Concrete Dining Table With Foam Core and Carbon Fiber Reinforcement

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Introduction: Concrete Dining Table With Foam Core and Carbon Fiber Reinforcement

About: If you build it he will come!

I do not really know why I came up with the idea of a concrete dining table but so it came.

First I looked if there was anything to buy, but what I found wasn't what I was looking for.

Either it was to thin and had a real fake surface feel or it was too heavy or not fitting into an interieur design.

Step 1: STEP1: Concept and Design

After that I summarized my requirements:

  • concrete surface feel
  • massive but "interieur" look
  • weight <250kg

Result:

  • Stainless steel table legs
  • 80mm thick plate with 40mm foam core
  • carbon fiber reinforcement instead of steel rebars
  • 220kg

Step 2: STEP 2: Foam Core and Carbon Fiber Reinforcement

I sawed the the 40mm foam plate into the designed shape and bolted screws on it.

Then I used 50k carbon fiber roving and started to wind this kind of framework structure.

Then I used epoxy to infiltrate the rovings and let it harden.

Step 3: STEP 3: Mold & Cast

The mold is very simple: Just a few wooden beams and panels.

The foam core with the carbon fiber reinforcements was connected upside down to the top of the mold.

I removed it from the mold about 4 weeks after casting.

Just used some very fine sand paper with water to smooth it.

Step 4: STEP 4: Welding Legs

I used 80x80x2 stainless steel tubes.

I cut them with a saw (today I would use lasercutting because it's so cheap and precise) and TIG-welded them.

Step 5: STEP 5: Carry It in the Living Room and Mount It

Well 220kg and is lighter than 450kg (which would have been the weight for a "classic" concrete steel design) bit it's still heavy. So it took 5 guys to move it from the garage into my living room and mount it on the legs.

But I'm really happy with the result.

This was my first instructable and I have to admit I rather banged it out. But done is better half-done and I'm going to improve it step by step. I'm looking forward to your suggestions and questions.

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    5 Comments

    0
    gabtrac
    gabtrac

    1 year ago

    Curious why you went with the much more expensive and complicated carbon fibre and not re-bar? Thanks!

    0
    gabtrac
    gabtrac

    Reply 1 year ago

    Cool, thanks.

    0
    Penolopy Bulnick
    Penolopy Bulnick

    1 year ago

    I like how the concrete tabletop looks with the metal base :)

    0
    RonaldM106
    RonaldM106

    Reply 1 year ago

    Thanks.