GB2457063A - Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work - Google Patents

Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work Download PDF

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Publication number
GB2457063A
GB2457063A GB0801814A GB0801814A GB2457063A GB 2457063 A GB2457063 A GB 2457063A GB 0801814 A GB0801814 A GB 0801814A GB 0801814 A GB0801814 A GB 0801814A GB 2457063 A GB2457063 A GB 2457063A
Authority
GB
United Kingdom
Prior art keywords
concrete
applying
formwork
coating
fabric
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB0801814A
Other versions
GB0801814D0 (en
Inventor
Andrew Neil Mountain
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB0801814A priority Critical patent/GB2457063A/en
Publication of GB0801814D0 publication Critical patent/GB0801814D0/en
Publication of GB2457063A publication Critical patent/GB2457063A/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/001Applying decorations on shaped articles, e.g. by painting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/34Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/06Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with powdered or granular material, e.g. sanding of shaped articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0818Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0007Machines or methods for applying the material to surfaces to form a permanent layer thereon for producing articles with exposed aggregate
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0075Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects for decorative purposes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0081Embedding aggregates to obtain particular properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/36Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24Pressing or stamping ornamental designs on surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4501Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with preformed sheet-like elements
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4501Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with preformed sheet-like elements
    • C04B41/4503Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with preformed sheet-like elements having an adhesive layer
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4505Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/4578Coating or impregnating of green ceramics or unset concrete
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/53After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete
    • C04B41/5323After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone involving the removal of at least part of the materials of the treated article, e.g. etching, drying of hardened concrete to make grain visible, e.g. for obtaining exposed aggregate concrete
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/72After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone involving the removal of part of the materials of the treated articles, e.g. etching

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Forms Removed On Construction Sites Or Auxiliary Members Thereof (AREA)

Abstract

The invention relates to a method of improving the surface characteristics and appearance of formed concrete, to allow the final appearance of the concrete to differ from that which would ordinarily be formed by the specific colour and texture characteristics of the concrete material. It consists of a flexible formwork, 1, optional impermeable membrane, 2, and adhesively bonded coating, 3, incorporating sand, 4, or similar texturing to the inside face of the formwork. Specifically, the invention provides a means of creating a thin surface texture and colouring to the concrete, by incorporating the texture and colouring as a thin layer attached to the flexible formwork, 1. Once the concrete has hardened and the textured and coloured layer becomes impregnated into the concrete structure, either the outer layer of the flexible formwork can be peeled away, or the outer layer, or layers, can be left to biodegrade, disintegrate, naturally deteriorate or be otherwise left to disappear.

