Host Paul Ryan demonstrates how to make and install a concrete countertop in this episode of Weekend Handyman. Ryan chose green for this particular project, but you can go with almost any color you want for your concrete countertop. Figure A Figure B Figure C Figure D Figure E Figure F

Note: Click here for a materials list and complete instructions without images.

Time: 2 days -- and extra time for the concrete to cure.

Difficulty Rating: It's rated a 3 on a scale of 1 to 5.

Materials for Complete Project:

Palm sander or random orbital sander
Screw gun and screws
Buffer
Bolt cutters
Caulk gun and silicone caulk
Five 1-gal. buckets
Magnesium float
Jigsaw
Circular saw
Table saw
Cement mixer
Melamine
100 percent silicone
Denatured alcohol
Kerosene-based release oil
Thick gauge wire mesh (hog fence)
Fiberglass or masonite
Type 1 or 2 cement
Two parts rock (3/8" pea gravel -- a natural lightweight aggregate)
Three parts sand
Water
Water reducer
Pigment
Mask
Goggles
Heavy rubber gloves
2 x 4
150 grit sandpaper
Shop vacuum cleaner
Putty knife
Damp rag
Water-based sealer
3/16" paint roller
Food-safe wax
Tape
2 x 6

Time to Mix the Concrete

The mixing of the concrete will be the most challenging task in making a concrete kitchen countertop. Ryan suggests that you mix your own concrete to create the most sturdy mixture possible

1. Determine the rough volume of the countertop -- for 1-1/2" layer of concrete use 15 lbs. per square foot. From the inside of the mold, measure the length, width and height and multiply all three to determine the square footage.

   Cement recipe:

   1 part cement (type 1 or 2)
   2 parts rock (3/8-inch pea gravel)
   3 parts sand (finest aggregate)
   Water, water reducer and pigment (your choice)

   Note: If you are going to use pigment, it should be 4 percent of the weight of the cement. Measure carefully.

   Safety Alert: It's important to wear heavy gloves, a mask and protective eye goggles when mixing cement.

   Preparation:

   Add small amount of water into mixer. Slowly add cement, more water and then add sand, pea gravel, more water, pigment (figure A -- note that pigment can be weighed on a home scale), more water and water reducer until consistency is like thick oatmeal.

   The best way to tell if you have the proper consistency is to scoop up a lump in your hand, and if it sticks together (figure B), it's ready! If you wiggle your fingers, the mixture should only "ooze" through, not drip or pour.

   Note: If you're having problems with the mixture, don't hesitate to call your local concrete store to get assistance.

2. Transfer wet concrete from mixer to a 5-gallon bucket. Pour concrete into mold and evenly distribute.

   Tip: It's best to have someone help when pouring the mixture into the mold.

3. Use magnesium float (figure C) to spread concrete.

   Tip: The best way to evenly distribute the concrete is to lightly vibrate the float, which is called "puddling." This helps reduce the amount of air pockets that may form in the mixture.

4. "Screed" with 2-by-4 sliding back and forth over concrete (figure D). A concrete mound will gather as you screed. Simply remove the excess when you get to the end of the form.

5. Put the hog-fence brace reinforcement on the surface, and be sure to center it (figure E) and force half-way down into the concrete form.

6. After the hog-fence reinforcement is in, you'll need to screed again.

7. Vibrate sides of form with palm sander (figure F) to release as much trapped air as possible to get rid of any air pockets.

8. Let it cure from two to four days.

   Note: The Ideal temperature for drying concrete is between 70 and 80 degrees. Don't disturb the concrete in any way, shape or form during the drying process!

RESOURCES :
Concrete Counter Fabrication and Design Concrete Artwork

Product Tips:

• It takes four days to cure the wet concrete in the mold.
  
• Vibrating the concrete mold helps to lessen the air bubbles.
  
• Melamine is the best material to use for making a mold.

Concrete Countertops: Design, Form, and Finishes for the New Kitchen and Bath
ISBN: 1561584843
Author: Fu-Tung Cheng
Order this title from Amazon.com.
The Taunton Press Inc.
Website: www.taunton.com

GUESTS :

Andrew Hankee
Concrete Artist
HardArt Studios
2105 Wabash Ave.
St. Paul, MN 55114
Phone: 651-644-8668
Fax: 651-695-1310
E-mail: ahankee@hardartstudios.com

Mike Hancock
Concrete Artist
HardArt Studios
See address, phone/fax above
E-mail: mhancock@hardartstudios.com