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How to make a do-it-yourself polymer concrete countertop

Creating a do-it-yourself polymer concrete countertop is a simple yet effective way to spruce up any kitchen or bathroom. Not only does this countertop provide a scratch-resistant, waterproof surface, but it is also easy to customize; adding marble or other materials to the concrete is an easy way to make the countertop one of a kind. After preparing the surface, mixing the mouldable polymer concrete, and adding a pre-made fibreglass mesh mat to the mixture, the creation process just requires a few more simple steps. This cost-effective DIY project will give any surface a unique look that can last for years.

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The article provides a step-by-step master class on making a tabletop of a conventional size with your own hands. Using this guide, you can create an “eternal” countertop from artificial stone, spending 2 times less money compared to the market value.

How to make a do-it-yourself polymer concrete countertop

The undoubted advantage of polymer concrete (or artificial granite) is the ability to make a simple product at home. This does not require special equipment – only hand tools from a home workshop. We show you how to create a simple, lightweight countertop with an area of ​​approximately 1.2 square meters. m and 30 mm thick in an economical version.

How to make a do-it-yourself polymer concrete countertop

For work you will need:

  1. Inventory – a few clean buckets, a spatula, measuring containers.
  2. Tool – mixer, compressor with spray gun (optional), vibrating table (optional), grinder, mallet.
  3. Ready-made matrix – for a simple tabletop, a box of a given depth (30 mm) can be assembled on the first prototype.
  4. Moisture-resistant plywood (not laminated!), Cut in the shape of the future table top, 30 mm smaller in size. The thickness of the sheet is equal to the thickness of the countertop minus 15 mm, i.e. 30 – 15 = 15 mm. The sheet should have holes O 20 mm in increments of 100–150 mm. Structure the plywood surface, make a deep cut.
  5. Materials for the coating layer (for 3 liters of ready-mixed mixture):
    • transparent spray gelcoat (or “under the brush”) – 2 l;
    • composite white granules – 0.2 l; gray – 0.4 l; black – 0.4 l;
    • hardener Luperox K-1 – 0.04 l.
  6. Materials for the polymer concrete itself (for 15 liters of the finished mixture):
    • polyester casting resin – 5 l;
    • aluminum hydroxide – 2 l;
    • poraver – 9 l;
    • hardener Luperox K-1 – 0.03 ml.
  7. Materials for the filling layer (for 5 liters of ready-mixed mixture):
    • casting resin – 4 l;
    • aluminum hydroxide – 1.5 l;
    • pigment paste – 0.02 l;
    • hardener Luperox K-1 – 0.03 l.

Operating procedure

Stage one.Application of the finishing layer. It is applied first of all, since it is closely adjacent to the matrix. This layer is done with gelcoat. In the absence of a spray gun, you can apply the mixture with a brush into the matrix and tap with a mallet. Please note that for this you need a gelcoat marked “for a brush”, or with the appropriate mention in the instructions.

Spray Granit method. All components (gelcoat, granules and hardener) are thoroughly mixed according to the instructions and loaded into the spray gun tank. You can use any container instead of a tank. The gun nozzle must be at least 2 mm in diameter. Then spray on the matrix until a layer of 5 mm is formed. Externally, the layer will look like gray granite. The view can be varied by changing the proportions of the granules.

Stage two.After the gelcoat has dried, you can lay the polymer concrete itself, or rather, install plywood on it. Mixing all the components together (add the hardener last!), Pour 5–6 mm over the top of the gelcoat and install the plywood. The mixture should be pressed through the holes, and the top of the sheet is sunk 5-10 mm from the edges of the matrix. Level the sheet with a mallet and remove excess mortar.

In the case of production of a solid concrete product (without plywood), reinforcing fiberglass mesh should be laid every 10-15 mm of the layer.

Stage three.After the polymer concrete has dried, the filling layer should be laid. To do this, mix all the components and fill the plywood in the matrix. All “liquid” work should be carefully tapped with a mallet, removing air. The product can be disassembled after 1 hour.

Stage four.Process the edges with a grinder and, if necessary, paint the tabletop.

In this case, plywood is used as a lightening and reinforcing layer, moreover, it reduces the cost of construction. You can also create a sink, but this will require additional equipment – collapsible molds and a vibrating table.

Tabletop calculation

In the previous article, we conducted a comparative analysis of the cost of components. The table below shows the approximate cost of the materials that were needed to make the countertop.

