U.S. patent application number 16/883511 was filed with the patent office on 2021-12-02 for concrete wall with decorative surface and method of forming same.
The applicant listed for this patent is Shaw Craftsmen Concrete, LLC. Invention is credited to Jeff Counterman, Ronald D. Shaw.
Application Number | 20210372136 16/883511 |
Document ID | / |
Family ID | 1000004867786 |
Filed Date | 2021-12-02 |
United States Patent
Application |
20210372136 |
Kind Code |
A1 |
Shaw; Ronald D. ; et
al. |
December 2, 2021 |
CONCRETE WALL WITH DECORATIVE SURFACE AND METHOD OF FORMING
SAME
Abstract
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 the surface is
still plastic, and without using bonding agents. The decorative
material may be further exposed by a surface treatment before or
after the front surface is floated and finished, with a sealant
optionally applied thereafter. The front surface may be created by
pneumatic methods or by pouring concrete into forms and removing
the front panel to expose the front surface while it is still
plastic but hydrated enough not to slump.
Inventors: |
Shaw; Ronald D.; (Costa
Mesa, CA) ; Counterman; Jeff; (Costa Mesa,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Shaw Craftsmen Concrete, LLC |
Costa Mesa |
CA |
US |
|
|
Family ID: |
1000004867786 |
Appl. No.: |
16/883511 |
Filed: |
May 26, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2002/8676 20130101;
E04F 13/14 20130101; E04B 2/8635 20130101; E04F 13/0871 20130101;
E04F 13/0733 20130101 |
International
Class: |
E04F 13/08 20060101
E04F013/08; E04B 2/86 20060101 E04B002/86; E04F 13/073 20060101
E04F013/073 |
Claims
1. A method of forming 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
containing wall rebar; the method comprising: projecting a concrete
mixture into the wall cavity sufficient to create a concrete wall
entraining the wall rebar, the concrete wall having two opposing
ends each adjoining a different one of the end panels, a back
surface adjoining the back panel and an exposed front wall surface
opposite the back panel; floating, cutting or both floating and
cutting the exposed front wall surface to achieve at least one of a
desired wall thickness or wall contour; and applying a decorative
material to the exposed front wall surface while that front wall
surface is still plastic.
2. The method of claim 1, comprising the further steps of:
finishing the front wall surface and applying a surface treatment
to the decorative material to further expose small particles of the
decorative material embedded in the front wall surface.
3. The method of claim 1, wherein the bottom panel comprises a
concrete foundation and further comprising a preliminary step of
placing foundation rebar in a foundation cavity, with the
foundation rebar extending into the wall cavity; and wherein the
step of projecting a concrete mixture further includes projecting
the concrete mixture into the foundation cavity to create the
foundation and wall at the same time.
4. The method of claim 1, wherein the bottom panel comprises a
concrete foundation and further comprising a preliminary step of
creating the foundation and allowing it to hydrate for at least one
day before applying the concrete mixture to the wall cavity.
5. The method of claim 2, wherein the bottom panel comprises a
concrete foundation and further comprising a preliminary step of
creating the foundation and allowing it to hydrate for at least one
day before applying the concrete mixture to the wall cavity.
6. The method of claim 2, comprising the further the steps of:
applying an acid cleaner to the decorative material; and applying a
sealant to the decorative material.
7. The method of claim 2, wherein the step of applying the surface
treatment comprises one of sandblasting, grinding or honing.
8. The method of claim 2, wherein the step of applying the surface
treatment comprises one of chemical etching, sponging or applying a
retarder and later washing some of the retarder off.
9. The method of claim 1, wherein the concrete wall is
substantially vertical.
10. The method of claim 1, wherein the decorative materials are
applied by hand.
11. The method of claim 1, wherein the decorative materials are
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.
12. The method of claim 2, wherein the decorative materials
comprise small particles having a mean size larger than a 1/64 of
an inch.
13. The method of claim 2, wherein the decorative materials
comprise color or minerals.
