The present disclosure relates to a method and apparatus for use in concrete construction, and is more specifically directed to a concrete wall with a decorate surface thereon, and a method of forming the concrete wall and decorative surface.
Cast In Place (CIP) concrete walls are constructed by pouring un-hydrated concrete between two generally parallel concrete forms (e.g., front and back forms) that rest on or create a footing, with rebar and/or suitable wire mesh between the concrete forms. Puddling or vibration may be used to remove entrained air while the concrete is still week. After the concrete hydrates and hardens, the concrete forms are removed—usually the day after pouring at the earliest. Applying decorative surfaces to such concrete wall surfaces requires a bonding agent to hold or adhere the decorative material to the concrete. Such decorative surfaces are time consuming to apply because the bonding material requires special application and/or cleanup steps, and the bonding materials may inadequately stick to the concrete or to the decorative material as they are applied one or more days after the wall is created. There is thus a need for an improved way to apply a decorative material to a concrete wall.
U.S. Pat. No. 8,962,088 describes a concrete wall formed by applying shotcrete to an assembly having a back concrete form on a footing, with appropriate rebar or wire mesh held in place inside the forms as needed. A first concrete mixture with large and small aggregate is shotcrete or pneumatically applied to the form to create a concrete wall with a first concrete wall portion and then before the first concrete wall portion hardens, a second, face mixture of concrete is applied which has the large aggregates removed such that when the face mixture is pneumatically applied to the first surface, the face mixture defines a uniform surface which can be floated to form the final, exterior surface of interest. While this process results in a uniform exterior surface, it requires time and effort to separate out the larger aggregate and to create and apply the second concrete face mixture in a timely manner to ensure the face mixture sticks to the underlying, first shotcrete mixture. While the resulting wall surface is uniform and of improved appearance, it lacks a decorative surface formed by select sands, color, minerals, etc. There thus remains a need for an improved way to create a concrete wall with a decorative material on the exterior surface of the concrete wall, and an improved concrete wall with a decorative surface connected to that wall.
U.S. Pat. Nos. 7,781,819 and 9,102,572 describe a concrete wall poured between vertical concrete forms which are removed after the surface hardens or cures, typically at least one day after the wall is created. The hardened concrete surface is then roughened and a second concrete mixture applied to that roughened surface with the second mixture requiring separating out larger aggregate. This process is time consuming, labor intensive and requires multiple steps extending over several days, which requires repeated stops at the job site, increases costs, extends the cleanup time and creates bonding issues between the concrete wall and the second concrete mixture which are only partially addressed by the need to roughen the concrete wall surface. There thus remains a need for an improved way to create a concrete wall with a decorative material on the exterior surface of the concrete wall, and an improved concrete wall with a decorative surface connected to that wall.
U.S. Pat. Nos. 8,246,269 and 9,695,602 describe processes for forming an architectural concrete structure on a poured, horizontal concrete slab which has no concrete form on the upper, horizontal surface of the slab. These patents rely on the horizontal orientation to achieve their desired result and do not indicate any applicability to concrete walls which are formed by different processes using different concrete forms in different orientations to prevent slumping of the wet concrete. There thus remains a need for an improved way to create a concrete wall with a decorative material on the exterior surface of the concrete wall, and an improved concrete wall with a decorative surface connected to that wall.
A concrete wall has a back surface supported by a back panel while a decorative material is applied to an opposing front surface of the wall by hand or by pneumatic projection while that front surface is still plastic, the same day the wall is poured. No bonding agents are needed as the decorative materials are embedded into the plastic concrete surface. The decorative material may be further exposed by a surface treatment either before or after the front surface of the concrete wall is floated or cut or finished, with a sealant optionally applied thereafter. The concrete wall may be created by pneumatically applying a concrete mixture to fill a cavity in a concrete wall form (e.g., shotcrete), or by pouring concrete into wall forms having opposing front and back panels and then removing the front panel to expose at least the front surface while that front surface is still plastic. Optionally, the back panel may be removed while the back surface is still plastic and the decorative material may also be applied to that back surface while it is still plastic.
