- 1). Construct a frame the size of your desired countertop, using plastic-coated particleboard, drywall screws and an electric screwdriver. Use plastic-coated particleboard to cover the bottom of the frame securely.
- 2). Place the fiber-free concrete mix into a large bucket. Consult the packaging for the amount of water to add, since this will differ between brands and package sizes. Add the water to the bucket. Mix the concrete well with a shovel.
- 3). Trowel a layer of fiber-free concrete onto all of the interior surfaces of the frame. Make this layer approximately 1 inch thick.
- 4). Clean the shovel. Mix the reinforced concrete with the correct amount of water in a second bucket. Fill the frame 3/4 full with reinforced concrete. Carefully tamp the surface of the concrete and then smooth it with a magnesium float.
- 5). Pour fiber-free concrete into the remainder of the frame. Level and smooth the surface of the concrete with a magnesium float. Screed the top of the concrete by running a metal screed from one end of the frame to the other. Allow the concrete to cure for two hours.
- 6). Smooth the surface of the concrete one final time, using a metal finishing trowel. Cure the finished countertop for 48 to 72 hours.
- 7). Disassemble the frame from around the countertop and remove the lumber.
- 8). Sand the countertop evenly, using an orbital sander fitted with a 100-grit disc. Continue until the countertop is level and smooth all over.
- 9). Mix together enough muriatic acid solution to cover your countertop. Combine four parts of water and one part of muriatic acid in a clean plastic bucket. Use a large paintbrush to brush a thin layer of the acid solution all over the surface of the countertop. Let the acid sit on the countertop for five minutes. Rinse the countertop completely with a garden hose. Allow the countertop to dry for two to three days.
- 10
Spread concrete filler evenly all over the countertop, using a rubber float. Turn the float so that it is angled at 45 degrees, then scrape it against the surface of the countertop to remove excess filler. Wait one hour for the filler to set. - 11
Sand the countertop a second time with the orbital sander and a new 100-grit disc. Rinse the countertop with the garden hose to remove any dust and debris. Allow the countertop to dry for two days. - 12
Apply a narrow line of silicone adhesive along each edge of the base. Make sure that the edges of the base for your countertop are clean and free of any dust, splinters, or other debris. - 13
Lift the finished countertop gently with the help of two or three people. Make sure not to leave any portion unsupported. Center the countertop over the base, then carefully set it into place atop the silicone adhesive. Let the adhesive dry for 24 hours.
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