Architectural concrete and method of forming the same
AssigneeShaw & Sons, Inc.
InventorRonald D. Shaw
Life of this patent
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Abstract
A method of forming an architectural concrete structure having a desired look (i.e., color) and texture, wherein the method generally includes pouring a base concrete layer using conventional concrete. A surface concrete mixture is prepared and includes a mixture of sand and small aggregates to give the surface concrete mixture the desired color and texture for the architectural concrete structure. The base concrete layer provides strength and durability to the concrete structure, while the surface concrete layer provides the desired look and texture of the concrete surface. The surface concrete mixture preferably includes small aggregates to create a smooth and uniform texture.
Claims20
A method of forming architectural concrete, the method comprising the steps of:
- pouring a base concrete mixture in an unhydrated state to define a base concrete layer comprising an exposed surface, the base concrete mixture including cement and large aggregate;
- preparing a surface concrete mixture including cement, small aggregate and sand, the small aggregate being smaller than the large aggregate used in the base concrete mixture;
- and
- pouring the surface concrete mixture over exposed surface of the base concrete layer while the base concrete mixture is in the unhydrated state to enable bonding between the surface concrete mixture and the base concrete mixture, the surface concrete mixture defining a surface layer.
A method of forming architectural concrete, the method comprising the steps of:
- pouring a base concrete mixture to define a base concrete layer, the base concrete mixture including cement and large aggregate having a mean diameter size of greater than three-eighths of one inch;
- preparing a surface concrete mixture including concrete, small aggregate and sand, the small aggregate having a mean diameter size of less than three-eighths of one inch, the surface concrete mixture being formed independent of large aggregate;
- and
- pouring the surface concrete mixture over the base concrete layer to define a surface layer which bonds to the base concrete layer without forming a cold joint therebetween.
An architectural concrete structure comprising:
- a base concrete layer formed from a base concrete mixture including cement and large aggregate, the base concrete layer defining a base surface;
- a surface layer formed on the base surface and extending over the base surface to substantially cover the base surface, the surface layer including concrete, small aggregate and sand, the small aggregate being smaller than the large aggregate in the base concrete mixture;
- and
- the surface layer being formed on the base surface while the base concrete mixture is in an unhydrated state to allow the surface layer to bond to the base concrete layer independent of a cold joint therebetween.
Dependencies are inferred from the claim text.