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 MyMason's Case Studies

 Chimneys and Brickwork Case Studies

    Chimney Repair

    Chimney Repair, Articulated Boom

    Custom Scaffold, Chimney Repair

    Chimney Flue Replacement

    Chimney - Sloped Side, Repair

    Brick Pillar

    Brick Sill Creates Wall Damage

    Brick Retaining Wall Rebuild

 
 Concrete Case Studies

    Broken Concrete Step

    Basement Window, Concrete cut-out

    Concrete Walkway, Landing

    Concrete Stairs and Landing

    Concrete Countertop

 
 Stone Work Case Studies

    Stone Wall Rebuild

    Granite Resurfacing of Concrete Stairs

    Stone Step Rebuild

    Stone Stair Rebuild - in Winter

    Stone Door Sill

    Stone Retaining Wall Rebuild

    Dry-Stack Stone Retaining Wall0

    Flagstone Patio Rebuild, Expansion

    FlagStone Step Repair

    Stone Replacement

    Interlocking Stone Walkway

    Tile Installation

 
 Algonquin College/MyMason Case Studies

    Cold Weather Masonry Rules

    Salt and Concrete Testing

    Concrete Curing Stress Tests

    Concrete and Rebar Stress Tests

 
 Parging Case Studies

    Parging, Cement Board

    Parging Examples & Techniques

 
 Fireplace Case Studies

    Fireplace Surround - Old Wood to New Wood Insert

    Fireplace Fire Brick Replacement

    Fireplace Surround - Natural Stone

    Electric, Natural Stone Fireplace

    Fireplace Hearth Replacement

    Stone Fireplace

    Cultured Stone Fireplace & New Framing

    Cultured Stone Fireplace Surround

    TV Mounted on Stone Fireplace

    Restructuring Fireplace: Wood to Gas

    Drywall to Stone Fireplace

    3-sided fireplace: Cultured Stone

    Fireplace Removal, Damper Removal
 

 

    Case Study: Concrete Countertop

        Before and After

   

 
Stages of Construction:
1) Frame & Molds   2) Concrete   3) The Cure   4) Sanding   5) Slurry, Sanding   6) Polishing   7) Oiling and Waxing

 

 
Stage 3: Curing the Countertop
The concrete has been curing in the form, now the curing will continue outside the form.

Inside, metal framing is tethered to the wood frame's sides, holding its position during vibration. The metalwork inside includes rebar bonded together, and large-cell wire mesh from end-to-end.

The Mix:   White portland cement, white stucco sand, white and coloured aggregate, and dye!

 
Form Removal
Gently.

You can just barely see a plywood sheet covering the sink area.

 
Corners
The form's sides are made of aborite, one of the materials that provide a sheer finish and an appropriate flexibility.

The foam within the wood form supports other materials like soft to rigid plastics and steel, even caulking and tape - permitting near unlimited shapes.

 

Sink & Faucet Knockouts
A thin plywood sheet covered the foam shaping the sink knockout,
Screws anchored the foam and plywood cover to the base, allowing for easy removal.
Plastic piping formed the plumbing holes.

The sink was mounted below the counter.

 

Custom Shapes
Many homes don't have truly squared spaces to work with.

This counter has a 89 degree angle at one end to fit an interior wall snugly.

 

Stage 4: Hours of Sanding
Another week of curing has elapsed since the counter left the form.

Now diamond sanding blocks and a water-fed polisher with 200 and 400 grit are employed for many hours.

Then a finer grit of 800 is used to prepare the concrete countertops for the slurry process.

In this case, some of the coloured aggregate has been purposely exposed by the sanding.

 

Vital: A Warm and Ample Workspace
Warm during the cure, and providing water drainage for the sanding, slurry and polishing process. Room sufficient for multiple work tables and multiple people to work together.

All the exposed surfaces are sanded, with particular attention given to the corners.  

The Tools
A water-fed polisher, diamond encrusted disks and diamond-blocks of various grits, a sponge, water, and safety glasses.

 

Stage 5: Slurry, More Sanding, Repeat
Sanding opens air pockets which can be filled with slurry, sanded and polished.

Note, you may want less sanding and slurry. For a use like a planter stand, you might want less polish and some air bubbles to remain unfilled,

 

Mixing the Slurry
One of the team prepares slurry, based on the original mix which was precisely recorded.

Applying Slurry
In this case, with three pairs of hands to apply it.
Slurry First Coat
After curing for 3 days, another sanding, and then again.

The coats of slurry add strength and density, and make a smoother finish.

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This page last modified: October 19 2009