The ink is just dry.....

[DavidC]

on our first contract for a concrete counter top. Technically we did one last year for a laundry room, about 4' long. But this one is for a galley kitchen retrofit. It will be 2 small ells with one sink cutout, about 17' linear total. No fancy add-ons and light on the grinding. Should be just about perfect for a starter job.

Wait the 3 days, make a template and order materials. I will make a small sample piece for customer approval before diving into the main course.

Progress reports and pics will be posted here.

Here is a before photo:
















(special thanks to Bender for the photo tips)

Good Luck
Dave

[knothead]

You may want to have a little chat with Bender Dave. I don't see any picture

[DavidC]

You may want to have a little chat with Bender Dave. I don't see any picture

It's a Polaroid. You have to wait for it.

Good Luck
Dave

[neolitic]

I shook the monitor for 60 seconds.


Now I can't see anything!

[OGStilts]

:2thumbsup: LMAO :2thumbsup:

Can't wait to follow it Dave! So dumb question here, you pour the concrete slabs on site right? It makes me nervous thinking about concrete being poured around my boxes after seeing the mess my mudders are constantly making but then again your not a mudder. (You're just one funny mudderfocker!) :grin:

[Bender]

Looks good Dave:grin:

[DavidC]

:2thumbsup: LMAO :2thumbsup:

Can't wait to follow it Dave! So dumb question here, you pour the concrete slabs on site right? It makes me nervous thinking about concrete being poured around my boxes after seeing the mess my mudders are constantly making but then again your not a mudder. (You're just one funny mudderfocker!) :grin:

No, we pour and grind at the shop and deliver the finished product. Some do the cast in place, and someday I'm sure I'll try it. But for now I can smash my screw ups in private and deliver a work of art.





Hopefully.

Good Luck
Dave

[DavidC]

Gathered up materials today, tomorrow it's time to mix up a couple of samples for client approval. I found out yesterday that she hasn't ordered her sink yet and we can't form the cast without it.

Can't believe that the masonry supplier doesn't have water reducer on the shelf. No problem for the color samples but we need it for the real pour. I'll check the concrete plants tomorrow to see if they will part with a small amount.

Good Luck
Dave

[framer55]

Gathered up materials today, tomorrow it's time to mix up a couple of samples for client approval. I found out yesterday that she hasn't ordered her sink yet and we can't form the cast without it.

Can't believe that the masonry supplier doesn't have water reducer on the shelf. No problem for the color samples but we need it for the real pour. I'll check the concrete plants tomorrow to see if they will part with a small amount.

Good Luck
Dave

Hey Dave. If you check out Fine Homebuilding site, there is a picture thread about pouring one that was interesting.

Just be patient with the new forum, it does searchs very slowly!

[DavidC]

Hey Dave. If you check out Fine Homebuilding site, there is a picture thread about pouring one that was interesting.

Just be patient with the new forum, it does searchs very slowly!

Is that in the photo gallery or a discussion thread? Searched concrete counter tops with no luck.

Good Luck
Dave

[DavidC]

Popped the color samples out of the forms this afternoon and ground them with the first pass of 50 grit, changed the pad for the second run and the grinder quits. Arrrggghhhh! Happened last fall also so I think I have a leg up on what it is. Not a serious problem just a PITA.

BTW, last year I lent my Cheng book to somebody that apparently needs it more than me. I was able to order a replacement via the RC Amazon store and had it within 3 days.

I'll post some pics of the samples plus an experimental piece that pretty much flopped after I get the grinding done.

Good Luck
Dave

[Leo G]

Brushes on the non working grinder?

[DavidC]

Brushes on the non working grinder?

Yep. ! side is wearing faster than the other. I cleaned it up and put it all back together. Got another hour out of it and the GFCI is tripping. Tomorrow I'll put in new brushes and hope for the best.

Any idea why one side would wear faster? There is rust on the holder spring, I wonder if that is a clue to the problem.

Good Luck
Dave

[Leo G]

Different spring pressure is the only thing I could think of that would make them wear differently.

[WarriorWithWood]

I'll guess one spring is stretched or harder then the other.

ETA: Beat me to it.

[DavidC]

I did manage to get these ground enough for pics. More grinding to go but it shouldn't affect the look, more polishing from here forward.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1020.jpg

When done these will go to the client for final selection of the finish look. They are all from the same batch but with different treatments in and after the form.

Good Luck
Dave

[DavidC]

Here's one that looked a whole lot better in my head. The idea was to mimic a geode.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1022.jpg

After seeing some Hubble pics that Jason posted on FB, maybe I was trying for a strange galaxy.

It'll probably end up in the dumpster, but I'll play with it a little more yet.

Good Luck
Dave

[Bender]

Could you have stirred it a little?

[DavidC]

Could you have stirred it a little?

Sure could. That's the coolest part, you can do anything you think of.

Good Luck
Dave

[Silvertree]

I think you should drop a little tab of sunshine when your mixing:mad2:

[DavidC]

I think you should drop a little tab of sunshine when your mixing:mad2:

Might be why I had the wet saw out today, slicing up rocks.

Good Luck
Dave

[Bender]

I think you should drop a little tab of sunshine when your mixing:mad2:

A man of common sense.

[DavidC]

I think you should drop a little tab of sunshine when your mixing:mad2:

Thanks for the advice, here's the latest experiment.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1053-1.jpg

Good Luck
Dave

[DavidC]

We wait for the last shipment, due Monday, to arrive so we can begin. Did get to mark out the template today. Here's what we are starting with;

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1054-1.jpg

I told my son, " This is an action shot so look like you're really doing something." He wasn't thrilled.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1060.jpg

Look behind him and see where the post formed laminate was "scribed in".

Good Luck
Dave

[DavidC]

It's not the most attractive ride at the fair, yet I seem to like riding the learning curve a lot. I planned on building the forms for the c-top yesterday but instead spent most of the day learning various ineffective methods for filling the pinholes that show up after grinding the samples.

Reread Chengs chapter and visited a couple of forums and managed to find a least one method that works like a champ. So this morning I finally had the pinholes cured, acid washed the pieces and now the sealer is drying, fingers crossed they still look good when dry.

BTW, you painters got nothing on me anymore. The Xylexin Concrete Countertop Coating is a 2 part mix, plus a 3rd secret ingredient, that in a closed room makes the afternoon a bit more interesting.

As a distraction from my frustrations with the pinholes yesterday I double checked my orders that have now all arrived only to discover that I ordered just 1/2 of the bull nose edging I need. Ordered up the balance this morning and bought another round of sealer just to make sure I didn't run short when I was almost done. At $160/qt. I hope I like it.

Going ahead with building the forms tomorrow. Worst case scenario is I pour 1 piece and wait 3 days for it to set, then take the form apart and reuse that bull nose in the other form.

It is taking longer than expected with a few interesting twist in the trail but the excitement is still pretty high. I can't wait to see and feel the final product.

Good Luck
Dave

[DavidC]

Fresh out of the forms;
http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1070-1.jpg

Let the grinding begin;
http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1071-1.jpg

After nearly 3 hours;
http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1076.jpg


Good Luck
Dave

[neolitic]

It's not the most attractive ride at the fair, yet I seem to like riding the learning curve a lot.

I surely do understand that!

BTW, you painters got nothing on me anymore. The Xylexin Concrete Countertop Coating is a 2 part mix, plus a 3rd secret ingredient, that in a closed room makes the afternoon a bit more interesting.

http://i634.photobucket.com/albums/uu61/neoliticman/smilie/smilielol.gifhttp://i634.photobucket.com/albums/uu61/neoliticman/smilie/smilielol.gifhttp://i634.photobucket.com/albums/uu61/neoliticman/smilie/smilieclap.gif

[DavidC]

A little set back today. The shop is really small and over crowded (I'm a pack rat) so we haul the slab outside to grind. Wet grinding is really messy work, so outside is good anyway.

But I'm working alone while the other guys are out building a porch to pay the bills. I can't move this slab alone. It's overcast most of the day so no problem, I'll do the slurry coat out here. Then the sun comes out full bore and I worry about baking the slurry on and having to regrind everything. I get out a high grit and start cleaning it up, but it's too soon and the slurry pulls right out of most of the pin holes.

The guys show up after work and we cart it back inside. I'll do the slurry tomorrow.

The good news is during the course of this project so far 3 yards have asked for samples to display. One is in a resort area (the 1,000 Islands) and services the seasonal folks, another is a kitchen/bath specialist supply.

Good Luck
Dave

[6StringMason]

Good luck with those! Looking good from the pics I saw.

I started out doing precast, but after getting some pour in place under my belt, I try and push those more often than not. Especially when the client doesnt want anything real fancy.

Sometimes though, the messy precast is all you can do. Especially with the glass agg finishes and such.

Keep up the good work, and keep the pictures coming.

Also for slurry, I mix with acrylic, aka goats milk. It sets faster and less shrinkage then mixing with water.

[neolitic]

Don't be a stranger over here 6String!

[DavidC]

Good luck with those! Looking good from the pics I saw.

I started out doing precast, but after getting some pour in place under my belt, I try and push those more often than not. Especially when the client doesnt want anything real fancy.

Sometimes though, the messy precast is all you can do. Especially with the glass agg finishes and such.

Keep up the good work, and keep the pictures coming.

Also for slurry, I mix with acrylic, aka goats milk. It sets faster and less shrinkage then mixing with water.