The method of forming the decorative surface on the concrete wall generally includes forming an underlying concrete wall using a single mixture of concrete and then applying a concrete decorative material to the exterior face of the concrete wall while it is still in a plastic or non-hydrated state. This allows for the decorative material to be applied without polymers or bonding chemicals to fasten the decorative material to the concrete wall, which drastically reduces labor and material costs. The decorative material is applied when the exterior surface of the concrete wall is still plastic but the underlying concrete wall may be sufficiently self-supporting that the exposed front surface does not slump. Thus, the hardening time for the concrete surface in which the decorative material is embedded is further reduced or eliminated, which additionally helps with project scheduling and sequencing. The decorative material is formed of smaller aggregates such that the decorative material may advantageously define a uniform texture and appearance.
There is thus advantageously provided a concrete wall with a decorative surface and a method of forming that decorative surface on the wall. The method includes forming a decorative surface on a concrete wall in a concrete form having two opposing end panels, a bottom panel and a back panel extending between the end panels to define a wall cavity. The wall cavity contains wall rebar and may contain foundation rebar. The method includes the step of projecting a concrete mixture into the wall cavity sufficient to create a concrete wall entraining the wall rebar and any foundation rebar. The concrete wall has two opposing end surfaces each adjoining a different one of the end panels, along with a back wall surface adjoining the back panel and an exposed front wall surface opposite the back panel. The method includes floating and/or cutting the exposed front wall surface to achieve at least one of a desired wall thickness or wall contour. The method also includes applying a decorative material to the exposed front wall surface while that front wall surface is still plastic.
In further variations, the above method optionally includes one or more further steps. These further steps may include finishing the front wall surface and/or applying a surface treatment to the decorative material to further expose small particles of the decorative material embedded in the front wall surface. The method may also include a concrete form having a bottom panel that comprises a concrete foundation and may further include a preliminary step of placing foundation rebar in a foundation cavity, with the foundation rebar extending into the wall cavity and then having the projecting step additionally project the concrete mixture into the foundation cavity to create the concrete foundation and concrete wall at the same time. Additionally, the method may include a bottom panel that includes a hardened concrete foundation and that includes the preliminary step of creating that concrete foundation and allowing it to hydrate for at least one day before applying the concrete mixture to the wall cavity. Each of these method variations, and the other variations summarized herein, are believed to result in improved concrete walls with variations in the wall and/or its decorative surface.
The method may include the further steps of applying an acid cleaner to the decorative material and then applying a sealant to the decorative material. The step of applying the surface treatment may include sandblasting, grinding, honing, chemical etching, sponging or applying a retarder and later washing some of the retarder off, or combinations thereof.
The concrete wall is preferably substantially vertical, but may be inclined relative to the vertical direction. The decorative materials may be applied by hand, including by floating or troweling, or they may be applied by projecting the decorative materials against the front surface of the concrete wall with sufficient force to embed the decorative materials into that front surface, as for example, by using mechanical or pneumatic projection devices. The decorative material 36 may comprise small particles having a mean size larger than a 1/64 of an inch such as small aggregate and shells, or it may include color or minerals or combinations of these (and other) decorative materials.
There is also provided a method of forming a concrete wall in a poured concrete form having two opposing end panels, a bottom panel and opposing front and back panels extending between the end panels to define a wall cavity. The wall cavity may contain wall rebar and may optionally contain foundation rebar. The method includes the steps of applying a wet concrete mixture to the wall cavity to create a concrete wall entraining the wall rebar, usually by pouring the mixture into the wall cavity until the form is full and then leveling off the top of the wet concrete parallel to the top of the side panels of the concrete form. The concrete wall has two opposing ends each adjoining a different one of the end panels, a top and opposing front and back surfaces adjoining the respective front and back panels. The method includes the further step of removing the front panel and applying a decorative material to the front surface of the concrete wall while that front wall surface is still plastic. Advantageously, the front panel is not removed until after the front wall surface has hydrated sufficiently that the concrete wall does not slump, and preferably does not slump sufficiently to increase a thickness of the concrete wall at the bottom panel by more than 5%.
