GB2573293A

GB2573293A - Method of casting a textured concrete walling slab

Info

Publication number: GB2573293A
Application number: GB1807023.5A
Authority: GB
Inventors: Benjamin Williams Scott; Andrew Williams Luke
Original assignee: Team Elite Ltd
Current assignee: Team Elite Ltd
Priority date: 2018-04-30
Filing date: 2018-04-30
Publication date: 2019-11-06
Also published as: GB201807023D0

Abstract

A method of casting a textured concrete walling slab (12, Figure 4) comprises the steps of providing a casting vessel 14 having the dimensions of the walling slab 12 to be cast. A textured-pattern surface mould portion 20 is inserted into the casting vessel. Liquid concrete mixture is poured into the casting vessel 14 and allowed to harden to form a textured concrete walling slab having a textured-pattern surface (26). A reinforcing element such as a mesh may be supported on a perimetral lip 18 of the casting vessel prior to pouring. An anchor element which may comprise a removable lifting loop (30) may be incorporated into the slab. Mould portion 20 may be formed from plastics, preferably polyuretahane, and may comprise several sections each having an individual textured pattern which may resemble stacked timber beams. Colouring agent such as brown oxide may be added to the concrete mixture. The slabs may be used for garden walling.

Description

The present invention relates to a method of casting a textured concrete walling slab, particularly suitable for use in border walling arrangements, in addition to a textured concrete walling slab. A walling system comprising a plurality of said textured concrete walling slabs is also provided.

Border or retaining walling has often utilised timber beams as structural members to provide a delineation between different areas of a garden, driveway or similar outdoor architectural feature. However, wooden beams can be prone to rot over time, which reduces the efficacy of the walling. Subsidence may also be an issue. There are similar issues with wooden fencing panels.

Stone or brick walling can be relatively durable in damp environmental conditions, but such walls are typically time-consuming to assemble, as a large number of individual bricks or stones must be assembled into a complete walling structure.

Concrete panels may also be considered, which are extremely durable. However, such panels are typically very unsightly, as well as being heavy and therefore difficult to install in situ. To improve the appearance of concrete panels, cladding units may be applied, but this significantly increases the labour-intensiveness of the installation of such a walling system.

The present invention seeks to provide a concrete walling arrangement which overcomes many of the deficiencies associated with traditional concrete panelling.

According to a first aspect of the invention, there is provided a method of casting a textured concrete walling slab, the method comprising the steps of: a] providing a casting vessel having the dimensions of the walling slab to be cast; b] providing a textured-pattem surface mould which is insertable into the casting vessel; c] pouring a liquid concrete mixture into the casting vessel; d] allowing the liquid concrete mixture to harden to form a textured concrete walling slab having a textured-pattem surface corresponding with the textured-pattern surface mould; and e] removing the textured concrete walling slab from the casting vessel.

The preparation of a concrete slab having a textured visible face immediately creates a walling system which is durable, strong, and which does not require additional cladding in order to produce a visually-appealing wall.

The method may further comprise a step b]i] which is prior to step c], of inserting a reinforcement element into the casting vessel around which the liquid concrete mixture can harden during step d],

A reinforcement element can be used to improve the strength of the slab, particularly in a region at or adjacent to the textured surface of the slab, since a textured or patterned surface may otherwise be more prone to crumbling or brittleness.

Preferably, the reinforcement element may be a reinforcement mesh.

A reinforcement mesh provides a reinforcement effect across a cross-section of the slab which is formed, and therefore may provide a more uniform strengthening effect than, for example, a rigid metal rod or beam encased within the concrete mixture.

Optionally, the casting vessel may comprise a perimeter lip for supporting the reinforcement element in position.

To ensure that the reinforcement element is correctly positioned within the slab, it is advisable to provide some mechanism by which the reinforcement element made be held, relative to the textured-pattern surface mould.

The method may further comprise a step b]ii] which is prior to step c], of inserting an anchor element at or adjacent to a wall of the casting vessel, the anchor element being at least partially encased in the textured concrete walling slab during step c].

The provision of an anchor element may advantageously allow for improved engagement by a user with the textured concrete walling slab, which otherwise may be difficult if the slab is a solid cuboid.

The anchor element may preferably include a removable lifting loop.

A removable lifting loop advantageously allows for the connection of the textured concrete walling slab to a lifting device, such as a mini-crane, so that it can be easily hoisted into position. The lifting loop can then be removed so as not to adversely affect the appearance of the walling.

In a preferred embodiment, the textured-pattern surface mould may be formed from a flexible plastics material, which may be formed from polyurethane.

