need to build a large work table

[TomFromStLouis]

That’s going to be big but torsion boxes can be relatively light weight. You don’t need 3/4” material for the skins.

[Wipedout]

5 by 10'- id say frame the top like a section of wall.
whats the max weight that this table may see on it?

Oh probably not more than 100 pounds if that

[Steve N]

You said 5x10. Worried about weight... build 2 smaller ones of whatever material you decide and put them together on site.
Ag

Either that or just assemble the torsion box onsite. Except when you glue or screw the sheathing down they are something you can disassemble easily. Assembly on some adjustable saw horses that you can level make for a flat, level construction. Of the two choices I think making a pre-fab torsion box to size would be easier than trying to marry 2 together.

[tomsteve]

Oh probably not more than 100 pounds if that

if thats the case, i dont think ya need to go overboard, although that would be my first instinct,too.
1/2" ply top with a frame of  1 by 4( you could use 3/4" ply ripped to 3 1/2" or even 3" so the frame would remain stable)) spaced 16" or even 12" and the top glued and screwed would make a very sturdy top. frame wouldnt be too bad. either. with the other info, i think id build 2- 5 by 5's and used some form of hardware to lock them together- something like whats used for leafs in kitchen tables.

[jteneyck]

Section modulus is related to stiffness and that formula is bh^2 where b = width and h = height.  So it's the height of the grid members that dominate the ultimate stiffness, not the thickness; think of hollow core doors that are made with corrugated cardboard.  I'm not suggesting you use that, but you can use 1/2" plywood around 5 - 6" in width for the grid then skin it with 1/4" plywood and it will be very light but very stiff.  Design the grid so that the legs fit up into it and bolt them to the grid on site by making relief holes in the bottom of the grid to do that.  If you want even more stiffness, add a stretcher between the legs under the torsion box.  Attach your Melamine work surface on site.

John

[packerguy®]

I have a friend (and client) whose business got flooded during Harvey 38 inches of water in her store.  Amazingly I recovered her data off her hard drives after they were submerged in nasty water for 3 days

She has her store back together and would like me to build her a work table where she can put shipments together and work on large print jobs.  It's a PostNet franchise.  I'll do this for her with minimal charge for my time.

She wants it to be 5 foot by ten foot on large casters.  I think a mdf covered in white melamine will be best - I can get a sheet of that for $35 locally.  I'll wrap the top with maple.  I need some help on the design

Im was thinking a torsion box setup but am open to ideas.  Thoughts?  Suggestions?

The base can be simple 4x4 construction with a single shelf at the bottom (above the casters) for her to store things on.

All ideas appreciated.  They didn't have insurance and lost over $70 K in equipment.  We helped them tear out the sheet rock and everything in the days after the water receded. She had the store up and running for at least shipping and faxing within 2 weeks of the flood (bare walls and all) so she could help the people in the neighborhood

Robert

Uline's packing tables are real hard to beat. I have a 3'x5' table and I would be hardpressed to make it for what it cost (Around $250) Heavy steel base and I have the composite top (mdf core with outside skins of particleboard, with a heavy poly finish...1-1/2 thick) 

I think the largest they sell is 4'x8'

If cost and strength is the main goal and nobody care what it looks like, id buy some 2x lumber and some mdf and sheet laminate and a gallon of paint and get it done.