14. A method of forming a concrete wall in a 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 containing wall rebar; the method comprising:
applying a wet concrete mixture to the wall cavity to create a
concrete wall entraining the wall rebar, the concrete wall having
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; removing the front panel after the front
wall surface has hydrated sufficiently that the concrete wall does
not slump sufficiently to increase a thickness of the concrete wall
at the bottom panel by more than 5%; and applying a decorative
material to the front surface of the concrete wall while that front
wall surface is still plastic.
15. The method of claim 14, further including the steps of floating
and finishing the front wall surface containing the decorative
material.
16. The method of claim 15, comprising 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.
17. The method of claim 16, comprising 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 surface is still plastic but after the concrete mix has
hydrated sufficiently that the concrete wall retains its shape; and
applying a decorative material to the back surface of the concrete
wall while that back surface is still plastic; and floating the
portion of the front wall surface containing the decorative
material.
18. The method of claim 16, wherein the step of applying the
surface treatment comprises one of sandblasting, grinding or
honing.
19. The method of claim 16, wherein the step of applying the
surface treatment comprises one of chemical etching, applying a
retarder and later washing some of the retarder off, or
sponging.
20. The method of claim 16 wherein the concrete wall is
substantially vertical.
21. The method of claim 16, wherein the decorative materials are
applied by hand.
22. The method of claim 16, wherein the decorative materials are
applied by projecting the decorative materials against the front
surface of the concrete wall with sufficient force to embed the
decorative materials into the front surface.
23. A concrete wall with decorative materials on the front surface
formed by the method of claim 2.
24. A concrete wall with decorative materials on the front surface
formed by the method of claim 16.
25. A concrete wall with decorative materials on the front and back
surfaces formed by the method of claim 17.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
BRIEF SUMMARY
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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%.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] 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;
[0020] FIG. 1 is a perspective view of a wall form that is used to
construct a concrete wall with the form having one exposed side for
applying the concrete mixture to that exposed side which is
initially referred to herein as the "front" side;
[0021] FIG. 2 is a perspective view of a concrete mixture being
projected into the wall form of FIG. 1;
[0022] FIG. 3 is a perspective view of a worker floating and/or
cutting the exterior surface of the concrete wall within the wall
form;
[0023] FIG. 4 is a perspective view of a decorative material being
applied to the concrete in the wall form of FIG. 3 by
projection;
[0024] FIG. 5 a perspective view of a decorative material being
floated into the plastic, exterior surface of the concrete
wall;
[0025] FIG. 6 is a perspective view of a poured wall form used to
construct a poured concrete wall with the form having two opposing
side panels for the opposing sides of the concrete wall;
[0026] FIG. 7 is a perspective view of a concrete mixture filling
the wall cavity created by the poured concrete form of FIG. 6;
[0027] FIG. 8 is a perspective view of the concrete form of FIGS.
6-7 with one side panel removed;
[0028] FIG. 9 is a perspective view of a worker applying a
decorative material to the concrete in the wall form of FIG. 8 by
projecting the decorative material into the exposed, plastic
exterior surface of the concrete wall after a side panel is removed
to expose that plastic surface; and
[0029] FIG. 10 is a perspective view of a worker floating the
exposed exterior surface of the concrete wall;
[0030] FIG. 11 is a flow diagram of several method steps for
applying decorative material to a plastic concrete surface to
create a decorative surface on the concrete wall;
[0031] FIG. 12A is a sectional view of a concrete trench or form
for pouring a concrete foundation with a hand floated top
surface;
[0032] FIG. 12B shows a sectional view of a vertical, poured
concrete wall form on the foundation of FIG. 12A with the concrete
form filled with concrete; and
[0033] FIG. 12C is a sectional view of an inclined poured concrete
wall form and foundation form, both filled with concrete.
DETAILED DESCRIPTION
[0034] 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
[0035] 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.
