CA1211924A - Method for rock reproduction - Google Patents
Method for rock reproductionInfo
- Publication number
- CA1211924A CA1211924A CA000498406A CA498406A CA1211924A CA 1211924 A CA1211924 A CA 1211924A CA 000498406 A CA000498406 A CA 000498406A CA 498406 A CA498406 A CA 498406A CA 1211924 A CA1211924 A CA 1211924A
- Authority
- CA
- Canada
- Prior art keywords
- rock
- panels
- natural
- natural rock
- panel
- 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.)
- Expired
Links
Landscapes
- Revetment (AREA)
Abstract
ROGERS, BERESKIN & PARR
TITLE: IMPROVED METHOD FOR ROCK REPRODUCTION
INVENTOR: PHILIP DI GIACOMO
ABSTRACT OF THE DISCLOSURE
This invention relates to improvements in methods for reproducing natural rock surfaces which are used as decorative faces for walls, facings, shorelines and the like. A rock surface to be reproduced is coated with latex and the latex is then coated with urethane resin to form a mold panel. The mold panel is removed from the rock sur-face and its inside is coated with a thin layer of sprayed concrete to form a concrete rock panel. The rock panel is removed from the mold panel and is used to form a cast-in-place reproduced rock wall. Tha concrete rock panel so formed is of sufficient strength to maintain its proper profile while concrete is poured behind it. Because of the concrete rock panels strength and rigidity, it can be read-ily supported in place by a simple framework.
In the case of larger surfaces mold panels can be made of various portions of the natural rock surface, and trimmed along natural issures. The corresponding rock panels formed from the mold panels can be overlapped and the edges grouted together to reproduce the entire natural rock surface. The joins are substantially invisible since they occur along the fissures.
TITLE: IMPROVED METHOD FOR ROCK REPRODUCTION
INVENTOR: PHILIP DI GIACOMO
ABSTRACT OF THE DISCLOSURE
This invention relates to improvements in methods for reproducing natural rock surfaces which are used as decorative faces for walls, facings, shorelines and the like. A rock surface to be reproduced is coated with latex and the latex is then coated with urethane resin to form a mold panel. The mold panel is removed from the rock sur-face and its inside is coated with a thin layer of sprayed concrete to form a concrete rock panel. The rock panel is removed from the mold panel and is used to form a cast-in-place reproduced rock wall. Tha concrete rock panel so formed is of sufficient strength to maintain its proper profile while concrete is poured behind it. Because of the concrete rock panels strength and rigidity, it can be read-ily supported in place by a simple framework.
In the case of larger surfaces mold panels can be made of various portions of the natural rock surface, and trimmed along natural issures. The corresponding rock panels formed from the mold panels can be overlapped and the edges grouted together to reproduce the entire natural rock surface. The joins are substantially invisible since they occur along the fissures.
Description
~L2~
The present invention relates to the field of construction, and more particularly to improvements in reproducing na~ural rock surfaces in the construction of decorative walls, facings, shorelines and the like.
Natural rock outcroppings have long been rec-ognized as features with inherent natural beauty.
Recently, it has become popular to use simulated natural rock decorative facings for walls and various other types of structures, such as simulated mountains, but because the cost of relocating natural rock to construct such facings is either too large, or the size of the desired project is of such a grand scale it is often impos-sible to use natural rocks, or rock outcroppings.
The increased demand for natural rock surfaces and outcroppings has led to the development of various techniques of simulation, including fibreglass panels simulating rock and mortar, sprayed concrete on artificial mountains, and molded concrete rock and mortar walls.
Hcwever, none of these simulation methods reproduce the ~0 particularly attractive naturalness of natural rock outcroppings.
Also, there is an increasing tendency to require reproduction of entire natural rock surfaces on a large scale. Accurate simulation is now required fox shorelines, outcroppings in parks r and even of small man-made mountains in amusements parks and the like. For cost and structural reasons, these applications preclude using individual natural rock or individual molded rock and mortar construction, and aesthetics precludes fibre-S glass or spray concrete techniques. Accordingly, tech-niques have been developed and are known in the prior art for reproducing natural rock surfaces, rather than simulating them, by making molds from natural rock sur-faces.
For example, in my United States Patent No.
4,070,~49 I disclosed a method whereby any given natural rock surface could be reproduced. This method includes the steps of cleaning the surface of the natural outcxop which is to be reproduced, and applying a releasing agent, such as soap flakes, to the surface. Then a layer of latex can be brushed on, a layer of cheesecloth applied, and another layer of la-tex applied. This is repeated four or five times until a latex thickness of one eighth to three-sixteenths of an inch is built up. Then a urethane resin can be applied which will foam in place to form a semi~
rigid mold support. The latex layer and the urethane resin layex are used in conjunction as a mold panel, which can be supported in place and used as a form against which concrete can be poured. After the concrete has set, the mold panel can 5 be peeled off, revealing the reproduced natural rock surface.
In this prior patent, I suggest this technique can be successfully used to make swimming pools, or shorelines, where a trench may be dug, and the mold panel can be suppor-ted against one wall of the trench.
This provides enough support to brace the mold panels under the weight of the cementatious material which is poured into the trench, and which when set forms the reproduced natural rock surface A major difficulty with this technique is that it is in fact very difficult to adequately support the mold panel. The surface of the mold panel is often very convoluted and under the pressure of the cementatious material poured into the trench may distort. If the semi-rigid mo~d panel stretches or bends, unsightly and un-natural deformations may occur in the finished reproduced rock surface. In addition, this method of using earth to support the mold panel against the hydrostatic pressures of the cementatious material is not suitable for above ground inclined rock faces of the type that are often desirable.
