Dave's Northern Virginia Build

[tfasz]

Re: Dave's Northern Virginia Build

Dave - Looking nice and would love to hear more about your experience with the counters. I'm thinking of casting some concrete tops for the sides of my oven platform. Been reading up on cast in place vs. pre-cast options, materials, and finishing options, etc. Lots to learn.

Where did you get started?

[DaveW]

Re: Dave's Northern Virginia Build

Thanks Guys,
As far as concrete countertop research goes, I have a couple of books from Home depot/Lowes and have done some internet research.

I considerd:

Regular Concrete with extra portland mixed in.
Dedicated bag mixes
Pourable Grout
White portland homebrew
High strength Concrete
High strength concrete with additives
High strenght concrete with Cheng's mix.

In the end we went with Cheng's because we could get the materials quickly and thought it would increase our chances of getting it right.

If you go with Chengs or with any other water reducers then I recommend three people. With my wife and I working together, I mixed and poured while she packed the form and screeded. By the time we went over it with a float it was too late to get a smooth surface. A third person ready to float after screeding would be helpful. We also tried to vibrate with an orbital sander but finally gave up and just beat the forms with a hammer. Come to think of it, it was pretty much a rush job.
We haven't had a chance to pull the forms but I'll let you know how it looks when we do.

Dave

[DaveW]

Re: Dave's Northern Virginia Build

Hi all,
Here are before and after photos of the pizza oven gable. I wasn't happy with the look of it and every time someone new saw it they would ask, with a furrowed brow, "Is it supposed to be like that?."

So my wife and I came up with the idea to add a few more rolled rake tiles and half barrels to finish off the gable.

The countertops came out ok, but with lots of holes to be filled.

On a side,
I started a thread in outdoor kitchen design asking if I can lay the clay pavers sandwiched between the walls in a sand bed, without fear of expansion damage.
Any thoughts?

Dave

[DaveW]

Counters Grinded

Except for sealing, I finished the concrete counters this morning.

Initially I was unhappy with the surface finish on the poured concrete but it turned out not to be a problem. I purchased a Hardin wet grinder on Amazon with 50 - 3000 grit diamond pads and a bullnose bit. The 50 pad smoothed out the surface in no time. Unfortunately, I didn't realise how deep I was cutting and the surface is now a little uneven. After the first pass of the 50, my wife I and mixed up a slurry of portland cement, concrete fortifier, and color (red)(It turned out pink) and filled the holes (most of them).

Once again I hit it with the 50 and then progressively up to the 3000. The surface is not perfect but I am out of patients and, for an outdoor application, I think it is good. I can see with some extra work and skill this could easily rival indoor granite. The wet grinder was great even if it did supply me with a steady stream of electricity. (The manufacturer recommends rubber gloves and boots)

When you run your hand across the finished surface you can detect a few fibers that for some reason didn't get cut with the grinder. I am not sure if I will try to correct this as it is very minor.

Dave

[WoodchuckDad]

Re: Dave's Northern Virginia Build

Dave, that looks amazing. you have to be quite pleased.

[DaveW]

Re: Dave's Northern Virginia Build

Dave, that looks amazing. you have to be quite pleased.

Thanks,
Your build is looking amazing also. I can't believe you worked all day in the heat. I have been limiting myself to morning and evening.
Dave

[DaveW]

Re: Dave's Northern Virginia Build

The stucco is on...what a bear! The 21A gravel is leveled (sort of) and compacted and the pavers are going in. Miller time!
Dave

[Tscarborough]

Re: Dave's Northern Virginia Build

Looks good, great in fact. Start sanding as soon as you can stay a foot or two from the working edge.

[countryboy]

Re: Dave's Northern Virginia Build

That looks really good, Dave. Sore today from the stucco/arm workout? I was after a bunch of stucco the other day... still have more to go...

The pavers look really nice, too! Glad to see it all coming together.

CB

[DaveW]

Re: Dave's Northern Virginia Build

Thanks guys, the Pavers are in! Lots of cutting with the HF Saw. I also installed a Kerr paver light kit from Home Depot. I like the light but not the quality of the plastic fixtures. I will look into making my own out of glass and stainless steel.

The stucco is still curing. After awhile it stops turning darker when wet, but the thin spots cure faster so it takes on a splotchy look after the rain. In a week or two I will seal the countertops and the stucco.

Almost there.

dave

[GianniFocaccia]

Re: Dave's Northern Virginia Build

Man, Dave! Nice job with your pavers! I like the paver lights alot. The whole setting looks great and will be the perfect place to gather and party!

Awesome job!

John

[Millstone Man]

Re: Dave's Northern Virginia Build

Dave - Thats a fantastic build and beautiful place. Great job. Please share what changes you make in the paver lights.

[countryboy]

Re: Dave's Northern Virginia Build

Looking really good, Dave. I like it a lot!!

One question. You mention sealing the stucco. Is that the finish coat, or are you applying something after that? I'm new to stucco and having fun with it, but want to make sure the job lasts...

Thanks

[DaveW]

Re: Dave's Northern Virginia Build

Looking really good, Dave. I like it a lot!!

One question. You mention sealing the stucco. Is that the finish coat, or are you applying something after that? I'm new to stucco and having fun with it, but want to make sure the job lasts...

Thanks

Thanks CB. I've never done stucco either. I used a few bags of the expensive fiber reinforced surface bonding stucco over the steel lintels and my exposed rafters. I then mixed up a total of about 1500 pounds of Portland/lime/sand/color and spread it 1/4 to 3/8 inch thick over everything. It was fun at first but, at this point, if I never mix another batch of stucco it will be too soon! There ain't no way I'm putting on a second coat. I am thinking a clear urethane sealer will help protect it from water penetration (but I might get lazy and blow that off too). Being on a concrete structure it should be pretty stable if the oven doesn't heat it up too much. If not, cracks can be pretty too.
P.S. I really like your oven and counters.
dave

[Tscarborough]

Re: Dave's Northern Virginia Build

Stucco lives longer if sealed with a breathable sealer like Prime-A-Pell 200 or ProSoCo Silox PD. Surface sealers (like urethanes) are not good for stucco.