In further variations, this method may include the steps of floating and/or finishing the front wall surface containing the decorative material. The method may also include the further step of applying a surface treatment to the front wall surface containing the decorative material to further expose small particles of the decorative material embedded in the front wall surface.
Additionally, the method may include the further steps of removing the back panel to expose a back surface of the concrete wall adjoining the back panel and removing that back panel while that back wall surface is still plastic and then applying a decorative material to the back surface of the concrete wall while that back wall surface is still plastic. Advantageously the back panel is removed after the concrete mix has hydrated sufficiently that the concrete wall retains its shape and preferably removed after the concrete mix has hydrated sufficiently so that the concrete wall does not slump sufficiently to increase the thickness of the concrete wall at the bottom panel by more than 5% compared to the thickness when the front panel is removed. The method may also include the further step of floating and finishing the portion of the back wall surface containing the decorative material, and/or sealing that decorative material on that back wall surface.
The step of applying the surface treatment comprises one of sandblasting, grinding, or honing, chemical etching, sponging or applying a retarder and later washing some of the retarder off. Advantageously, the concrete wall is substantially vertical, but it may be inclined, but advantageously not inclined more than 60 degrees from the vertical. The method may include the steps of applying the decorative materials by hand, or projecting the decorative materials against the selected plastic surface of the concrete wall with sufficient force to embed the decorative materials into the selected surface.
Advantageously, the concrete wall with decorative materials on the front surface is formed by one or more of the above described combinations of steps. Further, the concrete wall may be formed with the decorative materials on both the front and back surface as formed by one or more of the above described combinations of steps.
These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which;
As used herein, the following part numbers refer to the following parts throughout: 10 & 10′—concrete forms; 12— back panel; 14— end panel; 16—end panel; 18 & 18′— cavity; 20— bottom panel; 21— top panel; 22— brace; 24— wall rebar; 25—foundation rebar; 26— spacers; 28— protective floor panel; 30— concrete mixture; 31—hose; 32— exposed surface as shot; 34— floated surface; 36— decorative material; 38 & 38′— finished decorative surface; 42— front panel; 44— second brace; 46— exposed plastic concrete surface; 52— float concrete; 54— apply decorative materials; 56— final float/finish; 58— expose decorative materials; 60— frame/pour foundation; 62— provide concrete form; 64— add reinforcing materials to form; 66. — install wire gauges for depth; 68— frame or create foundation; 69—assemble forms; 70— pour concrete in forms; 72— strip forms; 73— float exposed surface; 74— apply decorative materials; 76— float & finish wall; 78— expose decorative materials; 80— applying sealant; 90— trench; 92— trench cavity; 94— top foundation panel
The detailed description set forth below is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the functions and sequences of steps for constructing and operating the invention. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments and that they are also intended to be encompassed within the scope of the invention.
Referring to
The wall form 10 is advantageously positioned over a bottom panel 20 which is typically a floor or shaped foundation that extends between the opposing end panels, 14, 16 and is the bottom side (or foundation) upon which the concrete wall may be constructed. As used herein, references to the bottom panel 20 will include both a foundation and a floor, as either the foundation or floor can function as a bottom panel for the concrete wall. For convenience, the description will usually refer to the bottom panel 20 as a foundation as that is the more common construction.
A top panel 21 may optionally be provided which extends between the side panels 14, 16 and is opposite the foundation 20 defining the top edge of the wall. Optionally, but less preferably, the foundation 20 may comprise both a foundation cavity and wall cavity having a combined shape defined by forms so the concrete wall and foundation may be created at the same time, in a single, substantially continuous pour of wet concrete or projection of pneumatically applied concrete as described later regarding
The location and orientation of the wall form 10 may correspond to the desired position and orientation of the hardened concrete wall. In
Internal support members, such as wall rebar 24 (which includes reinforcing wire) may be positioned within the wall cavity 18 so as to become encapsulated by the concrete as it is projected into the wall cavity 18 to provide internal support to the concrete wall and to better control potential cracking. The wall rebar 24 may be arranged to define a lattice framework to provide support along at least two axes, generally the horizontal and vertical axes. Furthermore, the wall rebar 24 may be positioned within two separated planes and may be spaced from the back wall 12 using spacers 26 to position the wall rebar 24 in spaced relation to each other. Each separated plane of wall rebar 24 is typically parallel to the back panel 12 when the concrete wall has generally parallel, opposing surfaces.
