Assembly Instructions

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FORM CONSTRUCTION:

• Use melamine coated particle board, not white painted particle board. Melamine is a particle board that has been treated with a

plastic coating on both sides. Make sure the melamine surface is free from any scratches, smears or cracking. Remove any stickers

from the melamine form and make sure all adhesive residue is removed.

• When forming the mold ensure screws don’t protrude from the surface of the melamine mold. Hint

: Put clear packing tape over all of

the screw heads to avoid concrete spillage in the screw heads which will make mold removal very difficult.

•

It is best to vacuum and wipe down the inside of the form with a clean rag and warm water or acetone. Use of other cleaning

products can leave streaks and residue on the form that you may not be able to see until the top is removed from the mold.

Thoroughly dry the inside of the form prior to pouring the mix.

• Do not apply a form release agent to the melamine

CAULKING OF FORMS:

• Use 100% silicone black caulk. All forms must be caulked in the corners to avoid having razor sharp edges.

Make sure that the

caulk is smooth as any imperfections in the caulk surface will be reflected in the edge of the concrete countertop

. Be careful that

sawdust residue does not get into the caulk or it will show up on the countertop. Any sawdust residue that gets on the melamine mold

can be simply vacuumed up with a shop vacuum.

•

Use painters tape to protect the caulking area. Remove the tape once the caulk is in place. Use a razor blade to remove

excess silicone caulk. Excess caulk that is not cleaned up prior to pouring the mix will leave a mark in the concrete.

MIXING:

• Plan out your mixing procedure. A 50# bag of Concrete Countertop Mix with proper water addition can fit and be mixed in a five

gallon bucket. It may be advisable, depending on the size of your pour, to have multiple five gallon buckets.

• Pre-measure all water to be used. Do not over water. Mix 5.5 pints of clean, potable water per 50# bag of Concrete Countertop Mix

for 3 minutes. Allow the product to sit/slake for 3 minutes and then remix for 2 minutes. Additional water is not required and may

negatively affect the finished product.

• Add water to the empty bucket first, then add Concrete Countertop Mix. Water and mix should be at room temperature (65°-75°F).

• Best results are obtained when a five gallon pail and a mechanical mixer are used to mix the product. Be sure to use a mechanical

paddle mixer – no shovels, hoes, wheelbarrows or barrel mixers.

POURING INTO FORM:

• For longer sections and large countertops, don’t mix material that you will not be able to lay in 20 minutes.

Always try to have

sufficient material to fill the bottom surface of the mold in one pour to minimize pour lines from showing on the surface.

• Make sure forms are tapped with a rubber mallet or lightly vibrated with a palm sander (without pad). This helps to consolidate the

mixture.

REMOVAL OF FORMS:

• Be sure to wait at least 18 hours before de-molding.

• After de-molding, it is desirable to allow the countertop a few hours of drying time before applying sealers. It is important to follow the

sealer manufacturer’s instructions as to timing of sealing and temperature considerations.

• Be sure to lightly sand and smooth the bottom edges of the countertop to eliminate sharp edges. Be careful sanding corners, always

sand lightly towards the top/piece to avoid chipping the edges.

PREMIUM CONCRETE COUNTERTOP MIX

PREMIUM CONCRETE COUNTERTOP MIX™

PROJECT TIPS

www.tccmaterials.com

• February 09 • Version 2.0