How to Build a Glass Bottle & Concrete Wall

Form a base for the glass bottle and concrete wall. Lay out two-by-fours in the shape of the base of the wall. Secure the ends of the form boards with nails to ensure that they don’t move when you fill them with concrete. With a paintbrush, coat the inside of the boards with a concrete release agent to make it easier when it’s time to remove the form boards.

Mix a batch of concrete by pouring the concrete powder mix into a 5-gallon bucket, and slowly adding water, stirring the mixture until it reaches a workable consistency. The concrete mixture should be relatively thick, holding its shape when you form a ball with your gloved hands. This consistency will allow it to remain in place without adding additional form boards when you begin laying the bottles.

Press the concrete mixture down into the form boards, pressing it down with a steel trowel to eliminate gaps and air bubbles. When the form boards are full, drag a short piece of two-by-four across the top of the form boards. This helps move excess concrete from the high spots into the low spots and provides a level base for your bottles.

Lay a series of bottles across the concrete base, pressing them gently into the concrete to secure their places. Leave 1 to 2 inches in between the bottles for the best results. Using the steel trowel, press the concrete mixture firmly into the gaps between the bottles. When the spaces are filled, place a solid 1-inch layer of concrete over the top of the bottles, pressing it down with the trowel to remove air bubbles. Remember, the concrete should be relatively firm so it can remain in place without assistance. If the concrete is too thin, add more concrete powder to thicken it.

Check the wall to ensure that it is plumb. To do this, hold a level up against the wall immediately after applying the concrete around the bottles. If the wall is slightly out of alignment, place a piece of plywood against the wall and tap it gently with a hammer, checking the alignment periodically with the level. Check and adjust the alignment after laying each row of bottles.

Position a second layer of bottles on the solid layer of concrete. Repeat the process of filling in the spaces and adding a solid of concrete over the bottles to firmly encase them. Allow the two rows of bottles, covered with a solid layer of concrete, to dry for two to three hours. This drying time allows the concrete to harden so it will not buckle under the weight of subsequent bottles and concrete.

Continue laying the bottles out and covering them with concrete in this manner. After every two rows of bottles, allow the concrete to harden for two to three hours. When the wall reaches the desired height, apply a final layer of concrete at least 1 inch thick. However, this layer may be thicker if you desire.