Fabric Formed Concrete Fire Table


A face coat of D-FRC Casting Blend is sprayed into the form, and then a backer mix is laid up by hand, at 1-1/2″ thick, to create a strong yet relatively lightweight fire table.

Step 1 – Mixing D-FRC Casting Blend

Mixing CHENG's D-FRC Mix | CHENG Concrete Exchange

Step 2 – Spraying

  • For full instructions on spraying, check out the Spraying GFRC Guide.
  • Begin spraying the face coat in the edges.
  • Be sure to blow out any loose material before spraying over it. This can trap unmixed sand and will result in a poor finish. Practice spraying before attempting a large project like this.
  • Continue spraying the base and then the walls, working in a circular motion, until a uniform layer about 1/8″ thick covers the inside of the form.
  • Take care spraying the vertical surfaces, especially on a tall form like this. Spraying the concrete on too thick will cause it to sag, which will be visible in the finished piece.

Step 3 – Cutting the Casting Blend with Basalt Fiber to Create the Structural Backer

  • Basalt Fiber can be added to the remaining Casting Blend to create fibrous mix that will be laid up over the face coat.

Step 4 – Backing

  • After the face coat has dried slightly, the structural backer can be applied.
  • Pack the backer mix into the form by hand. Build up the thickness of the walls to 1″.
  • Smooth the backer mix over the edges of the form walls to get it to hang.
  • Be careful not to press the backer through the face coat, and work gradually on the vertical surfaces to limit slumping.
  • Do not spray or cover the 1″ thick disc knockout. Build up a uniform thickness around the knockout, and smooth the top so the edge of the knockout is still visible.
  • Let the vacuum run for a few hours until the concrete has cured enough that it doesn’t change shape when the vacuum is turned off.
Previous: Vacuum HookupFabric Formed Concrete Fire Table - Vacuum Hookup | CHENG Concrete Exchange

A shop vac is attached to the form base during casting to provide suction that pulls the vinyl fabric into graceful curves around the rigid foam risers.

Next: DemoldingFabric Formed Concrete Fire Table - Demolding | CHENG Concrete Exchange

After the piece has cured for 12-24 hours, it can be removed from the formwork. Before demolding, the project is ground flat on the bottom edge.