The present invention xelates to an improved method of reproducing natural rock surfaces which is suitable for forming above grade, and which reauces the risk of mold deformation. In addition, a minimum of support is required to reproduce the rock surface. Further, the method is suitable for reproducing as large a surface as can be found naturally.
_~ 5 In one if its aspects, the improvement of the present invention comprises spraying a cementatious material into the mold panel to form a thin-walled concrete rock panel which can be supported in place as a non-deformable concrete form~
Unlike the rubber molds previously disclosed in my United States patent no. 4,070,849 and discussed above, the concrete rock panels disclosed in the present invention are rigid enough to withstand the pressures of a cementatious backfill without distortion. The rigidity of such panel allows the panels to be supported in place, by a simple framework, and allows the reproduced rock face to be cast at any angle, without fear o~ the panel bending or stretching and causing unnatural deformation in the final product. Therefore, the present invention discloses how to cast above-grade reproduced rock surfaces utilizing only a simple framework for support during casting, as opposed to the prior art which teaches that the full surface area of the mold must be supported by full contact with a support surface to avoid such unnatural deformations during the castin~ process.
Further, because the individual panels are substan~
tially self-supporting, rock panels reproducing adjacent por-tions of the surface of the natural rock outcrop being repro-duced can be joined, and the continuous reproduced rock face can also be supported in place bY a simple framework prior to casting. The joints between adjacent and abutting panels can be made within reproductions of the natural rock fissures.
In this manner the joints are substantially concealed. Once all of the panels reproducing adjacent portions of the surface have been joined, then cementatious backfill can be placed %~
~ - 6 -behind the completed reproduced rock face. The result is a reproduced rock outcropping which is to a greater extent indistinguishable from the natural rock outcropping.
For a better understanding of the present invention and to show more clearly how it may be carried into effect,reference will now be made, by way of example, to the accompanying drawings which show embodiments of the present invention and in which:
Figure 1 is a perspective view showing schemat-]0 ically a natural rock face from which molds may be for~ed;
Figure la is a sectional view showing a two layer mold formed on a natural rock face;
Figure 2 shows a mold and cementatious material being sprayed into the mold;
Figure 3 shows separation of a rock panel from a mold;
Figure 4 is a side view of a reproduced rock face, Figure 5 is a vertical section showing rein-forcing, and cementatious material being poured behind the reproduced rock face of Figure 4;
~%~
Figure 6 is an enlarged vertical section through the part VI of Figure 5, showing edges of two adjacent panels;
Figure 7 is a perspective view showing a com-plete reproduced rock face; and Figure 8 shows rock panels supported on an inside wall.
A natural rock surface, such as is shown in Figure 1 and indicated generally at 10 is of the type of rocky out-cropping common to certain geographical regions, such as the Canadian Shield RegionO Exploration of rocky outcrop-pings in such a region allows the builder to select a nat-ural rock face which, when reproduced, will well suit the proposed location, both in ~erms of size and shape.
Once a natural rock surface is chosen, it must be cleared of loose surface debris to expose the true features of the rock surface. A release agent~ such as soap flakes, is applied to the surfacé in preparation for applying a layer of latex.
The rock face has fissures 16, which serve to separate portions 17 of the rock face from one another. In many instances the face will be too large to mold all in one . . .
- 8 _ ~2~9~
piece. I~ the mold is taken in portions, it is desirable that the joint lines should not be visible in the reproduced rock wall. The joint lines can be hidden by making them along fissures 16.
For example, Figure 1 shows numerous latex panels 12 with ghost lines 13 marking the edges. It will be noted that edges 13 overlap adjacent latex panels. It is necessary to make the latex panels larger so the edges can be trimmed down later for exact coplanar abutm~nt between adjacent sec-tions of the joined rock wall. This is explained in greater detail below.
The latex can be applied in several coats, and is preferrably applied with a brush. A large open weave mater-ial such as unbleached cheesecloth can be used to reinforce the latex. The reinforcing adds shear strength, which ren-ders the latex panel less likely to rip or tear accidentally without adversely affecting the latex panel's elasticity. It has been found that good results are achieved bY alternat-ing four or five layers of cheesecloth, between layers of latex. Eowever, atotal of 5 to 7 alternating layers can be used.
This is best shown in Fig. la, which shows the inner laYer of latex at 15, the outer layer of latex at 23, and alternating layers of latex and cheesecloth diagrammatically at 19.
The latex and cheesecloth a:reapplied to one area at a time, such an area eventually ~orming a latex panel 1~ hav-ing edges 14. Care is taken to ensure that natural rock fissures 16 correspond approximately with edges 14 of panels 12. The latex panels 12 are generally about 2.5 meters square, to facilitate handling, but may be made slightly smaller or 3~ larger as required to con~orm with the natural rock fissures.
91 2~
~ g A mold panel is formed by applying urethane 25 (Fig.
la and Fig. 2) to the outer surface of a latex panel 12. The method of forming a mold panel involves applying a release agent to the surface of the dried latex panelandthen applying a urethane resin to the latex. It has been discov~red that the best results are obtained if the latex panel 12 is first pulled off the natural rock surface and then laid back in place.
This ensures that it is easily removable from the natural rock surface. The urethane resin can be of a foam in place, closed cell type, with a density of about two pounds per cubic foot.
It has been found that types 106-2A and 106-2B sold by Polymer Development Labs Inc. are satisfactory for this purpose.
