Mineral accretion of large surface structures, building components and elements

A large surface area building component of a hard, strong material made by:

• disposing a large surface area form shaped in the configuration desired for the large surface area building component and having inner and outer surfaces in a volume of electrolyte, said form serving as a cathode;
• disposing an anode in the electrolyte in proximity to the shaped form;
• and
• establishing a direct electrical current between the shaped cathodic form and the anode for a time sufficient to accrete a mass of electrodeposited mineral material that surrounds the shaped form and covers the inner and outer surfaces to a desired thickness such that the form becomes embedded therein.

A large surface area building component of a hard strong material made by:

• disposing a large surface area form of nonstructural material having inner and outer surfaces and shaped in the configuration desired for the large building component in a volume conductive and serving as a cathode;
• disposing an anode in the electrolyte in proximity to the shaped form;
• and
• establishing a direct electrical current between the electrodes for a time sufficient to accrete a solid mass of high strength electrodeposited mineral material covering the inner and outer surfaces to a desired thickness, the electrical current being of a density of 1-15,000 mA/sq.ft. with an electric field potential between the electrodes of 1-30,000 volts.

A method of constructing a large surface area building component, which comprises the step of covering a non-structural preshaped form having inner and outer surfaces with a hard, strong material of high structural integrity made by:

• disposing the large surface area preshaped form in a volume of electrolyte, said form serving as a cathode;
• disposing an anode in the electrolyte in proximity to the preshaped form;
• and
• establishing a direct electrical current between the cathode and the anode for a time sufficient to accrete the solid covering of material on the inner and outer surfaces of the form.

A method of constructing a large surface area building component, comprising the steps of:

• disposing a large surface area preshaped form having inner and outer surfaces in a volume of electrolyte, said form serving as a cathode;
• disposing an anode in the electrolyte in proximity to the preshaped form;
• establishing a direct electrical current between the cathode and the anode for a period of time sufficient to accrete a layer of high strength material on the inner and outer surfaces of the form;
• discontinuing the electrical current between the cathode and anode for a period of time;
• and
• re-establishing direct electrical current between the cathode and anode.

A method of constructing a large surface area building component, comprising the steps of:

• disposing a large surface area preshaped form having inner and outer surfaces in a volume of electrolyte, said form serving as an electrode;
• disposing a second electrode in the electrolyte in proximity to the preshaped form;
• establishing a direct electrical current between the electrodes in one direction for a period of time;
• switching the polarity of the electrical current between the electrodes to establish a direct electrical current between the electrodes in an opposite direction;
• and
• re-establishing the original polarity of direct electrical current between the electrodes, thereby accreting a solid mass of mineral of a desired thickness on the inner and outer surfaces of the form.

A method of constructing a large surface area building component, comprising steps:

• disposing a large surface area preshaped form having inner and outer surfaces in a volume of electrolyte, said form serving as a cathode;
• disposing an anode in the electrolyte in proximity to the preshaped form;
• establishing a direct electrical current between the cathode and anode;
• and
• varying the electrical current density of the electrical current to accrete a solid covering of mineral material of a desired thickness and composition on the inner and outer surfaces of the form.