HomeMade Modern EP103 CNC Concrete Walkway (original) (raw)

This episode shows how I made a concrete pavers for a walkway out of Quikrete 5000. I used my X-Carve CNC machine from Inventables to make reusable forms out of plywood. I created a modular design based off of the Quikrete Walkmaker system. This project takes about 5 hours and costs around $30.

SUPPLIES:

¾” Melamine
Available at Home Depot
I used a scrap piece of ¾” melamine to use for the bottom of the molds.

¾” Plywood
Available at Home Depot
I made the forms out of ¾” furniture grade plywood.

Quikrete 5000
Available at Home Depot
I used Quikrete 5000 to cast this fire pit.

Silicone Caulk
Available at Home Depot
I used silicone caulk to seal the molds.

Fire Bricks
Available at Masonry Supply Store
I used fire bricks from a local masonry supply yard. They aren't the prettiest looking, but after a few fires they will turn black from the soot. Firebricks are heat-resistant and will protect the concrete from cracking.

Quikrete ¾" Gravel
Available at Home Depot
I used about 4 bags of Quikrete 3/4" gravel for the foundation layer.

Miniwax Polyurethane
Available at Home Depot
I sealed the forms with minwax polyurethane.

TOOLS:

Inventables X-Carve (Small)
Available at Inventables

RYOBI Orbital Sander
Available at Home Depot

INSTRUCTIONS:

STEP 1: Design
I used FormZ 3D modeling software to model the firebricks. I don’t recommend this software and am now switching to Fusion by Autodesk. I then arranged the firebricks into an octagon. I designed eight modular blocks to go around the firebricks. At first I designed the blocks with simple symmetrical points but then changed them to an asymmetrical design. I then designed the profile of a mold for the blocks and exported the outline of the pieces to easel software to get ready for CNCing. I made some of the pieces have tabs that would let me clamp the molds down to a base piece of melamine.

STEP 2: Cut the Pieces
I used my X-carve CNC machine by Inventables to cut out the pieces for the mold out of ¾” furniture grade plywood that I bought from Home Depot. The CNC machine leaves small tabs between the pieces so that the pieces don’t move when being cut. I used a handsaw to cut these small tabs and then used sand paper to smooth down the cut edges.

STEP 3: Glue the Pieces Together
I used wood glue to glue the pieces of plywood together and clamped them in place while the glue cured. I started with just a few pieces at a time and then glued those pieces together. This way it is easier to keep the pieces aligned.

STEP 4: Sand and Seal the Mold
I used wood glue to glue the pieces of plywood together and clamped them in place while the glue cured. I started with just two pieces at a time and then glued the 3rd after the first two dried. This way it is easier to keep the pieces aligned.

STEP 5: Mix and Pour the Concrete
I placed the mold in the desired location and then mixed the Quikrete 5000 in a mixing tray. I then shoveled the wet concrete into the mold and pushed it down into all the corners. I used a scrap piece of 2x4 to screed the top of the form. I wiggled the form and slowly pulled it away from the wet concrete. Properly mixed concrete will hold its form even when wet. I then placed the form and got ready to mix more concrete and make the next set of pavers.

STEP 6: Smooth and Cure
I used a trowel to smooth down the edges of the pavers. I made sure to keep the pavers moist by spraying them with a mister while the concrete cured.

STEP 7: Stain
Once the concrete had fully cured I stained the pavers with Quikrete Penetrating Concrete Stain.

The original Quikrete Walkmaker system that inspired this project can be seen here.

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