[0036] Referring to FIGS. 1-2, a concrete wall form 10 may be used
for constructing a concrete wall. The illustrative wall form 10
includes a back panel 12 and a pair of opposed end panels 14, 16
disposed on opposite ends of the back panel 12. The back panel 12
and end panels 14, 16 collectively define three sides of a box-like
wall cavity 18 within which concrete may be disposed to form a
portion of a concrete wall. The end panels 14, 16 are
advantageously perpendicular to the back panel 12 to form a square
edge, but could be inclined thereto to form an inclined edge. The
side panels are preferably planar and parallel to each other, but
need not be so.
[0037] 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.
[0038] 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 FIG.
12C. The back panel 12, opposing end panels 14, 16, and opposing
bottom and top panels 20, 21 form five sides of a box-like wall
cavity 18 within which concrete may be disposed to form at least a
portion of a concrete wall. The facing surfaces of the end panels
14 and 16 are typically parallel to each other, as are the facing
surfaces of the bottom and top panels 20, 21, but need not be so.
The panels 14, 16, 20, 21 typically form a rectangular wall cavity
18, but other shapes are possible as the concrete form 10 is
illustrative. The wall form 10 depicted in the Figures is used to
create a concrete wall having a generally rectangular cross-section
and rectangular peripheral shape. It is understood that the
methodologies described herein may be used with wall forms 10 that
define other shapes and sizes, including curved surfaces.
[0039] The location and orientation of the wall form 10 may
correspond to the desired position and orientation of the hardened
concrete wall. In FIGS. 1 and 2, the wall form 10 is supported by a
brace 22 to maintain the wall form 10 at an angled orientation
relative to a vertical plane. The wall form 10 may be arranged at
various angles relative to the ground but is typically arranged at
a 90.degree. angle to the ground to create a vertical concrete
wall. Even with a vertical orientation of the wall form 10, the
brace 22 is commonly used as it provides lateral support to the
wall form 10 so as to maintain the wall form 10 in its upright
configuration when concrete is projected thereon, as will be
described in more detail below. Additionally, the wet concrete is
heavy and not self-supporting until it hydrates and hardens
sufficiently, so the brace 22 and wall form 10 maintain the shape
of the back side and edges of the concrete wall during formation
and curing of the concrete without unacceptable deformation from
the weight of the concrete.
[0040] 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.
[0041] 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.
[0042] As best seen in FIG. 2, an optional, protective floor panel
28 may be connected to or placed adjacent to the wall form 10 to
provide a flat, preferably horizontal surface for a worker to stand
on when filling the wall cavity 18 with concrete. And working on
the wall 2. The protective floor panel 28 advantageously extends
between the pair of opposing end panels 14, 16 and has an inner
edge that is parallel to a lower edge of the back panel 12.
Advantageously, the inner edge of the protective floor panel 28
provides a visual and physical guide for the thickness of the
concrete wall along the length of the panel 28.
[0043] FIG. 2 shows the wall cavity 18 of the wall form 10 being
filled with a concrete mixture 30 by a shotcrete-type projection
process that projects wet concrete mixture 30 at a high velocity
into the wall cavity 18 to create a body of wet, compacted concrete
in the wall cavity 18. The wet concrete is pumped or otherwise
forced through a hose 32 from a holding tank into the wall cavity
18. The concrete mixture 30 may include gunite and other concrete
mixtures known by those skilled in the art that are suitable for
high pressure spray applications, suitable for pneumatic
application through a hose 31 to form vertical walls, or other
concrete mixtures suitable for walls which allow use of the methods
described herein. The concrete mixture 30 preferably includes a
combination of small and large aggregate. This concrete mixture 30
may form part of an exposed surface of the concrete wall. The
concrete mixture 30 is projected into the wall cavity 18 until the
wall cavity 18 is filled sufficiently to form a concrete wall of
the desired thickness or slightly less than the desired thickness
and having an exposed wall surface 32 that is usually generally
planar but non-uniform because of the impact used to create the
concrete wall surface.
