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Concrete countertop with fiber optics
Before you begin building your concrete forms, decide where you will build the countertop. Are you going to build it off site and then move it in later or are you going to build it in place. I recommend building the countertop in place. You end up with a better fitting countertop and you don't have to move it if you build it in place. - 2
Concrete countertop plans
Now decide how you want your concrete countertops to look. I recommend drawing a design on a sketch pad first. Now that you have your plans, it is time to build the forms. You will be using melamine. Melamine has a smooth surface that will give you a nice concrete finish. - 3
Concrete countertop forms built with melamine
Start by laying a sheet of melamine on the bottom of the form. Now screw in your melamine 2 x 4's on the outside edge of the concrete form. Most concrete countertops are 1.5 inches to 2 inches thick. If there is any bare wood exposed, be sure to cover it with electrical tape. This keeps the concrete from sticking to the wood. Now that the forms are built, take silicone caulk and run a bead along the inner corners of the concrete forms. Wet your finger and run it over the freshly laid silicone bead. This will give you a nice finish and your concrete countertop edges will be smooth. - 4). Now take your sink and faucet knockouts and place them exactly where the need to go. This is important because set concrete is not very forgiving if they are placed improperly.
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Add steel reinforcing
Now, take some steel reinforcing mesh and place it inside the form. Steel mesh adds strength to the concrete countertop and also helps prevent the concrete from cracking while it cures. - 6
Pouring the concrete
Now it's time to pour the concrete. You will have two separate concrete pours. The first concrete pour will be a little drier than a usual concrete mix. The second concrete pour will have coloring pigments in it. After you have poured the first layer of concrete you must tamp the concrete down to get rid of any air pockets that may be in the concrete. This is very important. Let the countertop cure for a couple of hours and then apply your second pour which will be wetter then a normal concrete mix, use a steel trowel to smooth the concrete, but do not over work it as this will weaken the countertop. - 7
Custom concrete countertop
Now let the concrete countertop cure for 24 hours before you remove the forms from the finished countertop. Now apply the concrete sealant let that cure and that's it. Now you have beautiful new custom concrete countertops.
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