Description

1 2457063
METHOD OF APPLYING A TEXTURED COATING TO CONCRETE
FORMED USING FABRIC OR SIMILAR FLEXIBLE NON-RIGID SHEET
MATERIAL FORMWORK
DESCRIPTION
The invention relates to a method of improving the surface characteristics and appearance of formed concrete, to allow the final appearance of the concrete to differ from that which would ordinarily be formed by the specific colour and texture characteristics of the concrete material.
For the purpose of this specification, concrete refers to any structural or non-structural concretion, and can include ordinary aggregate concrete, micro-concrete, grout or similar cementitious type material.
Concrete can be formed and shaped until it hardens or cures, using formwork. Formwork can be manufactured using traditional timbers, or flexible formwork can be made from fabric, membranes or even paper. With specific reference to this invention, the invention relates to flexible forms of formwork.
The colour, texture and to some degree appearance of the finished hardened concrete is * ** currently dependent upon the characteristics of the concrete matter placed within the formwork. *.*.
A textured surface to the cast concrete, when using flexible forms of formwork, is presently . : achievable using fabrics, in which case the fabric can imprint a fabric like texture to the concrete * surface, mirroring the weave of the material used in the formwork. It is also possible to achieve the desired sand like appearance to the formed concrete by carefully selecting the composition : ** of the concrete mix, making the concrete very sandy for example. However, this requires that T the entire block of concrete be formed of the same concrete composition, which may be S. undesirable in many instances, for example if a very strong concrete is required with a high cement content, or if the concrete has to be pumped and in which case a very fluid grout would be preferred. Coloured surfaces are also possible utilising coloured additives to the concrete, in which case the entire concrete is coloured.
Specifically, the invention provides a means of creating a thin surface texture and colouring to the concrete, without the need for colouring of the entire concrete structure, by incorporating the texture and colouring as a thin layer attached to the flexible formwork. Once the concrete has hardened and the textured and coloured layer becomes impregnated into the concrete structure, either the outer layer of the flexible formwork can be peeled away, or the outer layer, or layers, can be left to biodegrade, disintegrate, naturally deteriorate or be otherwise left to
I
disappear. What then remains is the concrete structure, with the surface texture and colour that is specified and designed, according to the composition of the coating on the formwork rather than the natural appearance and characteristics of the placed concrete. The ability to improve the surface appearance of the formed concrete would be particularly useful for methods of in-situ placed concrete scour protection, where it may be desirable to improve the appearance of the placed concrete protection, making it look more natural, and less like traditional grey forms of concrete. In other words, the appearance of the formed concrete scour protection would be different from the concrete material used to form the scour protection, for example. Having the ability to incorporate this coating property into a biodegradable fabric formwork would also have many advantages for placing fabric formed concrete scour protection, in which case the formwork would naturally biodegrade over time, in an environmentally acceptable manner. It may also be useful for architectural purposes.
In essence, the invention is a means of improving the surface characteristics of the concrete, typically masking the natural appearance of the concrete or grout material used to fill the formwork.
A preferred embodiment of the invention will now be described with reference to the accompanying drawings in which: * S. * . S * SI "s., Figure 1 shows the layered approach to the formwork S...
Ftgure 2 shows the configuration of the formwork in relation to the placed concrete *:*. Figure 3 shows the concrete in its hardened state, with the outer layer or layers removed and the remaining impregnated textured coating bonded to the hardened concrete structure.
:.:.. Figure 1 shows a typical configuration of the flexible formwork, incorporating in this example, a ** formwork material composed of fabric, 1, with an optional impermeable coating, 2, formed from polyurethane, pcv, estane, or similar, to make the formwork impermeable to liquids or cement fines. The inside face of the formwork is coated with an adhesive attached coating, 3, impregnated with sand, grit, or similar, 4. The outermost layer or material may be fabric such as hemp, jute, hessian, polyester, nylon or similar natural or man-made fabrics, be of paper, or consist of a membrane such as polythene, for example The use of membranes would typically negate the need for an additional impermeable coating, 2.
Figure 2 shows the formwork in relation to the placed concrete. The outermost layer, 5, in this example a fabric, has an optional impermeable coating, 6, with adhesive attached coating, 7, of sand particles, 8, on the innermost surface against the wet concrete, 9.
Figure 3 shows the same concrete shape, shown in Figure 2, in this case where the concrete, 10, has hardened. Once hardened, the outermost layer, or layers can either be peeled away or naturally left to biodegrade or disintegrate to leave the sand particles, 11, impregnated into the hardened concrete, 10, shape. The result is a visibly different surface appearance to the concrete shape * I. ** * * be S... * * *. C. S * S. * SS
S I..
S * S. * . S S... * S..

Claims (8)

