Nothing makes a home’s outdoor space feel as comfortable and inviting as furniture. However, you don’t want to spend money on nice outdoor furniture just for Mother Nature to ruin it.

    Therefore, durable outdoor furniture that can face the elements and stand the test of time is a must. That furniture doesn’t have to cost an arm and a leg.

    Our friends at Quikrete have a great DIY project to prove it — casting a concrete mold from a cheap plastic chair. The results will last for generations.

    If you want to begin a concrete project, like making your own concrete chair, here’s what you will need:


    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

    This shopping list contains all the necessary materials and tools that I find useful for casting a concrete patio chair. Having these items on hand before starting will make the project go smoothly. Some key items to note are:

    • Quikrete products to create the concrete mixture
    • A plastic lawn chair to use as the mold
    • Tools for cutting, drilling, and shaping the concrete like wrenches, screwdrivers, saws, and an angle grinder
    • Safety equipment like glasses and waterproof gloves to protect yourself while working with concrete
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    It is a good idea to get more than enough concrete mix and liquid cement color, just in case. Be sure the plastic chair you choose is sturdy and free of defects so your finished concrete chair will hold its shape.

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


    Prepping the Chair

    Choose a plastic resin chair with arms that fits the style you want for your finished concrete chair. Make sure the chair is intact and has no cracks or defects.

    Use duct tape to cover the entire chair, sealing seams and edges. This prevents the concrete from sticking to the chair.

    Cut slits in the tape at corners and curves to help the tape conform to the chair’s shape.

    Stuff crumpled magazines or other filler material into any open cavities in the chair’s frame to prevent concrete seepage.


    Creating the Concrete Mix

    Mix the concrete following the product directions. Only make as much as you can quickly use before it starts to set.

    If desired, add liquid cement color and mix it in thoroughly for even color distribution.

    The concrete mixture should flow easily but not be watery.


    Pouring the Concrete

    Set the prepped chair on blocks so the legs are off the ground. You’ll slowly pour concrete into the seat, spreading and tapping the chair to eliminate air pockets. Fill it until it’s just below the top.

    Next, pour concrete into the leg openings until full. Fill the chair arms and backrest cavities in the same manner.


    Adding the Base

    Once the chair mold is full of concrete, allow it to set up for 1–2 hours.

    Then, carefully remove the tape and plastic filler materials while the concrete is still semi-soft. Position a wood dowel across the legs about 2 inches from the ground, creating a void for the base. Pack the wet concrete mix into the base area under the dowel. 


    Finishing Touches

    • Once your concrete chair has been set up properly, it’s time to finalize the shape and smoothness. This finishing work is important for functionality and aesthetics.
    • Give the concrete at least 24 hours to fully cure before moving the chair.
    • Use an angle grinder to smooth and shape the concrete as needed.
    • Drill holes for anchor bolts to secure the chair in place on a patio or deck.
    • Seal the concrete and enjoy your new heavy-duty chair.

    With a few basic tools and materials, this easy DIY project produces a stylish, durable concrete chair. Maintaining an outdoor concrete chair is also simple — wash it with soap and water as needed. You can also paint or stain it down the road to change up the look.


    Tips for the Best Results

    Here are some additional pointers to ensure your homemade concrete chair turns out perfectly:

    Choose a plastic chair with a simple, smooth design. Intricate chairs don’t mold well.

    Work in sections when pouring the concrete to prevent spillage and leaks.

    Carefully vibrate the chair as you pour to minimize air pockets.

    Don’t make the concrete mixture too thin or watery. It should readily hold its shape.

    Let the concrete cure undisturbed for at least 24 hours before handling it.

    Start smoothing and shaping the concrete within 3-4 days while it is still somewhat pliable.

    Consider adding concrete reinforcement like rebar or mesh for maximum strength.

    Use an epoxy-based sealer made for concrete to protect the finish.


