Forming Concrete Countertops
Here are some instructions for forming concrete countertops using the cast in place method.
Make the base or platform for the concrete with 1/2 inch plywood. Cut it to fit with the front and sides beveled at 45 degrees.
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Cut and place 1x4 boards along the front and sides of the cabinets making sure they are flush with the top of the cabinets. Attach with 1 1/2 screws. Apply tape along all the seams.
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Use 1x4 boards to form the faces of the countertop. If the concrete is to be 2 inches thick, then chalk a line 2 1/2 inches (to account for 1/2 inch plywood) down the length of the board. Line up chalk line with top of cabinets and attach board to cabinet with 1 1/2 screws. You don't need to sink the screws, but insert enough to attach board securely.
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To make the sink cutout, you can use 2 inch foam board. Cut it to size and then wrap the sides with tape for easier removal later. Place the cutout exactly where it needs to be on the plywood and insert a few 2 1/2 inch screws through the foam down into the plywood. This will hold it in place during pouring.
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On the wall, make a chalk line to mark the height of the concrete (2 inches).
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Cut and place wire mesh keeping it about 1/2 inch from the face boards. Use 1 1/2 inch screws and steel wire to keep the wire mesh elevated.
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