Best material for concrete countertop forms?

[Jruhl]

What is the best material for making forms for concrete countertops? I would like to use plexiglass, but it costs way too much. I was thinking I could use the smooth coated hardboard that is used for bathroom walls, but I am concerned that the chemicals in the concrete can eat through the coating. The other material I thought of is the smooth formica that is used for formica countertops, but sometimes even that isn't completely smooth. If I do do use these materials, what is the best saw blade to use in my table saw to cut them? Also, is there any forums where the pro's exchange ideas? It seems like they are all pretty secretive so far. Thanks for any info!

[Sponsored Links]

[Paul D.]

The April-May issue of Fine Homebuilding has an article on countertops. They use melamine-coated MDF to build the forms. Similar to your Plexiglas idea, but much more workable and cost effective. FH/ Taunton press has a new book out as well. Search John's site here for concrete countertops and you'll get a couple of threads that include some links to othter sites, compliments of Cami and others.

You know how secretive pros can be. Won't let a bit of information go, and sarcastic as you-know-what...;)

Dave Ashton has several posts on the countertop project. He's done several and has put in some good pointers. Good luck...

[Cami A]

Jruhl, here's the original discussion on concrete countertops. (http://www.johnbridge.com/vbulletin/showthread.php?threadid=1759) Somewhere buried in that thread are links to a few sites, and one or two of them have forums.

The book Concrete Countertops mentioned in the first post of that thread suggests melamine, but also mentions glass, plastic laminate, 6mil plastic, Mylar, Plexiglass..."any material may work, as long as it has a waterproof surface over a dimensionally stable substrate." -F. Cheng.

[John Bridge]

Welcome aboard, Jruhl.

[Jruhl]

I did buy the book about a month ago, it was one of the best investments I've made. The idea of melamine is a good one, but I was thinking that something that is completely smooth would require less grinding. I am going to Lowe's tomorrow, and I am going to check out the formica sheets, if I put them over particle board that should produce a flat, smooth surface. I can't wait to get started making countertops, I am in a dead end job right now and it will be not only a help for my income, but I think it's something I'll actually like to do. I bought a nice water fed diamond grinder and pads on ebay, and I have figured out how I want to make the forms, I was just undecided on what surface to pour on. Hopefully I will be ready to start producing some samples by next week!
Thanks,
Jeff

[John Bridge]

Jeff,

I think formica is about the same as melamine on its surface. I mean, there are all sorts of different textures. Melamine is much thinner and much cheaper.

We'll be standing by for reports on how you're doing. Hell, I might even change trades again. Haven't had a switch for 30 years!

:)

[Cami A]

Detailed reports, please!

Jack just thumbed through the book, rolled his eyes and said, "Whatever you want me to do, honey..."

(That would be green, curved, inlaid countertops....Heh heh heh...)