Although the Figures depict wall rebar 24 disposed within the wall cavity 18, it is understood that other items may be placed within the wall cavity 18 before concrete is projected therein. For instance, wire gauges may be installed to allow installers to determine the depth or thickness of the concrete projected into the wall cavity 18. Furthermore, electrical lines may be placed within the wall cavity 18 if the concrete wall includes lights or electrical outlet. Drainage lines or other plumbing lines may additionally be included as needed. Pass through fittings for various conduits and pipes may likewise be provided before the concrete is applied to the concrete form 10.
As best seen in
Referring to
The compacting of the concrete mixture 30 from being projected against the back panel 12 helps set the concrete and reduce slumping. As used herein, slumping of a concrete wall formed by projecting concrete occurs when the thickness of the concrete wall at the bottom panel 20 increases by 5% or more after the exposed front surface 32 is first floated or cut to create surface 34.
Referring to
The decorative material 36 may comprise select sands, colored sands, color, colored concrete, colored cement minerals, shells, stones, pebbles, glass fragments, brick fragments, cement and other small materials, aggregate or combinations thereof, to define the desired appearance. The decorative material 36 preferably has only small sized particles contained therein by which is meant particles having a mean diameter of less than three-eighths of one inch.
The decorative material 36 is advantageously applied in a manner that forces the decorative material 36 into the plastic exterior wall surface 32, 34 of the non-hydrated concrete and preferably forces the mixture 36 a sufficient distance into that exterior wall surface so that a majority of any aggregate and sand in the decorative material have a majority and preferably more than a majority, of the surface of each particle (e.g., aggregate, sand, shell) entrained in that exterior wall surface so as to securely embed any particulates in the decorative material 36 into the plastic concrete wall surface 32, 34 to form a finished concrete wall surface 38. For decorative materials 36 (including colors) which contain no particulates that are even the size of fine sand ( 1/64 inch mean diameter), the decorative material is applied so that it either wicks into or is forced into the plastic concrete wall surface 32, 34 to a depth of at least half the mean size of the decorative material over a majority of the surface area to which the decorative material is applied. Advantageously, if the decorative material 36 comprises color or other decorative material that is a liquid having no discrete physical particles detectible by rubbing the liquid between a person's fingers, the liquid penetrates to a depth of at least 0.1 inches, and as used herein, such a liquid is considered to penetrate plastic concrete surface a distance of at least half the mean size of the decorative material.
The objective of the particle entrainment (including color penetration) is to hold the materials and particles in the decorative material 36 to the concrete wall surface for considerable lengths of time amounting to at least five years. The decorative material 36 may be applied by a pneumatic process with or without floating to smooth and shape the wall surface 32, 34. The decorative material 36 may also be applied by hand as by floating the material 36 into the plastic concrete surface. The decorative material may further be broadcast onto the plastic concrete wall surface 32, 34 or applied by hand, as for example, by using brushes, by rollers, by hand implements such as floats or trowels, or by other mechanisms.
The finished concrete wall surface 38 comprises the concrete wall with the decorative material 36 applied to the plastic, exposed surface 32, 34 by any of the described steps without further finishing steps. Advantageously though, the finished concrete wall surface 38 is further floated to further embed the decorative material 36 and is further finished by surface troweling to draw the cement toward the exposed surface while further embedding the decorative material in the wall.
