The Tools, Supplies, and Materials for Building a Concrete Countertop

This article is for you if you want to build a concrete countertop but have no idea what you need. With the development of quick-drying concrete, you can pour and cure your concrete countertops without waiting weeks. DIY concrete countertops will not be as smooth as those purchased from a professional, but you will save hundreds of dollars on materials. Plus, there is the whole experience of building a concrete countertop yourself! Imagine the joy you'd feel when you succeed, which you will if you have the right tools and supplies we have for you in this post.

Tools You Need to Build a Concrete Countertop

The success of projects such as this highly depends on the available tools. Make sure you have the RIGHT tools. That said, here are the tools you will need:

● Table Saw: You can cut melamine safely with a table saw. Don't buy a small portable saw. The saw needs to have legs or a solid base. The fence must be able to cut through material that is 24 inches wide or wider. Think about getting a hybrid saw. Your saw must have a good rip fence and a blade that can cut melamine that is sharp.

● Miter Saws: Miter saws can cross-cut materials like melamine effectively and safely. To get the work done smoothly, have a sliding compound saw.

● Cordless Drills: You screw molds or forms together with cordless drills. Take it from us, a lithium-ion drill and impact driver set is the best choice.

● Jigsaw: You use a jigsaw to cut curves.

● Drill Bits for Screws: For #2 screws, a 7/64′′ drill bit is what you use. Buy different screwdriver bits to fit different screw heads.

● Random orbit sander with 120, 180, 220, 320, and 400 grit sanding pads

● Tape measure

● Pencils

● Plastic scoops (big and small)

● Framing squares.

● Flush trim pattern router bit.

● Wet-and-dry silicon carbide sandpaper

● Lots of 5 gallons buckets.

● Two 2" x 5" trowels for the margins.

● Wood router w/ 1/2″ collet

● A sharp utility knife

● Hammer

● Rubber boots

● Heavyweight rubber apron

● Rubber gloves

● Dust mask and eye protection

● Heavy-duty hand cleaner

● Prybar

● Microfiber cloths

● Concrete cleaner

● Disposable bristle brush (Ideally 1.5 inches wide)

● A stiff grout brush made of nylon for cleaning the hopper gun and compaction rollers.

Supplies and Materials You Need for a Concrete Countertop

Portland Cement:

This can be white or grey. However, white cement is best, and you get to use it on its own. Make sure that grey cement does not contain any fly ash or pozzolans. Store in a dry, dehumidified area on a pallet or off the ground. Oh, buy at least four sacks each (about 376 lbs).

Sand:

Dry, fine, clean, screened silica sand with an average particle diameter of 0.3 mm to 0.5 mm and a maximum particle size of 1 mm. Fines shouldn't exceed 2 percent of a 0.15mm sieve. This should be a #30 screen silica blasting sand, if possible. The sand should be of the following: Silica – 96 -100%. Clay and organic matter can lose up to 0.5% of their weight when they burn. And buy white-colored or light-tanned sands. They are the best. A minimum of 500 lbs of sand will do.

Casting Table:

You'd usually pour GFRC into melamine molds made for the job. But the forms still need to be on strong, flat tables or carts. Minimum 4′ x 8′, 1 table. The table should be 30 to 32 inches off the ground. The tops of tables should be level to within 1/16" over 8'.

Forming Materials:

3/4-inch-thick particle board with a melamine finish. 48-foot sheets. Buy a minimum of 8 sheets.

Screws:

You will need at least 200 wood screws or drywall screws that can hold the particle board together. For 3/4′′ material, the length should be 1.25′′. Torx or square drive is what you want. The style of a head with a straight slot is not acceptable.

Form Release Agent:

Melamine doesn't need a form release agent. But if you use fiberglass molds or steel-topped casting tables, you need a form release agent.

Rolling Carts:

Get some strong mobile carts that can hold a 300-pound form. Height should be between 24 and 28 inches. The cart should have swiveling wheels that can each hold 100 pounds. The best dimensions for a cart are 24" wide by 48" long and 24" wide by 96" long. Get at least two of each size of cart.

Silicone Caulking:

You'd need 100% silicone in a hue that contrasts with the forming material. For example, if the melamine is white, buy black silicone caulk. Purchase no latex, acrylic, or water-based caulk. GE Type 2 silicone performs admirably, and you need at least three tubes.

Paste Wax:

You will need beeswax, carnauba wax, or a similar mixture of soft paste wax for wood. This doesn't go on the concrete; you'd need this to get the silicone off. One can is enough.

Double-Sided Tapes:

Get the thin double-sided tape for carpets, not the thicker foam. One roll of tape will be enough.

Template Stock:

Concrete companies in Orange County usually sell this in 4'x8 ′ sheets. Get at least two sheets.

Other than all that above, you'd also be needing one (1) gallon of acetone, two (2) sets of saw horses that could each hold 300 pounds, and an extruded polystyrene foam insulation board.

Conclusion

One of the more difficult and rewarding DIY projects is making your concrete countertop. If you're a rookie, keep your goals simple — plan for simple colors and straight edges. The key to success is making a strong mold that won't leak where the concrete will go. Also, plan to work on this project over a few weekends. Orange county concrete needs about a week to harden, so work in a place where you won't need to keep moving the countertop.

If you want to add custom color combinations, features like drain boards, butcher blocks, integral sinks, embedded stones, glass, tile, or inlays to your concrete countertop, you have moved out of the DIY space. And you should call a professional concrete contractor in Orange County.