Method for manufacture of facing bricks with sharply delineated portions of different color and texture

A process for repeatedly and concurrently making a plurality of colored and coated concrete bricks of differing surface texture and color which process comprises the cycle of steps of

• a. filling each of plurality of verically extending chambers in a mold with concrete mix, vibrating the mold and compacting the concrete mix in each of said chambers to form a plurality of plastic concrete brick masses, and spraying the mold surfaces of each chamber with a first fluid liquid slurry comprising cement and a first pigment prior to each filling of each said chamber of said mold with said concrete mix and thereby distributing said liquid slurry over surfaces of each of said plastic concrete brick masses adjacent said mold and thereby coloring each of said plastic brick masses prior to removal of each of such plastic masses from said mold;
• then
• b. removing thus-coated brick masses from the mold to thereby provide and thereafter maintaining a longitudinally and transversely extending array of a plurality of vertically extending spaced apart brick masses of predetermined width, depth, and height having between the separate brick masses in said array vertically and longitudinally extending spaces and vertically and transversely extending spaces, said spaced being narrow relative to said width, depth, and height of said brick masses said array of brick masses having between longitudinally neighboring masses of said array longitudinally and horizontally spaced apart parallel transversely and vertically extending surfaces and between transversely neighboring brick masses horizontally and transversely spaced apart parallel longitudinally and vertically extending surfaces, said vertically extending and relatively narrow spaces located between said vertically extending surfaces;
• c.
• i. preparing a viscous pigmented cementitious slurry thickened to be selectively adherent to a hydrophyllic wet surface,
• ii. then periodically pressurising and atomizing said viscous pigmented cementitious thickened slurry and forming, at a spray source, a stream of small globules of atomized slurry and, while said brick masses are in a fixed spatial relation to said spray source, directing the said stream of small globules of atomized slurry towards and between and against
• aa. a pair of inwardly sloped guide surfaces, said pair of guide surfaces having a wide opening at its top and a narrow opening at its bottom, said lower opening located above and parallel to the upper edges of a pair of said vertically extending spaced apart surfaces of neighboring brick masses in said array of plurality of spaced apart plastic concrete brick masses, each of said sloped guide surfaces having a slurry repellent surface and located above said vertically extending mass, and said guide surfaces of each said pair of guide surfaces having a common line of intersection below the top surface of said array of spaced apart vertically extending brick masses and within the vertically extending space located between said pair of vertically extending surfaces, and wherein a flat planar extrapolation of each of said surfaces of said pair of guide surfaces extends above the said upper edge of said vertically extending spaced apart surfaces of neighboring brick masses and
• bb. into said vertically extending and relatively narrow spaces between said spaced apart vertically extending surfaces of neighboring brick masses in said array of a plurality of plastic concrete brick masses below said guide surfaces, and developing a turbulent flow of said stream of small globules at the top of the said vertically extending spaces and thereby then
• iii. applying said small globules of atomized slurry selectively to a portion of a vertically extending surface of each of said plastic concrete brick masses in said array in an amount sufficiently thin to be static on said surface of said plastic concrete brick mass and sufficiently thick to provide an optically opaque layer, said portion of said vertically extending surface of each of said plastic concrete brick masses for each of such masses extending from an upper edge of said mass, said upper edge joining two corners of said mass and the contiguous area of a vertically extending surface thereof adjacent to said upper edge to a lower lobular edge, said lower lobular edge spaced away from the bottom edge of said brick, and providing a sharp delineation between each said optically opaque layer and the area of said plastic concrete brick mass surface therebelow.