– Melamine board for form making
– Dap/Silicone/crack sealer (www.dap.com/media/53609/kwikseal_ctg_tube_pairshotbig.jpg)
– 2 bags of concrete (www.homedepot.com/catalog/productImages/400/49/491b0835-cba0-4f1b-9bfa-f748464675cc_400.jpg)
– Poly fibres for concrete reinforcement- 1" thick rigid styrofoam insulation (s7d2.scene7.com/is/image/homedepotcanada/p_1000155124.jpg)
– Threaded pipe fittings, 3/4" and 1/2" (image.shutterstock.com/z/stock-photo-various-threaded-metal-pipe-fittings-used-in-the-trade-14567743.jpg)
– Threaded rod and nuts (www.thepipefittings.com/gifs/threaded-rods.jpg)
– Concrete sealer
– Sand paper
– Dust Masks
– Bucket for concrete mixing
The majority of the cost was in the threaded pipe fittings. They run close to $2 CAD each. We were fortunate enough to get a few things for free as well – Concrete sealer and poly fibres. Our total build cost was $160ish CAD but if we had to buy the sealer and fibres, we would have been about $200 CAD all in.
Gus had just been neutered when this picture was taken so he has his anti-ball-licking shirt/onesie on. It is almost more ridiculous than a cone.
You use melamine for it's smoothness. Any scratches, dents, blemishes on the form will show up on your finished concrete. If that's the look you're going for, good on ya. If you want smooth: go melamine.
After screwing the whole thing together, we sealed all the edges with Dap to ensure the corners would not leak.
If you look closely at the left "wall" of the form, you can see a pencil line. That line is at the 1/2" mark. In order to reduce the overall weight of the table, we decided to add rigid insulation to the core of the table. Remember how your parents used to have an empty jar or something similar in the toilet tank to take up space so you didn't use so much water? Well, this is the same idea. The insulation takes up the space that would normally be solid concrete, thus reducing the concrete volume used and reducing the overall weight.
Our total table thickness is 2":
1" rigid insulation core
The insulation is cut back about 2" from the long edges and 5-6" from the short edges. This gives us solidity around the whole table and a place to attach our legs directly into concrete and not into the insulation.
If you look closely, you can see the threaded rod and nuts sticking out of the flanges on the left side. These will embed directly into the concrete. More on that later.