As desired, the finished concrete wall surface 38 may be further enhanced by applying a surface treatment, such as surface retarder, sandblasting, acid etching or sponging or other methods that further expose any small particles in the surface materials that are embedded in the front surface of the concrete, including small particles such as aggregate, shells, sand or other small particles. The surface retarder is applied before the concrete is fully hydrated and is optionally masked or covered by a vapor barrier to allow the body of the concrete wall to hydrate or harden, while allowing the wall surface penetrated by the retarder to hydrate or harden at a slower rate so that a portion of the retarder and concrete may be washed off to further expose the outer portion of the decorative material 36 embedded in or penetrated into the finished concrete wall surface 38. Sandblasting is typically applied to green concrete or hydrated concrete and uses abrasive particles applied pneumatically to remove an outer layer of the finished wall surface 38 to further expose the decorative material 36 such as aggregate or other particulates embedded in the finished concrete wall surface 38. High pressure water may be used similar to sandblasting to expose more of the decorative material 36. Acid etching is typically applied to green concrete or hydrated concrete and uses a weak acid solution, applied by spraying or by sponges using rubber gloves to expose the decorative material 36 such as aggregate or other particulates embedded in the finished concrete wall surface 38. Sponging is usually applied to concrete that is still plastic and uses water and sponges to hand wash away the outer layer of cement and expose the particulates of the decorative materials 36 embedded in the finished concrete wall surface 38.
After the concrete wall is hydrated sufficiently that the concrete form 10 can be removed without altering the shape or surface of the hardened concrete wall, the concrete form 10 is removed. The decorative materials 36 on the finished concrete wall surface 38 may be sealed by applying a sealant, typically a polymer. The application of the sealant may be preceded by an acid wash, preferably after the concrete is no longer plastic enough to embed the decorative material 36.
Referring to
The method may include one or more of the preliminary steps of framing and pouring the foundation 20, before or concurrently with projecting concrete to form the wall as in step 60. The framing may include forming trenches in the ground that define a wall of the resulting concrete foundation 20, and in some cases the trench may define at least a portion of a concrete wall. The method may include the preliminary step of framing the wall by creating concrete form 10, 10′, as in step 62, or adding reinforcing material such as wall rebar 24 and spacers 26 to reinforce the resulting concrete wall as in step 62. The method may include adding wire gages in the concrete form 10 to allow monitoring of thickness of the concrete wall or the depth of the concrete inside the concrete form 10.
The step 54 of applying the decorative coating 36 method may include one or more of the steps of applying the decorative coating by a pneumatic device or other device imparting sufficient velocity to the decorative material 36 to embed it into the plastic concrete surface 32, 34, preferably to the depths describe herein; or applying the decorative material 36 by hand as by broadcasting color or floating/troweling the material 36 into the plastic concrete surface.
The step 58 of exposing the decorative materials 36 may include applying a surface retarder and later washing the retarder to remove cement entraining the particles in the decorative materials to further expose those particles. The step 58 may also include exposing particles in the decorative materials 36 by acid etching, or chemical etching, or sandblasting, or high pressure spray, or grinding and/or honing, or water sponging.
Referring to
The front and back panels 42, 12 are typically each planar and parallel to one another to define a wall of a uniform thickness defined by the space between the forms. But the front and back panels 42, 12 need not be planar or parallel as the shapes and relative inclination and/or orientation of the panels may be altered to vary the thickness of the concrete wall and the shape of the concrete wall. For example, the panels 12, 42 may have convex or concave portions that are conforming and parallel, or opposing and diverging. The same applies to the end panels 14, 16. The modified form 10′ and front and back panels 42, 12 may be inclined to the horizontal but is usually vertical, with the braces 22, 44 supporting the parts of the modified form 10 to which they are attached.
Wall rebar 24 is placed in the wall cavity 18′ as described. In addition to the rebar 24, the wall cavity 18′ may contain other items, including wire gages, electrical conduits, plumbing fittings, pass through fittings and other items to be entrained in the concrete wall. Wet, non-hydrated concrete mixture 30′ is poured into the wall cavity 18′ to entrain the rebar and other items in the cavity 18′. The concrete mixture 30′ preferably includes a combination of small and large aggregate and may include any concrete mixture believed suitable for the particular needs of the concrete wall being constructed, and may include the sprayed concrete mixtures and gunite described above. This concrete mixture 30′ may form part of an exposed surface of the finished concrete wall. The concrete mixture 30′ is poured or otherwise placed into the wall cavity 18′ until the wall cavity 18′ is filled sufficiently to form a concrete wall of the desired dimensions.