A flexible plastics material can be readily extracted from a hardened concrete slab if the mould has become lodged in the textured surface of the slab following hardening.

Preferably, the textured-pattern surface mould may be provided as a plurality of mould sections each having an individual textured pattern thereon.

By segmenting the textured-pattern surface mould into a plurality of sections, bespoke designs for each textured concrete walling slab can be created, giving a more natural appearance to the final product.

A textured pattern of the textured-pattern surface mould may be a timber-effect pattern, and more preferably, the timber-effect pattern may have an appearance of a plurality of stacked timber beams. Optionally, the liquid concrete mixture may be doped with a colouring agent, such as a brown oxide colouring.

Such an arrangement can provide the aesthetic appearance of timber beams, without inheriting any of the adverse characteristics associated with wooden products in external environments.

According to a second aspect of the invention, there is provided a textured concrete walling slab comprising a slab body having a plurality of surfaces, the slab body being formed from concrete material, one of the plurality of surfaces being formed as a textured-pattern surface, the or each other of the plurality of surfaces having a nonpatterned surface.

The provision of such a textured concrete walling slab provides the advantages of concrete retaining walling without needing to apply additional cladding to improve the aesthetics of the walling system with which it is associated.

Preferably, the slab body may be or substantially be cuboidal.

Cuboidal slabs may be effective in creating a continuous and/or contiguous appearance between adjacent slabs in a walling system.

In one embodiment, the textured-pattern surface may be a timber-effect surface, preferably having an appearance of a plurality of stacked timber beams.

Optionally, a reinforcement element may be embedded into the slab body. Said reinforcement element may be a reinforcement mesh.

An anchor element may be provided at or adjacent to one of the non-pattemed surfaces of the slab body, which may preferably include a removable lifting loop.

In a preferred embodiment, the concrete material of the slab body may include a colouring agent, such as a brown oxide colouring.

According to a third aspect of the invention there is provided a walling system comprising a plurality of textured concrete walling slabs in accordance with the second aspect of the invention, wherein adjacent non-patterned surfaces of the slab bodies of the textured concrete walling slabs are abuttably engagable with one another.

The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a perspective representation of one embodiment of a texturedpattern surface mould and casting vessel suitable for use in connection with a method of casting a textured concrete walling slab in accordance with the first aspect of the invention;

Figure 2 shows a perspective representation of the casting vessel of Figure 1 during insertion of a reinforcement element as part of the said method;

Figure 3 shows a perspective representation of the casting vessel of Figure 1 during pouring of a liquid concrete mixture into the casting vessel; and

Figure 4 shows a perspective representation of a textured concrete walling slab in accordance with the second aspect of the invention, as form in accordance with the method of the first aspect of the invention.

Referring to Figure 1, there is indicated a casting apparatus, indicated globally at 10 for creating textured concrete walling slabs 12, such as those indicated in Figure 4 in detail. Such textured concrete walling slabs 12 are suitable for use in a walling system, for example, as border walling in a garden.

The terms textured and textured pattern are intended to differentiate the present concrete walling slabs from plain panels, though it is appreciated that plain concrete panels have some texturing due to the presence of air bubbles in the concrete mixture as it sets.

The casting apparatus 10 comprises a casting vessel 14 which is dimensioned to the size of textured concrete walling slab 12 to be produced. Typically, the casting vessel 14 will be a cuboidal vessel having a plurality of walls 16 defining a volume into which liquid concrete mixture may be poured. It will, however, be appreciated that the casting vessel 14 may be dimensioned and/or shaped in accordance with the shape of the textured concrete walling slab 12 to be manufactured.

The casting vessel 14 is preferably a shuttered casting vessel, that is, having a shutter which can be opened and closed to enclose the liquid concrete mixture therein during the hardening process. This will allow all sides of the casting vessel 14 to be formed having a smooth or planar surface finish as appropriate. The casting vessel 14 shown in Figure 1 is shown without a shutter for clarity, however.

Inside the casting vessel 14, there may be provided a lip or ridge 18 upon which one or more elements to be inserted into the textured concrete walling slab 12 can be inserted during the casting process. Whilst this is illustrated as a perimeter lip in Figure 1, it will be appreciated that any appropriately-formed support, such as struts, props or grips, could be provided so as to enable the elements to be supported in the correct position within the casting vessel 14 and therefore in the final textured concrete walling slab 12. A plurality of identical or different supports could be provided if more than one element or type of element is desired.

