 miles! …if you have a fast charger…
You’re a brave man.
I considered doing this for my yuuuge kitchen counters, but I am glad I didn’t, even though we went a little premium on the countertop.
My concrete finishing is only fit for below ground surfaces and I *hate* sanding. Also, sounds like you’ve done this before.
You need more counter space.
Good first installment though.
Good morning you weirdos.
☕😒
https://m.youtube.com/watch?v=Ob3buKk6ALc *
🎶🎶
*May be too much for the weak or infirm.
“German Court Sentences Judge For Ruling Against Government’s Mask Mandates”
https://www.zerohedge.com/geopolitical/german-court-sentences-judge-ruling-against-governments-mask-mandates
Damn Germany, you’ve become a joke-an unfunny one.
” two-year suspended prison sentence for allegedly “perverting the law.”
😯
When hasn’t Germany been a joke?
Ask augustus
https://www.youtube.com/watch?v=uVUlQ9k9oaw
Good morning all!
Today’s selections are from America’s, if not the world’s, strangest band — The Residents. Yes, the dapper folks in eyeball masks.
First up, almost a pop tune, is Harry the Head.
Then, from their only album to be played in its entirety on radio*, the (seriously) lovely When We Were Young.
*The Commercial Album, a set of 40 1 minute carefully crafted utterly Residential, songs. Living up to their quirkiness, they bought 40 advertising slots on local radio and provided the album tunes as content.
For those into serious, in all senses of the term, weirdness, The Mark of the Mole is outstanding.
*waves*
Waves back 🙂
Good morning, Shirley, Sean, Roat, Lack, and Stinky!
I’m finding it a challenge to type with Big Dumb-But-Sweet Cat leaning his head against my left forearm.
https://www.cbsnews.com/philadelphia/news/wildwood-power-outage-boardwalk-jersey-shore/
Haha!
Suck it, NJ. 🤡🤡
Wildwood is actually part of Philadelphia, this is known.
Practice for the progressive future of rolling blackouts. Praise Gaia.
16-year-old fatally stabbed after dispute over sweet-and-sour sauce near McDonald’s in Northwest DC
Another story of teens with poor conflict resolution skills out a 2 AM. I blame the knife.
We need to mandate Smart Knives!
…and Sweet-and-Sour Sauce equity.
Only licensed chefs should be allowed to possess knives.
I feel sorry for the mother, but at the same time, why was your 16-year old out at 2 am?
As my parents would say: nothing good happens after midnight.
It would be interesting to see the video, sounds like it could have been justified.
Dispute over sweet-and-sour sauce? Not buying it, likely drugs involved.
You aren’t familiar with the local slang?
The print finished in the overnight, but I’m still trying to figure out how to safely remove the supports. They just don’t want to budge.
Razor blade?
Blow torch?
Nuclear bomb?
How did you remove them from the resin-printed forms?
Poorly
And that was a different style with a different structure and connection surface.
I like Lack’s razor blade idea. It might be easier to find single-edge blades at a hardware store than at a drug store.
razor blade + stove burner?
I have a hot wire knife, but it’s probably too large in diameter for what you want.
I’m using needle-nose pliers and sprue clippers.
👍
Print is overrated. Bring back scribes and scrolls.
I’m doing my part – just bought a calligraphy pen set! 😃
Ooh. Italic? Uncial? Gothic?
This one. Total impulse purchase to top off an order of planner refill & accessories to get to the “free shipping” threshold, but I thought, “That could be fun!”
And probably a bit of a challenge because I’m left-handed.
A glance at the instruction book suggests that they start with Italic.
https://www.goodreads.com/author/list/1116271.Tom_Gourdie
A family hobby. I took a class as a kid. I’m not great at it (rusty but serviceable) but at least it ain’t Meghan Markle’s curlicues.
https://i.pinimg.com/736x/33/9e/1d/339e1d03d1b2b8d2556dcfec4768fe05–penmanship.jpg
Kinda loopy.
As is her handwriting.
And buy a great gross of these (e.g.): https://www.artistsupplysource.com/product/525869/inovart-calligraphy-practice-paper-pad-50-sheets/
👍
I foresee using a lot of the orange ink for practice, as I don’t see myself using it much for actual projects. Unless I’m illustrating an Ode to Pumpkin Spice.
GT in full scribe regalia.
https://sites01.lsu.edu/faculty/jgellri/wp-content/uploads/sites/3/2014/06/Medieval%20Scribe.jpg
Mornin’, reprobates!
I’m looking forward to being bombarded with climate change propaganda as Idalia (really?) targets Florida. Bonus points for assigning equal blame to DeSantis since government is responsible for every bad thing that happens except some bad things like inflation, the plague of mentally ill on the streets of major cities and a hundred other things which my age-addled brain can’t recall at the moment. As we all know, hurricanes striking the Gulf Coast is a very recent development.
No biggie. It’s the same shit that has been going on for 20 years.
Good morning, ‘patzie!
I thought Idalia was a type of onion.
Fuck.
I hate stupid people who have no idea what the fuck they are talking about.
Especially when we do work for them. 🙁
Come one now, that’s a bit harsh! I said ‘caveat emptor’ and everything!
Hoo Boy.
Someone who was promoted to a place where he wouldn’t have any effect on product manufacturing has declared that all of our documentation is invalid and has issued demands of our group.
I’m not going to need coffee today.