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Concrete Countertop Series #9: Filling Small Pits and Repair Job

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Blog entry by Siegel_KenEvil posted 1319 days ago 5775 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 8: Molds Removed - Top Surface is Exposed Part 9 of Concrete Countertop Series series Part 10: Final Entry »

Late for a party so I have to be quick

This was my set-up last night to fill the voids. It’s midnight black sanded grout.

This is how I left it to dry last night.

Close-up… didn’t work too well. I seem to have a habit of doing things wrong before reading up on how to properly do it. I should have and will use just cement and water to fill in these little buggers. Maybe some color too.

While grouting, I attempted to fix my problem area. When I attempted to remove the wood blocks, the grout stuck to the wood and broke free from the concrete. I did it again using wax paper. Don’t know if it’ll work yet. Again, I may have to read on the proper way to fix this.


Orbital sander worked great on dry concrete. Very dusty and went thru pads quick. You can shape rads just like you would in wood. Next time, I am not going to wast time caulking the corners. I am a terrible caulker and it’s too easy to put them in with sand paper. On the right, I wet-sanded. This didn’t work well. I kept getting a course slurry that was defeating the purpose of using fine grits. I see the need for a wet stone polisher.

Close-up after sanding.

I’ve got to run. I have a lot more to say but no time.

-- Scott



6 comments so far

View Jimthecarver's profile

Jimthecarver

1121 posts in 2383 days


#1 posted 1319 days ago

A few years back I was working on a refurb of an old train station and there was alot of holes and spalding in the concrete block and beams. To repair some spots I used a slury mix on the clean preped area as a primer. I was informed this method would create a better bond when applying the finish coat in the holes or spalded areas.
There is a product on the market for polishing marble tiles or granit tops. They fit a small 4 inch grinder and there is four different wheels in the box starting from course to fine.
Quick crete if 5000 psi crete I think it should polish up very nicely with those type of wheels w/o using a wet stone that takes many fingers off.
I watched terrazo being installed and almost all of the guys that used wet stone grinders were missing fingers.
If you go to a store that sells tile and or marble tiles they should beable to order or have polishing wheels on hand.
I hope this may have been of some help to you.
Good luck.

-- Can't never could do anything, to try is to advance.

View Siegel_KenEvil's profile

Siegel_KenEvil

114 posts in 1435 days


#2 posted 1319 days ago

Hey Jim,

Good bonding tip. I was recently told concrete wont stick to concrete. They sell bonding primers but I rather try your method.

since seeing this article… http://www.concretedecor.net/All_Access/702/CD702-Technique.cfm I’ve been looking into getting a Makita PW5001C 4-inch Electronic Wet Stone Polisher. It sounds like what you are describing but the description sounds like what you are warning against. “stone polisher” must be too vague of a term. If you can take a look and answer this, is the Makita something that will or will not easily take off my finger?

This tool is going to cost me over $250 if I decide to buy it but the pads look pricey too. I didn’t price pads separately but if I buy the polisher with a few pads, the price goes up to $450.

-- Scott

View Siegel_KenEvil's profile

Siegel_KenEvil

114 posts in 1435 days


#3 posted 1319 days ago

The 2nd repair attempt seems to have worked. After 16 hours of curing, I removed the blocks and wax paper and was easily able to sand it flush using regular 120 grit sand paper.

The red blotches are supposed to say “before” and “after”

-- Scott

View Cantputjamontoast's profile

Cantputjamontoast

331 posts in 2029 days


#4 posted 1318 days ago

At the precast plant I worked at we had a guy named Joe(his real name) “The Patch Man”.

Joe was a great patch guy who took a tremendous amout of pride in his work.

One day Joe had to patch a big(2’ x 3’ ) oops on the corner of a box culvert joint that was like 12’ span by 7’ rise. A substanial chunk of product with a huge defect. The company had to produce about 100 of these for a stream re-routing.

Joe pacthed it up and the Asst. Plant mgr came out to see how he was doing. He asked Joe which one it was, with great pride and a mutual admiration Joe said’ “F you go find it yourself”. There were about 20 lined up and with some difficulty he was able to find the patched item.

Did I mention Joe had one arm and was a victim of the drug Thalidomide(spelling?)? Joe was never to be held back by this he used to tell his nieces and nephews “a big bear ate it off”. I don’t think those kids were ever much for camping!!!

Looking at this from afar you can patch and grind but remember you are thinking about a $250 tool for $30 worth of concrete. At which point do you re-use your form ammending some surfaces with formica, vibrating it better taking some other advice here? Pour another one, chaulk the first up to education and use it as a slop sink in a utility room. I think it looks great as is, but you could patch forever and still not be happy.

-- "Not skilled enough to wipe jam on toast!"

View Siegel_KenEvil's profile

Siegel_KenEvil

114 posts in 1435 days


#5 posted 1318 days ago

Joe sounds like a stand-up guy. I wish more people with challenges had his attitude.

I’m taking this one to the end before I scrap it or use it in the garage but I have consider it. Even if I was going to scrap it, I’d still polish, stain, and seal it so that I can see what kind of results I’d get with my processes. Also, most the work was in the form which is maybe why this is appropriate for this forum. The last two posts were less than an hour of work each. I figure I’m about 5 hours away from finishing.

The tool is a little tough to swallow. The plan is to do all my countertops in my house and then continue doing it for cash. If I really do that, then the tool isn’t a bad idea. There is always the chance I buy the tool and never do another counter-top in which case, I think I’ll have an over-priced angle grinder.

-- Scott

View Siegel_KenEvil's profile

Siegel_KenEvil

114 posts in 1435 days


#6 posted 1297 days ago

I just read this article.

http://www.concretecountertopinstitute.com/modules/smartsection/item.php?itemid=99

It appears the correct way to fill voids is to sand up to 200 grit, then grout. Next time.

-- Scott

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