How Little London Studio Creates High-Performance Glass Fibre Reinforced Concrete Tables

At Little London Studio, we blend traditional concrete craftsmanship with cutting-edge technological advancements to create high-performance glass fibre reinforced concrete (GFRC) tables. By using RADMIX from Kodiak Pro, we produce tables that are not only durable but also feature a stunning polished concrete finish. This unique process marries time-honoured materials with innovative techniques, ensuring each piece is both functional and beautiful. Here’s a step-by-step breakdown of how we craft our signature tables.

What Makes Our GFRC Tables Special?

We begin with RADMIX, a specialised mix that incorporates glass fibres for reinforcement, blending seamlessly with traditional concrete. To improve strength and workability, we add plasticiser, which reduces water content and increases the mix’s density and durability. After pouring, we float basalt bars into the surface to provide additional structural reinforcement. This careful selection of materials ensures that each table is not only visually striking but also incredibly durable, lightweight, and long-lasting.

The Process: How We Make Our High-Performance GFRC Tables

Creating our GFRC tables involves a precise, multi-step process that combines craftsmanship with modern technology. Here’s how we do it:

1. Mixing RADMIX – The Ideal Concrete Formula

We begin by mixing RADMIX from Kodiak Pro with plasticiser to reduce the water-to-cement ratio, which results in a stronger, denser, and more durable concrete mix. To control the temperature of the mix and ensure a stable reaction, we add ice. Once the mix is ready, we pour it into custom moulds, where it naturally self-levels due to its self-compacting properties. After levelling, we float basalt bars into the surface, reinforcing the concrete’s tensile strength without compromising its lightweight nature.

2. Curing the Concrete to Build Strength

After pouring, we cover the concrete with felt, plastic, and heated blankets to ensure consistent temperature control. Over 24 to 48 hours, the concrete cures and hardens. During this time, the glass fibres, plasticiser, and basalt bars work together to create a strong, flexible structure. This curing period is essential for the concrete to achieve maximum strength before moving on to the next phase. The temperature of the concrete can be extremely high during this initial reaction, which is why proper curing is critical.

3. Polishing the Concrete Surface

Once the concrete has cured, we begin the polishing process. First, we smooth the back of the table to ensure all surfaces are even and touch-friendly. Using our specialised planetary wet polisher with diamond grinding tools, we gradually smooth the surface to reveal the natural textures and color variations of the concrete. This step creates the signature polished concrete finish - refined, glossy, and modern - while preserving the organic beauty of the material.

4. Acid Washing for Scratch Resistance

After polishing, we apply an acid wash to the surface. The mild acid reacts with the concrete, dissolving a thin layer of cement. This process refines the finish and increases the concrete's scratch resistance, making the table more durable and able to withstand daily use. The acid wash also helps prepare the surface, ensuring that the polyurethane sealer adheres properly.

5. Waiting for the Concrete to Harden and Lose Water Before Sealing

After the acid wash, we wait for up to a week for the concrete to fully harden and allow any residual moisture to evaporate. This is a crucial step - applying the polyurethane sealer before the concrete has had time to lose its water can trap moisture inside. If this happens, it could lead to issues with the concrete’s curing process, such as bubbling or discolouration. By waiting for the water to evaporate, we ensure the sealer does not interfere with the concrete's natural ability to breathe, guaranteeing a long-lasting, durable finish.

6. Sealing with Polyurethane for Protection

After the concrete has sufficiently hardened and the moisture has evaporated, we apply a polyurethane sealer to protect the table and enhance its durability. This protective coating acts as a barrier against stains, moisture, and UV damage. It also enhances the depth and gloss of the polished concrete, ensuring that the table maintains its vibrant, sleek appearance while being low-maintenance and easy to clean.

Why Sealing with Polyurethane Is Essential

The application of a polyurethane sealer is crucial for ensuring long-term protection and performance of our GFRC tables. Here's why it's essential:

Enhanced Durability: The sealer protects the concrete from scratches, stains, and general wear, especially in high-traffic or outdoor environments.

Water and Stain Resistance: Concrete is naturally porous, but the sealer prevents liquids and stains from penetrating the surface, making cleaning quick and easy.

UV Protection: Unsealed concrete can fade or discolour over time due to UV exposure. The polyurethane sealer helps protect the table from harmful UV rays, maintaining its appearance over time.

Glossy Finish: The sealer not only offers protection but also enhances the polished concrete finish, giving it a sleek, glossy shine that highlights the material’s natural beauty.

Why Choose Our High-Performance GFRC Tables?

Our GFRC tables strike the perfect balance between durability, style, and functionality. Here’s why they’re an excellent investment:

1. Strength and Durability: The combination of glass fibres, plasticiser, and basalt bars creates tables that are incredibly strong and resistant to cracking, chipping, and general wear, even in demanding environments.

2. Lightweight Yet Strong: Thanks to the GFRC mix, our tables are lighter than traditional concrete but retain superior strength and flexibility. On average, our tables weigh around 70kg per meter, making them practical for both indoor and outdoor spaces.

3. Sleek, Modern Aesthetic: The polished concrete finish provides a high-end, contemporary look that fits seamlessly into a variety of design styles, from minimalist to industrial.

4. Low Maintenance: The polyurethane sealer and acid washing protect the table from stains, scratches, and UV damage, ensuring that minimal upkeep is required to keep them looking pristine.

5. Cost-Effective Investment: The long lifespan and low maintenance requirements of our GFRC tables make them a cost-effective investment. You won’t need to replace or repair them frequently, offering excellent value over time.

Conclusion

At Little London Studio, we combine traditional concrete techniques with modern innovations to create high-performance glass fibre reinforced concrete tables. By using RADMIX from Kodiak Pro, along with plasticiser and basalt bars, we craft tables that are stronger, lighter, and more durable than traditional concrete. Our polished concrete tables are finished with acid washing for added scratch resistance and sealed with polyurethane to ensure long-lasting beauty and performance.

Invest in a high-performance polished concrete table from Little London Studio, and enjoy a stunning, low-maintenance piece of furniture that will stand the test of time.