Thanks for stopping by. If you care to indulge us in one of the longest welcome threads you've every started I'll waive the bacon requirements.

Appreciate the encouragement.

Good Luck
Dave

[Leo G]

Do you have the authority to waive the bacon requirement?

[DavidC]

Do you have the authority to waive the bacon requirement?

Well, actually I was banking on Mike still being mentally on vacation. It's a gamble, but I might pull it off.

Good Luck
Dave

[DavidC]

Bummer day today. Stripped the forms of the back splash pieces and started working on grinding those today. These would be the last parts to make. One at a time, by the end of the afternoon I managed to break all 3 of them. I can salvage some of it but will remake the entire set as insurance for having enough.

On top of that the grinder is acting up again. The motor is running faster than the pad now. Don't know yet what the problem is but I think I need to replace the pad. If your ever in the market for a wet grinder I can tell you which one to avoid.

But I don't have to end the day on a sour note just yet. Going on a call to finish a basement and possibly some kitchen renovations. Just the first contact, but still good to finish the day on a positive note.

Good Luck
Dave

[DavidC]

I didn't realize I had so many tickets to ride the learning curve. I did remake those back splashes, did my grinding and then broke them all one by one. Spoke with the client and we agreed on an alternative plan, a.k.a. installing shorter pieces like they were tiles. We delivered the slabs today and hooked up the sink.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1116.jpg

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1117.jpg

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1121.jpg

After some careful questioning today I figured out that the customer was settling. I can't have that, tomorrow I start a fresh attempt at the back splashes.

Good Luck
Dave

[DavidC]

Got to pour the back splash forms for the third time today. Added some small rebar to maybe help hold the long thin pieces together.

It might sound discouraging, but the good part is I got to pour a couple more practice pieces also. Playing with different dye techniques this time.

Good Luck
Dave

[nEighter]

can you put in that "netting"? that rebar square netting? not sure what it is called, just remember seeing it for concrete sidewalks my dad poured with my granddad when I was a kid.

[DavidC]

can you put in that "netting"? that rebar square netting? not sure what it is called, just remember seeing it for concrete sidewalks my dad poured with my granddad when I was a kid.

Yes but no. The back splash pieces are 3 1/2"x1"x8'. The mesh would be to large. I tried to go without because they are so thin I worried about the rebar ghosting through. I had a bunch of those yard sign stems hanging around so I cut them up to use. Hopefully this will be the last time.

Good Luck
Dave

[Leo G]

What about Expanded Metal Lath (http://www.cemcosteel.com/ca-44.aspx)

[DavidC]

What about Expanded Metal Lath (http://www.cemcosteel.com/ca-44.aspx)

Good idea, but the mesh needs to be large enough to allow the gravel through. I could do a half fill, mesh and fill, but it's hard enough getting the right amount in place for a 1" pour.

I was thinking hardware cloth for next time. A way to flatten it off the roll would be the thing, a crown would be NG.

Good Luck
Dave

[6StringMason]

The tops look great! What did you use for a sealer on them?

For the backsplashes, try your local brick yard. Go and ask for a product called durawall. At least thats what we call it around here.

Its the horizontal reinforcement for block walls. You can get it for 4" block all the way up to 12". Its perfect for reinforcement and what I use on all my tops.

[DavidC]

The tops look great! What did you use for a sealer on them?

For the backsplashes, try your local brick yard. Go and ask for a product called durawall. At least thats what we call it around here.

Its the horizontal reinforcement for block walls. You can get it for 4" block all the way up to 12". Its perfect for reinforcement and what I use on all my tops.

That sounds like a winner, thanks.

The finish is a 2 part Xylene sprayed on.

Good Luck
Dave

[DavidC]

Round 3 of the back splashes has progressed further than any other attempt so far. Just sprayed the sealer tonight, now they sit for 3 days to cure before we can handle them.

I plan on trucking them in the forms and strapped to 2x6's for safety. I'll probably hold my breath from the time they leave the driveway until the last piece is safely in place. Mon., Tues., or Thurs. depending on how other work progresses. Client is out of town for the week, so no pressure as long as their in when they get home.

Good Luck
Dave

[DavidC]

Third time is the charm they say.

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1142.jpg

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1140.jpg

http://i571.photobucket.com/albums/ss156/CookContractingllc/Shampine%20Counter%20Top/IMG_1137.jpg

Now I just need the electrician (their son) to wrap up the new outlets so I can get the real after shots.

This job did not go anything like I thought it would, but I am really pleased with the results. We'll see if the client agrees once they return.

Good Luck
Dave

[J F]

Very nice...I love those rounded inside corners. :2thumbsup:

[DavidC]

Very nice...I love those rounded inside corners. :2thumbsup:

Mrs. HO went right for that corner, leaned in and declared it was just her size.

Good Luck
Dave