Has anyone ever done do it yourself concrete counter tops and could you recommend a book?

Question:My husband thinks he can do this and he is very handy but he hasn't done this before so anyone who has done it themselves, if you could give me some advice or recommend a book, website, etc.

Answers:
I don't know what sort of concrete countertop you want to do but this is how i do it in a home with brick/concrete walls and for a countertop finished with tiles.

Assuming all necessary plumbing work is already prepared (drain pipe, pipe for running water ready, etc)

1. Mark out a level line on the walls where you want the height of the countertop. If you are going to lay tiles on top of it, then you'd need to minus out the height of the thickness of tiles, and another 1/2 inch for cement. Eg., if your finished height is 3' and your tile thickness is 1/4", then the line should be at 2' 11 1/4".

2. Prepare the wall where the countertop will be. Hack out a 1/4" depth, the height of the countertop thickness all along the entire length. Drill holes along the entire length of wall where the countertop is to be (where you just hacked), at 1' or less intervals. The holes should be about 1/2" to 3/4" lower than the line you have drawn. The depth of the holes should be at least 2-3" into the wall. Diameter of holes should be about 1/2".

3. Cut and insert rebar (1/4" or 3/8") into the holes. Lay additional bars on top of these, that run the entire length of the countertop, also spread out at 1' intervals or less (you'd need 3 at most for the long ones). Secure all bars by tying them together using thin wire at the joints.

4. Where you want the sink to be located, make sure your do not have any rebars blocking the opening. You might have to cut smaller / shorter lengths to enable this space to be made.

5. Prepare the formwork. Get straight edged 2x2s and nail to the wall using concrete nails (1 nail every 2'). Make sure the top of the 2x2 is slightly lower than the line drawn (leave enough for your plywood thickness). Build "legs" with 2x2s and space out the legs so they provide enough support for the weight of the concrete. Nail on the plywood on top of these "legs" and the 2x2 nailed to the wall. Take a pipe level (clear plastic hose with water in it) to ensure the plywood sits level front and back. Nail more 2x2s that mark out the front and sides of the countertop. Remember to minus out thickness of tiles and cement. Take pipe level to check levels again. You would want to brace the bottom of the plywood as well so that it can take the weight of the concrete. Do this using more 2x2s spread at 2' intervals.

6. Insert the sink face down into the space where you want the sink to be. Line the sides of the sink with crumpled, wet newspaper. Thickness of the newspaper should be enough to enable a smooth fit for your sink. Newspaper is wet so that the concrete won't adhere to it.

7. Mix and pour in the concrete (I use a mix of 5 or 6 sand, 3 cement, 2 granite). Spread it out and poke in with trowel to ensure no bubbles. Leave to set for 3-4 days (with the sink in).

8. Remove the formwork working backwards and removing the legs, then the plywood. When plywood is removed, remove sink by sliding it down through the hole created.

9. Start tiling. Work from the front of the countertop towards the back to have a nice asethetic look. If tiling the front/sides, bear in mind the final finish and how the tiles on top will join those tiles at the sides/front. Will you use 1/4 round siding?

10. Sink should be recessed in countertop for effective water-flow, so put sink in before tiling around sink. Grout with cement or white cement depending on your preference.

11. Once all is set and dry, then can fix the plumbing for the drain pipe, taps, etc. and can take measurements for cabinets below the countertop.

If you need more help on this or a diagram, email me.

Good luck!