The use of two materials in forming the mold panels has certain ~mique advantages. The latex panel, while some-what thin and delicate, is elastic enough to conform exactlywith any surface anomalies of the natural rock face while at the same time being removeable therefrom. The semi-rigid polyurethane foam, on the other hand, is flexible enough to he removably adapted to larger surface anomalies, and provides structural support for the thin and weaker latex layer.
The two layers of mold panel 20 depicted in Figure
The present invention relates to the field of construction, and more particularly to improvements in reproducing na~ural rock surfaces in the construction of decorative walls, facings, shorelines and the like.
Natural rock outcroppings have long been rec-ognized as features with inherent natural beauty.
Recently, it has become popular to use simulated natural rock decorative facings for walls and various other types of structures, such as simulated mountains, but because the cost of relocating natural rock to construct such facings is either too large, or the size of the desired project is of such a grand scale it is often impos-sible to use natural rocks, or rock outcroppings.
The increased demand for natural rock surfaces and outcroppings has led to the development of various techniques of simulation, including fibreglass panels simulating rock and mortar, sprayed concrete on artificial mountains, and molded concrete rock and mortar walls.
Hcwever, none of these simulation methods reproduce the ~0 particularly attractive naturalness of natural rock outcroppings.
Also, there is an increasing tendency to require reproduction of entire natural rock surfaces on a large scale. Accurate simulation is now required fox shorelines, outcroppings in parks r and even of small man-made mountains in amusements parks and the like. For cost and structural reasons, these applications preclude using individual natural rock or individual molded rock and mortar construction, and aesthetics precludes fibre-S glass or spray concrete techniques. Accordingly, tech-niques have been developed and are known in the prior art for reproducing natural rock surfaces, rather than simulating them, by making molds from natural rock sur-faces.
For example, in my United States Patent No.
4,070,~49 I disclosed a method whereby any given natural rock surface could be reproduced. This method includes the steps of cleaning the surface of the natural outcxop which is to be reproduced, and applying a releasing agent, such as soap flakes, to the surface. Then a layer of latex can be brushed on, a layer of cheesecloth applied, and another layer of la-tex applied. This is repeated four or five times until a latex thickness of one eighth to three-sixteenths of an inch is built up. Then a urethane resin can be applied which will foam in place to form a semi~
rigid mold support. The latex layer and the urethane resin layex are used in conjunction as a mold panel, which can be supported in place and used as a form against which concrete can be poured. After the concrete has set, the mold panel can 5 be peeled off, revealing the reproduced natural rock surface.
In this prior patent, I suggest this technique can be successfully used to make swimming pools, or shorelines, where a trench may be dug, and the mold panel can be suppor-ted against one wall of the trench.
This provides enough support to brace the mold panels under the weight of the cementatious material which is poured into the trench, and which when set forms the reproduced natural rock surface A major difficulty with this technique is that it is in fact very difficult to adequately support the mold panel. The surface of the mold panel is often very convoluted and under the pressure of the cementatious material poured into the trench may distort. If the semi-rigid mo~d panel stretches or bends, unsightly and un-natural deformations may occur in the finished reproduced rock surface. In addition, this method of using earth to support the mold panel against the hydrostatic pressures of the cementatious material is not suitable for above ground inclined rock faces of the type that are often desirable.
The present invention xelates to an improved method of reproducing natural rock surfaces which is suitable for forming above grade, and which reauces the risk of mold deformation. In addition, a minimum of support is required to reproduce the rock surface. Further, the method is suitable for reproducing as large a surface as can be found naturally.
_~ 5 In one if its aspects, the improvement of the present invention comprises spraying a cementatious material into the mold panel to form a thin-walled concrete rock panel which can be supported in place as a non-deformable concrete form~
Unlike the rubber molds previously disclosed in my United States patent no. 4,070,849 and discussed above, the concrete rock panels disclosed in the present invention are rigid enough to withstand the pressures of a cementatious backfill without distortion. The rigidity of such panel allows the panels to be supported in place, by a simple framework, and allows the reproduced rock face to be cast at any angle, without fear o~ the panel bending or stretching and causing unnatural deformation in the final product. Therefore, the present invention discloses how to cast above-grade reproduced rock surfaces utilizing only a simple framework for support during casting, as opposed to the prior art which teaches that the full surface area of the mold must be supported by full contact with a support surface to avoid such unnatural deformations during the castin~ process.
Further, because the individual panels are substan~
tially self-supporting, rock panels reproducing adjacent por-tions of the surface of the natural rock outcrop being repro-duced can be joined, and the continuous reproduced rock face can also be supported in place bY a simple framework prior to casting. The joints between adjacent and abutting panels can be made within reproductions of the natural rock fissures.
In this manner the joints are substantially concealed. Once all of the panels reproducing adjacent portions of the surface have been joined, then cementatious backfill can be placed %~
~ - 6 -behind the completed reproduced rock face. The result is a reproduced rock outcropping which is to a greater extent indistinguishable from the natural rock outcropping.
For a better understanding of the present invention and to show more clearly how it may be carried into effect,reference will now be made, by way of example, to the accompanying drawings which show embodiments of the present invention and in which:
Figure 1 is a perspective view showing schemat-]0 ically a natural rock face from which molds may be for~ed;
Figure la is a sectional view showing a two layer mold formed on a natural rock face;
Figure 2 shows a mold and cementatious material being sprayed into the mold;
Figure 3 shows separation of a rock panel from a mold;
Figure 4 is a side view of a reproduced rock face, Figure 5 is a vertical section showing rein-forcing, and cementatious material being poured behind the reproduced rock face of Figure 4;
~%~
Figure 6 is an enlarged vertical section through the part VI of Figure 5, showing edges of two adjacent panels;
Figure 7 is a perspective view showing a com-plete reproduced rock face; and Figure 8 shows rock panels supported on an inside wall.
