Concrete Countertops - Part 1, Setting the Forms

Be sure it lines up with your cabinets so you can attach the edge profile.

We thought it would be very simple to cut the hole for the sink, but this step took us way longer than we expected. Be sure to measure twice and cut once!

STEP TWO

Cut and assemble the edge profile.

This part is really neat. Z Counterform has a lot of different options to pick from. I wanted a simple square edge, however, if you want something different there are curved edges, fancy ones, slanted ones, etc. 

When they shipped us the materials, the forms all came together in a large box. 

For this step, you simply will need to measure your cabinet/countertop, cut the edge profile with the chop saw and then attach it to the durock with screws. You will need to miter the corners.

The kit comes with pieces for the front and the back of your countertop. The pieces for the front and side have a slight hangover on them and the forms actually break off so you don’t see them when it’s finished. The underside stays forever and you will never see it! How cool is that!?

(Sorry for the messy photos, but this is real life, we live here and we are messy.)

For the edges where the stove and refrigerator are going to be, we simply used a wood board to create a flush side to the concrete. Once the concrete is set, we will remove the boards.

STEP THREE

Caulk where needed and tape the corners.

You will not want your concrete to leak through the forms, so caulk where you feel it’s needed. This may be everywhere! Also, where the corners meet at a 45 degree angle, you will need to tape the outside to keep everything square.

STEP FOUR

Cut the fiberglass mesh to size.

Once you unroll the mesh, cut it to fit inside your forms. You can use a basic pair of scissors for this. Be sure the curves are going downward. 

**Tip** Use gloves when handling the mesh.



STEP FIVE

Attach the Z clips to the fiberglass mesh and the durock.

For the fiberglass to work correctly, it needs to be in the center of the concrete. Without the Z clips, the fiberglass would probably sink to the bottom (or rise to the top) of the concrete. The Z clips help hold it in the middle.

The Z clips come with 4 plastic pieces sticking out from them. You only need two, so break off two of the sides (opposite of each other).

Attach the Z clips to the underside of the fiberglass and then screw them to the durock. We spaced our clips out about every 6 inches or so.

**Tip** Be sure to SLOWLY screw in the screws to the durock. If you do this step too quickly with the drill, they will not be sturdy!

**Tip** We put the Z clips on the fiberglass mess with the two lines (see above), as we found it stayed in place better.

STEP SIX

Cover your cabinets and floor with paper or plastic.

The concrete will get messy! We found an inexpensive paper at the hardware store that we used. It took us about 5 minutes to tape the paper to the cabinets and floor.

Yes, I covered the entire floor. And I am so glad I did!

Here's a breakdown of cost:

$40 Durock

$129 Z Counterform edge profile

$50 Fiberglass mesh

$20 Z clips

$15 Screws

$10 Paper/plastic (to cover your cabinets)

And you’re done! Well, with the first part anyway. My next post will cover the concrete making, pouring and finishing process.

In the meantime, check out my blog posts for the next steps!

Part 2, finishing and pouring

Part 3, lessons learned

For a full post on PART 1, head over to my blog here!

www.greywoodmama.com