Bespoke Concrete Products

The process of creating a piece of concrete furniture from Ultra High Performance Concrete involves several stages, each crucial to achieving a high-quality, durable, and aesthetically pleasing end product. From the initial drawing and design stage to the final sealing of the cured piece, meticulous attention to detail and craftsmanship are essential to ensure the successful production of UHPC furniture.

Drawing and design stage:

The first step in creating a piece of concrete furniture is the drawing and design stage. Here, we collaborate to develop detailed drawings and specifications, taking into account the intended functionality, aesthetic appeal, and structural requirements of the piece.

Mould making:

Once the design is finalised, the next step is the creation of moulds that will define the shape and form of the UHPC furniture piece. Moulds can be made from a variety of materials, such as wood, silicone, urethane, or other flexible materials, to accurately capture the intricate details and contours of the design. Careful attention is given to the mould-making process to ensure that it translates the design specifications into a precise and functional mould for casting the concrete. This is by far the most time consuming part of the process. 

Casting:

The casting stage involves the careful preparation and pouring of the UHPC mixture into the moulds. UHPC is a composite material consisting of cement, fine aggregates and glass fibres. During casting, the UHPC mixture is  poured or sprayed into the moulds ensuring uniform distribution. This process requires precision and expertise to achieve the desired density, surface finish, and structural integrity of the final piece.

Curing:

After casting, the concrete piece undergoes a curing process to allow the material to develop its full strength and durability. Curing will involve a combination of hydration, controlled temperature, and humidity to promote the proper chemical reactions within the UHPC mixture, ensuring comprehensive curing and strengthening of the material.

Finishing and sealing:

Once cured, the concrete piece undergoes meticulous finishing processes to achieve the desired texture, colour, and surface appearance. This may involve techniques such as sanding, polishing, or applying surface treatments to enhance the aesthetics and tactile qualities of the furniture. Additionally, the piece is sealed with a protective coating to safeguard it against environmental elements, stains, and wear, further enhancing its longevity and performance.

Throughout the entire process, Andy’s expertise and our skilled craftsmen play a critical role in overseeing and executing each stage with precision and expertise, ensuring that the final product meets the highest standards of quality and craftsmanship. From the initial design and mould-making to casting, curing, and sealing, the production of UHPC polished concrete furniture demands a meticulous and collaborative approach, resulting in bespoke, durable, and visually striking pieces that embody the unique properties and versatility of concrete as a material for furniture design and fabrication.