Concrete Countertops: The Design and Construction Process

Concrete manufacturer and designer Fu-Tung Cheng brings shape to a countertop as he smooths concrete mix into a mold with a helper. Photo by Matthew Millman, courtesy of Taunton Press. Do It Yourself DIY-ers are increasingly drawn to concrete countertops because of their customizability, according to Concrete Décor, a magazine that follows trends in concrete manufacturing and design. Artisans interact closely to help customers realize their desired design, which also makes concrete countertops attractive. A simple countertop can be made over the course of two weeks, Cheng says. Depending on how hands-on you are, the process may seem shorter or longer than your usual half-day DIY project, but in the end, your concrete countertop will be a timeless addition to your home. When Cheng struggled to break the concrete countertop scene years ago, a customer who took an interest in his work helped launch him into the limelight. To give back and to share his craft with others, Cheng offers workshops for DIY-ers who want to build their own concrete countertops. He simplifies the once-complicated process in his book and offers helpful tips for the everyday DIY-er. Getting Started: Basic Tools The essential tools to construct and refine your concrete countertop are a drill, a hot glue gun, a felt-tipped marker for measurements, a SPEED ® Square, measuring tape, blue painter’s masking tape, silicone caulk and a framing square. Cheng suggests renting the bigger tools you’ll need for mixing, pouring Concrete Countertops Made Simple courtesy of Fu-Tung Cheng and Taunton Press. and finishing the concrete like an electric- or gas-powered mixer, a vibrator that will remove trapped air in the pits of the concrete surface when it finishes and a variable-speed polisher with a suggested speed of 900 rpm to 2,700 rpm. He recommends a double-insulated orbital sander that is used with a ground fault circuit interrupter on a grounded outlet to avoid severe electric shock risks. The Template The construction of a concrete countertop begins with a template, which will lay the foundations and act as a blueprint.“I make my templates by hot-gluing together strips of an eight-of-an-inch-thick lauan plywood,” Cheng says. Measure the dimensions where your countertop will be installed. Cheng says to cut the template for the base a half-inch shorter than the depth of the desired space on which you will place the countertop, which allows for smoother installation. Place three-inch-wide lauan plywood strips the length of the desired countertop along the back and front lengths of the area. On top, glue plywood strips with the desired depth dimensions along the left and right sides of the countertop space. Make sure to take into account measurements for an overhang, which allows the cabinetry underneath to “tuck in” beneath the countertop and prevents any sink water from dripping into the drawers. Cheng suggests giving two-and-a-half inches for the overhang. Creating the Concrete Mold Base and Knockouts Next, flip the template over and re-mark all the knockout measurements. Knockouts are the holes or crevices of your countertop where everything from the sink to the faucet to a creative addition like a sponge holder will go. Because the countertop will be made face-down in the mold, the measurements must be transferred to the other side of the template. Cut a Melamine baseboard wrapped in durable plastic into the size of the template and transfer the knockout dimensions to the baseboard. “Now’s a good time to break out your digital camera and take a photo of the template,” says Cheng; taking a photo will keep track of progress. After you’ve

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