Length - 03:34
Award winning kitchen & bath designer Fu Tung Cheng discusses how to use foam forms when making concrete countertops. The most important facet in making a concrete counter is the mold. One of the newest ways of making molds is using foam.
Foam forms allow for quick mold-making, they are easy to use, and can be used by just about anyone. Fu-Tung uses the foam along with double-stick tape to adhere the foam to the melamine base. You don't have to know how to work with wood or be a cabinetmaker—originally the molds were made out of wood.
All that is needed for this foam forming system is the foam, a mat knife, and double-stick tape. Once you have your template ready, take the double-stick tape and line the edges of your template. Then place the foam rails on top of the tape. You will also need form tape that will line the inside edge of the foam. This ensures that the edge of the countertop you are making comes out smooth and does not have ridges and impression left by the raw foam.
You may think the foam system is weak, it's not. When you pour the concrete into the mold the foam forms will not bend. As you place the foam into place around the template, be sure to create tight corners and joints. It is also important to get the formliner very flat against the foam. You don't want any curling or bubbling. Finally, begin caulking all the joints or seams that have been created in the mold with 100% Silicone caulk.