Now you may think concrete is a fail-proof material to work with, as did I having seen it humming along in a mixer on the motorway. How hard could this be? Upon closer investigation I began to worry. There are three main components to be ideally proportioned, and curing conditions to be met, meaning things easily can go very wrong. And at the time I suggested either black or white, I didn’t know how different it was to achieve each colour. For black, you can use standard concrete and add a colour powder to the mix. For a homogenous white concrete (and not end up with a pseudo-white speckled slab), you cannot simply dye the powder or paste. You must start with pure white materials, both the cement and the fine aggregate. In short, this would be an expensive mistake if it didn’t work, which is exactly what happened. My first mould was too thin as I tried to strike a balance between ‘thick enough for strength’ and ‘the cabinet won’t buckle under the weight’. Extracting the thin slab was easy. But not in a good way. Each corner I touched cracked off as if I were breaking a biscuit. I re-built the mould, doubled in depth, but now it was too heavy to carry even empty. Moreover, the cabinet would need further underpinning to support the greater weight, and now I must ask Roy for help. With his capable skills the second slab was a success and all we needed to do once extracted was place some boards underneath to create an uneven surface. Then jump!
I numbered the pieces to make reconstruction easier, then used adhesive to re-join them back together. Two applications of grout leaving enough of a groove for effect, and we were ready for the gold leafing.