12 Foot Conference Room Table – Concrete Conference Room Table

The “Big Idea” -

Just when we thought that we were already making large scale concrete tables and islands, the past monsters were dwarfed by this incredible 12′ x 5′ concrete conference room table.  A marketing company located in Westchester county, NY, asked Trueform Concrete to create this 60 sqft table top for their main conference room. The existing table that they had made them feel crammed and unorganized with wires everywhere.  It’s not every day clients come to us with projects of this scale so the challenges that this table posed pushed our team to tweak process and stretch our abilities.

Building the concrete mold -

One of our initial challenges was actually finding the correct surface to cast this project on.  Keep in mind that concrete is cast on water resistant surfaces, and finding a surface in one piece that is 60 sqft is a challenge in itself.  Once we secured our casting surface it became clear that we needed to create a cart that would support and allow us to cast this table top flat and level.  We were able to manipulate an existing 10′ x 4′ casting cart to handle this project by adding some steel runners and supports.  Precast concrete is typically cast upside-down in the mold and flipped over the following day to expose the finished surface.  As we thought this project out, the third challenge surfaced about how to flip this large concrete table top safely for the piece and for the staff.  We decided to place two casting sheets on top of each other and then separate them with wood strips every 10″ the whole length on the mold.  The idea was to elevate our casting surface and allow us to place our nylon slings under the concrete table top before we started casting.  Because of the high and early strengths of our concrete mixes, we can typically de-mold and flip pieces the morning after we pour.  With a project of this scale it was better to have everything setup before hand and reduce the risk of stressing the table while flipping it over.

Casting the concrete table –

This project required about 800 lbs of raw casting material so all the separate mixes were prepared before we began.  Because of the large size of this concrete table, we created a pulley system with a bungee cord support for our GFRC spray equipment.  The pulley was constructed to handle the weight of the concrete in the GFRC gun.  It also allowed us to spray this table with two men, one on each long side of the mold.  The spraying portion of this project took about a solid 40 minutes of continuous spraying.  Several layers of fiber mesh were placed into this table to create support and strength.  The casting process continued for about another 2 hours leaving us with a monster to face the next day.

Flipping the table –

Before flipping the table over, it was ground and sanded smooth on all of the undersides because people’s knees, hands, and legs, would interact with the bottom of this table on a regular basis.  Once the table was clean and smooth, we used a chain fall hoist and strapped it into the pre-placed slings.  We were able to flip this table right over and back onto the cart it was cast on.  The table sat on that cart for another two weeks and went though our standard process to receive the desired finish and look the client had requested.

Delivery and Installation –

The conference room table was much too large to fit in our truck, so we got a 16’ trailer and mounted our A-frame on it.  With all of the pieces loaded, strapped, and in place, we were off to our destination.  The table was transferred to a sheetrock A-frame and rolled into the conference room to be set on its base.  It was a 4 man operation getting this table top to set onto the steel base.

The project also included a countertops along built-in cabinets and a floating side table with a waterfall leg.  The tables and the countertops all had  our signature finish and a thickness of 2.5”.

concrete conference table - Trueform Concrete

concrete conference table - Trueform Concrete

Loading the A-frame – Trueform Concrete

concrete conference table - Trueform Concrete
Concrete conference table – Trueform Concrete
Concrete conference table - Trueform Concrete

Concrete conference table – Trueform Concrete

Concrete conference table - Trueform Concrete

Concrete conference table – Trueform Concrete

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