How to Cast Concrete Counters

Concrete counters can provide a durable, lasting addition to your home. The counters will normally have a rustic look in their original unfinished appearance. Alternatively, the counters can be made to create a smooth, colorful look that will accentuate the look of your home. 

What you will need:

Pre-formulated concrete, carpenter's level, paper, pencil, table saw, 4x8 sheets of melamine board, drill motor, 1 1/2-inch screws, glue, 3/4-inch rebar, scrolling sabre saw, tape measure, wire mesh, wire clippers, wire, caulk, work bench or flat work surface, hack saw, water, hoe, plastic roll, rubber mallet, wheelbarrow, buffing pad, concrete sealer and wax, grinding pads, speed grinder, brush

Casting the concrete counters:

1. Find a work area that has a flat surface and support the weight of the concrete.


2. Draft the pattern for the countertop. This can be done on paper or, preferably, luan. Make sure to include cut outs for the sink and faucets. When the pattern is complete, cut out with a sabre saw.


3. Make a mold from the cut out pattern using melamine board. Trace the pattern onto the melamine board and use the sabre saw to cut it out. Once the pattern has been cut out, including openings for sink and faucets, use pre-fab knockouts to plug the openings. Cut melamine strips to the thickness you want the counter top, and screw the strips into the base edges.


4. Using caulk, seal the mold's interior. Use the level to make sure the mold is even.


5. Cut out the rebar and wire mesh to fit into the mold's interior. They should then be tied together with wire. The rebar and wire mesh will be held up by wood screws in the outside walls to the mold.


6. Mix the concrete in a wheelbarrow with a hoe. Once it has been properly mixed, pour it into the mold. To ensure there are no bubbles, lightly tap the mold along its side.


7. Place a layer of sheet plastic over the concrete. This will make sure it sets properly. Keep it out of direct sunlight and let it cure for four days.


8. Take the sides off the mold and let the concrete cure for an additional three days.


9. When the concrete has cured, turn it over and remove the melamine base. 


10. Sand down the countertop's surface using a speed grinder. Gradually work down to finer pads to make the surface smooth.


11. Seal and wax the top of the counter. This will create a more attractive surface and prevent stains.