Instructables
Picture of Bent Concrete Side Table from a Rubber Mold.
This Instructable will demonstrate how to make a rubber mold for casting a bent concrete table. It will cover making a cardboard mockup, producing the positive, casting a rubber mold, and finally casting the finished concrete piece using a fiber-reinforced mix and bending it to shape.

This project was completed during the 3 day Advanced Fiber Reinforced Concrete Training at CHENG Concrete in Berkeley, California with guest instructor Chris Franzen from Surecrete. The unique characteristics of a fiber-reinforced concrete mix make it possible to cast a flat piece, wait until it enters a "false-set," and then bend the piece. For this we need a flexible mold, and in this Instructable we'll outline the steps needed to create a polyurethane rubber mold that will work for this technique.

Even if you aren't using a fiber-reinforced concrete system and bending concrete, the rubber mold-making steps are general enough to apply to any casting project.

Be sure to enter the Concrete & Casting Contest for a chance to win some nice prizes!
 
General Materials and Supplies:
 
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In addition to having a good idea for an item to make, you do a wonderful job documenting and explaining the process. The instruction to make a mold would be good to have as a separate Instructable.

It also makes we want to get some of your blue pigment.

andrea biffi2 months ago

wow! I have to make it!

Stone_UFO6 months ago

that's awesome

trippy

So cool...
wow...
wow...
splatman1 year ago
The nice part about the rubber mold, is you can bend it, say, to a lesser degree, so the piece would be shorter and wider, or to a higher degree, to make a taller, skinnier piece. Or have the legs slope out, like in Cheng's example below, or make the legs wavy. Making the top concave is another possibility. A concave top can be used to hold a round object.
j_mark21 year ago
Oчень красивое изделие, но трудоемкое в изготовлении. ))) А почему бы не сделать 3 ножки ?
CHENG Concrete (author)  j_mark21 year ago
3 legs would be more stable, but 4 legs are stronger for the first test piece. At the same time we also cast a low table with 3 legs. Cпасибо за комментарий!
green_table_mold1.jpg
hay_jumper1 year ago
Anyone wondering how to write an Instructable should read this; Well documented, well written, and smart. Thumbs up all around.
Totally agree with that. I'd still say it's some magic I just saw here. :)
mkadri1 year ago
Lots of time and if u drop it will break not cheap
CHENG Concrete (author)  mkadri1 year ago
The concrete material used for this retailed for about $58 USD. The most expensive component of this instructable was the casting rubber which is roughly $8 USD per pound, but the rubber mold can be used to make hundreds of copies.
artworker1 year ago
freaking genius!
Ninzerbean1 year ago
Amazing! What ever gave you the idea to bend concrete?
nicko01 year ago
what type of fibers are in this gfrc
CHENG Concrete (author)  nicko01 year ago
The mix contains Glass AR, PVA and Nano fibers. Heavier fibers can be added to the mix, providing extra strength for using it as a structural backer.
james.m.k1 year ago
Wow! I was concerned that concrete would snap easily, making it a hazard to children and elderly, (and goofing adults) but I guess you answered that with the reinforced concrete. I find the bending of the concrete especially awesome! Blew my mind!

My only other thought is that it's heavy for indoor use, but maybe you could add crumbled foam bits to lower the weight.

It should be very nice for outdoor furniture. Though if you don't have other nice outdoor furniture to go with it, it will look out of place. Goodness knows it probably will never need to support 400 lbs!

Should make a handsome pot holder!
Oops, I meant to put the "Goodness knows it probably will never need to support 400 lbs!", after I suggested adding foam crumbles to the mix. :-))
Cool project, thanks for sharing it!
jwmock1 year ago
great job, great pictures and explanation!
simply awesome
linda601 year ago
how much all this will cost ??
studleylee1 year ago
Wild and very cool. thanks!!!!
jbarziza1 year ago
Thank you for posting this. I'd never heard of Glass Fiber Reinforced Concrete before. Many new things to look at. This was very, very interesting.
CandyLV1 year ago
I really dig the fluid pieces made from material known more for its immobility!
jon3laze1 year ago
Great instructable,what is the weight of the finished table?
CHENG Concrete (author)  jon3laze1 year ago
Thanks, the finished weight is right around 35 lbs.
phoe1 year ago
Nice instructable ! - I didn't know products like this existed, but they probably cost a fortune in the UK (if available at all)
mbonet1 year ago
Great project . How about plans to make a small wall mount Urinal out of concrete ?
ac-dc mbonet1 year ago
Wrong material, porcelain that's glazed won't absorb moisture and will be easier to clean.
zap19981 year ago
Amazing.
Horef1 year ago
holy gremlin snaps batman! this is awesome!
marc.cryan1 year ago
insane!
vdvoort1 year ago
Wow... I.. just.. its beautiful!!! love it! great instructable, hope I find the time and money to try this in the future.
Gregbot1 year ago
sweet!