The casting apparatus 10 also comprises a textured-pattern surface mould 20 which is positioned or positionable within the casting vessel 14 so as to abut one of the walls, lid or base of the casting vessel 14. The textured-pattern surface mould 20 provides a textured surface against which liquid concrete mixture poured into the casting vessel 14 can flow, and which can harden to form a textured surface for the textured concrete walling slab 12.

Preferably the textured-pattern surface mould 20 is provided as a mould which is receivable into the casting vessel 14, and a plurality of different textured-pattern surface moulds 20 may be provided to permit different textured effects to be produced.

In the present example, the textured-pattern surface mould 20 has a textured surface having a timber effect, effectively reproducing the appearance of timber beams or sleepers stacked on top of one another. The textured-pattern surface mould 20 may therefore be produced by casting an imprint from real timber beams or sleepers. Alternative appropriate textured pattern surfaces could also be considered, such as stone-work, slate, rock, brick, or metallic appearances.

The textured-pattern surface mould 20 is preferably formed from a flexible plastics material, such as polyurethane, to facilitate removal of the textured-pattern surface mould 20 from the textured concrete walling slab 12 once hardened.

The textured-pattern surface mould 20 may be provided as a unitary mould, for example, as a single sheet of plastics material which is dimensioned to the size of a wall of the casting vessel 14. However, it may be possible to provide a plurality of different individual textured-pattern surface mould segments 20a which can be interengaged or positioned relative to one another so as to form a complete textured-pattern surface mould 20. This is of particular interest for the scenario described above, wherein each textured-pattern surface mould segment 20a may correspond with a different imprint of a timber beam or sleeper.

It may be possible for the textured-pattern surface mould 20 to be formed so as to be permanently or semi-permanently attached or affixed in the casting vessel 14; however, it is preferred that the textured-pattern surface mould 20 be removable to ensure that different textured-pattern surface moulds 20 can be used with a single casting vessel 14.

Once the textured-pattern surface mould 20 is in position in the casting vessel 14, any additional elements can be inserted into the casting vessel 14. The insertion of a reinforcement element, such as a reinforcement mesh 22 is illustrated in Figure 2.

The reinforcement mesh 22 is positioned so as to be seatable in position on the lip 18 of the casting vessel 14 so as to be spaced inwardly of a wall of the casting vessel 14 at which the textured-pattern surface mould 20 is positioned. Other elements could be inserted, such as reinforcement bars or rigidifying members, typically for improving the strength of the concrete walling. It may also be possible to insert one or more anchoring elements into the casting vessel 14, at or adjacent to one of the walls which is adjacent to the textured-pattern surface mould 20, such that at least part of the anchoring element is exposed at the surface of the textured concrete walling slab 12 once hardened.

Once any elements are introduced into the casting vessel 14, the liquid concrete mixture can be poured into the casting vessel 14, typically through any shutter in the casting vessel 14. The liquid concrete mixture will fill the casting vessel 14, and any air pockets can be removed by agitation of the mixture. The liquid concrete mixture will flow over the textured-pattern surface mould 20 and the reinforcement mesh 22, creating a textured face of the eventual textured concrete walling slab 12. This process is illustrated in Figure 3.

To improve an appearance of the liquid concrete mixture, it may be doped with a colouring agent, such as a brown oxide colouring. This may help to provide the textured concrete walling slab with an appearance close to that of timber.

The liquid concrete mixture is then allowed to harden, and the textured concrete walling slab 12 removed from the casting vessel 14. If applicable, the textured-pattern surface mould 20 can be removed from the front-facing face of the textured concrete walling slab 12, as the textured-pattern surface mould 20 will have a tendency to adhere to the liquid concrete during the hardening process.

Figure 4 shows the resultant textured concrete walling slab 12. It has a concrete body 24 which encases the reinforcement mesh 22 and part of the anchor element, and has a single textured-pattem surface 26 which corresponds with the textured-pattern surface mould 20. The remaining non-patterned surfaces 28 are plain, and are here planar so as to form a cuboidal shape. The textured concrete walling slabs 12 can therefore be abuttably engaged to one another to form a walling system.

The textured-pattem surface 26 therefore has the appearance of a plurality of stacked timber beams, as imprinted by hardening over the textured-pattern surface mould 20, and this textured-pattern surface 26 is intended to be one of or the only visible surface in use.

The anchor element is here coupled with a lifting loop 30 which is preferably provided as a releasable lifting loop. This allows for the connection of the textured concrete walling slab 12 to a lifting mechanism, such as a mini-crane or hoist, thereby permitting the textured concrete walling slab 12 to be lifted into position. The lifting loop 30 can then be detached once the textured concrete walling slab 12 is in position.

