U.S. patent application number 16/774821 was filed with the patent office on 2020-05-28 for architectural concrete and method of forming the same.
The applicant listed for this patent is Shaw & Sons, Inc.. Invention is credited to Ronald D. Shaw.
Application Number | 20200165827 16/774821 |
Document ID | / |
Family ID | 52479111 |
Filed Date | 2020-05-28 |
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United States Patent
Application |
20200165827 |
Kind Code |
A1 |
Shaw; Ronald D. |
May 28, 2020 |
ARCHITECTURAL CONCRETE AND METHOD OF FORMING THE SAME
Abstract
A method of forming an architectural concrete structure having a
desired look (i.e., color) and texture, wherein the method
generally includes pouring a base concrete layer using conventional
concrete. A surface concrete mixture is prepared and includes a
mixture of sand and small aggregates to give the surface concrete
mixture the desired color and texture for the architectural
concrete structure. The base concrete layer provides strength and
durability to the concrete structure, while the surface concrete
layer provides the desired look and texture of the concrete
surface. The surface concrete mixture preferably includes small
aggregates to create a smooth and uniform texture.
Inventors: |
Shaw; Ronald D.; (Corona Del
Mar, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shaw & Sons, Inc. |
Costa Mesa |
CA |
US |
|
|
Family ID: |
52479111 |
Appl. No.: |
16/774821 |
Filed: |
January 28, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16172250 |
Oct 26, 2018 |
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16774821 |
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15619275 |
Jun 9, 2017 |
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16172250 |
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14882922 |
Oct 14, 2015 |
9695602 |
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15619275 |
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13971706 |
Aug 20, 2013 |
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14882922 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29L 2031/776 20130101;
B29C 39/146 20130101; E04C 2/044 20130101; E04C 2/06 20130101; E04F
15/126 20130101; B29L 2009/00 20130101 |
International
Class: |
E04F 15/12 20060101
E04F015/12; E04C 2/06 20060101 E04C002/06; B29C 39/14 20060101
B29C039/14; E04C 2/04 20060101 E04C002/04 |
Claims
1. A method of forming architectural concrete, the method
comprising the steps of: pouring a base concrete mixture in an
unhydrated state to define a base concrete layer, the base concrete
mixture including large aggregate; preparing a surface concrete
mixture including small aggregate and sand, the small aggregate
being smaller than the large aggregate used in the base concrete
mixture, the small aggregate and sand being mixed to define a
prescribed color; and pouring the surface concrete mixture over the
base concrete layer while the base concrete mixture is in the
unhydrated state, the surface concrete mixture defining a surface
layer.
2-20. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
Technical Field of the Invention
[0003] The present invention relates generally to a method and
finish for concrete structures, and more specifically to a method
of forming architectural concrete structure having customized
architectural attributes (i.e., color and texture), while at the
same time exhibiting sufficient strength and durability.
Description of the Related Art
[0004] As is well known in the construction industry, concrete is a
commonly used material for the fabrication of structures. The
desirability of the use of concrete as a construction material is
attributable to certain characteristics that concrete possesses in
comparison to other construction materials. Due to its durability,
wear resistance and cost economy, concrete is gaining widespread
use in flooring applications. As a result of its widespread use,
there is an increasing demand for variations in color and surface
texture of the concrete such that the concrete possesses improved
aesthetics similar to more conventional and costly flooring
surfaces such as marble, stone and granite.
[0005] To meet the demand, the concrete industry has heretofore
developed various coloring and surface finishing techniques for
enhancing the aesthetics of the concrete. Exemplary finishing
techniques include salt finishing, multiple brook finish, form
press finish, and exposed aggregate finish.
[0006] In relation to exposed aggregate finishes, there are two
commonly used techniques to achieve the desired finish, i.e.,
integrally exposed aggregate and surface seeded exposed aggregate.
Integrally exposed aggregate tends to be the more conventional of
the two methods and generally includes washing or removal of the
surface cement and fines from the concrete while the concrete
surface is still plastic, i.e., before full curing, such that the
aggregate, normally rock or gravel, is left exposed on the surface
of the concrete. Due to the normal size of such concrete aggregate
being relatively large, as well as the washing process not being
uniform in nature, the resultant concrete surface derived by the
integrally exposed aggregate method is extremely rough and gagged,
thereby limiting its widespread use in flooring applications.
