Method and finish for concrete walls
View Patent ↗A method for forming a uniform texture concrete wall using Shotcrete or other pneumatically projected concrete materials. The method generally includes forming an exterior face mixture from a concrete mixture wherein the large aggregates are removed such that when the face mixture is pneumatically applied to a base structure, the face mixture defines a uniform surface.
1. A method of forming a concrete wall, the method comprising the steps of:
providing a wall form;
pneumatically projecting a first shotcrete concrete mixture in a non-hydrated state onto the wall form to construct a base concrete layer;
providing a second concrete mixture including large aggregate and small aggregate;
removing the large aggregate from the second concrete mixture to define a face concrete mixture; and
applying the face concrete mixture to the base concrete layer while the base concrete layer is in the non-hydrated state.
2. The method recited in claim 1 , wherein the face mixture is applied within four hours after the base concrete layer is formed.
3. The method recited in claim 1 , wherein the face mixture is applied within one hour after the base concrete layer is formed.
4. The method recited in claim 1 , wherein the step of providing the second concrete mixture includes forming the second concrete mixture from the first shotcrete concrete mixture.
5. The method recited in claim 1 , wherein the step of providing the second concrete mixture includes forming the second concrete mixture independent of the first shotcrete concrete mixture.
6. The method recited in claim 1 , further comprising the steps of:
pouring a foundation upon which the base concrete layer is constructed;
installing rebar within the form; and
installing at least one wire gauge to control the depth of the base concrete layer.
7. The method recited in claim 1 , further comprising the step of adding at least one of a coloring agent, sand, cement, an aggregate, a polymer, a bonder or an admixture to the face mixture.
8. The method recited in claim 1 , wherein the face mixture is pneumatically applied to the base concrete layer.
9. The method recited in claim 1 , wherein the face mixture is applied to the base mixture by hand.
10. The method recited in claim 1 , further comprising the step of broadcasting sands and aggregates toward the face mixture.
11. The method recited in claim 1 , further comprising the steps of:
allowing the face mixture and base concrete layer to harden to define a concrete wall; and
exposing the wall.
12. A method of forming a concrete wall, the method comprising the steps of:
providing a wall form;
pneumatically projecting a first shotcrete concrete mixture in a non-hydrated state onto the form to construct a base concrete layer, the first shotcrete concrete mixture including a combination of large aggregate and small aggregate;
providing a face mixture formed independent of large aggregate, wherein providing the face mixture includes removing large aggregate from a second concrete mixture including large aggregate and small aggregate; and
applying the face mixture onto the base concrete layer while the base concrete layer is in the non-hydrated state.
13. The method of claim 12 , wherein the second concrete mixture is formed from the first shotcrete concrete mixture.
14. The method of claim 12 , wherein the second concrete mixture is formed independent of the first shotcrete concrete mixture.
15. The method recited in claim 12 , further comprising the steps of:
pouring a foundation upon which the base concrete layer is constructed;
installing rebar within the form; and
installing at least one wire gauge to control the depth of the base concrete layer.
16. The method recited in claim 12 , further comprising the step of adding at least one of a coloring agent, sand, cement, an aggregate, a polymer, a bonder or an admixture to the face mixture.
17. The method recited in claim 12 , wherein the face mixture is pneumatically applied to the base concrete layer.
18. The method recited in claim 12 , wherein the face mixture is applied to the base mixture by hand.
19. The method recited in claim 12 , further comprising the step of broadcasting sands and aggregates toward the face mixture.