The concrete mixture 30′ is preferably vibrated to remove air bubbles and consolidate the concrete mixture and the top edge of the concrete wall is finished to whatever texture is deemed appropriate, usually by floating the top edge to a flat, horizontal shape. The concrete mixture is allowed to partially hydrate until such time that the front panel 42 can be removed without the concrete wall slumping at the bottom panel 20 and while the exposed concrete wall surface 46 that was adjoining the front panel 42 is still plastic. As used herein, slumping of a poured concrete wall formed between front and back panels 12, 42 occurs when the thickness of the concrete wall at the bottom panel 20 increases by 5% or more after the first of the front or back panels 12, 42 is removed.
As shown in
In some situations the decorative material 36 embedded in the exposed concrete surface 46 may be floated (
The finished decorative concrete wall surface 38′ may comprise the concrete wall with the decorative material 36 applied to the concrete surface 46 by any of the described steps without further finishing steps. Advantageously though, the finished concrete wall surface 38′ is further floated to further embed the decorative material 36 in the concrete wall and is further finished by surface troweling to draw the cement toward the exposed surface while further embedding the decorative material 36 in the wall.
Advantageously, when the front panel 42 is removed, the remaining portions of concrete form 10′ are left in place to protect the concrete wall from marring and damage and to further support the wall so it does not slump at the bottom panel 20 or is otherwise marred while the surface is in the plastic state. After the concrete wall is more fully hydrated to its rock-like hardness, the remaining removable portions of concrete form 10 are removed, at least by one day after pouring the wall.
Referring to
Method step 72 includes stripping at least one of the panels of the concrete form 10′, preferably stripping the front panel 42 from the concrete form to expose the plastic concrete surface 46 previously adjoining that front panel 42 (or panels 12, 14, 16) while that exposed concrete surface is still plastic but will not slump. Step 73 is optional and includes floating the recently exposed, plastic concrete surface 46. Step 74 applies the decorative material 36 to the exposed concrete surface 46 (optionally including applying the material 36 to the surface previously adjoining panels 12, 14, 16) while that concrete surface is still plastic and to any other visible portions of the concrete wall to which the coating is desired to be applied. Optional step 76 floats the exposed concrete surface 46 and decorative material 36 to further embed the material 36 into the plastic surface of the concrete wall (including surfaces adjoining panels 12, 14, 16 or the top edge of the wall) and to bring cement from the wall to the surface 46. Optional step 78 further exposes the decorative materials 76 using processes described herein to further expose the decorative materials 36 to enhance the aesthetic appearance of these materials 36, especially the particulate materials.
In
It is believed possible to apply the decorative surface material 36 to both exposed plastic side surfaces of the concrete wall using the above described steps of
Depending on the internal support to the concrete wall from wall rebar 24 and internal strengthening parts, and the concrete mixture and wall design, it is further believed possible to remove one or both of the end panels 14, 16 to expose end surfaces of the concrete wall and to then apply the decorative material 36 to one or both of the exposed end surfaces of the concrete wall. Thus, it is believed that all exposed faces of the concrete wall could have decorative material applied to those exposed surfaces.
The process for applying the decorative material 36 is described above and not repeated here. Depending on the concrete mixture and environmental conditions, it may be desirable to leave one or more of the end panels 14, 16 or the back panel 12 in place while the front panel 42 is removed in order to reduce hydration of the concrete surfaces adjoining those panels and thus extend the time when those underlying surfaces are sufficiently plastic to receive the decorative material 36 or to be floated to further embed the decorative material 36 into the concrete surfaces.
Multiple workers may simultaneously apply decorative material 36 to one or more surfaces previously underlying panels 12, 14, 16 or 44, or the panels may be removed at different times or in different combinations and decorative material applied sequentially or at different times to those different combinations of the underlying surfaces beneath the panels as the panels are removed.
