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.
E04F 13/08 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
E04B 2/86 - Walls made by casting, pouring, or tamping in situ made in permanent forms
E04F 13/073 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements for particular building parts, e.g. corners or columns
E04F 13/14 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of glass
Systems and methods of shotcrete construction are contemplated whereby guide rails are placed in proximity and forward to a shotcrete receiving surface, with any guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset from the receiving surface allowing shotcrete to be sprayed behind the offset guide rails. Following application of shotcrete, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, thereby removing excess shotcrete and imparting to the shotcrete surface a contour at least partially defined by the configuration of the guide rails and the configuration of the protruding region of the screed. Complex, precise, and even exotic architectural shotcrete installations may be created in this fashion by providing a suitable set of guide rails and screed.
A method of laying one or more concrete topping slabs over an existing concrete structure includes providing a concrete form defining an area on a surface of the concrete structure, drilling a hole into the surface of the concrete structure within the area, the hole being closer to a first border of the concrete form than to a second border of the concrete form opposite the first border, attaching first and second slip-dowel receiving sheaths respectively to the first and second borders, securing a first end portion of a bent metal bar in the hole with a second end portion of the bent metal bar extending parallel to the surface and the slip-dowel receiving sheaths toward the second border, and pouring a concrete mixture over the surface of the concrete structure and about the first and second slip-dowel receiving sheaths and the second end portion of the bent metal bar.
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
E04B 5/32 - Floor structures wholly cast in situ with or without form units or reinforcements
Systems and methods of shotcrete construction are contemplated whereby guide rails are placed in proximity and forward to a shotcrete receiving surface, with any guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset from the receiving surface allowing shotcrete to be sprayed behind the offset guide rails. Following application of shotcrete, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, thereby removing excess shotcrete and imparting to the shotcrete surface a contour at least partially defined by the configuration of the guide rails and the configuration of the protruding region of the screed. Complex, precise, and even exotic architectural shotcrete installations may be created in this fashion by providing a suitable set of guide rails and screed.
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.
E04B 2/86 - Walls made by casting, pouring, or tamping in situ made in permanent forms
E04F 13/073 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements for particular building parts, e.g. corners or columns
E04F 13/08 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
E04F 13/14 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of glass
Systems and methods of shotcrete construction are contemplated whereby guide rails are placed in proximity and forward to a shotcrete receiving surface, with any guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset from the receiving surface allowing shotcrete to be sprayed behind the offset guide rails. Following application of shotcrete, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, thereby removing excess shotcrete and imparting to the shotcrete surface a contour at least partially defined by the configuration of the guide rails and the configuration of the protruding region of the screed. Complex, precise, and even exotic architectural shotcrete installations may be created in this fashion by providing a suitable set of guide rails and screed.
A method of laying one or more concrete topping slabs over an existing concrete structure includes providing a concrete form defining an area on a surface of the concrete structure, drilling a hole into the surface of the concrete structure within the area, the hole being closer to a first border of the concrete form than to a second border of the concrete form opposite the first border, attaching first and second slip-dowel receiving sheaths respectively to the first and second borders, securing a first end portion of a bent metal bar in the hole with a second end portion of the bent metal bar extending parallel to the surface and the slip-dowel receiving sheaths toward the second border, and pouring a concrete mixture over the surface of the concrete structure and about the first and second slip-dowel receiving sheaths and the second end portion of the bent metal bar.
E04C 5/06 - Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
E04B 5/32 - Floor structures wholly cast in situ with or without form units or reinforcements
Systems and methods of shotcrete construction are contemplated whereby guide rails are placed in proximity and forward to a shotcrete receiving surface, with any guide rails disposed directly in front of the shotcrete receiving surface being configured to be offset from the receiving surface allowing shotcrete to be sprayed behind the offset guide rails. Following application of shotcrete, a screed configured to engage with and traverse along at least two of the guide rails may be used to rod the shotcrete via a protruding region of the screed extending beyond the guide rails, thereby removing excess shotcrete and imparting to the shotcrete surface a contour at least partially defined by the configuration of the guide rails and the configuration of the protruding region of the screed. Complex, precise, and even exotic architectural shotcrete installations may be created in this fashion by providing a suitable set of guide rails and screed.