[0007] Surface seeded exposed aggregate has been introduced, which
subsequent to the pouring of the concrete, rock or gravel aggregate
is broadcasted, i.e., seeded, over the top surface of the concrete
and subsequently troweled into the same wherein upon curing the
aggregate broadcast over the surface adheres to the surface and is
thus exposed. Various sized aggregate can be broadcast over the
surface of the concrete in the surface seeded exposed aggregate
technique, normally the aggregate includes sheared or jagged edges
such that the same can be worked into the surface of the concrete
and be adequately adhered thereto. Thus, the resultant concrete
surface, although generally flatter and not possessing as many
surface irregularities as the integrally exposed aggregate surface,
still possesses an extremely rough surface which limits its
widespread use in flooring applications.
[0008] Therefore, there exists a substantial need in the art for an
improved method of forming an architectural concrete surface having
a surface which is smoother and more uniform than surfaces formed
using existing techniques.
BRIEF SUMMARY OF THE INVENTION
[0009] There is provided a method of forming an architectural
concrete structure having a prescribed look (i.e., color) and
texture. The method generally includes pouring a base concrete
layer using conventional concrete. A surface concrete mixture is
prepared and includes a mixture of sand and small aggregates to
give the surface concrete mixture the desired color and texture for
the architectural concrete structure. The base concrete layer
provides strength and durability to the concrete structure, while
the surface concrete layer provides the desired look and texture of
the concrete surface. The surface concrete mixture preferably
includes small aggregates to create a smooth and uniform
texture.
[0010] According to one embodiment, the method includes pouring a
base concrete mixture in an unhydrated state to define a base
concrete layer, wherein the base concrete mixture includes large
aggregate. The method further includes preparing a surface concrete
mixture including small aggregate and sand, wherein the small
aggregate are smaller than the large aggregate used in the base
concrete mixture. The small aggregate and sand are mixed to define
a prescribed color. The surface concrete mixture is then poured
over the base concrete layer while the base concrete mixture is in
an unhydrated state, such that the surface concrete mixture defines
a surface layer.
[0011] The method may further include the step of forming a
subgrade upon which the base concrete mixture is poured. The method
may additionally include providing a concrete form, and pouring the
base concrete mixture within the concrete form. The surface of the
base concrete layer may be leveled prior to pouring the surface
concrete mixture over the base concrete layer. The method may
further include the step of floating the surface concrete mixture
after it is poured over the base concrete layer.
[0012] The surface concrete mixture may be finished after it is
poured over the base concrete layer. The finishing step may include
grinding the surface layer, etching the surface layer, and/or
sand-blasting the surface layer.
[0013] The step of preparing the surface concrete mixture may
include removing large aggregate from the base concrete mixture to
form the surface concrete mixture.
[0014] The step of pouring the surface concrete mixture may include
pneumatically projecting the surface concrete mixture over the base
concrete layer.
[0015] The surface concrete mixture may be poured over the base
concrete layer within eight hours after forming the base concrete
layer.
[0016] According to another aspect of the present invention, there
is provided an architectural concrete structure including a base
concrete layer formed from a base concrete mixture including large
aggregate, wherein the base concrete layer defining a base surface.
A surface layer is formed on the base surface, wherein the surface
layer includes small aggregate and sand. The small aggregates are
smaller than the large aggregate in the base concrete mixture, and
the small aggregate and sand being mixed to define a prescribed
color. The surface layer is formed on the base surface while the
base concrete mixture is in an unhydrated state to allow the
surface layer to bond to the base concrete layer independent of a
cold joint therebetween.
[0017] The present invention is best understood by reference to the
following detailed description when read in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These as well as other features of the present invention
will become more apparent upon reference to the drawings
wherein:
[0019] FIG. 1 is an upper perspective view of an embodiment of an
architectural concrete structure formed in accordance with an
embodiment of the present invention; and
[0020] FIG. 2 is a flowchart of one embodiment of a method of
forming the architectural concrete surface.
[0021] Common reference numerals are used throughout the drawings
and detailed description to indicate like elements
DETAILED DESCRIPTION OF THE INVENTION
[0022] 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.