1. A method of applying a textured coating to concrete consisting of a flexible, non-rigid sheet material formwork with adhesive applied sand, or similar, texture coating to the inside formwork face, such that when the concrete cures or hardens, the sand textured coating is incorporated into the finished concrete or grout shape.
2. A method of applying a textured coating to concrete, as claimed in claim 1, where the flexible, non-rigid sheet material is fabric.
3. A method of applying a textured coating to concrete, as claimed in claim 1 where the flexible, non-rigid sheet material is an impermeable membrane.
4 A method of applying a textured coating to concrete, as claimed in claim 1 where the flexible, non-rigid sheet material is paper.
5. A method of applying a textured coating to concrete, as claimed in claims 1 or 2, whereby the fabric incorporates bio-degradable yarns, such as hemp, jute or similar, such that the fabric component to the formwork disintegrates or naturally bio-degrades, * ** leaving the internal coating impregnated into the formed concrete. * S..
6. A method of applying a textured coating to concrete, as claimed in claims 1 or 2, whereby the laminations are weakly bonded to allow the outer fabric material to be pealed away, once cured, to leave the sand coating impregnated into the formed concrete shape. * *. * . . *S..
*
7. A method of applying a textured coating to concrete, as claimed in claims 2 or 4, S..
whereby the fabric or paper formwork incorporates or is coated with an additional coating, lamination or layer, to form an impermeable formwork and therefore better containment of the concrete.
8. A method of applying a textured coating to concrete, as herein described above and illustrated in the accompanying drawings or description.
GB0801814A 2008-02-01 2008-02-01 Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work Pending GB2457063A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0801814A GB2457063A (en) 2008-02-01 2008-02-01 Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0801814A GB2457063A (en) 2008-02-01 2008-02-01 Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work

Publications (2)

Publication Number Publication Date
GB0801814D0 GB0801814D0 (en) 2008-03-05
GB2457063A true GB2457063A (en) 2009-08-05

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Family Applications (1)

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GB0801814A Pending GB2457063A (en) 2008-02-01 2008-02-01 Method of applying a textured coating to concrete formed using fabric or similar flexible non-rigid sheet material form work

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2283986A2 (en) * 2009-08-13 2011-02-16 Selcuk Iplik San Ve Tic AS Method of manufacturing a textured composite stone plate
EP2789439A1 (en) 2013-04-09 2014-10-15 Niels Pieter Gerard Nieuweboer Method for manufacturing a variety of esthetic concrete surfaces using metal molds and a magnetic substrate
CN109591178A (en) * 2018-12-24 2019-04-09 湖北工业大学 The preparation method of masstone pattern transfer concrete

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4378405A (en) * 1979-05-30 1983-03-29 Bpb Industries Public Limited Company Of Ferguson House Production of building board
GB2231527A (en) * 1990-05-01 1990-11-21 Christopher Brian Waite Mould release lining and mould having lining locating means
JPH0397681A (en) * 1989-09-07 1991-04-23 Toppan Printing Co Ltd Method for ornamenting alc
US5735094A (en) * 1994-01-03 1998-04-07 Ultra-Tex Surfaces, Inc. Method for producing an ornamental concrete surface

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4378405A (en) * 1979-05-30 1983-03-29 Bpb Industries Public Limited Company Of Ferguson House Production of building board
JPH0397681A (en) * 1989-09-07 1991-04-23 Toppan Printing Co Ltd Method for ornamenting alc
GB2231527A (en) * 1990-05-01 1990-11-21 Christopher Brian Waite Mould release lining and mould having lining locating means
US5735094A (en) * 1994-01-03 1998-04-07 Ultra-Tex Surfaces, Inc. Method for producing an ornamental concrete surface

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2283986A2 (en) * 2009-08-13 2011-02-16 Selcuk Iplik San Ve Tic AS Method of manufacturing a textured composite stone plate
EP2283986A3 (en) * 2009-08-13 2011-03-09 Selcuk Iplik San Ve Tic AS Method of manufacturing a textured composite stone plate
EP2789439A1 (en) 2013-04-09 2014-10-15 Niels Pieter Gerard Nieuweboer Method for manufacturing a variety of esthetic concrete surfaces using metal molds and a magnetic substrate
WO2014166625A1 (en) 2013-04-09 2014-10-16 Nieuweboer Niels Pieter Gerard Method for manufacturing a variety of esthetic concrete surfaces using metal molds and a flexible sheet with at least one magnetic side
CN109591178A (en) * 2018-12-24 2019-04-09 湖北工业大学 The preparation method of masstone pattern transfer concrete
CN109591178B (en) * 2018-12-24 2020-06-02 湖北工业大学 Preparation method of multi-tone pattern transfer printing concrete

Also Published As

Publication number Publication date
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