Provided is a method of installing a tile mosaic upon a vertical concrete surface. The method includes providing a plurality of tiles, a tile support, and a concrete form. The plurality of tiles are adhered to the tile support to define a mosaic assembly. The tiles are positioned on the tile support corresponding to the mosaic. The mosaic assembly is connected to the concrete form, and concrete is poured within the concrete form such that a portion of the tiles become embedded within the concrete. The tile support is subsequently detached from the concrete form and the concrete form is removed from the hardened concrete. The tile support is additionally removed from the plurality of tiles to reveal the mosaic on vertical surface of the concrete structure.
E04F 13/072 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
E04F 13/08 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
E04G 21/14 - Conveying or assembling building elements
B44C 1/28 - Uniting ornamental elements on a support, e.g. mosaics
E04F 13/14 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of glass
E04F 19/00 - Other details or constructional parts for finishing work on buildings
B28B 1/14 - Producing shaped articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
E04F 15/12 - Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo
E04F 19/04 - Borders; Finishing strips, e.g. beadings; Light coves for use between floor or ceiling and wall, e.g. skirtings
10.
Decorative concrete and method of installing the same
A method of imprinting a visual and textural pattern upon a concrete surface. The method includes configuring a decorative finishing tool to define a particular visual and textural pattern. An exposed surface of a concrete mixture is finished to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof. The exposed surface of the concrete mixture is further finished with the decorative finishing tool to imprint the visual and textural pattern upon the exposed surface, with at least a portion of the decorative finishing tool being troweled over the exposed surface to create the visual and textural pattern in the concrete.
E04C 2/06 - Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of asbestos cement reinforced
E04F 21/16 - Implements for after-treatment of plaster or the like, e.g. smoothing tools, profile trowels
E04F 21/04 - Patterns or templates; Jointing rulers
E04B 5/32 - Floor structures wholly cast in situ with or without form units or reinforcements
E04G 21/02 - Conveying or working-up concrete or similar masses able to be heaped or cast
A mosaic concrete product, methods of creating the same, and methods of fabricating a module for use in creating the mosaic are provided. The methods of installing the mosaic upon an uncured concrete surface utilize the module. The module may be fabricated by mapping out tile in a design corresponding to the mosaic; adhering the tile to a template utilizing an adhesive, the tile being positioned thereon corresponding to the design; and allowing the adhesive to set. The module may define upper and lower surfaces, the upper surface including the tile adhered thereto. The methods of installing the mosaic comprises: positioning the module upon the uncured concrete surface; embedding the tile into the concrete surface; massaging the tile into the concrete surface to interpose a quantity of cement/fines paste between the adjacent tiles; and finishing the concrete surface.
E04B 1/00 - Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
E04G 21/00 - Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
E04G 23/00 - Working measures on existing buildings
B44C 3/12 - Uniting ornamental elements to structures, e.g. mosaic plates
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
E04B 5/32 - Floor structures wholly cast in situ with or without form units or reinforcements
E04F 15/12 - Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo
B32B 13/04 - Layered products essentially comprising a water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such substances as the main or only constituent of a layer, next to another layer of a specific substance
B32B 3/14 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a face layer formed of separate pieces of material
B28B 23/00 - Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material
B44C 1/28 - Uniting ornamental elements on a support, e.g. mosaics
B44C 3/04 - Modelling plastic materials, e.g. clay
B32B 38/10 - Removing layers, or parts of layers, mechanically or chemically
E04F 13/08 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
A method of forming architectural concrete in a quicker and more cost effective manner relative to conventional concrete formation methods. The method includes forming the architectural concrete without the use of a surface retarder, and using prescribed amounts of fine sand and aggregate to allow for creation of the desired aesthetic look of the architectural concrete.