[0044] Referring to FIG. 3, while the concrete wall surface 32 is
still in a non-hydrated, plastic state, the wall surface is
preferably floated or cut, typically using a bull float or trowel
40 or straight edge and guides to cut and/or float the surface to
create a floated wall surface 34 that is smoother than the as-shot
wall surface and that has the specified wall thickness and/or
contour. The top panel 21 may be removed before the floating or
left in place until later and may serve as a thickness and/or
contour guide. If no top panel 21 is present then the top edge of
the concrete wall is usually floated to create a top edge that is
flat or has the desired shape with whatever texture is deemed
appropriate.
[0045] 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.
[0046] Referring to FIG. 4, while the cut and/or floated wall
surface 34 is still in a non-hydrated, plastic state a concrete
decorative material 36 is forced into the plastic exterior of the
floated wall surface 34 or alternatively, forced into the as-shot
concrete wall surface 32. The decorative material 36 may optionally
be applied to the top edge of the wall as well as to the floated
wall surface 34 or the un-floated wall surface 32. If present, the
top panel 21 would be removed before applying decorative material
36 to the top ledge of the wall.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] Referring to FIG. 11, the various steps of the method of
producing the decorative concrete wall may include projecting
shotcrete concrete or gunite or a non-hydrated concrete mixture
into a wall cavity 18 of concrete form 10 to form a wall as in step
50. The concrete wall may be cut and/or floated to a desired
thickness and contour as in step 52. The decorative coating 36 may
be applied to visible portions of the wall while the wall is still
sufficiently plastic to embed the decorative coating or allow
wicking or color penetration to the above described depth as in
step 54. An optional final float/finish step may be applied to the
decorative coating 36 on the concrete wall as in step 56. An
optional enhancing step may further expose any particles in the
decorative material 36 embedded in the concrete wall as in step
58.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] Referring to FIGS. 6-10, an alternative method of forming
the decorative surface on a concrete wall is disclosed. The
concrete form 10 and foundation or bottom panel 20 and wall rebar
24 and brace 22 are as previously described. But a front panel 42
is provided and is typically fastened to the end panels 14, 16 to
create a modified concrete form 10' that further defines wall
cavity 18' to include the space between the front and back panels
42, 12, as well as the end panels 14, 16 and foundation or bottom
panel 20. A second brace 44 is optionally fastened as needed to the
end panels 14, 26 and/or front panel 42 to maintain the desired
shape of the front panel when the weight of the concrete between
the front and back panels 42, 12 urges those panels apart or bows
those panels. The front and back panels 42, 12 may be connected
intermediate the end panels 14, 16 by various ties to maintain the
spacing between panels 12, 42 under the weight of wet concrete. The
main difference with modified form 10' is that it encloses all but
the top of the wall cavity 18' which will shape the concrete wall
when filled with concrete.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] As shown in FIGS. 8 and 9, the front panel 42 is removed at
a time such that the concrete is hydrated sufficiently to stand and
not slump at the bottom panel 20 or along a height of the wall. The
front panel 42 is removed to expose the plastic surface 46 and the
decorative material 36 is then applied (FIG. 9) as described herein
to the exposed plastic concrete wall surface 46. Depending on the
roughness and desired treatment of the exposed plastic concrete
wall surface 46 after the front panel 42 is removed, the wall
surface 42 may optionally be floated, typically using a bull float
or trowel to further smooth the plastic surface of the concrete
wall, before the decorative material 36 is applied. Referring to
FIG. 9, the decorative material 36 may be applied to the wall
surface 46 without floating the exposed concrete wall surface 46,
or applied after such floating. The decorative material 36 is
applied as described above, for example by pneumatic pressure
through hose 31, or broadcast by hand, or applied to the float 40
(See FIGS. 3, 10) which then applies the material to the wall
surface 46. The decorative material 36 may optionally be applied to
the top edge of the wall as well as to the exposed wall surface
46.
[0062] Because the top edge is typically uncovered as the concrete
wall cures and hydrates, the decorative material 36 may be applied
at any time after the concrete mixture 30 is poured and the top
edge is formed.