Name Average price for 1 liter, cu e. Amount of material per product, l Material cost per product, USD e.
Casting resin 6.15 nine 55.35
Aluminum hydroxide 1.4 3.5 4.9
Gelcoat 6.75 2 13.5
Composite granules 1,2 1 1,2
Poraver 0.3 nine 2.7
Pigment paste 10.2 0.02 0.2
Hardener 5.7 0.1 0.57
Product volume (excluding plywood) 24.62
Product cost (excluding plywood) 78.42

The result is a material volume of 25 liters or 0.025 cubic meters. m. They can be disposed of in different ways. For example, cast a solid concrete countertop or slab 30 mm thick. Then its area will be equal to:

  • Smonolith = 0.025 / 0.03 = 0.83 sq. m

Moreover, the cost of 1 sq. m of such a product will be equal to: 78.42 / 0.83 = 95 cu. e.

If we use plywood as a solid filler, we get twice the area and a much lower specific gravity of 1 sq. m. Plywood takes up almost 50% of the volume (we accept 45%), which means that the area of ​​the lightweight economy countertop will be equal to:

  • Sease. = 0.83 + 45% = 1.2 sq. m

The cost of 1 sq. m will be equal to: 78.42 / 1.2 = 65.35 cu. e.

For comparison, 1 sq. m of finished tabletops to order costs an average of 120-140 USD. e.

Care of polymer concrete products

Exceptional properties of coating rigidity and structural strength make it possible to handle polymer concrete products in the most careless way. A well-made element is quite difficult to damage, even on purpose. There are no utensils in the kitchen that can destroy the polymer coating. It can withstand any household chemicals, abrasives, scrapers. After final drying, the resin loses its ability to adhere to substances used in everyday life and in a home workshop. We can say that all efforts to preserve the appearance have been invested in these products at the stage of creation..

How to make a do-it-yourself polymer concrete countertop

When choosing a finished product that is on sale (for example, sinks), you can be guided exclusively by your own taste and wishes. Sinks, countertops and other plumbing can withstand repeated installation, reinstallation, allow you to drill holes in any places without chips and special tools (a simple crown is enough).

At home, you can produce not only countertops, but also more complex products – baths, sinks, decor. To do this, you only need skill and a desire for results. Polymer concrete is the material of the future, thanks to which familiar things become more reliable, lighter and more affordable.

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Comments: 4
  1. Serenity

    I’m curious to know if anyone has successfully created a DIY polymer concrete countertop. Could you please share your personal experiences and provide step-by-step instructions on the process? I’d also appreciate any tips or advice you have to ensure a smooth and durable finish. Thank you in advance!

    Reply
  2. Aspen

    What are the step-by-step instructions for creating a DIY polymer concrete countertop?

    Reply
  3. Emily Mitchell

    I’m intrigued by the idea of creating a polymer concrete countertop myself. Could you kindly guide me on the step-by-step process of making a DIY polymer concrete countertop? I’m quite curious about the materials required, mixing instructions, curing time, and any essential tips you might have to ensure a successful outcome. Any recommendations on where to buy the necessary supplies would be greatly appreciated too. Thank you!

    Reply
    1. Liam Robinson

      To create a DIY polymer concrete countertop, you will need the following materials: polymer concrete mix, mold, reinforcing fibers, release agent, color additives (optional), measuring tools, mixing container, mixing paddle, and a concrete vibrator.

      Here is a step-by-step process:
      1. Choose your countertop design and dimensions, then prepare the mold accordingly.
      2. Apply a release agent to the mold to prevent sticking.
      3. Mix the polymer concrete according to the manufacturer’s instructions, ensuring exact measurements for water and mix ratios.
      4. Slowly add the concrete mix to a mixing container, gradually incorporating the water. Stir thoroughly until the mixture is smooth and consistent.
      5. If desired, add color additives to achieve the desired hue.
      6. Integrate reinforcing fibers into the mixture to enhance strength and durability.
      7. Pour the mixture into the prepared mold, ensuring even distribution and avoiding air bubbles.
      8. Use a concrete vibrator to eliminate any trapped air and achieve a smooth surface.
      9. Allow the countertop to cure for the recommended time, usually 24-48 hours.
      10. Carefully remove the countertop from the mold and let it continue curing for a few weeks.
      11. Sand the surface to achieve the desired finish and apply a sealant for protection.

      For supplies, you can check local hardware stores, online retailers, or specialized concrete suppliers for the required materials. Verify specific brands and availability with these sellers. Remember to prioritize safety measures and follow instructions meticulously for the best results. Good luck with your project!

      Reply
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