E04B 1/16 - Structures made from masses, e.g. concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, sub-structures to be coated with load-bearing material
A method of forming a concrete wall having a substantially uniform exterior surface texture. The method includes the initial step of pouring concrete into a wall form. The concrete is poured from a first mixture and is allowed to cure. After the concrete is cured, the wall form is removed from the resultant concrete base structure. A roughened texture is then created on the base structure. A finishing mixture is then applied to the roughened texture. The finishing mixture may be created by separating the aggregate from a portion of the remaining first mixture. The finishing mixture creates a smooth texture on the exterior surfaces of the initially formed base structure.
C04B 41/00 - After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
C04B 28/02 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
C04B 41/50 - Coating or impregnating with inorganic materials
C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone
A mosaic concrete product, methods of creating the same, and methods of fabricating a module for use in creating the mosaic are provided. The methods of installing the mosaic upon an uncured concrete surface utilize the module. The module may be fabricated by mapping out tile in a design corresponding to the mosaic; adhering the tile to a template utilizing an adhesive, the tile being positioned thereon corresponding to the design; and allowing the adhesive to set. The module may define upper and lower surfaces, the upper surface including the tile adhered thereto. The methods of installing the mosaic comprises: positioning the module upon the uncured concrete surface; embedding the tile into the concrete surface; massaging the tile into the concrete surface to interpose a quantity of cement/fines paste between the adjacent tiles; and finishing the concrete surface.
E04F 13/08 - Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
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.
A decorative concrete product and method of making the same is provided. The concrete surface carries a unique textural and visual decorative pattern that is troweled over the uncured surface. The decorative pattern strategically conceals any imperfections in the concrete surface. A decorative finishing tool is utilized to create a unique and consistent pattern throughout the exposed surface of the concrete. Unique visual patterns may include any aesthetic design including wood grain, or lightly finished honed or cut stone. The decorative finishing tool may be configured so that varying textures and contours may consistently be imprinted throughout the concrete. Advantageously, the cured concrete retains the durability of a concrete surface while carrying a visually and texturally appealing appearance.
E04G 21/10 - Devices for levelling, e.g. templates or boards
E04C 2/06 - Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of asbestos cement reinforced
E04F 15/12 - Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo
E04F 21/24 - Implements for finishing work on buildings for laying flooring of masses made in situ, e.g. smoothing tools
A method of forming a concrete wall having a substantially uniform exterior surface texture. The method includes the initial step of pouring concrete into a wall form. The concrete is poured from a first mixture and is allowed to cure. After the concrete is cured, the wall form is removed from the resultant concrete base structure. A roughened texture is then created on the base structure. A finishing mixture is then applied to the roughened texture. The finishing mixture may be created by separating the aggregate from a portion of the remaining first mixture. The finishing mixture creates a smooth texture on the exterior surfaces of the initially formed base structure.
E04B 2/84 - Walls made by casting, pouring, or tamping in situ
C04B 41/50 - Coating or impregnating with inorganic materials
C04B 41/00 - After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
C04B 28/02 - Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
C04B 111/00 - Function, property or use of the mortars, concrete or artificial stone
A mosaic concrete product, methods of creating the same, and methods of fabricating a module for use in creating the mosaic are provided. The methods of installing the mosaic upon an uncured concrete surface utilize the module. The module may be fabricated by mapping out tile in a design corresponding to the mosaic; adhering the tile to a template utilizing an adhesive, the tile being positioned thereon corresponding to the design; and allowing the adhesive to set. The module may define upper and lower surfaces, the upper surface including the tile adhered thereto. The methods of installing the mosaic comprises: positioning the module upon the uncured concrete surface; embedding the tile into the concrete surface; massaging the tile into the concrete surface to interpose a quantity of cement/fines paste between the adjacent tiles; and finishing the concrete surface.
A decorative concrete product and method of making the same is provided. The concrete surface carries a unique textural and visual decorative pattern that is troweled over the uncured surface. The decorative pattern strategically conceals any imperfections in the concrete surface. A decorative finishing tool is utilized to create a unique and consistent pattern throughout the exposed surface of the concrete. Unique visual patterns may include any aesthetic design including wood grain, or lightly finished honed or cut stone. The decorative finishing tool may be configured so that varying textures and contours may consistently be imprinted throughout the concrete. Advantageously, the cured concrete retains the durability of a concrete surface while carrying a visually and texturally appealing appearance.
