STEP 1: COUNTER TOP LAYOUT AND PLANNING

When building counter tops, as with any construction project, planning is the most important step! Since every counter top design is different, your template needs to be extremely precise. So take your time with this step. Measure twice, pour once! Sometimes it is better to have someone else look at this and double check your measurements.

STEP 2: LAYING OUT THE COUNTER TOP TEMPLATE

Start building your countertop or furniture template mold using a form material such as melamine.  Remember that you will be casting “upside-down” so make sure your measurements translate correctly (casting mold reversed)! Silicone any corners and create a nice tight radius using one of our Caulking Tools.  Clean up and excess silicone prior to the next step. 

STEP 3: MIXING YOUR COUNTER TOP MIX AND CONCRETE POURED

Once you have your countertop mold set up and on a completely level casting surface, it’s time to mix the concrete countertop mix. The first thing you want to do is pour the pre-measured 1-gallon liquid solution we call “modifier” into a clean 5 gallon mixing bucket. Now it is time to add your preferred color mix (see pictures below) with a mixer until well blended. This will ensure that your color will be consistent in your final counter top. Now slowly add in the 50-pound pre-blended concrete mix with a mechanical mixer until you get the consistency of the mix you’re looking for. In most cases, you will want it to look like thick pancake batter, thick but able to pour. If too thick, you could add additional water if necessary while mixing. (up to 16 ounces)

STEP 4: POURING CONCRETE COUNTER MIX AND ADDING DESIRED TEXTURE

Once your mix is the right consistency, it is time to start pouring into your mold, making sure to get it into every corner so as to not allow air-holes to form. When pouring the countertop mix, if using the veining technique, pour XS Precast to the edge of your first “vein” and then apply veining material (blended Slurry Mix and powder cement pigment) along the desired edge, then clean any excess veining material with light air or vacuum. Then finish pouring your mix material into your mold until it is to the top of the form. NOTE: Once your mold is full poured, gently “pat” the mix lightly to make sure no air pockets form underneath and get trapped. There is no need to use a vibrating table with this mix. 

STEP 5: DE-MOLDING AND CLEANING YOU CEMENT COUNTERTOP

In most cases, your pour counter top can be de-molded after only 4 to 6 hours, depending on the size of your top this step may require two or more people. Carefully remove the sides to your forms. Gently tilt your piece in a manner that does not cause flex in the concrete (similar to granite or glass). Place your cast piece on top of some of your form side pieces, or pieces of foam, to ensure breath-ability of the counter while finishing. Clean the top of your top using diluted SCR (Super Concrete Renovator). Rinse thoroughly and wipe clean. 

STEP 6: SEALING YOUR COUNTER

When looking for a more natural look and design, XS-327 is the ideal choice for sealing the surface.  It's a water-based (no VOC/odor) and a food safe sealer that is very durable, virtually stain proof, and very scratch resistant. See the TDS for XS-327 for specific mixing and application instructions, Here are the basic instructions when applying this sealer: First coat should be implemented at a 7:1 water to sealer ratio. You should thoroughly saturate the piece until no more product can be absorbed, then remove all excess material by back rolling with very light pressure to get a consistent even coating. The following two coats should be applied at a mixing ratio of 2:1 water to the sealer. As with the first layer, work XS-327 vigorously into the surface helping the counter absorb as much of the sealer as possible. Once applied thoroughly, back roll the sealer gently with little to no pressure on your roller to ensure no sealer marks show up later. Please keep in mind you can always get a polished look if these coats are applied evenly, just like concrete floors.

STEP 7: INSTALL YOUR NEW CONCRETE COUNTERTOP

Congratulations! You are almost done. The installation will vary greatly depending on the size of the concrete counter top you have cast and the way your kitchen is designed, but installation is typically very simple. Again, depending on the size of your countertop, two or more people may be required for installation to ensure that your countertop does not break when installing. Any seams can be joined with colored epoxy or an equivalent product of your choosing. Concrete Countertops that are sealed properly are extremely low maintenance and very durable, so now just sit back and enjoy your creation!