Method and manufacture for constructing watertight concrete structures

Abstract

A method and article of manufacture for building waterproof concrete structures. An integral casing comprised of a rigid plastic shell with an armature attached to its face is covered with concrete. The shell is formed either in the shape of a desired structure or in a generic shape to be used to splice together a larger custom structural shape in a mosaic fashion. The shell acts both as a form to support the wet poured concrete and becomes an integral part of the finished structure to provide waterproofing.

What is claimed is:  
     
         1 . A three-dimensional waterproof concrete structure used in an environment in which the structure will be exposed to water, comprising: 
 a free-standing, integral casing comprising: 
 a three-dimensional, free-standing, waterproof shell having an exterior surface, that is sufficiently rigid to support a layer of concrete material;  
 a plurality of fasteners directly attached to the shell; and  
 a matrix of structural reinforcement material having a side facing the exterior surface of the shell, the side being attached by the fasteners to and spaced from the exterior surface to define a three-dimensional gap therebetween, the matrix conforming to and covering at least a substantial portion of the exterior surface; and a hardened cementatious material covering the integral casing, the cementatious material being initially flowable so as to envelop the matrix and enter the gap, thus bonding the matrix to the shell when hardened,  
   wherein the free-standing shell is substantially hollow so as to form an interior area.    
     
     
         2 . The structure of  claim 1 , wherein the structure is formed in the shape of an artificial rock structure.  
     
     
         3 . The structure of  claim 1 , wherein the structure is provided with a pump and plumbing to create a waterfall over the exterior of the structure.  
     
     
         4 . The structure of  claim 3 , further including at least one natural rock attached to the exterior thereof.  
     
     
         5 . The structure of  claim 3 , further including at least one artificial rock casting attached to the exterior thereof.  
     
     
         6 . A method of making a three-dimensional waterproof concrete structure used in an environment in which the structure will be exposed to water, comprising the steps of: 
 providing a three-dimensional, free-standing, waterproof shell that is sufficiently rigid to support a layer of concrete material, having an exterior surface;    providing a plurailty of fasteners and attaching the fasteners to the shell, and fastening a three-dimensional matrix of structural reinforcement material to the exterior surface of the shell by the fasteners, the matrix having a side facing the exterior surface of the shell that is fastened to be spaced from the exterior surface and define a three-dimensional gap therebetween, the matrix conforming to and covering at least a substantial portion of the exterior surface; and    enveloping the matrix with a hardenable cementatious material, the material entering the gap and bonding the matrix to the shell when the material hardens, wherein the shell is substantially hollow and the method comprises molding the shell from a polymer.    
     
     
         7 . The method of  claim 6 , further including providing at least two of the waterproof shells, attaching the shells together, and fastening the three-dimensional matrix of structural reinforcement material over the attached shells.  
     
     
         8 . The method of  claim 6 , wherein the concrete structure is formed in the shape of an artificial rock structure, and further including attaching natural rock to the exterior thereof, wherein the natural rock is attached to the matrix of structural reinforcement material prior to enveloping the matrix with the cementatious material.  
     
     
         9 . The method of  claim 6 , wherein the concrete structure is formed in the shape of an artificial rock structure, and further including attaching an artificial rock casting to the exterior thereof, wherein the casting is attached to the matrix of structural reinforcement material prior to enveloping the matrix with the cementatious material.  
     
     
         10 . The method  claim 6 , wherein the concrete structure is formed in the shape of an artificial rock waterfall, and further including installing in the structure a pump and plumbing for the waterfall.  
     
     
         11 . An integral casing for constructing a three-dimensional waterproof concrete structure used in an environment in which the structure will be exposed to water, comprising: 
 a free-standing substantially hollow, so as to form an interior area, three-dimensional and waterproof shell that is sufficiently rigid to support a layer of concrete material, having an exterior surface;    a plurality of fasteners directly attached to the shell; and    a matrix of structural reinforcement material having a side facing the exterior surface of the shell, the side being attached by the fasteners to and spaced from the exterior surface to define a three-dimensional gap therebetween, the matrix conforming to and covering at least a substantial portion of the exterior surface, and the matrix is adapted to retain a hardened cementatious material covering the integral casing, the cementatious material being initially flowable so as to envelop the matrix and enter the gap, thus bonding the matrix to the shell when hardened.    
     
     
         12 . The integral casing of  claim 11 , further including a door provided in one side of the shell to enable access into the hollow interior of the shell.  
     
     
         13 . The integral casing of  claim 11 , wherein the integral casing is formed in a general shape of an artificial rock structure.  
     
     
         14 . The integral casing of  claim 13 , wherein the integral casing is provided with a pump and plumbing to create a waterfall over the exterior of the structure.