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mike, there is a company in GR that caters to the concrete trade with re-bar, forms, molds for stamped concrete, and stains. Concrete Central. find a company like that in Saginaw, and they will be able to help you with sealers, etc. my neighbor down the street has a concrete ping pong table out by his pool..the contractor built it just like a countertop, on a frame made out of rough sawn cedar 6x6's. another day, another project??
I used a wet grinder/polisher on the counter top today. Started with 50 grit, then proceeded through the series (50,100,200,400,800,1500). I'm pretty happy with how it's looking so far. The aggregate is really pretty, and it's quite smooth.
I put a small 1/8" flat piece of steel under the edge to shim the counter, creating a slight slope for water. A thick bead of silicone caulk around the edge, and set the counter in place (very heavy).
Still have to put a sealant on the concrete. I thought I'd wait a little longer, to be sure it is fully cured.
I followed recommendations from the book "Concrete Countertops" by Fu-Tung Cheng.
I did the initial grinding, starting at 50 grit down to 400 grit the day I pulled the forms, which was 4 days after the pour. I waited until day 10 to do the polishing with finer grit pads.
This is the grinder/polisher I used. It's designed just for this, with a water intake. The discs are a hook and loop system that exchange easily. It took a fair amount of time. The edges were more difficult. When I thought I was done, my wife wanted the bottom side of the cantilevered portion done as well. I could have kept going to get a real mirror like finish, but I wanted it to look like concrete still.
I used concrete on mine as well but did a pour in place with multiple color batches in an attempt to simulate old multicolored weathered stone.... I'm not pleased with the results. I ground down too much trying to expose the different color mortars but while doing that I exposed the larger aggregates in some spots.. It looks like it has white pokadots on it.... Doesn't give you that 'Ahhhrrrrrr' feeling, ya know?
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