Recipie for self leveling concrete?

[tabletop]

Hello,
I would like to build a router table top out of self leveling concrete. Is it simply a matter of using plain ordinary cement and thinning it down the required consistency to pour? Also, to make a table say 4 foot square and 1.5 inches thick (I need it heavy) should I cast the main slab with rod mesh reinforcement and aggregate etc, let it set and then pour the ‘self leveling’ mix on top? Or can pour the mix that deep with only the mesh for reinforcement?
And yes, I know there may be better materials, Im looking into epoxy etc but concrete has other advantages for my application.


Thanks, Shae.

 

[MikeHalloran]

In my limited understanding, if you make concrete watery enough to be self- leveling, the resulting surface will be dust, not solid.

Assuming that you could make concrete self- leveling and strong, it would still be abrasive, which does not seem like an optimal surface for a router table.

How about a nice strong concrete slab, and 1/4" of self- leveling epoxy (it's sold for flooring) on top?



Mike Halloran
Pembroke Pines, FL, USA

 

[FoMoCoMoFo]

cast it on a very flat surface then turn over

 

[tabletop]

Mike,
yep thats pretty much what I had in mind untill I thought about self levelling concrete and hoped I could eliminate the epoxy. I think you're right about the dust factor too.

FoMoCoMoFo <-- Funny!
....nice simple solution, now why didnt I think of that.

Done a little more research and found self levelling concrete products from Ardex and Gypcrete ready to go. Unfortunately Im on the other side of the globe. Any idea if one can 'DIY' a mixture that?? Come in very handy.

 

[DRC1]

You can buy self leveling epoxy concretes by the bag (generally 1/2 ft to the bag) You can use non shrink grout(also available by the bag). You dont want it so wet itself levels, as the surface will be soft. If you keep it at a reasonable consistancy and sceed & finish the top, it should work. I would definately do a practice run. You can add hardners and seal the top for durability. They now make kitchen counter tops from cast in place concrete, and may be what you are looking for. If you talk to some cabinet supply places, they may be able to hook you up with an insatller. He can probably do it cheaper and faster.
Note on the self levelig epoxies - I have used those and they are tricky to get right and can be somewhat messy - not as easy to use as I thought.

Good Luck

 

[concretemasonry]

Cast it on a flat surface, use plenty of wire reinforcement with some additional very small reinforcement at the edges.

Cure well for handling strength. I assume you will have to move it and turn it over, so some temporary stiffening will be necessary since the slab will weigh over 300# (~ 150 kg).

When in place you can grind, polish and seal the surface as desired.

 

[FoMoCoMoFo]

Say...Sounds suspiciously similar to the solution some simpleton suggested in a prior post.

 

[concretemasonry]

There must be more than one "simpleton" that has seen the process used numerous times.

It is done internationally for many types of applications ranging from from kitchen countertops, chemical laboratories, testing laboratories to industrial applications.

Often the surfaces are ground, filled (for voids), reground, refilled (for pore voids) and then polished with several different grits.

If you want stability and accuracy levelers are not adequate. the 1.5" thickness makes it somewhat difficult.

 

[FoMoCoMoFo]

concretemasonry. i am well aware of all that. the simpleton i refer to is me,the post i refer to is above, read it and read the reply and hopefully you will see what i meant.

 

[MikeHalloran]

I asked my sister at the concrete plant for a recipe. Her QC guy said "Self Consolidating Concrete" is very popular right now, for greatly reducing labor costs. This might get you started:

http://selfconsolidatingconcrete.org/

Mike Halloran
Pembroke Pines, FL, USA

 

[concretemasonry]

Self consolidating concrete (SCC) and self consolidating grout (SCG) are two products aimed mainly at the placement issues of concrete and grout and not the final or sufacing of the materials.

A smaller area would still require final finishing to acheive the desired properties and tolerences.

Dick

 

[Zambo]

I just had an excellent idea - cast it on a very flat surface then turn over

 

[FoMoCoMoFo]

I like it.. and it might have gone over better earlier if i had spent some time answering the question instead of just telling him what to do. but i type slow. at this point i think others have done that. Sum. none of those products (if you had access to them) nor anything you mix up in the shop is going to work like that. the beauty of the cast it and flip it method (besides being simple)is that it's cheap (about $15 in material where i live) and the finished surface can be very hard and very flat. yes it's possible to cast in place and then machine micro flat, but not very practical. $15 wouldn't get you a glimpse at the tools required. Good luck.

 

[DTGT2002]

And if you are going to cast it flat and flip, be sure to vibrate it well. I'd suggest grabbing your electric sander with no paper and running all over the bottom of the form or using your recipricating saw with no blade in a similar manner.

Get help to flip it and you are done.

However, you will probably hate your first attempt.

For what you are doing, it won't be too expensive to do a trial and a final product.

Good luck.

I've known lots of folks who have made beautiful cast concrete counters and tables. The hardest part is getting the smooth finish by selecting an appropriate form material.

Daniel