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SOME ASSEMBLY REQUIRED – The Hands-On Handbook 4 5 6


Reinforce. To build the grid, place 3/8” rebar around the perimeter, tied off with wire every 16”, so that the assembly “fl oats” in mid-cavity. Lay remesh atop the rebar and wire to rebar at a few spots.


7 8


Mix and fi ll. You’ll need enough volume to fi ll the whole cavity, so use a rented concrete mixer (unless you own one). Press the concrete into cavities. The mix should have the consistency of oatmeal.


Screed and vibrate. Any straight piece of wood can serve as a screed board to level the surface. Use a hand-held vibrator to get rid of air bubbles.


9


Turn it over. All screws should be removed from the form before fl ipping over the countertop for fi nal fi nishing.


Add a slurry coat. A thin slurry coat will cover up any small cracks and blemishes. The author did two slurry passes: one with Quikrete 5000, the second with Fu-Tung Cheng’s slurry mix. This was applied with a trowel or putty knife.


Ready for fi nal sanding. Here’s the top with slurry applied, prior to fi nal sanding and waterproofi ng with a food-safe concrete sealer.


MATERIAL LIST ❑ Melamine laminate boards for the sides of the form


❑ Sturdy and level sawhorses to build on (The fi nished top weighs around 400 lbs.)


❑ 3/8” rebar for inner support ❑ Remesh for more inner support ❑ Wire for attaching the rebar and remesh to the form ❑ Screws for building the form (3” and 1 5/8” drywall screws) ❑ Silicone caulk in a color easily seen on the melamine ❑ Rubbing alcohol ❑ Concrete (This top was made with Quikrete 5000 without additives.) ❑ Pigment of choice (The author used a little black.)


Continued on next page


Project courtesy of Brian Redmond www.brianredmond.net


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