    Problems to Avoid

    When casting a concrete patio chair, here are some potential problems to watch out for:

    • Using a flimsy plastic chair that deforms under the concrete weight
    • Not sealing the mold tightly enough, allowing leaks
    • Pouring too much concrete at once, causing overflow
    • Letting air pockets get trapped when pouring concrete
    • Allowing the concrete to set and cure unevenly
    • Removing the mold too soon or too late
    • Failure to adequately smooth and seal the concrete surface
    • Not protecting the concrete from freezing temperatures while curing
    • Attempting to move or handle the chair before it has fully cured

    These common mistakes can result in a poorly cast chair that is unstable, prone to damage, or unattractive. Avoid them with proper preparation and by following the step-by-step instructions.


    So, Is Casting Your Own Concrete Patio Chair Worth It?

    If you have basic DIY skills and tools, making your own concrete patio chair is certainly doable. You’ll have a sturdy, weather-resistant chair, exactly the style you want, for a fraction of the cost of buying a pre-made concrete patio chair. 

    The only downsides are the time investment and physical labor involved. You’ll also need to exercise patience while the concrete fully cures before enjoying your finished chair. With proper preparation and care, you can avoid these issues and produce a chair that will serve you well for years to come.

    Keep in mind that pre-made concrete patio chairs are available in many styles these days, which are much quicker and easier. If your priority is a completely customized concrete chair, casting one yourself lets you choose the exact shape, size, color, and embellishments. For those up for the challenge, creating your own concrete chair can be extremely rewarding.

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    FAQs About Casting Concrete Patio Chairs

    What is the best concrete mix to use for a patio chair?

    When casting a concrete patio chair, it is best to use high-strength premixed concrete designed for such a project. Quikrete or Sakrete concrete mixes work very well. Aim for at least a 5,000 PSI rating.


    How long does it take for concrete to fully cure when making a patio chair?

    I find it best to allow a full seven days for concrete to properly cure when casting a patio chair. The concrete will be set and rigid enough to remove from the mold after 24 hours but will continue curing and gaining strength for a week.


    How much does it cost to make a concrete patio chair?

    Making a concrete patio chair costs about $50–$100, depending on the size and materials needed. The concrete mix is the biggest expense, usually between $20–$50 for most chairs. The plastic chair mold, tools, tape, etc., add around $20–$30 more.


    What colors can you make a concrete patio chair?

    Concrete patio chairs can be left natural gray or colored using liquid cement colors, which come in standard options like red, green, black, yellow, and brown. To achieve specialty colors, use concrete stains or outdoor paints after it has fully cured.


    Should you seal a concrete patio chair?

    It is highly recommended to seal your concrete patio chair once fully cured, especially if it will remain outdoors and exposed to the elements. An epoxy-based penetrating concrete sealer will protect it from moisture damage, freezing, and thawing, as well as prevent staining. Reapply the sealer every 2-3 years.


    Can you stack or bolt multiple concrete chairs together?

    Yes, it is possible to stack or bolt concrete patio chairs together. The chairs must be well-braced and secured to prevent them from shifting and toppling over. Some screws or bolts through the legs embedded deep into the concrete will keep stacked chairs stable.


    Editorial Contributors
    avatar for Coty Perry

    Coty Perry

    Expert Writer & Reviewer

    Coty Perry is a lawn and garden writer for Today’s Homeowner. He focuses on providing homeowners with actionable tips that relate to the “Average Joe” who is looking to achieve a healthier and greener lawn. When he isn’t writing he can almost always be found coaching youth football or on some trail in Pennsylvania in search of the next greatest fishing hole.

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    Andrew Foligno

    Andrew Foligno is an editor for Today’s Homeowner, with over 6 years of experience working in digital marketing. He started his career as a content writer at an agency, covering industries such as HVAC, plumbing, painting, lawn care, and more. Soon, he was promoted to an editor position where he oversaw a team of writers before moving on to other facets of digital marketing. When he isn’t working, Andrew enjoys going to the gym to be active, as well as going to the movies to unwind.

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