How To Form Small Concrete Projects The Easy Way

When you’re making small scale architectural elements out of concrete, you could use a stick to make sure that the concrete is compacted into all of the voids, but there’s a better way.

We’re making some pilasters for a concrete fireplace surround, but the same technique should apply to any small masonry project.

Here's how to do it:

• Build a mold out of plywood assembled with drywall screws
• For more detail, use pieces of trim or other found objects in the mold. We used cove moldings at the bottom to give a rounded reveal along the edge of our pilaster
• Cover the inside of the mold with blue masking tape. This acts as a form release agent so your cured concrete should fall right out
• When half the concrete is in your mold, run the shoe of your sawzall (without a blade installed) along the sides of the form. The vibrations will settle the concrete and get rid of the voids
• Top the mold off with concrete, and wait for your project to cure before removing it
  

I heard about using a sawzall for this purpose on a jobsite one time; no one has ever sent it in.  It’s just a tip I’ve been using over the years and it really works well.  Thanks whoever.