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Changing shape of concrete columns

Flail

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Aug 5, 2016
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Kin folk said, “Californias the place you wanna be
I have 4 columns at front of house holding up a horizontal beam that holds up the outside edge of a shed roof. The columns were cast in 12” diameter sonotubes and are 9’ tall. The darling wife wants the shape changed to square and then stuccoed to match the home. I was thinking of painting the round columns with concrete bonding adhesive then setting a square form around the column then and pouring fresh concrete. I would like the final shape to be a square column of 12”x12”. Does this seem possible? What products (concrete type and adhesive) would you recommend?
 
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wssix99

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Mar 2, 2011
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Chicago, IL
No. If you pour concrete around that cylinder, you will be left with thin areas where the square cross section intersects the circular cross section. As the new concrete cures, it will shrink and crack/spall at those areas.

Your best bet is going to use a different but compatible material to wrap the column. I would go for composite or wood. You could fill the void with a low pressure foam (so it doesn't burst your boards), but I expect whatever you would find to do that would be $$$.
 

Neggy

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May 30, 2021
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Many of the stucco decorative coverings are done in styrofoam over the support structure, then stucco over the styrofoam

No reason you could not do that over the existing concrete

Architectural foam columns


foamtrim_06.jpg
 

jack stand

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Lakes Region Maine
Find either a new house, or a new wife.
Then there's option 3 (reccomended) removal of these monsters and replacing with the columns of her choice. They make some nice fiberglass columns that will support the (sounds like) minor load. I could see these posts growing to 14-16" after trying to box them. Design wise they'll look out of place unless you have a unique design with other bold oversized designs features, ie; timberframe or something along those lines.
 
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quickfarms

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Many of the stucco decorative coverings are done in styrofoam over the support structure, then stucco over the styrofoam

No reason you could not do that over the existing concrete

Architectural foam columns


foamtrim_06.jpg
This is a very common practice and will get you close to the desired dimensions
 

rayra

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Dec 1, 2014
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Escaped from Los Angeles
It will be a lot easier to do the above. An applique of architectural styrofoam pieces, with a cementitious topcoating.

But your square column will wind up a good bit thicker than 12".

There are a lot of style options and you will likely be much happier with something with some surface detail, rather than a plain 15-16" rectangle box.

I did the reverse and did it the hard way. Hollow concrete cylindrical segments around 4x6 posts.
 

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larry4406

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Northern Virginia
I had a commercial renovation of an 1870's building where we created a front entrance to the building where none existed prior. Demo'd the perimeter wall, removed windows, and put in a store-front type door to the lobby.

The architect specified a stucco/foam product over a metal framed build-out. When it was done it was quite impressive. The GC did a fantastic job.
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Zeke

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Long Beach CA, the sewer by the sea.
Foam might work but you need a good fit and some hellacious glue. If you decide to do this with wood, band it with steel banding. I've done this. You can take 2 x 4's and cut a double 45º on the outside edge and use construction adhesive to attach at each new corner. You will want to put braces or gussets every 2', also glued . Put the banding over those, wrapping and overlapping all around with one length of steel. They make perforated bracing that works fine. If you can't get long enough steel, then overlap any ends.. I'd use 6d nails in predrilled holes and as many as there are holes over enough wood.

And use carpenter's glue on the wood to wood parts of the gussets with 6d toe nails. Then you're ready for lath and plaster. This is where foam takes the lead in less labor aside from the cost of the custom foam. Normally no lathing needed but I might wrap the whole thing in fiberglass netting made for foam block structures. 2 coasts of premix should do it.

I agree that if you're going to the trouble, make some features like a plinth at the base and a capital at the top. If I was ordering foam I might have a tendency to have them put some vertical details in the pieces near the corners like flutes. Anything but a plain straight square column. Have your wife buy a coupe of magazines that feature houses, or Google the hell out of this. It's an opportunity to make something really cool or something totally stupid looking.

You could also show her some examples of classical round columns with all the trimmings. There are some available precast in composite just about ready to paint. You can cut them across and place them on the column with adhesive, then caulk and paint. Here's a base you could cut in half:

k1152.jpg
 
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