Concrete Grill Countertop

The rebuild of the built-in grill for the Big Green Egg is complete. The countertop is prebagged Type S mortar with 1:1 latex to water and the equivalent of 5 pcy polypropylene fibers. It was cast grey and then slurried with a darker Portland cement latex slurry.

A cutout was cast in place for a mahogany cutting board supplied by studio build.

Drain channels were formed under the cutting board with clay and some green color was randomly placed on the mold.

Last weekend we had a party and it seemed to get the job done.

Studio Build and I just received a job to construct 50 concrete design awards. The originals are going to be constructed from wood and cast into a polyurethane mold. Stay tuned, I am going to use it as an opportunity to refine my home made mortar design.

Concrete Grill Construction

Last weekend we got a new grill and the old built-in needed some work. I deconstructed the existing grill and rebuilt it back for the new top. The old grill was an nonfunctional grill flat top from the 50's that got replaced with a big green egg. The bright mortar in the top three courses was what it took to get back to solid material.

Fiberboard template.
The top will have a knockout for a cutting board which is on the right side here. The cutting board area is sloped to the front to minimize ponding water. I split the knockout hole for the grill to make it easy to pull everything out. The pattern on the bottom of the cutting board area is modeling clay for some drainage. The hole for the egg is surrounded with ribbed foam to allow for the concrete to shrink without cracking.