A natural rock surface, such as is shown in Figure 1 and indicated generally at 10 is of the type of rocky out-cropping common to certain geographical regions, such as the Canadian Shield RegionO Exploration of rocky outcrop-pings in such a region allows the builder to select a nat-ural rock face which, when reproduced, will well suit the proposed location, both in ~erms of size and shape.
Once a natural rock surface is chosen, it must be cleared of loose surface debris to expose the true features of the rock surface. A release agent~ such as soap flakes, is applied to the surfacé in preparation for applying a layer of latex.
The rock face has fissures 16, which serve to separate portions 17 of the rock face from one another. In many instances the face will be too large to mold all in one . . .
- 8 _ ~2~9~
piece. I~ the mold is taken in portions, it is desirable that the joint lines should not be visible in the reproduced rock wall. The joint lines can be hidden by making them along fissures 16.
For example, Figure 1 shows numerous latex panels 12 with ghost lines 13 marking the edges. It will be noted that edges 13 overlap adjacent latex panels. It is necessary to make the latex panels larger so the edges can be trimmed down later for exact coplanar abutm~nt between adjacent sec-tions of the joined rock wall. This is explained in greater detail below.
The latex can be applied in several coats, and is preferrably applied with a brush. A large open weave mater-ial such as unbleached cheesecloth can be used to reinforce the latex. The reinforcing adds shear strength, which ren-ders the latex panel less likely to rip or tear accidentally without adversely affecting the latex panel's elasticity. It has been found that good results are achieved bY alternat-ing four or five layers of cheesecloth, between layers of latex. Eowever, atotal of 5 to 7 alternating layers can be used.
This is best shown in Fig. la, which shows the inner laYer of latex at 15, the outer layer of latex at 23, and alternating layers of latex and cheesecloth diagrammatically at 19.
The latex and cheesecloth a:reapplied to one area at a time, such an area eventually ~orming a latex panel 1~ hav-ing edges 14. Care is taken to ensure that natural rock fissures 16 correspond approximately with edges 14 of panels 12. The latex panels 12 are generally about 2.5 meters square, to facilitate handling, but may be made slightly smaller or 3~ larger as required to con~orm with the natural rock fissures.
91 2~
~ g A mold panel is formed by applying urethane 25 (Fig.
la and Fig. 2) to the outer surface of a latex panel 12. The method of forming a mold panel involves applying a release agent to the surface of the dried latex panelandthen applying a urethane resin to the latex. It has been discov~red that the best results are obtained if the latex panel 12 is first pulled off the natural rock surface and then laid back in place.
This ensures that it is easily removable from the natural rock surface. The urethane resin can be of a foam in place, closed cell type, with a density of about two pounds per cubic foot.
It has been found that types 106-2A and 106-2B sold by Polymer Development Labs Inc. are satisfactory for this purpose.
The use of two materials in forming the mold panels has certain ~mique advantages. The latex panel, while some-what thin and delicate, is elastic enough to conform exactlywith any surface anomalies of the natural rock face while at the same time being removeable therefrom. The semi-rigid polyurethane foam, on the other hand, is flexible enough to he removably adapted to larger surface anomalies, and provides structural support for the thin and weaker latex layer.
The two layers of mold panel 20 depicted in Figure
2, one being the latex 12 and the other being the polyurethane 25, are cured in place and then separately removed from the natural rock surface 10 of Figure 1. First, the polyurethane layer 25 is removed, and then the latex layer 12 is peeled off the natural rock surface. Then, the latex layer is laid into th~ polyurethane layer to form the two layered mold panel 20.
In this form it can be readily transported without being easily damaged, as the polyurethane layer protects the latex layer.
Each two layered mold panel 20 can be used to form a number of rock pan~ls 28 as depicted in Figure 3. Mold panel 20 is supported, such as by a bed oE sand 22 to provide rela-tively firm and uni~orm support ~or the convoluted and irreg-5 ular exterior surface 21 of mold panel 20. ~ thin layer of concrete is then sprayed into mold panel 20. The method of spraying concrete is uniquely suited to coating the complex inside surface of the mold panel 20 with a continuous layer of concrete material. However, because the concrete is being sprayed it has been found that conventional aggregate such as gravel is inappropriate.
A satisfactory spray concrete can be formed using standard type II Portland Riverside Cement, ~60 silica sand, and chopped alkali-resistant glass fibre roving, as a sub-stitute for a normal aggregate. Glass fibre roving type AR2500-H-103 sold by Nippon Elect. Glass Company L~d. has been found a suitable aggregate for this type of application, for two reasons. Firstly, it can be sprayed in the method described below. Secondly, the fibregalss roving has the beneficial effect of increasing the tensile strength of the concrete. As is described more fully below, the rock panel 28 may be back-filled with ordinary concrete on instal-lation. This introduces for a short duration some substantial tensile stresses in the rock panel 28. The fibreglass roving set into the rock panel 28 ailows the rock panel to withstand these tensile stresses.
The roving comes as single long strands, and is most suitably applied by using a chopper gun. The chopper gun per-forms two functions; it chops the roviny into 1/2" to 2" sized pieces, and it provides a nozzle for spraying the concrete.
