This Instructable documents the construction of my new Modern desk with a polished concrete desktop!
Step 1: Plans!
Plan and layout the desk. Take measurements of the location you plan to place it. Nothing is worse than building something you wont be able to use. Make sure the concrete is broken up into manageable pieces both to prevent fractures, and to make sure that it is humanly possible to carry it to its final location! Also consider styling and other design elements. I decided to build a relatively minimal and modern corner desk.
Step 2: Buy Materials and Tools
about 30-35 board-feet of Lyptus wood,
a sheet of lyptus plywood,
some birch plywood,
2 sheets of 3/4" melamine,
2 94lb bags Portland cement,
6 50lb bags washed plaster sand,
acrylic concrete fortifier,
tube of silicone caulking,
Fiber optic cables,
other decorative elements.
air powered or waterproof angle grinder,
polishing pad set (from Ebay),
concrete working tools,
Step 3: Build the wood desk frame
I am not going to describe in depth this part, partly because I did not take enough pictures and partly because my dad mostly did this part. My desk is constructed of lyptus, which i found out is a genetically modified combination of Eucalyptus and Mahogany. It has two shelf/drawer cabinets ant the ends supporting a center frame with a pencil drawer. The main structural parts of the desk are double thicknesses of solid wood. The cabinets are made of panels holding a piece of plywood to cut down on the amount of solid wood necessary for this project.
Step 4: Construct Concrete Form
for the concrete portion of this project I followed doubleabattery's excellent concrete counter top Instructable here:http://www.instructables.com/id/Concrete-Countertops-for-the-Kitchen---Solid-Surfa/
The form was constructed out of 3/4" melamine sheet, with sides 2" high to ensure the concrete is strong enough. measure your desk frame and make the mold accordingly. make sure to test fit your desk before casting the concrete! It is easier to make changes now than later when it is literally set in stone. Use silicone in the corners to radius the edge of the concrete when it comes out of the mold.