A non-slick surface-seeded exposed aggregate concrete product and method of making the same enhances the coefficient of friction of an exposed surface thereof to reduce undesirable slipping and sliding. Implementations of the present invention are characterized by the use of fine sand and aggregate broadcast over the exposed surface, which surface has been prepared to receive the same. After curing, the exposed surface is then ground and acid-etched to define fissures, cracks, and/or sharp edges of the aggregate. Subsequently finishing steps are performed to produce the non-slick concrete product which may be used for high traffic pedestrian areas where foot gripping and traction are important, such as on stairs, ramps, walkways, courtyards, and the like.
A concrete structure for replenishing an aquifer and a method for constructing the same is provided. The structure is comprised of a pavement layer with surface drains that extend through the pavement layer and into an aggregate leach field. The leach field includes leach lines spanning the leach field. An aggregate drain extends from the leach field into a sand lens. Precipitation which falls upon the structure thus flows through the surface drain, absorbed into the aggregate leach field, and transported to the aggregate drains by way of aggregate leach lines. The water is then absorbed into the sand lens, ultimately replenishing the aquifer. Existing conventional pavement structures are retrofitted by the removal of a section of the pavement, and filling the same with porous concrete.
A method of forming a concrete wall having a substantially uniform exterior surface texture. The method includes the initial step of pouring concrete into a wall form. The concrete is poured from a first mixture and is allowed to cure. After the concrete is cured, the wall form is removed from the resultant concrete base structure. A roughened texture is then created on the base structure. A finishing mixture is then applied to the roughened texture. The finishing mixture may be created by separating the aggregate from a portion of the remaining first mixture. The finishing mixture creates a smooth texture on the exterior surfaces of the initially formed base structure.
A non-slick surface-seeded exposed aggregate concrete product and method of making the same enhances the coefficient of friction of an exposed surface thereof to reduce undesirable slipping and sliding. Implementations of the present invention are characterized by the use of fine sand and aggregate broadcast over the exposed surface, which surface has been prepared to receive the same. After curing, the exposed surface is then ground and acid-etched to define fissures, cracks, and/or sharp edges of the aggregate. Subsequently finishing steps are performed to produce the non-slick concrete product which may be used for high traffic pedestrian areas where foot gripping and traction are important, such as on stairs, ramps, walkways, courtyards, and the like.
A mosaic concrete product, methods of creating the same, and methods of fabricating a module for use in creating the mosaic are provided. The methods of installing the mosaic upon an uncured concrete surface utilize the module. The module may be fabricated by mapping out tile in a design corresponding to the mosaic; adhering the tile to a template utilizing an adhesive, the tile being positioned thereon corresponding to the design; and allowing the adhesive to set. The module may define upper and lower surfaces, the upper surface including the tile adhered thereto. The methods of installing the mosaic comprises: positioning the module upon the uncured concrete surface; embedding the tile into the concrete surface; massaging the tile into the concrete surface to interpose a quantity of cement/fines paste between the adjacent tiles; and finishing the concrete surface.
A method and a surface seeded exposed aggregate concrete product are provided that precisely simulate the appearance and qualities of various types of natural quarried stone, such as granite, marble, rhinestone, bluestone, and brownstone, to name a few. Implementations of the present invention are characterized by the use of fine sand and aggregate broadcast over the exposed surface of poured concrete, which surface has been prepared to receive the same. Subsequently, a surface retarder and finishing steps are performed to produce the concrete product which assimilates the characteristics and colors of natural quarried stone, such as speckles, inclusions, flecks, graining, fractures, joints, knots, crystallization patterns, streaks, weathering, etc.
A method of surface seeded fine aggregate to produce simulated quarried stone. The method comprises preparing a subgrade, pouring a concrete mixture over the subgrate, and broadcasting one of fine sand and aggregate over 5% to 60% of an exposed surface of the concrete mixture. Alternatively, both the fine sand and the aggregate can be broadcast over 5% to 60% of the exposed surface of the concrete mixture to obtain a desired aesthetic effect as provided by the quarried stone.
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