It has been found that a Downland Sprayer, namely a Downland ~Z~ 2~
~ -- 11 ~
Mark II Gun is suitable for these functions of chopping and spraying.
The spray concrete can be applied in a layer of 1/4"
to 1" thick. The curing agent sold under the trade mark Pozzolith 200n can be added to the spray concrete, to reduce the curing time by causing the concrete to set faster. Where a large number of panels are to be reproduced, use of this admixture can economically reduce ~he production time.
The concrete rock panel 28 is allowed to cure in latex-urethane mold panel 20. Once cured, it is removed as depicted in Figure 3.
Figure 4 depicts the concrete rock panel 28 joined to an adjoining concrete rock panel 30 along natural fissures i6.
It will be remembered that mold panPl 20 is formed to ensure lS that natural rock fissures 16 correspond approximately with edges 14 of panels 12. Care is taken to ensure that ad~oin-ing mold panels extend beyond the natural fissure on each side, to ensure that an overlap is provided between adjoining concrete rock panels when for~ed. Once the mold panels have been formed, and removed from the natural roek surface7 a com-parison can be made adjoining panels to determine the extent of the ovexlap between edges of concrete rock panels cast in these molds. The amount of overlap between two adjacent mold panels can be reduced if necessary by trimming the edges of mold panels to ensure that adjacent edges of adjacent panels lie in co-planar relationship along the entire edge. It can be appreciated that considerable skill is required to ensure that all sides of the panels are in co-planar edge relation-ship. I~ addition, skillful trimmlng of the mold panels, having .~(1 regard to the natural rock fissures, ensures the joint between 92~
adjacent concrete rock panels is substantially hidden from view on the ~inal joined rock face. This is accomplished by locating the joint between adjacent concrete rock panels inside one of the natural rock fissures.
Figure 5 depicts a plan view of the simulated nat-ural rock face. Concrete rock panel 28 is joined to adjoin-ing concrete rock panel 30, along natural fissure 32. It will now be appreciated that it is necessary to trim the edges of mold panels to ensure the overlap between adjoining 1~ concrete rock panels remains hidden.
The simulated rock face is supported as follows. A
boundary 34 (fig. 5) is provided, which may be either an earth wall or a retaining wall, depending upon the circumstances, and which forms one edge of a cavity 35 into which cementatious material 36 may be placed. Reinforcing rods 38 may be used if necessary to provide structural s~rength to the simulated natural rock wall. Reinforcing rods 38 also provide support to keep the adjoining concrete rock panels 28 and 30 in place~
as the cementatious material 36 fills cavity 35. Additional exterior bracing 39 can be used to support the adjoining con-crete rock panels 28 and 30 while the cementatious material 36 fills cavity 35. By means of interior reinforcing rods 38, and exterior bracing 39, the concrete rock panels are held securely in place until the supporting cementatious material sets. Once the cementatious material has set, exterior bracing 3g can be removed.
Figure 6 depicts an expanded view of a cross-section of interface 32 between concrete rock panels 28 and 30.
Through careful trimming of the mold panels, and through care-ful fitting o~ the concrete rock panels 28 and 30, respective edges 50 and 48 of the rock panels 2~, 30 lie in close rela-tion. Then, a skillful application of grout 54 bonds end 48 to end 50. It can be seen from Figure 5, that the grout 54 will be substantially hidden from view, theraby creating the desired impression that the reproduced natural rock sur-face is one solid piece, without visible joints.
Figure 7 depicts -the comple-ted reproduced natural rock wall or outcropping generally at 56. Rock panel 28 is joined to adjoining rock panels using the technique described above, whereby the joint follows along a reproduction of a natural fissure 58 as depicted by ghost lines 60. The cemen-tatious backfill has set and cured, and bonds the rock panels together. ~he strength and mass o the simulated natural rock surface now closely resembles that of the natural rock outcrop.
In addition, there are no visible joint lines, and the sim-ulated natural r~ck surface exactly mimics the minute natural detail of the rock surface from which the molds were taken.
The final stage of simulation comes with the addit-ion of the proper colour to the simulated natural rock sur-~ace 56. This can be done by using paints to provide the natural colour of the rock.
It will be appreciated that the present invention can be used as a decorative facing for interior surfaces as well as a decorative fac:ing for exterior surfaces. For exam-ple, in Figure 8, another embodiment of the invention is depicted where it has been applied to internal wall 62. Tie rods 64 act as support, and adjoining concrete rock panels 65 are attached in the same manner as described in the prev-
In this form it can be readily transported without being easily damaged, as the polyurethane layer protects the latex layer.
Each two layered mold panel 20 can be used to form a number of rock pan~ls 28 as depicted in Figure 3. Mold panel 20 is supported, such as by a bed oE sand 22 to provide rela-tively firm and uni~orm support ~or the convoluted and irreg-5 ular exterior surface 21 of mold panel 20. ~ thin layer of concrete is then sprayed into mold panel 20. The method of spraying concrete is uniquely suited to coating the complex inside surface of the mold panel 20 with a continuous layer of concrete material. However, because the concrete is being sprayed it has been found that conventional aggregate such as gravel is inappropriate.
