Introduction: Concrete Dining Table With Foam Core and Carbon Fiber Reinforcement
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
- Stainless steel table legs
- 80mm thick plate with 40mm foam core
- carbon fiber reinforcement instead of steel rebars
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.
Participated in the
Stone, Concrete, Cement Challenge