When people say it won't work , don't listen.
So if you see it on Youtube it has to be possible
that's Ivan's moto anyways !
Along with the new idea he needs to spend 10 mins each day grounding
in other words walking in the garden with no shoes ???
And everyone thinks i am the weird one.
I will list the people who said we were crazy and making concrete countertops was just impossible.'
The builder, our architect friend , the staff at the the garden center, bunnings , masters , the concreter on the island and a lot more people, so many I can't list them all. Well i think i even said it, but Ivan said " babe, what have we got to loose $300 and some time, let's try it"
We had a mammoth shopping day that involved yet again a ferry, a barge, a Car, a truck and a lot of shopping. We stocked up on 30 bags of 20 kg bags of concrete. melamine , tools on and on .
Here we are at Bunnings, not that we like Bunnings cause,
we really love Masters !!! Too bad it's going out of buisness.
I think it's the lighting there.
The plastering was finally finished the exciting day arrived . I was so excited, minimal sleep for me.
The melamine mould for the concrete took all day to be built and concrete only got poured the next day.
We had bought 3 pieces, 2400 mm by 1200 mm of melamine as we had three separate countertops to make . We would use one for the island , the other one we cut into strips to make the borders and the last one would be for the last two countertops .
We started by covering our Ikea island cabinets with 9mm plywood
and putting in the sink, (which will be undermounted.) We caulked it,
and drilled a hole for the tap.
.
We drilled our precut 70mm strips of melamine to the melamine board and
into each other at the corners we covered the outside of the screw with tape .
We then created a makette of where the sink go, remembering that the bottom of the mould was going to be our top surface of the countertop
We built up a border where the sink would be and a piece of the a vaccum cleaner because we couldn't find a piece of PVC piping, this is where the hole for the tap will be .
making sure to caulk .
We then caulked all the edges
We vacuumed and cleaned the inside of the mould and then oiled it with olive oil,
any oil will do.
We then added aggregate ( Limestone ) to the bottom of the mold which would flip over and be the top we thought this would add interest and make the tops sparkly when polished. Unfortunately this did not work well and we actually left it out in the two next countertops . The stone was too soft and sorted of melted into the concrete.
Luckily we borrowed this baby from our neighbour , it saves a lot of back breaking mixing and makes things go so much faster
We used concrete Super Strength 55 from Bunnings at $9.50 for 20 kg
We poured water into the mixer, turned it on and then added our concrete
1.9 liters of H20/1 bag of concrete we mixed it 3 minutes and added h20 till it fell away from the back of the mixer and looked wet with no dry patches.
We poured it into a bucket and then used a shovel to shovel it into the mould
We used 18 bags for a 2400mm by 1200mm by 6mm countertop
We made sure to pack the concrete into the corners.
We used a heavy hoe to pack it down and spent a lot of time smacking it down
We vibrated the edges with a rubber mallett
We only filled it half full with the concrete , then we laid Rebar carefully so as not to touch any of the edges with the rebar . We then covered it with concrete so that the concrete was flush with the melamine edges
We skreeted it, so it was flat
We made sure it was flat and then let it dry out for 4 four days covered with plastic , we checked it twice a day and kept spraying it with water.
We broke the the mould off and luckily it was perfect and came off easily. We then hired 9 guys at 50$ each, to help us lift it onto the island. after alot of debate it got lifted with ease , so they all said onto the island . the island did some serious creaking when it went on . but it didn't buckle of crack and there it sits .
Installing taps on the countertop

So here it is , I don't think you can understand how happy we are here. We couldn't stop jumping up and down , It's not finished yet , We have let it dry and then we will finish it off with slurry, sealer, and then wax . stay tuned for the finished product