[0063] In some situations the decorative material 36 embedded in
the exposed concrete surface 46 may be floated (FIG. 10) to further
embed the decorative material into the plastic concrete surface and
to create the desired surface texture or finish or configuration.
The steps for applying the decorative material 36 are as described
above and elsewhere herein. While the description of those steps in
detail is not repeated, the steps result in a finished decorative
surface 38'.
[0064] 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.
[0065] 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.
[0066] Referring to FIGS. 6-12 and especially to FIG. 11, the
method of forming the decorative concrete wall may include the step
68 of framing and/or pouring a foundation 20 that creates a bottom
panel for the concrete wall. Typically, foundation rebar 25 is
embedded in the foundation 10 and extends upward so as to be
entrained in the resulting concrete wall that is typically poured
later (e.g., FIGS. 1-2, 12A-12B). Method step 69 of assembling the
concrete form 10' which form is configured to create a wall of
desired dimensions, and where the form has at least a front panel
42 that is preferably configured to be removed while the remaining
portions of the concrete form 10' remain, and where optionally one
or more of the back panel 12 and end panels 14, 16 may be removed.
Step 70 includes pouring wet concrete into the concrete form 10' to
fill the wall cavity 18' and create a body of wet, un-hydrated
concrete conforming the shape of wall cavity 18'.
[0067] 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.
[0068] In FIG. 6-10, only one panel (front panel 42) was removed to
expose the underlying plastic concrete surface 46. Removing only
the front panel 42 while leaving the remainder of the poured
concrete wall encased in the remainder of the concrete form 10'
allows the form 10' to provide support to the concrete wall and
helps avoid slumping, surface marring or other undesirable
deformations on the faces of the wall adjoining the respective
concrete forms. The internal wall rebar 24 and any foundation rebar
25 extending into and entrained within the wall also helps maintain
the wall in the desired configuration. It is believed possible to
remove both the side panels 12, 42 (and associated braces 22, 44)
while leaving the end panels 14, 16.
[0069] 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 FIG. 11 for exposed surface
46 and for the exposed surfaces adjoining panels 12, 14, 16 while
the underlying concrete surface is still sufficiently pliable.
Because the concrete continues to hydrate and harden with time,
applying the decorative material 36 is done while the exposed
concrete surface 46 is still pliable enough to accept the
decorative material when applied as described herein, without
causing cracking, spalling or chipping of the exposed concrete
surface to which the decorative material is applied. It is believed
possible to remove one or more of the panels 12, 14, 16 and 42,
apply surface retarder to the adjoining concrete surface(s) and
then replace the removed panel to extend the time during which the
adjoining concrete surface is plastic in order to allow more time
to work on the surface while allowing the bulk of the wall to
harden and become self-supporting and reducing potential
slumping.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] The method embodied in FIGS. 5-11 may include the
preliminary step 68 (FIG. 11) of framing and/or pouring a
foundation or bottom panel 20 and may further include the
preliminary step of assembling the wall frame 10' and installing
reinforcing such as wall rebar 24 and spacers 26 and other
components to be entrained within the wall. The step FIG. 11 74 of
applying decorative materials 36 may include applying the materials
using a pneumatic device to project the materials into the plastic
surface of the concrete wall, or it may include applying the
decorative materials by hand as by broadcasting them against the
plastic surface or troweling them into the plastic surface or
applying a liquid containing the decorative material with a brush
or roller.
[0074] The FIG. 11 step 78 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 78
may include further 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.
[0075] The methods reflected in FIGS. 1-12 and described with
respect to FIG. 11 may further include the optional step 80 of
applying a sealant to the decorative surface 38, 38', including
applying a sealant to the further exposed decorative materials. The
sealant is applied when the decorative surface 38, 38' is created
and ready to receive the sealant, so the timing and sequence of
step 80 may vary. The sealant is typically a clear polymer selected
to allow and/or enhance visibility and appearance of the decorative
materials 36 and usually to also help avoid the decorative
materials 36 from being removed from the concrete wall in which
they materials are at least partially entrained. The application of
the sealant may be preceded by an acid wash, with the acid wash
preferably after the concrete is no longer plastic enough to apply
the decorative material as embedded particulates, although the acid
wash could be part of an step to enhance the appearance of the
decorative material.
