How to cast a concrete patio chair


By Danny Lipford
Nothing makes a home’s outdoor space feel comfortable and inviting like furniture does. But Mother Nature is pretty unpredictable! Sunny days can turn into rainy nights. The same clear skies last week can produce hail and snow this week. So durable outdoor furniture that can face the elements and stand the test of time is a must. And that furniture doesn’t have to cost an arm and a leg!
Our friends at Quikrete share a great DIY project to prove the point. It involves casting a concrete mold from a cheap plastic chair. The results will last for generations!
Want to make your own concrete chair on a budget? First, here’s what you’ll need for this project:
Shopping list
• Quikrete Concrete Mix
• Quikrete Liquid Cement Color (optional)
• Plastic Chair
• Duct Tape
• Magazines (if needed)
• Glue sticks
• Glue Gun
• Blocks of wood
• Wooden Dowel
• Anchor Bolts
• Water Bottles
• Scissors
• Wrenches
• Screwdrivers
• Circular Saw (optional)
• Angle Grinder with a flat disc
• Waterproof Gloves
• Safety Glasses

Now, on to the step-by-step guide!

  1. Seal holes in the plastic chair frame, using old magazines, duct tape and hot glue. Tape larger openings or gaps using duct tape.
  2. Flip the chair upside down and use blocks of wood to make sure it is level.
  3. Mix the concrete mix, according to the bag’s instructions, and fill the seat and back of the mold. Use a wooden dowel to make sure the concrete mix fills to each of the corners, and vibrate the chair, to release any air bubbles. Adding Quikrete Liquid Cement Color to the mixing water, before mixing the concrete mix, is an easy way to add a more decorative touch and guarantees consistent color, throughout the mix.
  4. Place anchor bolts where each of the four chair legs will be, for reinforcement.
  5. Cut up four water bottles to serve as containing molds for the legs of the chair, and duct tape them to the chair.
  6. Cut up four water bottles to serve as containing molds for the legs of the chair, and duct tape them to the chair.
  7. Let the concrete cure for at least 48 hours, before removing the mold.
  8. Once dry, pry off the mold using a screwdriver. To fully remove the mold, you may need to use a circular saw to cut it away. If this is the case, set the blade to 1/8 of an inch deep. Use wrenches as spacers to avoid nicking the newly cast concrete surface. If you do not damage the mold in the removal process, you can reuse it to make another cast concrete chair.
  9. Use an angle grinder to smooth any rougher edges.
    Watch the video for details.
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