The method embodied in
The
The methods reflected in
Referring to
The trench cavity 92 (or forms defining the sides of the floor or foundation) is then filled with concrete mixture 30 with the top surface being floated to the desired configuration, which is usually a flat, horizontal surface. If the foundation is a floor, the concrete surface is usually machine troweled and that troweling may extend close to but does not contact the foundation rebar 25 extending out of the surface of foundation or bottom panel 20. Typically, the foundation 20 is poured separately from the concrete wall and before the wall forms 10, 10′ are put in place. After the concrete in the trench cavity 92 (or floor) hardens to form the foundation 20 of the desired shape, any foundation forms (or other forms) are removed and any empty spaces between the trench and foundation 20 may be filled with earth or other materials, or left until the concrete wall is formed before being filled.
Referring to
Referring to
Because the weight of the concrete in the wall cavity 18, 18′ may affect the shape of the foundation's top surface while the concrete is wet and before the concrete foundation hydrates and hardens sufficiently to support the weight of the wall, top foundation panel 94 may be provided to form the top side of the foundation 20, and the protective floor panel 28 may be used as a top foundation panel on a side of the foundation opposite panel 94. The top foundation panel 94 and panel 28 may be used with the foundation formation process of
The present methods offer advantages reflected in the resulting concrete wall. By applying the decorative material 36 while the wall is still in a plastic state, the decorative material may be applied without polymers or bonders and without the need to entrain the decorative material in a second, different mixture of concrete and then applying that second mixture to the wall. That avoids the cost and cleanup and environmental issues associated with such polymers and bonders. The ability to apply the decorative material to the plastic wall surface and to embed the decorative material 36 into the concrete surface or wick the decorative material into the plastic concrete surface is believed to provide several additional advantages. The process allows a much simpler application process which reduces labor costs. It allows a much faster process because it can be completed the same day the concrete wall is poured or s hot, and is completed before the concrete hydrates to its rock-like hardness. It requires less cleanup as there is no second cement or concrete coating or bonding agent applied. It avoids the need to roughened a hardened concrete surface to improve adhesion of decorative materials. It avoids the need to repeatedly return to the job site. It avoids the need for a costly finishing layer and avoids the need to segregate aggregates by size as in U.S. Pat. No. 8,962,088. It allows a wide variety of materials to be applied as the decorative material 36. It also provides secure entrainment of the decorative material in the concrete surface using the concrete itself, and thus avoids the degradation which can arise from prolonged exposure to sunlight of some bonding agents.
The process of forming a decorative wall described herein also produces a wall having new and improved properties. Because the decorative material 36 is applied to the concrete wall while it is still plastic, the bonding of the material to the wall is improved and the decorative surface 38, 38′ are believed to be less subject to cracking, chipping and spalling than decorative surfaces on prior art walls.
If the foundation or bottom panel 20 is poured or formed at the same time as the concrete wall, then the wall rebar 24 and foundation rebar 25 will extend between the bottom panel 20 and the concrete wall and be entrained in the concrete mixture 30, 30′ as the bottom panel and wall can be simultaneously formed, resulting in a superior structural connection. Typically, the foundation or bottom panel 20 comprises a concrete foundation that is poured and allowed cure before the concrete forms 10, 10′ for the wall are created are created with the foundation rebar 25 connected to the wall rebar 24 by wires or welding, or interconnected by the concrete mixture 30 forming the concrete wall that is poured after the foundation cures. Advantageously, the foundation 20 is poured and hydrates for at least a day before the concrete wall is poured into concrete forms 10′ or projected into concrete forms 10. Either foundation or bottom panel 10 provides a strong base for the resulting concrete wall with the decorative material 36. Alternatively, the rebar 24 may be places so its bottom portion is located in the foundation cavity and the rebar 24 extends continuously along the length and height of the wall form 10′ (and 10) as in
Further, the plastic concrete surface 32, 34, 46 is preferably vertical or generally vertical when the decorative material 36 is applied and the resulting finished decorative surface 38, 38′ will have a final appearance that can be readily determined. For example, tiles cast horizontally and viewed in a horizontal orientation in a store or warehouse may appear different when applied to a vertical wall, and even vertically displayed tiles present a different appearance when presented in isolation compared to the appearance created by multiple tiles assembled together. As long as the exposed surfaces 32, 46 are sufficiently plastic the decorative material 36 may be further manipulated to adjust the appearance, as for example by further floating, applying more decorative material 36, or applying surface treatments—especially those suitable for use with plastic concrete.
