Custom, Coloured, Concrete Countertops

Case Study 1 - Chimney Repair Case Study 2 - Concrete Countertop Case Study 3 - Parging Examples, Tools & Techniques Case Study 4 - Fireplace Brick Replacement Case Study 5 - Tile Installation Case Study 6 - Chimney Flue Replacement Case Study 7 - Broken Concrete Step Case Study 8 - Brick Sill Creates Wall Damage Case Study 9 - Brick Retaining Wall Rebuild	Case Study 10 - Basement Window, Cut-out, installation Case Study 11 - Concrete Walkway, Landing Case Study 12 - Stone Wall Rebuild Case Study 13 - Stone Step Rebuild Case Study 14 - Fireplace Surround - Cultured Stone Case Study 15 - Stone Stair Rebuild - in Winter Case Study 16 - Fireplace Surround - Natural Stone Case Study 17 - Stone Retaining Wall Rebuild Case Study 18 - Dry-Stack Stone Retaining Wall Rebuild
	Case Study 2 - Concrete Countertop Stages of Construction: 1) Frame & Molds 2) Concrete 3) The Cure 4) Sanding 5) Slurry, Sanding 6) Polishing 7) Oiling and Waxing
Stage 3: Curing the Countertop The concrete has been curing in the form, now the curing will continue outside the form. Inside, metal framing is tethered to the wood frame's sides, holding its position during vibration. The metalwork inside includes rebar bonded together, and large-cell wire mesh from end-to-end. The Mix: White portland cement, white stucco sand, white and coloured aggregate, and dye!
	Form Removal Gently. You can just barely see a plywood sheet covering the sink area.
Corners The form's sides are made of aborite, one of the materials that provide a sheer finish and an appropriate flexibility. The foam within the wood form supports other materials like soft to rigid plastics and steel, even caulking and tape - permitting near unlimited shapes.
	Sink & Faucet Knockouts A thin plywood sheet covered the foam shaping the sink knockout, Screws anchored the foam and plywood cover to the base, allowing for easy removal. Plastic piping formed the plumbing holes. The sink was mounted below the counter.
Custom Shapes Many homes don't have truly squared spaces to work with. This counter has a 89 degree angle at one end to fit an interior wall snugly.
	Stage 4: Hours of Sanding Another week of curing has elapsed since the counter left the form. Now diamond sanding blocks and a water-fed polisher with 200 and 400 grit are employed for many hours. Then a finer grit of 800 is used to prepare the concrete countertops for the slurry process. In this case, some of the coloured aggregate has been purposely exposed by the sanding.
Vital: A Warm and Ample Workspace Warm during the cure, and providing water drainage for the sanding, slurry and polishing process. Room sufficient for multiple work tables and multiple people to work together. All the exposed surfaces are sanded, with particular attention given to the corners.
	The Tools A water-fed polisher, diamond encrusted disks and diamond-blocks of various grits, a sponge, water, and safety glasses.
Stage 5: Slurry, More Sanding, Repeat Sanding opens air pockets which can be filled with slurry, sanded and polished. Note, you may want less sanding and slurry. For a use like a planter stand, you might want less polish and some air bubbles to remain unfilled,
	Mixing the Slurry One of the team prepares slurry, based on the original mix which was precisely recorded.
Applying Slurry In this case, with three pairs of hands to apply it.
	Slurry First Coat After curing for 3 days, another sanding, and then again. The coats of slurry add strength and density, and make a smoother finish.

This page last modified: October 19 2009