[0023] Referring now to the drawings, wherein the showings are for
purposes of illustrating a preferred embodiment of the present
invention only, and are not for purposes of limiting the same,
there is shown an architectural concrete structure 10 having a base
concrete layer 12 and an outer surface concrete layer 14. According
to various aspects of the present invention, the base concrete
layer 12 is formed from conventional concrete, while the surface
concrete layer 14 is customized to have prescribed architectural
characteristics (i.e., color, texture, etc.). In order to ensure
proper bonding/adhering between the base concrete layer 12 and the
surface concrete layer 14, the surface concrete layer 14 is poured
over the base concrete layer 12 while the base concrete layer 12 is
in an unhydrated, plastic state, which allows the surface concrete
layer 14 to bond to the base concrete layer 12 without a cold joint
being formed therebetween.
[0024] As used herein, the term "architectural concrete structure"
may be used to refer to patios, parking lots, decks, porches,
walkways, flooring, garages, sidewalks, plazas, entryways,
fountains, or other surfaces formed of concrete. Along these lines,
architectural concrete structures provide desirable strength and
durability which is derived from the concrete used to form the
structure, while at the same time incorporating artistic design
elements to achieve a preferred look and texture.
[0025] FIG. 2 is a flow chart illustrating one embodiment of a
method of forming the architectural concrete structure. The method
includes the step of preparing a subgrade 16 (see FIG. 1), which
includes forming the subgrade 16 to a desired elevation and grade,
and compacting the subgrade 16 to a proper compaction standard.
Furthermore, any utilities (i.e., sleeve and pipes--not shown) that
must extend under the architectural concrete structure 10
preferably extend under the subgrade 16.
[0026] The method further includes preparing and placing a form 18
on the subgrade 16. In general, the form 18 defines at least one
edge of the architectural concrete structure 10, and may be
constructed from wood or other materials known by those skilled in
the art. In the exemplary embodiment depicted in FIG. 1, the form
18 includes two elongate members 20 (i.e., wood beams) positioned
on the ground 22 adjacent the subgrade 16 to define a pour area for
the concrete. The form 18 is preferably arranged to create a pour
area having the specific dimensions required for the resultant
architectural concrete structure 10. In the exemplary embodiment,
the architectural concrete structure 10 is formed above-ground, and
thus, the form 18 rests on the ground 22. However, in other
embodiments, it may be desirable to form the architectural concrete
structure 10 such that the top/exposed surface of the architectural
concrete structure 10 is substantially flush with the ground level
22. In that case, the form 18 may extend at least partially below
ground level to accommodate the designs of the architectural
structure 10.
[0027] In order to increase the resultant strength of the structure
10 and reduce subsequent cracking of the same, reinforcement wire
mesh or steel rebar 24 may be positioned above the subgrade 16
within the area defined by the form 18. In the exemplary
embodiment, the concrete structure 10 includes a plurality of
rebars 24 positioned longitudinally between the form members 20.
Although the exemplary embodiment only shows rebars 24 arranged in
a spaced, parallel arrangement, it is understood that other
embodiments may include rebars 24 arranged in a lattice framework,
which includes rebars 24 arranged in an intersecting fashion.
[0028] In addition to preparing the pour area for the architectural
concrete structure 10, as noted above, the concrete used in forming
the architectural structure 10 is also prepared. The preparation of
the concrete may be performed before, during, or after preparation
of the pour are&
[0029] The concrete used in forming the architectural concrete
structure 10 includes a base concrete mixture 26 and a surface
concrete mixture 28. The base concrete mixture 26 preferably
includes cement, sand and aggregate, including small aggregate and
large aggregate. As used herein, the term "small aggregate" will
typically refer to aggregate preferably having a mean average
diameter of less than three-eighths of one inch, while "large
aggregate" will typically refer to aggregate preferably having a
mean average diameter of greater than three-eighths of an inch.
According to various embodiments, the base concrete mixture 26 may
be prepared in a manlier similar to conventional concrete.
[0030] Once the base concrete mixture 26 is prepared, the base
concrete mixture 26 is preferably poured to a depth which covers
any rebar 24 or reinforcement member placed within the pour area
over the subgrade 16. After the base concrete layer 12 is poured,
the base concrete layer 12 defines an exposed surface 30, which may
be leveled after the base concrete mixture 26 is poured to define a
generally smooth, planar surface.