Additionally, the application of the decorative material 36 to a vertical or off-vertical wall is believed to cause a different appearance and a different interlock with the plastic concrete surface 32, 46 than arises if the decorative material were applied to a horizontal surface. As used herein, the generally vertical orientation refers to angles of inclination of up to 30° from the vertical, and substantially vertical includes inclined angles of 5° or less from the vertical. But the method described herein is believed usable with walls inclined at angles of up to 80° from the vertical, although the inclined angle is advantageously 60° to 45° from the vertical and is preferably less 5° inclined from the vertical. If the decorative material 36 is broadcast by hand or machine, the angle of inclination of the wall (and of the forms 10, 10′) affects how gravity disperses the decorative material 36 and how that material initially penetrates the exposed surfaces 32, 46.
If the decorative material 36 is projected into the exposed concrete surface 32, 46 the relative angle of inclination between the trajectory of the decorative material and the exposed concrete surfaces affects the depth and orientation of the decorative particles as they are embedded into the exposed concrete surfaces. If the decorative material 36 is applied by floats, or floated after application, gravity will affect how the material is embedded into and interlocked with the exposed concrete surface 32, 46. If the decorative material 36 is applied by brushes or rollers, gravity affects how the decorative material will flow down and penetrate the exposed surface 32, 46 and how air-born contaminants affect that exposed surface and the applied decorative materials. The resulting finished decorative surface 38, 38′ lacks the distinctive layered construction that results from the prior art processes that apply first and second concrete mixtures with different sizes of aggregate in the concrete mixes as is done in U.S. Pat. No. 8,962,088, and avoids the issues that arise from the attempts to interlock two separately applied layers of concrete mix.
The vertical or off-vertical orientation of the exposed concrete surfaces also affects how surface treatments affect the decorative material 36 as the orientation of the wall affects how the surface treatments are applied, especially as a vertical or inclined wall will cause liquid surface treatments flow downward compared to a horizontal orientation which would puddle the liquids at low spots. Also, applying the decorative materials in the as-used, vertical or off-vertical orientation is believed to result in a finished decorative surface 38, 38′ with a different residual stress adjacent the surface of the concrete wall (i.e., within 0.5 inches) compared to the decorative surfaces that would result if they were prepared using a horizontal form 10, 10′, or if the decorative surface is applied as a separate layer of concrete mixture to a vertical wall as in U.S. Pat. No. 8,962,088. Embedding the decorative material into a plastic concrete surface 32, 46 is believed to be very different than entraining the material in a concrete mixture and applying the mixture as a separate layer. Thus, the resulting concrete wall with a finished decorative surface 38, 38′ is believed to have new and different properties and characteristics compared to the prior art.
The complete contents of all patents and patent applications identified herein are incorporated by reference.
The detailed description set forth above in connection with the drawings is intended as a description of some, but not all, of contemplated embodiments of the disclosure, and is not intended to represent the only form in which the present disclosure may be constructed or utilized. The description sets forth the functions and the sequence of steps for developing and operating the disclosure in connection with the illustrated embodiments.
It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the disclosure. It is further understood that the use of relational terms such as first and second, top and bottom, and the like are used solely to distinguish one entity from another entity without necessarily requiring or implying any actual such relationship or order between such entities.
The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present disclosure only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present disclosure. In this regard, no attempt is made to show structural details of the present disclosure in more detail than is necessary for the fundamental understanding of the present disclosure, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present disclosure may be embodied in practice.
The present application is a continuation of U.S. patent application Ser. No. 16/883,511, filed May 26, 2020, the entire disclosure of which is expressly incorporated herein by reference. Not Applicable
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Number | Date | Country | |
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20220290443 A1 | Sep 2022 | US |
Number | Date | Country | |
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Parent | 16883511 | May 2020 | US |
Child | 17827586 | US |