A satisfactory spray concrete can be formed using standard type II Portland Riverside Cement, ~60 silica sand, and chopped alkali-resistant glass fibre roving, as a sub-stitute for a normal aggregate. Glass fibre roving type AR2500-H-103 sold by Nippon Elect. Glass Company L~d. has been found a suitable aggregate for this type of application, for two reasons. Firstly, it can be sprayed in the method described below. Secondly, the fibregalss roving has the beneficial effect of increasing the tensile strength of the concrete. As is described more fully below, the rock panel 28 may be back-filled with ordinary concrete on instal-lation. This introduces for a short duration some substantial tensile stresses in the rock panel 28. The fibreglass roving set into the rock panel 28 ailows the rock panel to withstand these tensile stresses.
The roving comes as single long strands, and is most suitably applied by using a chopper gun. The chopper gun per-forms two functions; it chops the roviny into 1/2" to 2" sized pieces, and it provides a nozzle for spraying the concrete.
It has been found that a Downland Sprayer, namely a Downland ~Z~ 2~
~ -- 11 ~
Mark II Gun is suitable for these functions of chopping and spraying.
The spray concrete can be applied in a layer of 1/4"
to 1" thick. The curing agent sold under the trade mark Pozzolith 200n can be added to the spray concrete, to reduce the curing time by causing the concrete to set faster. Where a large number of panels are to be reproduced, use of this admixture can economically reduce ~he production time.
The concrete rock panel 28 is allowed to cure in latex-urethane mold panel 20. Once cured, it is removed as depicted in Figure 3.
Figure 4 depicts the concrete rock panel 28 joined to an adjoining concrete rock panel 30 along natural fissures i6.
It will be remembered that mold panPl 20 is formed to ensure lS that natural rock fissures 16 correspond approximately with edges 14 of panels 12. Care is taken to ensure that ad~oin-ing mold panels extend beyond the natural fissure on each side, to ensure that an overlap is provided between adjoining concrete rock panels when for~ed. Once the mold panels have been formed, and removed from the natural roek surface7 a com-parison can be made adjoining panels to determine the extent of the ovexlap between edges of concrete rock panels cast in these molds. The amount of overlap between two adjacent mold panels can be reduced if necessary by trimming the edges of mold panels to ensure that adjacent edges of adjacent panels lie in co-planar relationship along the entire edge. It can be appreciated that considerable skill is required to ensure that all sides of the panels are in co-planar edge relation-ship. I~ addition, skillful trimmlng of the mold panels, having .~(1 regard to the natural rock fissures, ensures the joint between 92~
adjacent concrete rock panels is substantially hidden from view on the ~inal joined rock face. This is accomplished by locating the joint between adjacent concrete rock panels inside one of the natural rock fissures.
Figure 5 depicts a plan view of the simulated nat-ural rock face. Concrete rock panel 28 is joined to adjoin-ing concrete rock panel 30, along natural fissure 32. It will now be appreciated that it is necessary to trim the edges of mold panels to ensure the overlap between adjoining 1~ concrete rock panels remains hidden.
The simulated rock face is supported as follows. A
boundary 34 (fig. 5) is provided, which may be either an earth wall or a retaining wall, depending upon the circumstances, and which forms one edge of a cavity 35 into which cementatious material 36 may be placed. Reinforcing rods 38 may be used if necessary to provide structural s~rength to the simulated natural rock wall. Reinforcing rods 38 also provide support to keep the adjoining concrete rock panels 28 and 30 in place~
as the cementatious material 36 fills cavity 35. Additional exterior bracing 39 can be used to support the adjoining con-crete rock panels 28 and 30 while the cementatious material 36 fills cavity 35. By means of interior reinforcing rods 38, and exterior bracing 39, the concrete rock panels are held securely in place until the supporting cementatious material sets. Once the cementatious material has set, exterior bracing 3g can be removed.
Figure 6 depicts an expanded view of a cross-section of interface 32 between concrete rock panels 28 and 30.
Through careful trimming of the mold panels, and through care-ful fitting o~ the concrete rock panels 28 and 30, respective edges 50 and 48 of the rock panels 2~, 30 lie in close rela-tion. Then, a skillful application of grout 54 bonds end 48 to end 50. It can be seen from Figure 5, that the grout 54 will be substantially hidden from view, theraby creating the desired impression that the reproduced natural rock sur-face is one solid piece, without visible joints.
Figure 7 depicts -the comple-ted reproduced natural rock wall or outcropping generally at 56. Rock panel 28 is joined to adjoining rock panels using the technique described above, whereby the joint follows along a reproduction of a natural fissure 58 as depicted by ghost lines 60. The cemen-tatious backfill has set and cured, and bonds the rock panels together. ~he strength and mass o the simulated natural rock surface now closely resembles that of the natural rock outcrop.
In addition, there are no visible joint lines, and the sim-ulated natural r~ck surface exactly mimics the minute natural detail of the rock surface from which the molds were taken.
The final stage of simulation comes with the addit-ion of the proper colour to the simulated natural rock sur-~ace 56. This can be done by using paints to provide the natural colour of the rock.
It will be appreciated that the present invention can be used as a decorative facing for interior surfaces as well as a decorative fac:ing for exterior surfaces. For exam-ple, in Figure 8, another embodiment of the invention is depicted where it has been applied to internal wall 62. Tie rods 64 act as support, and adjoining concrete rock panels 65 are attached in the same manner as described in the prev-
3~ iously described embodiment. Of course, in the interior appli-cation it may be impossible to back fill with cementatious 29~
--~ 14 -material due to weight considerations. Specifically, adding a large weight load may not be possible in certain upper-story applications. In addition, it may be desirable to have the decorative facing removable, in case different decorative facings are desired in the future. ~owever, provided sufficient number of tie rods 64 are used, and sufficient care is taken in securing the rods 64 to the interior wall 62 and to concrete rock panels 66, the simulated natural rock face should be adequately supported in place even without a cementatious back~ill.
