DrBoost
DrBoost SuperDork
11/8/11 6:51 p.m.

It's time for me to spend more time on things that don't have wheels or boobs soon. Dangit!
We need countertops and I'm cheap and hate to pay someone else to do something I can do (especially when it comes to things with boobs).
I saw a home-improvement show where they did poured countertops and I've read a bit on the interwebs but those folks are looking to sell something. So, what can you folks tell me about:
The process
The price
The advantages
The drawbacks
The day-to-day living
Boobs.

Thanks in advance.

sorry folks, I guess I have something on my mind tonight.....

mtn
mtn SuperDork
11/8/11 7:21 p.m.
DrBoost wrote: Boobs.

Motorboating, bouncing, fun, happy, awesome, fun, awesome,

Wait, what?

fritzsch
fritzsch Reader
11/8/11 7:28 p.m.

I can tell you James May poured a DIY cement countertop in the first episode of Man Lab. http://en.wikipedia.org/wiki/James_May's_Man_Lab

Id say the hardest part is getting the mold made up. Absolute price of materials would be pretty cheap i think.

Xceler8x
Xceler8x GRM+ Memberand SuperDork
11/8/11 7:29 p.m.
DrBoost wrote: Boobs.

They're like motorcycles. Whether they're big or small, old or young, they're all fun.

BAMF
BAMF Reader
11/8/11 8:45 p.m.

One of my coworkers used to do that full time. So when someone at work needed new counters we all participated in making new ones.

There is a reason that nice ones are about as expensive as engineered "granite" when installed. Making the molds takes some time and effort, but it's not bad if you're handy. Melamine works really well. It produces a nice smooth surface. If you need a cut out for a sink, styrofoam with a smooth layer of packing tape on the edge works really well. A bead of silicone seals things up and leaves a nice rounded edge.

You will need rebar, especially where you have a sink or other cut out.

Next hurdle is getting the mixture absolutely right. If you've got an aggregate you want to expose for a terrazzo look, there are a lot of little secret tricks to getting that right.

If you want smooth, you need to grind it. That's not very hard, but it's dusty.

Finally, installation can be tricky. Your slab will want to crack if you move it into another orientation or leave a part of it unsupported, even if briefly. This is especially true around openings and holes. It's not insurmountable at all though, and if you don't mind putting in the time, it's pretty cool.

Also, your counter tops should be sealed. There are food safe sealers specifically for this. Like the other steps, there's a bit of an experience factor. Things like temperature and humidity make some difference in how well everything goes.

Concrete is not as impervious as real granite, or the quartz and resin "granites". It stains about as easily as marble. So don't leave spills on it for too long. It's more heat resistant than the plastic based stuff (Corian, etc.) though.

If you've got the time and want to do it for the fun of doing it, go for it. It's a cool process, but it takes longer than you might expect. On the plus side, almost everything is cheap enough that you can make them twice and be under what you would have spent on something else.

stuart in mn
stuart in mn SuperDork
11/8/11 9:13 p.m.

Fu-Tung Cheng's book is supposed to be THE reference book for countertops: http://store.concreteexchange.com/CHENG-Concrete-Online-Store_5/Instructional-Products/Concrete-Countertops-Book

DrBoost
DrBoost SuperDork
11/9/11 7:04 a.m.

Thanks BAMF and Stuart!

Duke
Duke SuperDork
11/9/11 7:06 a.m.

I will add that poured concrete countertops are not as rugged as their appearance might suggest. You need to be careful putting hot stuff on them, banging pots into them, etc.

However, I can probably put you in touch with a friend of mine who has done his own and can give you some tips. PM me your email address, please.

itsarebuild
itsarebuild GRM+ Memberand HalfDork
11/9/11 2:03 p.m.

i did them for my kitchen and everything BAMF and Stuart and Duke said is true. the only things i would add are:

that you dont HAVE to grind them. an alternative is to cast them face down and then flip the pre-cast slabs on to the cabinets after it has had some time to cure. if you do it this way the part of the countertop that was next to the melamine formwork is now face up and if you vibrate the form when you cast it, it it really smooth. it helps in this process if you put a radius on all the inside corners of the formwork. this also helps with avoiding damaged corners later when it is use. as a "vibrator" i attached an orbital buffer to the formwork upside down and let it run thoughout the casting process. it made a big difference!

also, wire mesh reinforcement usually works better than rebar since the slabs are generally too thin to generate grip on the rebar and provide adequate coverage. 1.4x6x6 WWF works well in multiple layers

4cylndrfury
4cylndrfury SuperDork
11/9/11 2:17 p.m.

Its on my list of things to do - Here is a tutorial thats not trying to sell you anything. DIY network has some of the best how to's that arent also a commercial for a product.

Rusted_Busted_Spit
Rusted_Busted_Spit GRM+ Memberand SuperDork
11/9/11 2:20 p.m.

I would go the closest one of these to you and see what you can find Habitat ReStore Directory - Michigan

ST_ZX2
ST_ZX2 Reader
11/9/11 2:29 p.m.
Xceler8x wrote:
DrBoost wrote: Boobs.
They're like motorcycles. Whether they're big or small, old or young, they're all fun.

http://www.youtube.com/watch?v=uQvnjGF28Pg

You'll need to log in to post.

Our Preferred Partners
K0Ozp3FAXgYyptWRLWyJ1pkT1doEPLKkVBafOUBPWUUidBEcMJ5n7WUMRS6cBMgR