Whilst a single textured-pattern surface mould is disclosed, it will be appreciated that different moulds could be used to produce textured concrete walling slabs having different appearances. This allows for the production of a walling system having a bespoke or randomised appearance, for a more natural aesthetic.

Additionally, whilst the casting vessel here is used with only a single textured-pattem surface mould, it will be appreciated that a plurality of different walls of the casting vessel could each be provided with a textured-pattern surface mould. This would result in a textured concrete walling slab having more than one textured-pattern surface, which may be useful where more than one surface of the slab is visible as part of a walling system, such as both the front and top surfaces of the slab.

It is therefore possible to provide concrete walling which can be installed as part of a retaining wall which is strong and durable, and which does not require additional cladding to have an improved aesthetic appearance.

The words ‘comprises/comprising’ and the words ‘having/including’ when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components, but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

The embodiments described above are provided by way of examples only, and various other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.

Claims

1. A method of casting a textured concrete walling slab, the method comprising the steps of:

a] providing a casting vessel having the dimensions of the walling slab to be cast;

b] providing a textured-pattern surface mould which is insertable into the casting vessel;

c] pouring a liquid concrete mixture into the casting vessel;

d] allowing the liquid concrete mixture to harden to form a textured concrete walling slab having a textured-pattern surface corresponding with the textured-pattern surface mould; and

e] removing the textured concrete walling slab from the casting vessel.

2. A method as claimed in claim 1, further comprising a step b]i] which is prior to step c], of inserting a reinforcement element into the casting vessel around which the liquid concrete mixture can harden during step d],

3. A method as claimed in claim 2, wherein the reinforcement element is a reinforcement mesh.

4. A method as claimed in claim 2 or claim 3, wherein the casting vessel comprises a perimeter lip for supporting the reinforcement element in position.

5. A method as claimed in any one of claims 1 to 4, further comprising a step b]ii] which is prior to step c], of inserting an anchor element at or adjacent to a wall of the casting vessel, the anchor element being at least partially encased in the textured concrete walling slab during step c],

6. A method as claimed in claim 5, wherein the anchor element includes a removable lifting loop.

7. A method as claimed in any one of the preceding claims, wherein the texturedpattern surface mould is formed from a flexible plastics material.

8. A method as claimed in claim 7, wherein the textured-pattern surface mould is formed from polyurethane.

9. A method as claimed in any one of the preceding claims, wherein the texturedpattern surface mould is provided as a plurality of mould sections each having an individual textured pattern thereon.

10. A method as claimed in any one of the preceding claims, wherein a textured pattern of the textured-pattern surface mould is a timber-effect pattern.

11. A method as claimed in claim 10, wherein the timber-effect pattern has an appearance of a plurality of stacked timber beams.

12. A method as claimed in any one of the preceding claims, wherein during step c], the liquid concrete mixture is doped with a colouring agent.

13. A method as claimed in claim 12, wherein the colouring agent is a brown oxide colouring.

14. A textured concrete walling slab comprising a slab body having a plurality of surfaces, the slab body being formed from concrete material, one of the plurality of surfaces being formed as a textured-pattern surface, the or each other of the plurality of surfaces having a non-pattemed surface.

15. A textured concrete walling slab as claimed in claim 14, wherein the slab body is or is substantially cuboidal.

16. A textured concrete walling slab as claimed in claim 14 or claim 15, wherein the textured-pattern surface is a timber-effect surface.

17. A textured concrete walling slab as claimed in claim 16, wherein the texturedpattern surface has an appearance of a plurality of stacked timber beams

18. A textured concrete walling slab as claimed in any one of claims 14 to 17, further comprises a reinforcement element embedded into the slab body.

19. A textured concrete walling slab as claimed in claim 18, wherein the reinforcement element is a reinforcement mesh.

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20. A textured concrete walling slab as claimed in any one of claims 14 to 19, further an anchor element at or adjacent to one of the non-pattemed surfaces of the slab body.

21. A textured concrete walling slab as claimed in claim 20, wherein the anchor element includes a removable lifting loop.

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22. A textured concrete walling slab as claimed in any one of claims 14 to 21, wherein the concrete material of the slab body includes a colouring agent.

23. A textured concrete walling slab as claimed in claim 22, wherein the colouring agent is a brown oxide colouring.

24. A walling system comprising a plurality of textured concrete walling slabs as 15 claimed in any one of claims 14 to 23, wherein adjacent non-patterned surfaces of the slab bodies of the textured concrete walling slabs are abuttably engagable with one another.