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~ Rob Z Remodeling ~ Loudoun County, Virginia, USA. Robert Zschoche Remodeling, LLC VA Class A 2705 87502 MD MHIC 85036 |
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Ceramic Tile Counter Tops I started out by removing the old counters, sink, faucet, Instant-Hot and disposal. The disposal is new and will be re-installed. |
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I kerfed the underside of the 3/4" AC Fir plywood. This helps prevent the plywood from warping. The kerf is about 1/8" deep. |
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I added supports in the middle of the large corner cabinet, and where the sheets of plywood met. I used a bit of construction adhesive and screws to fasten the plywood to the tops of the cabinets. These counters are going to be tough to remove! |
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The plywood is securely fastened to the cabinets, with heavy poly and metal lath stapled to the plywood. Metal edging is installed around the perimeter of the plywood, and has been set level and square. This metal edging serves as a dam for the deck mud that will be floated on the top of the counters. It also serves as a form to hold the "fat mud", which is troweled in the vertical channel formed by the metal edging. |
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1/4" galvanized metal rebar is bent and ready to be placed around the sink and the inside corner of the counter. This rebar reinforces the mud, which is particularly important around the narrow and relatively weak mud in front of and behind the sink. |
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Here sand and cement are mixed with just a small amount of moisture to make dry pack (deck mud).. The float strip is placed level and parallel to the metal edging. Metal edging for the sink opening is placed level relative to the counter front and serves a dam for the mud. The metal in the opening for the sink will be removed once the mud has hardened. Metal straightedges of various lengths are used to strike off the excess mud. The straightedges are pulled along the surface of the mud until they make contact with the float strips and metal edging. |
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Once the deck mud is finished, I used a margin trowel to rake out a bit of mud just on the inside of the metal edging. I then troweled in fat mud (wall mud). Wall mud is mixed much wetter than deck mud, and has a bit of lime in it to make it sticky. This mud is floated into the vertical channel formed by the metal edging. Since this mud is fairly wet, it squirts like toothpaste through the holes in the metal and flows into the small channel raked out of the mud on the counter. The excess is troweled smooth on the top of the counter, while the mud in the channel needs a bit of time to firm up before it can be struck off. A steel trowel and wood float give the surface its final finish. This work is a bit messy, so plenty of plastic and drops protect the cabinets and the floor. |
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The Cerim porcelain tile has been set with modified thinset. The installation has been grouted with an epoxy grout. The corners are caulked with a flexible sealant that matches the color of the grout. The four tiles above the sink were handmade in Italy, and match the ceramic dish ware in the kitchen. The new Kohler sink and faucet are installed. A new Kohler Insta-Hot will be installed later. |
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Now that the counters are done, the next step is to reface the cabinets and hang new doors and drawers. |
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