--~ 14 -material due to weight considerations. Specifically, adding a large weight load may not be possible in certain upper-story applications. In addition, it may be desirable to have the decorative facing removable, in case different decorative facings are desired in the future. ~owever, provided sufficient number of tie rods 64 are used, and sufficient care is taken in securing the rods 64 to the interior wall 62 and to concrete rock panels 66, the simulated natural rock face should be adequately supported in place even without a cementatious back~ill.
Claims (17)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of producing panels which reproduce natural rock faces,which method comprises the steps of:
a) applying molding material to a natural rock surface to form a mold having a first surface conforming to said natural rock surface, b) removing said mold from said natural rock surface, c) applying a second material to said first surface of said mold, d) allowing said second material to set to form a thin panel which is substantially self-supporting and which has a surface reproducing the natural rock surface, e) removing said thin panel from said mold.
a) applying molding material to a natural rock surface to form a mold having a first surface conforming to said natural rock surface, b) removing said mold from said natural rock surface, c) applying a second material to said first surface of said mold, d) allowing said second material to set to form a thin panel which is substantially self-supporting and which has a surface reproducing the natural rock surface, e) removing said thin panel from said mold.
2. The method of claim 1 wherein said molding material is comprised of a plurality of layers of latex alternated with layers of an open weave material.
3. The method of claim 1 for producing panels, wherein step (a) comprises:
i) applying a first elastic material on said natural rock surface to be reproduced, ii) removing said first elastic material from said natural rock surface and then replacing said first elastic material on said natural rock surface, iii) applying another material over said first elas-tic material to form said mold.
i) applying a first elastic material on said natural rock surface to be reproduced, ii) removing said first elastic material from said natural rock surface and then replacing said first elastic material on said natural rock surface, iii) applying another material over said first elas-tic material to form said mold.
4. The method of claim 3 wherein said first elastic material is comprised of a plurality of layers of latex alternating with layers of an open weave material.
5. The method of claim 3 wherein said other material is a foam in place polyurethane closed-cell foam.
6. The method of claims 1 or 3 wherein said second material is sprayable concrete reinforced with alkalai resistant glass fiber and when applied has a thickness in the range of 1/4" to 1".
7. A method of reproducing a natural rock surface using a plurality of panels produced by the method of claim 1, the method comprising:
i) supporting said panels in place, and ii) securing said panels so as to form a substantially continuous reproduced natural rock surface.
i) supporting said panels in place, and ii) securing said panels so as to form a substantially continuous reproduced natural rock surface.
8. The method of claim 7 wherein said panels are secured in place by cementatious backfill.
9. A method of reproducing a natural rock surface comprising:
a) removing loose surface debris from said natural rock surface to be reproduced, b) applying a plurality of alternating layers of latex and open weave cloth to said surface of said natural rock to form a plurality of molds having surface forms conforming to adjacent sections of said natural rock surface, c) removing and then replacing said molds on said natural rock surface, d) applying a foam in place polyurethane closed-cell foam onto said molds, e) removing said polyurethane backed molds from said natural rock surface, f) trimming said polyurethane backed molds along lines of natural fissures whereby adjacent mold edges are in exact abutting relationship.
g) applying sprayable concrete into said polyurethane backed molds, h) allowing said sprayable concrete to set to form concrete rock panels, i) removing said concrete rock panels from said poly-urethane backed molds, j) supporting adjacent concrete rock panels in place, and k) joining said adjacent concrete rock panels by applying grout to adjacent abutting edges thereof.
a) removing loose surface debris from said natural rock surface to be reproduced, b) applying a plurality of alternating layers of latex and open weave cloth to said surface of said natural rock to form a plurality of molds having surface forms conforming to adjacent sections of said natural rock surface, c) removing and then replacing said molds on said natural rock surface, d) applying a foam in place polyurethane closed-cell foam onto said molds, e) removing said polyurethane backed molds from said natural rock surface, f) trimming said polyurethane backed molds along lines of natural fissures whereby adjacent mold edges are in exact abutting relationship.
g) applying sprayable concrete into said polyurethane backed molds, h) allowing said sprayable concrete to set to form concrete rock panels, i) removing said concrete rock panels from said poly-urethane backed molds, j) supporting adjacent concrete rock panels in place, and k) joining said adjacent concrete rock panels by applying grout to adjacent abutting edges thereof.
10) The method of claim 9 further comprising supporting adjacent rock panels in place, placing reinforcement there behind, and backfilling with a cementatious material.
11) The method of claim 10 further comprising painting said rock panels to simulate the colouration of said natural rock surface.
12) A panel made in accordance with the method of claim 1 or 3.
13) A reproduced natural surface made in accordance with the method of claims 7 or 9.
14) An artificial rock panel to form part of an artificial rock face reproducing a natural rock face comprising:
a thin substantially self-supporting panel having a surface conforming to a portion of said natural rock face, said panel having edges located substan-tially along fissures reproduced from said natural rock face into a said surface of said panel, so that when a number of said panels are joined together, the joins between adjacent panels will be of reduced visibility.
a thin substantially self-supporting panel having a surface conforming to a portion of said natural rock face, said panel having edges located substan-tially along fissures reproduced from said natural rock face into a said surface of said panel, so that when a number of said panels are joined together, the joins between adjacent panels will be of reduced visibility.
