outdoor concrete counter top with grill
DIY

My DIY concrete outdoor countertops

Not a project to be taken lightly. They were seriously heavy.

Someone should really stop me from taking on DIY projects too complex, requiring too many skills, that require patience, and are too heavy for me to lift. I’m not very bright, studying up on YouTube videos on making countertops from bags of cement does not make one that much smarter. But they did make me fearless.

concrete counter top before slate tile countertop
This is what I replaced. The slate tiles were disintegrating (too many freeze/thaw cycles) and the wood was rotting in places.

I had built countertops around our free-standing pedestal grill about a dozen years ago. I loved them. They were slate tiles, grouted in a diamond pattern (like my checkerboard garden, dwarf pear tree espaliers, lattice panels, it’s a theme in the garden…). The counter had a built-in planter that was switched to an ice bucket for dinner parties. It also had a built-in planter below an iron grate affixed to the side of the house. We would grow flowering annual vines there each year. I even made a light from a wine bottle that hangs over the grill for late-night grilling. And wine bottle torches affixed to the arbor’s uprights.

CIMG7972
I still loved the inserted planter here that we switched out with an ice bucket for parties, and the built-tin planter for vines to grow on the grate attached to the house. This year it was mandevilla.

Basically, I like everything– except for the fact that it was coming apart. Nothing made of wood lasts forever. And Buffalo winters can be tough on tiles. And there was much moss growing in between tiles. It was time to say goodbye. But I like the design, size, scale, features I built into it. I just needed something that would last longer.

I’d always liked the idea of making my own concrete countertops. This was my chance. We bought the grill first. I needed to know exactly what size space was required for a countertop grill (this time without a pedestal).

And I kept the planter/ice bucket hole for party switch-overs. And the planter under the grate. But I had some glass tiles left over from a bathroom renovation and I added the rectangular glass tiles to the plan. The intent is to add rope light under the countertops so the light shines up through the frosted glass. That’ll be phase 18d that I’ll get to in the spring.

outdoor concrete counter top cardboard template
First I made a template in cardboard for each of the two pieces.

So, armed with a YouTube full of concrete countertop videos, off I went. Seriously, I am much smarter than I look, but this project might have proved otherwise.

You know the expression, “measure twice, cut once“? We’ll when you have to make a concrete form that is upside down and backwards, you have to measure about 40 times. The only tip I can impart here was to make a cardboard template and build the form around that. The countertop was so large I had to make it in two sections. And, of course, the two sections met in the middle – behind where the grill would sit, so it had to meet up and be EXACTLY the right width in that area to accommodate the grill. There’s no fudging space, no quick fixes in case the measurements were wrong. That was enough pressure. Having them be upside down and backwards didn’t help. And I didn’t form them in place. I did all this in my garage, mere feet away. I felt as though I was guessing – and second guessing when it came to measuring.

outdoor concrete counter top melamine form with cardboard template
Then I made the form.

I created the forms from white-paneled melamine boards. The edges are about 3″ thick, the rest of the concrete is really about 1.5″ thick. It’s not needed to be 3″ thick throughout, and would be too heavy to lift. It does have chicken wire throughout and rebar embedded into the concrete to keep the pieces whole. Despite that, I did break one countertop in half while lifting it to turn it over, Clean break though, you can’t see the crack unless you’re looking for it. And I did tell myself that if anything did break or crack, I was going to follow the Japanese practice of Kintsugi, or golden joinery, whereby I would fix the crack with gold paint to celebrate the countertops unique history. But since it’s a clean break, so concrete adhesive will do.

outdoor concrete counter top melamine form
Then I laid out where the hole for the ice bucket would go, and the glass tiles.

It took a few weeks for the concrete to cure in the forms — covered with tarps so they would harden slowly. I was able to lift them and turn them upside down (right side up, at this point). Doing that just let me know there was no way I could have lifted them on my own.

I had added some terracotta stain to the concrete mix when I was making them, but that came out as just a slightly less dull color of gray. I used a slough coat of concrete to fill in the craters in the tops to make them smoother. I painted them with a terracotta colored stain – three times – to get the color I wanted.

Once that was all done, it was time to move them. I ended up hiring two guys to move them for me. It took only about 20 minutes, but it was hard work. I spent and afternoon leveling them on the new structure I had built to support them, of 4’x4’s and 2’x2’s. Once leveled, I added the grill — which fit in perfectly!

outdoor concrete counter top melamine form with mesh and rebar being pored
Then it was time to pour…

I now have to coat them with a sealant, caulk up where the countertops and house meet, and do some finish wood work (and staining) to below the countertops to cover the 2’x4’s and shims. I’ll cover them with tarps this winter and do that stuff in the spring.

I also have to add the lights under them. I’ll have it spiffy-looking for our first barbecue of the season — and for Garden Walk!

Start to finish, including hiring two guys to  move them, I probably spent around $300, definitely less than $350. (This does not include the grill).

I’ll post again in the spring when it’s all put together. The grill is working and we’ll use it through the winter.

concrete outdoor countertop concrete stain out of form
This is the larger of the two pieces. This was a bear to lift. You’re looking at four 80 lb. bags of concrete mix, plus wire mesh and rebar.
outdoor concrete countertop concrete stain terracotta stain
This is the larger of the two pieces. This was a bear to lift. You’re looking at four 80 lb. bags of concrete mix, plus wire mesh and rebar.
outdoor concrete countertops terracotta stain concrete stain
A slough coat of concrete went on to fill craters and holes before the stain was added. This is the final surface texture and color.
outdoor concrete countertop construction gas lines
Old counters in the trash. I kept the bar to the left. It’s a gas grill, so I kept the grill where the old one was. I was NOT going to mess around with moving gas lines!
outdoor concrete coutnertpos construction
The bar was newer wood that got painted the same time as the deck. Though the deck’s been stained, stripped and stained again a few times over the years.
outdoor concrete coutnertpos construction placed and being leveled
Placed and being leveled.
outdoor concrete coutnertpos construction placed with built-in grill
The grill fits like a glove. That was the most stressful part of the whole project — having the two sections of the countertop line up with the correct space for the grill between them.
outdoor concrete coutnertpos construction placed with built-in grill
Some finishing trim work, stain, sealant coats, and under-counter lights and I’ll have some countertops that should last for the rest of my natural life.

7 comments on “My DIY concrete outdoor countertops

  1. Impressive…Love them. I have wanted concrete countertops for 20 years and know that this project is way beyond my ability. Geeze, the bags are too heavy for me. Congrats on a well done project.

    Like

    • Thanks Gail! I think, at the onset, I’d be able to just get a friend to help me move them. Then I considered having a few youngsters in their 20s come over for pizza and beers to move them. Once I got them done, and had invested so much time, I thought I’d rather have it in the hands of a few handymen I had met that deal with large objects like this. NOT a project for the feint of heart.

      Like

  2. Joanne

    You are brave. What a great job. Those bags of concrete are very heavy. I learned just asking Hypertufa that I can’t lift them. I can’t wait to see your completed project on The Buffalo Garden Walk. You are quite a talent.

    Like

  3. Congrats, Jim. It will look way cool with the light coming up through the glass tiles. But–if your wife can’t stop you “from taking on DIY projects too complex, requiring too many skills, that require patience, and are too heavy for [you] to lift,” I don’t think any of the rest of us will be able to stop you, either. Just sayin’.

    Like

  4. Pingback: Garden deadlines

  5. Pingback: A garden post post

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google photo

You are commenting using your Google account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s

This site uses Akismet to reduce spam. Learn how your comment data is processed.

<span>%d</span> bloggers like this: