The Formative Stage.

Building the forms for the kitchen countertops began with 3/4" sheets of melamine. Using a table saw, the edges of the forms were ripped down to 1-1/2". They are 8' long.



Carefully reversing the measurements made for the countertops, the sides were clamped and screwed into place using 2" drywall screws.



The holes for the screws were predrilled. An entire box of screws, plus 8 others found around the basement, were used. The spacing is roughly 4".



The cutout for the kitchen sink had to be installed on the longest form. The materials are all 8', but the countertop needs to be 102". There is a seam. It was caulked with silicone caulk and will create a line on the finished surface. Sanding and buffing will hopefully remove the imperfection after the concrete has mostly cured. Clamps were used to hold pieces in place as they were drilled and screwed.



Strips of laminate were used to round off the edges of the sink opening. They were cut to height, then length, and finally superglued to the melamine pieces. No exposed wood can be left. The water from the concrete would swell the melamine before it cured creating unwanted depressions.



After everything was in place, the two pieces were hauled upstairs into the dining room. The concrete will be mixed outside. Silicone caulk will be applied to all the joints this evening after work. Once cured, the concrete will be poured. Rebar and wire mesh will be used to stiffen and strengthen the final product. I'd like to say it will be done before the weekend. Maybe.



It's 72 degrees and humid. Rain is in the forecast. Heavy showers yesterday afternoon as we were finishing the last pieces. The high should reach the mid 80s today.