Create your own concrete beam

[SilverShadow]

Hey all,

 

Bit of a random one, but hopefully one or more of your guys might be in the know 😁

 

I'm looking to fill a small gap under a upvc door frame (between the concrete floor and base of the frame). I was struggling to find something suitable of the right dimensions. A mate of mine suggested doing a 'concrete-pour' & making my own beam. After i'd stopped chuckling & picked myself off the floor, i realised he was serious, and so wondered what you guys thought to his plan. Don't have exact measurements to hand, but lets assume about 850mm long x 75mm wide x 50mm depth

 

• Has anyone made their own beam before? I was thinking of creating a wooden-frame cast & lining it
• If lining the frame what would be the best option, so it doesn't stick (my friend suggestion oiling the wood)?
• What mix of sand/cement/aggregate would you guys suggest? It's not taking any real structural load, just needs to be reasonably weatherpoof (with some water seal applied afterwards)
• Would you use any rebar? I wasn't sure whether to add 1 or 2 6mm bars - more for helping with it's longevity, than for support

 

Many thanks for your time, all - be great to hear how you'd approach this undertaking

 

BR

Shadow

 

 

[JohnMo]

Can you not just do it with block work, way easier if frame already there.

[joe90]

A beam suggests spanning a gap (lintel etc) but if this is just to fill a gap then why not do as @JohnMo says above, cut some block 40mm thick and bed on mortar 🤷‍♂️

[ProDave]

Or if you create shuttering and pour concrete, is is not really a "beam" as it will be fully supported on what is there already and will just fill the gap you want exactly.

[SilverShadow]

Thanks guys

 

I was considering cutting blocks via angle grinder to this, but was intrigued by my mates idea. I'll have a look to see what blocks /slips there are around 40mm thick - but the only concrete ones i've seen were too wide

 

As i need it around 70mm width, then i could chop the concrete every 70mm to make smaller blocks and lay those. Way more preferable than trying to cut 70mm along the whole length 👍

 

On saying that, i've seen some recycled plastic edging that might do also do the trick, if i can find the right size

 

 

Edited Sunday at 17:50 by SilverShadow

[joe90]

Is the door frame already in place? Are you not creating a trip hazard having the door that high? (Pet hate of mine is high door threshold).

[Mr Punter]

What about a piece of timber?  4 x 2?

[Iceverge]

Pics would help. 

 

For something like that 3:2:1 chips,sand, cement would be fine. 

 

It's so little you could mix it with a bucket and trowel. 

 

Jam a board against the edge and spoon the mix in. Give it a few kicks to knock the air bubbles out (or use a blunt bit and the hammer function on an SDS to vibrate the board). 

 

S

 

[SilverShadow]

1 hour ago, joe90 said:

Is the door frame already in place? Are you not creating a trip hazard having the door that high? (Pet hate of mine is high door threshold).

 

 

Hey Joe - i need to raise the existing door frame about 40 or 50mm (so the door is high enough to open while allowing for floor insulation/boards for an outbuilding). So essentially i need something to fill the void it leaves. There'll be no load on this (other than door, which the frame will be screwed into the wall anyway)

 

It'll be a trip hazard, but that's inevitable i'm afraid. All i'm after is something the width of the frame, about 40mm thick and say 70-80mm wide to fill the void

[saveasteading]

4 hours ago, SilverShadow said:

850mm long x 75mm wide x 50mm depth

That's a lintel. Ready-made at b and q ir any builders merchant.

But home made will fit perfectly and be satisfying. If you keep the concrete on the dry side, it can be forced up under an existing frame.

Don't use oil. Either remove your timber formers after a couple of hours, or put a polythene face on it.

[SilverShadow]

38 minutes ago, Mr Punter said:

What about a piece of timber?  4 x 2?

 

 

I did consider timber, but around the doorway is bound to be damp for large periods of time (as it's exposed to the elements) - so i really want something weatherproof that won't rot. It really needs minimal to no water absorption, so it doesn't invade into the flooring of the outbuilding

[joe90]

5 minutes ago, SilverShadow said:

allowing for floor insulation/boards for an outbuilding)

Ah, fair enough.

[SilverShadow]

38 minutes ago, Iceverge said:

Pics would help. 

 

For something like that 3:2:1 chips,sand, cement would be fine. 

 

It's so little you could mix it with a bucket and trowel. 

 

Jam a board against the edge and spoon the mix in. Give it a few kicks to knock the air bubbles out (or use a blunt bit and the hammer function on an SDS to vibrate the board). 

 

S

 

 

Many thanks 😁

 

Alas i don't have any pics to hand, but i'll try and get some soon

 

It's basically a Upvc door to an outbuilding, about 10-15mm above concrete slabs outside & a solid concrete floor inside the outbuilding. The only way to fit floor insulation/board inside the outbuilding is to lift the door frame 40-50mm & fit something weather proof between the frame and concrete floor

[SilverShadow]

8 minutes ago, saveasteading said:

That's a lintel. Ready-made at b and q ir any builders merchant.

But home made will fit perfectly and be satisfying. If you keep the concrete on the dry side, it can be forced up under an existing frame.

Don't use oil. Either remove your timber formers after a couple of hours, or put a polythene face on it.

 

 

Thanks, man

 

I did look around, but all the prefab concrete products i could see were either too thick, too wide, or i needed to bulk buy. If i can find something 40mm x 40mm up to 1m long from a national retailer (eg: Travis Perkins) then that would be easiest.

 

If not then i'm happy to try casting one as a project/experiment - the idea is to pour into a wooden cast it & let it solidify, take the doorframe out & lay it in place, then put the frame back (rather than try to slide into place or make it in-situ). Sounds like good advice for how to make it 👍

[ProDave]

23 minutes ago, SilverShadow said:

If not then i'm happy to try casting one as a project/experiment - the idea is to pour into a wooden cast it & let it solidify, take the doorframe out & lay it in place, then put the frame back (rather than try to slide into place or make it in-situ). Sounds like good advice for how to make it 👍

I would not.

 

I would take the door frame out.  Build shuttering either side and pour the concrete IN PLACE.  When dry, put door frame back.

[JohnMo]

20 hours ago, Iceverge said:

For something like that 3:2:1 chips,sand, cement would be fine. 

 

It's so little you could mix it with a bucket and trowel.

20 minutes later you are finished.

 

If your not sure what to buy or mix go to B&Q, to the bit with the sand and cement, and there will be ready mixed stuff you just add water. Mix stiff and trowel in place. Done.

 

Procrastination gets you nowhere.

[Iceverge]

5 hours ago, JohnMo said:

Procrastination gets you nowhere

 

I'd argue that point. 

 

Very occasionally, if I procrastinate long  enough about something, my wife does it for me....