Concrete Countertop Series

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Blog series by Siegel_KenEvil updated 01-08-2011 03:05 AM 10 parts 56906 reads 71 comments total

Part 1: 1st Entry

11-15-2010 01:41 PM by Siegel_KenEvil | 15 comments »

After two years of pondering, I finally started a concrete counter-top. This will be going in a master bathroom. I have the mold construction complete. Next step is to radius off the corners and fill the small voids using caulk and/or bondo. I’m ordering a new product from Lowes by Quikrete called “Countertop Mix”. ( I’ll need two 80lb bags costing about $11 each. I calculated the finished weight to be a...

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Part 2: No progress, just gathering information

11-16-2010 06:26 PM by Siegel_KenEvil | 8 comments »

Yesterday I ordered the concrete mix from Lowes. Tried to find plasticizer there but they didn’t know what I was talking about. I then whet to Home Depot and found some under the name “water reducer”. Neither Lowes or Home Depot had color charts for Quikcrete’s color additives so I have an e-mail into Quickcrete to try to get one. This link has a lot of information about reinforcing concrete but I’m having trouble finding the products in small quantities. ...

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Part 3: Waiting for the concrete

11-21-2010 04:54 PM by Siegel_KenEvil | 6 comments »

My order for two 80 pound bags of Quikcrete Countertop Mix is expected to arrive at the end of this month. In the meantime, I’m doing a bunch of work that probably isn’t necessary but it keeps me active in the shop. I used Bondo to smooth out my corners. Today I’ll hope to get the forms done for the back splashes. In the pictures, you can see the side view profile screed I created. I have a different one for the front view. You may also notice the 1 1/4” do...

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Part 4: Computer Analysis on Concrete Countertop

11-23-2010 03:16 PM by Siegel_KenEvil | 4 comments »

Still killing time waiting for the concrete. One week to go. I work for an engineering and design company. It’s not uncommon for us to virtually simulate car crashes and structure stiffness on designs before they are made. Doing a counter-top design was a walk in the park for the FEA (Finite Element Analysis) guys. The images below show the results of simulating two 200 pound loads (people) positioned on each side of the sink. The counter-top is only supported on the outer edg...

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Part 5: The Big Pour

12-03-2010 11:18 PM by Siegel_KenEvil | 2 comments »

The concrete is poured and it was nothing like I was expecting. I had my daughters fill the back-splash forms but I was short on concrete so I had to use the material from the back-splashes to complete the sink. I kind of panicked and I didn’t spend as much time as I wanted packing the undercuts. Not too worried. If there are voids, I’ll fill them when I pour the back splashes. I have learned a lot but most of it’s, “what not to do”. I’ll know bette...

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Part 6: Concrete Curing

12-05-2010 04:21 PM by Siegel_KenEvil | 9 comments »

It’s been two days since the first pour. When I pulled off the top form, I discovered that the concrete didn’t fill completely. I also had the back-splash forms to fill so I mixed up a sand/cement mix. To this, I added acrylic fortifier and liquid charcoal dye. I filled the back-splash forms and troweled in the voids on the sink. I’m learning about curing. My approach is to spray with water every couple hours and cover with plastic trash bags. The concrete mix was w...

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Part 7: Be Carefull, Cement Burns!

12-09-2010 10:00 PM by Siegel_KenEvil | 11 comments »

I ended up in the hospital last night after 4 days of agony.“When traditional Portland cement is mixed with water the dissolution of calcium, sodium and potassium hydroxides produces a highly alkaline solution (pH 13): gloves, goggles and a filter mask should be used for protection, and hands should be washed after contact as most cement can cause acute ulcerative damage 8–12 hours after contact if skin is not washed promptly. The reaction...

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Part 8: Molds Removed - Top Surface is Exposed

12-10-2010 02:29 AM by Siegel_KenEvil | 7 comments »

It’s been 6 days since the first pour and 5 days since the back-splash and void fills. I was going to wait two weeks but seeing the undercuts gone, after chipping away a little every day, I got excited and removed the forms. Things are starting to come together. Instead of drilling out the faucet hole after the concrete hardens, I inserted a 1-1/4” dowel and 2-1/2” counter sink. It works fine but here are some things I’ll change next time. First, the thru ho...

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Part 9: Filling Small Pits and Repair Job

12-12-2010 08:52 PM by Siegel_KenEvil | 6 comments »

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...

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Part 10: Final Entry

01-08-2011 03:05 AM by Siegel_KenEvil | 3 comments »

This will be my final blog entry. I’ll post a finished project after applying calk and getting the plumbing done. The below image shows what it will look like but it’s not really plumbed. Need the finish to harden first. Since my last entry, I filled in the voids again with just a cement/water mix and sanded to 200 grit with and orbital sander. A little hand work was required in the corners. I then used a copper sulfate (root killer) / water mix for the color according...

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