Uniform Texture Concrete Wall Using Segmented Shotcrete Layers
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Solution Overview
Problem
Current methods for constructing concrete walls using pneumatically projected concrete, such as Shotcrete, often result in rough and inconsistent surface textures due to air entrapment and other factors, which detract from the aesthetic appeal and require additional processing to achieve uniformity.
Innovation Solution
A method involving the formation of a base concrete layer followed by application of a face mixture without large aggregates, applied while the base layer is in a non-hydrated state, to create a smooth and uniform exterior surface, potentially using a common or separate batch of concrete and incorporating additives for desired appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Shotcrete or pneumatically projected concrete is used to construct walls quickly and easily, then construction efficiency and productivity are improved, but the surface texture becomes rough and inconsistent with air entrapment and holes
Solution Approach 1:
The concrete wall is divided into two distinct layers: a base layer constructed through Shotcrete for structural integrity and construction efficiency, and a separate face mixture layer applied afterward for aesthetic surface quality. This segmentation allows each layer to fulfill its specific function without compromising the other.
Solution Approach 2:
The base layer is constructed first using Shotcrete to establish the structural foundation, and then the face mixture is applied as a preliminary finishing step before final curing. This sequential approach ensures the structural layer is in place before applying the aesthetic layer.
2Strength
If a cast in place wall is constructed with traditional concrete pouring, then the wall can be formed with structural integrity, but the exposed surface has rough texture and inconsistencies after form removal
Solution Approach 1:
The wall construction is segmented into a structural base layer and a cosmetic face layer. The base layer provides structural integrity through traditional concrete pouring or Shotcrete, while the separate face mixture layer addresses surface finish consistency independently.
Solution Approach 2:
Different material qualities are applied to different parts of the wall: the base layer uses standard concrete mix for structural requirements, while the face mixture uses a refined mix without large aggregates specifically for the exposed surface area to achieve uniform texture and consistency.
3Manufacturing precision
If pre cast walls are manufactured with uniform texture by placing the cast face side down, then surface uniformity is improved, but the method is not suitable for pneumatically projected concrete structures
Solution Approach 1:
Instead of trying to achieve uniform surface texture during the Shotcrete projection process itself (which is inherently difficult), the invention inverts the approach by applying a separate uniform face mixture layer after the base layer is constructed, thereby achieving surface uniformity through a reverse sequencing of operations.
Solution Approach 2:
The face mixture acts as an intermediary layer between the structural base layer and the external environment. This intermediate layer provides the uniform surface texture that cannot be achieved directly through Shotcrete projection, while the base layer maintains structural integrity.
4Ease of manufacture
If sandblasting is applied to the exposed wall surface to apply finishing texture, then surface texture can be modified, but additional time and complexity are required
Solution Approach 1:
The uniform face mixture layer is applied as a preliminary step while the base layer is still in a non-hydrated or plastic state, allowing the face mixture to bond naturally without requiring subsequent sandblasting or other time-consuming surface modification processes.
Solution Approach 2:
The face mixture self-bonds to the base layer through natural adhesion when applied in the plastic state, eliminating the need for additional bonding agents, polymers, or mechanical surface preparation processes like sandblasting that would consume additional time and resources.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces labor and material costs, minimizes cold joints, and allows for faster hardening, resulting in a uniform texture and appearance without the need for polymers or bonders, enhancing the aesthetic appeal and construction efficiency of Shotcrete walls.
Implementation Method 1
applying the face mixture to the base layer while the base layer is in a plastic state
Implementation Method 2
pneumatically projecting a first concrete mixture onto the wall form to construct a base concrete layer
Data Source
AI summary
A method for forming a uniform texture concrete wall using Shotcrete or other pneumatically projected concrete materials. The method generally includes forming an exterior face mixture from a concrete mixture wherein the large aggregates are removed such that when the face mixture is pneumatically applied to a base structure, the face mixture defines a uniform surface.