[0076] Referring to FIGS. 12A-12B, the foundation 20 is typically
created by digging a trench 90 so the dimensions of the trench form
a trench cavity 92 to define the size of the foundation. The end of
the trench may also be formed by the ground, or alternatively one
or more end panels 14, 16 may be placed in the trench to define the
length of the foundation and the length of the trench cavity. The
end panels are usually held in place by stakes driven into the
ground. Front and back panels 12, 42 may also be used to define the
long sides of the cavity for the foundation 20. Foundation rebar 25
(which includes any other strengthening components or members) is
placed in the trench 90 (or floor or foundation forms) and held
apart from the trench walls and bottom of the trench by spacers 26.
Typically, foundation rebar 25 extends upward out of the foundation
to interconnect with the wall rebar 24 used to form the wall and/or
to interconnect with the concrete forming the wall. Sometimes the
foundation 20 comprises a concrete floor, in which case the floor
has foundation rebar 25 placed along the length of the wall and
sized to extend above the finished surface of the floor.
[0077] 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.
[0078] Referring to FIG. 12B, the concrete form 10 or 10' is then
assembled on the foundation 20 and adjacent ground (or floor), with
foundation rebar 25 placed within the cavity 18, 18' as required by
the particular strength needed for the concrete wall. The wall
rebar 24 for the concrete wall may optionally be fastened to any
foundation rebar 25 extending from the foundation 20 (or floor) by
wires even welding or by placing the bottom end of a continuous
strip of wall rebar into the foundation 20 before the foundation is
formed so it is entrained in both the foundation and wall whether
or not those parts are formed simultaneously. The concrete wall is
then constructed as described above regarding FIGS. 1-10.
[0079] Referring to FIG. 12C, the foundation 20 may be formed
concurrently with the concrete wall. The trench cavity 92 is
created by digging a shaped trench in the ground or by placing
foundation forms in the trench to shape the foundation or bottom
panel 20. The various wall panels 12, 14, 16, 21 and 42 are put in
place to define the wall cavity 18, 18', depending on the shape of
the concrete wall and the process used to form the wall. Foundation
rebar 25, wall rebar 24, spacers, wire gages and any other
components to be entrained in the concrete are then placed in the
cavities 18, 18' and 92. The foundation rebar 25 may extend from
the foundation's trench cavity 92 into the wall cavity 18, 18'. The
concrete mixture 30 is then projected into both the foundation
trench cavity 92 and wall cavity 18, or the concrete mixture is
poured into both the foundation trench cavity 92 and the wall
cavity 18'. After the formation of the concrete wall is completed
and the concrete is sufficiently hardened, any remaining concrete
forms 10, 10' are removed.
[0080] 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 FIGS. 12A, 12B and the panels 28,
94 may be considered as part of the concrete forms 10, 10'. The
concrete mixture 30 may have to be vibrated or specially projected
to ensure it fills the cavity 92 below the top foundation panel 94
and panel 28.
[0081] 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.
[0082] 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.
[0083] 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 FIGS. 1-2.
[0084] 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.
[0085] 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.degree.
from the vertical, and substantially vertical includes inclined
angles of 5.degree. or less from the vertical. But the method
described herein is believed usable with walls inclined at angles
of up to 80.degree. from the vertical, although the inclined angle
is advantageously 60.degree. to 45.degree. from the vertical and is
preferably less 5.degree. 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.
[0086] 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.
[0087] 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.
[0088] The complete contents of all patents and patent applications
identified herein are incorporated by reference.
[0089] 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.
[0090] 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.
[0091] 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.
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