[0031] The surface concrete mixture 28 is different from the base
concrete mixture 26 and is used to form the exposed surface layer
14 of the architectural concrete structure 10. In this regard,
surface concrete mixture 28 may include unique additives to achieve
the desired look and texture of the architectural concrete
structure 10. Along these lines, the preferred implementation of
the surface concrete mixture 28 includes cement, select sands and
small aggregates which create the desired look and texture of the
architectural concrete structure 10. Along these lines, the sand
and small aggregates mixed into the surface concrete mixture 28 may
correlate to the prescribed color of the architectural structure 10
(i.e., if the desired color of the architectural structure 10 is
red, then red sands and small aggregates are mixed into the surface
concrete mixture 28). The selected sands and small aggregates may
not only relate to the desired color of the architectural structure
10, but may also relate to the reflective qualities (i.e., dull or
polished) or other aesthetic characteristics of the architectural
structure 10 known by those skilled in the art.
[0032] Once the surface concrete mixture 28 is prepared, it is
poured over the exposed surface 30 of the base concrete layer 12
while the base concrete mixture 26 is in an unhydrated, plastic
state. According to a preferred embodiment, the surface concrete
layer 14 is approximately 1/4'' thick, wherein the thickness is
defined as the distance between the upper exposed surface 32 of the
surface concrete layer 14 and the interface of the surface concrete
layer 14 and the base concrete layer 12. However, other embodiments
may include a surface concrete layer that is more than 1/4'' thick
or less than 1/4'' thick.
[0033] According to various embodiments of the present invention,
the surface concrete mixture 28 is poured over the base concrete
layer 12 within eight hours of forming the base concrete layer 12.
Pouring the surface concrete mixture 28 over the base concrete
layer 12 while the base concrete mixture 26 remains in an
unhydrated, plastic state allows the surface concrete mixture 28 to
bond to the base concrete mixture 26 and also prevents a cold joint
from forming between the two layers 12, 14. This results in a more
structurally uniform and sound concrete structure.
[0034] According to one embodiment, the surface concrete mixture 28
and the base concrete mixture 26 are formed as separate batches. As
previously noted, the base concrete mixture 26 is formed similar to
conventional concrete, and includes a mixture of cement, s2nd,
large aggregate and small aggregate. On the other hand, the surface
concrete mixture 28 includes cement, sand and small aggregates,
wherein the sand and small aggregates are selectively added to the
surface concrete mixture to define the desired look and texture of
the structure 10.
[0035] According to another embodiment, the surface concrete
mixture 28 is formed from the same batch as the base concrete
mixture 26. There may be structural advantages associated with
forming the surface concrete mixture 28 from the same batch as the
base concrete mixture 26, such as having a degree of uniformity
throughout the concrete structure 10. The surface concrete mixture
28 may be formed from the base concrete mixture batch by removing
the large aggregates from the base concrete mixture batch, and then
optionally adding sand and other small aggregates to achieve the
desired look and texture for the surface concrete mixture 28.
[0036] After the surface concrete mixture 28 is poured over the
base concrete layer 12, the surface concrete mixture 28 is floated
to define a uniform outer surface. The surface concrete layer is
then finished to reveal the color and texture of the surface
mixture 28. For instance, the surface layer 14 may be ground,
etched (acid etching or chemical etching), or sandblasted to reveal
the color of the select sands and small aggregates mixed into the
surface mixture 28.
[0037] The novel and unique concrete structure 10, and related
method of forming the same described herein, uniquely includes a
two-layer construction including the base concrete layer 12 and the
surface concrete layer 14. The base concrete layer 12 provides
structural support to the structure 10, while the surface concrete
layer 14 provides aesthetic qualities to the structure 10. In this
regard, the two-layer construction provides structural, as well as
economic advantages when compared to a structure formed completely
with concrete devoid of large aggregates. Along these lines, the
use of large aggregates in the base mixture 26 strengthens the base
miicture, and is also more advantageous from a cost
perspective.
[0038] Additional modifications and improvements of the present
invention may also be apparent to those of ordinary skill in the
art. Thus, the particular combination of components and steps
described and illustrated herein is intended to represent only
certain embodiments of the present invention, and is not intended
to serve as limitations of alternative devices and methods within
the spirit and scope of the invention.
* * * * *