15) An artificial rock face reproducing a natural rock face comprising:
a plurality of thin substantially self-support-ing panels, each panel having a surface conforming to a portion of said natural rock face, adjacent panels having surfaces conforming to adjacent por-tions of said natural rock face, and borders between said adjacent panels, said borders being located substantially along fissures reproduced from said natural rock face/
wherein adjacent panels are joined along said borders to form said continuous artificial rock face, thus reducing the visibility of the joins between adjacent panels.
a plurality of thin substantially self-support-ing panels, each panel having a surface conforming to a portion of said natural rock face, adjacent panels having surfaces conforming to adjacent por-tions of said natural rock face, and borders between said adjacent panels, said borders being located substantially along fissures reproduced from said natural rock face/
wherein adjacent panels are joined along said borders to form said continuous artificial rock face, thus reducing the visibility of the joins between adjacent panels.
16) An artificial rock face reproducing a natural rock face as claimed in claim 15 further comprising:
overlaps between adjacent panels along said borders located substantially along said fissures, and bonding compound, located within said overlap, along said borders said bonding compound being substantially concealed by said over-laps and said fissures.
overlaps between adjacent panels along said borders located substantially along said fissures, and bonding compound, located within said overlap, along said borders said bonding compound being substantially concealed by said over-laps and said fissures.
17) An artificial rock face as claimed in claim 16 wherein said bonding compound is grout.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000498406A CA1211924A (en) | 1985-12-04 | 1985-12-04 | Method for rock reproduction |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000498406A CA1211924A (en) | 1985-12-04 | 1985-12-04 | Method for rock reproduction |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1211924A true CA1211924A (en) | 1986-09-30 |
Family
ID=4132153
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000498406A Expired CA1211924A (en) | 1985-12-04 | 1985-12-04 | Method for rock reproduction |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1211924A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2381277A (en) * | 2001-10-24 | 2003-04-30 | Raymond Price | Precast facing panel, resembling stone wall, e.g. for gabion |
| GB2575307A (en) * | 2018-07-05 | 2020-01-08 | Paul James Bishop Ip Holdings Ltd | Building-wall flexible cladding |
| CN113526905A (en) * | 2020-04-18 | 2021-10-22 | 中国石油化工股份有限公司 | Stress-sensitive fractured reservoir seismic physical model and manufacturing method thereof |
-
1985
- 1985-12-04 CA CA000498406A patent/CA1211924A/en not_active Expired
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2381277A (en) * | 2001-10-24 | 2003-04-30 | Raymond Price | Precast facing panel, resembling stone wall, e.g. for gabion |
| GB2575307A (en) * | 2018-07-05 | 2020-01-08 | Paul James Bishop Ip Holdings Ltd | Building-wall flexible cladding |
| WO2020008176A1 (en) * | 2018-07-05 | 2020-01-09 | Paul James Bishop Ip Holdings Limited | Building-wall flexible cladding |
| US11326352B2 (en) | 2018-07-05 | 2022-05-10 | Paul James Bishop Ip Holdings Limited | Building-wall flexible cladding |
| GB2575307B (en) * | 2018-07-05 | 2022-11-23 | Paul James Bishop Ip Holdings Ltd | Building-wall flexible cladding |
| CN113526905A (en) * | 2020-04-18 | 2021-10-22 | 中国石油化工股份有限公司 | Stress-sensitive fractured reservoir seismic physical model and manufacturing method thereof |
| CN113526905B (en) * | 2020-04-18 | 2022-11-15 | 中国石油化工股份有限公司 | Method for manufacturing stress-sensitive fractured reservoir seismic physical model |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US20070248804A1 (en) | Prefabricated lightweight concrete structure including columns | |
| US4948296A (en) | Swimming pool construction | |
| US3874140A (en) | Structural wall member with sculptured surface and method of making same | |
| JP2003504541A (en) | Building panel and its manufacturing equipment | |
| US4070849A (en) | Method of forming walls for pools, waterfalls and the like | |
| CA1211924A (en) | Method for rock reproduction | |
| US20020100241A1 (en) | Sheet of articulated masonry-like units and method for producing the same | |
| US20100133725A1 (en) | Mold With Reinforced Hinge | |
| US20040123556A1 (en) | Wall unit forming method and apparatus | |
| CN1132985C (en) | Formwork and its use method in building construction and outside decoration | |
| US3700516A (en) | Method of making cellular plastic building panel | |
| JP2516881B2 (en) | Pseudolite block and its manufacturing method | |
| US20030150181A1 (en) | Method and manufacture for constructing watertight concrete structures | |
| CN108422792A (en) | Make the preparation method of scape modeling stone | |
| CN113417354B (en) | Soft film forming and manufacturing process of high-simulation stone ecological landscape fish pond and landscape water pond | |
| JPS5847812A (en) | Artificial river bed | |
| JP2562790B2 (en) | Pseudolite and its manufacturing method | |
| JP3377280B2 (en) | Method for manufacturing a female mold for forming a massive large-sized object, and method for producing a massive large-sized object | |
| JP2688924B2 (en) | Face plate for surface decorative concrete block molding and method for producing surface decorative concrete block | |
| JP6888855B1 (en) | How to make a replica of the replica | |
| JP3857777B2 (en) | Method for manufacturing formwork for concrete | |
| JP2670535B2 (en) | Artificial megalith formwork and method for manufacturing artificial megalith | |
| CA2359639A1 (en) | A sheet of articulated masonry-like units and method for producing the same | |
| JP2003334807A (en) | Form for manufacturing block and method for manufacturing block having natural stone decorative surface using form | |
| JP3120296U (en) | Decorative concrete body |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |