Finishing A Concrete

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Finishing the concrete...

Release the concrete forms by carefully separating the joints with a small, flat prybar. Unscrew the blockout, but
don't remove it unless you plan to install an undermount sink and need to finish the inside edges. Otherwise, wait
until you've actually installed the countertop.
Ease sharp edges and corners of the slab by sanding with a random-orbit sander and 100-grit sandpaper. Wear a
respirator to avoid inhaling the silica particles.
Etch the surface with a 1-ounce-per-gallon solution of muriatic acid and water. For tops made with pigmented
concrete, such as this charcoal-gray unit, the acid wash exposes more of the color and texture variations. Be sure to
follow the safety precautions on the acid label regarding eye and skin protection and ventilation. When you are
done, rinse the countertop slab thoroughly with water to remove the acid residue, then let it air dry.
Prepare a mixture of Portland cement, latex additive and liquid pigment to the consistency of peanut butter and
apply it to the exposed surfaces using a rubber-faced grout float. Then plow (or skiff) the surfaces with the leading
edge of the float raised so the material remains in all of the small voids but is removed from the flats. After this filler
dries and cures for an hour, sand it with an orbital sander and 180-grit discs until you are satisfied with the
smoothness. Plan on going through a lot of discs!
Installation on the cabinets.. get lots of help!
When it comes time to move and install the top, get plenty of help. The slab will be heavy (about 20 pounds per
square foot) and awkward to maneuver through the house, and you must support it evenly to prevent stress fractures.
The more hands the better. Concrete normally takes three to four weeks to reach full strength. It's best to let it cure
fully before attempting to move it, and leave the block-out in place when you do to support the narrow edge.
Apply a thin bead of construction adhesive or silicone caulk to the top edges of the base cabinet (if you use too
much it will squeeze out and make a mess) and set the top. With the counter in place, cut the blockout into pieces
with a jigsaw and remove it.
Seal the exposed surfaces of the slab with a concrete sealing product according to the manufacturer's directions. This
will prevent the surface from absorbing food stains and odors and make it easier to clean. After the coating dries,
buff out the surface using a Scotch-brite pad. Then apply a coat of acrylic clear finish such as Minwax Polycrylic.
To achieve a high-gloss surface, use a car buffer or an electric drill fitted with a buffing pad.

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