Apparatus and method for impressing patterns in a slip-formed concrete wall

Abstract

An apparatus and a method for impressing three-dimensional patterns in a slip-formed concrete wall. At least one impression roller is provided at the discharge end of a slip form. The impression roller includes an outer periphery, provided with a layer or coating of resilient material. The layer is pre-formed or pre-cast to include an aesthetically pleasing, three-dimensional pattern. The axis of the roller is maintained in parallel relation to the plane of the exposed surface of the wall, with the outer periphery of the roller slightly depressed into the wall surface. As the uncured concrete wall emerges from the slip form, the impression roller places a pattern into the wall surface which corresponds to the pattern on the roller. Movement of the roller along the wall causes the impression roller to rotate, impressing successively formed portions of the wall with the pattern. Additional rollers may be used to impress patterns on the opposing wall surface, as well as the top wall surface. After the concrete wall has fully cured, stain, paint, or other decorative features may be applied to the pattern, adding further visual interest and variety.

1 - 23 . (canceled)  
   
   
       24 . A method for continuously impressing a pattern into a slip-formed concrete wall, comprising: 
 continuously slip-forming a concrete wall, the concrete wall having opposing side walls and a top wall, said top wall spanning a transverse distance between said opposing side walls;    partially depressing a first patterned surface into a first exposed surface of one of said opposing side walls;    advancing said first patterned surface along said concrete wall to impress successive portions of said first exposed surface with the first patterned surface as the wall is formed.    
   
   
       25 . A method as recited in  claim 24 , further comprising: 
 engaging a second exposed surface opposite the first exposed surface while the first exposed surface is impressed with the first patterned surface.    
   
   
       26 . A method as recited in  claim 25 , wherein engaging a second exposed surface comprises supporting the second exposed surface while the first exposed surface is impressed with the first patterned surface.  
   
   
       27 . A method as recited in  claim 26 , wherein the second exposed surface is supported with a side wall form extending adjacent to the second exposed surface and opposite to said first exposed surface.  
   
   
       28 . A method as recited in  claim 25 , wherein engaging a second exposed surface comprises partially depressing a second patterned surface into the second exposed surface.  
   
   
       29 . A method as recited in  claim 24 , wherein: 
 said first patterned surface is arcuate;    said first patterned surface having an axis of rotation substantially parallel to said first exposed surface; and    wherein advancing said first patterned surface along said concrete wall comprises rotating said first patterned surface about said axis so that successive portions of said first patterned surface impress successive exposed portions of said first exposed surface.    
   
   
       30 . A method as recited in  claim 29 , wherein: 
 said arcuate surface has a three dimensional pattern; and    wherein partially depressing a first patterned surface comprises rolling the arcuate surface along first exposed surface to create a three dimensional impression in the first exposed surface.    
   
   
       31 . A method as recited in  claim 28 , further comprising: 
 partially depressing a third patterned surface into a third exposed surface;    the third exposed surface being on the same side wall as the first exposed surface and oriented at an angle with respect to the first exposed surface.    
   
   
       32 . A method as recited in  claim 31 , further comprising: 
 partially depressing a fourth patterned surface into a fourth exposed surface;    the fourth exposed surface being on the same side wall as the second exposed surface and oriented at an angle with respect to the second exposed surface.    
   
   
       33 . A method as recited in  claim 28 , further comprising: 
 partially depressing an upper patterned surface into an upper exposed surface;    the upper exposed surface being on the top wall spanning the opposing side walls.    
   
   
       34 . A method as recited in  claim 24 , further comprising: 
 applying a release agent to the concrete wall prior to depressing the first patterned surface into the first exposed surface.    
   
   
       35 . A method as recited in  claim 24 , further comprising: 
 applying a plastic film to the concrete wall prior to depressing the first patterned surface into the first exposed surface.    
   
   
       36 . A method for impressing a pattern into a concrete wall emerging from a slip-form, the concrete wall having parallel opposing side walls and a top wall, said top wall spanning a transverse distance between said opposing side walls, comprising: 
 partially depressing a first patterned surface into a first exposed surface of one of said opposing side walls emerging from the slip-form; and    advancing said first patterned surface along said concrete wall to impress successive portions of said first exposed surface with the first patterned surface.    
   
   
       37 . A method as recited in  claim 36 , wherein the first patterned surface is advanced at the same rate as the formation of the wall emerging from the slip-form.  
   
   
       38 . A method as recited in  claim 36 , further comprising: 
 engaging a second exposed surface opposite the first exposed surface while the first exposed surface is impressed with the first patterned surface.    
   
   
       39 . A method as recited in  claim 38 , wherein engaging a second exposed surface comprises supporting the second exposed surface while the first exposed surface is impressed with the first patterned surface.  
   
   
       40 . A method as recited in  claim 39 , wherein the second exposed surface is supported with a side wall form extending adjacent to the second exposed surface and opposite to said first exposed surface.  
   
   
       41 . A method as recited in  claim 38 , wherein engaging a second exposed surface comprises partially depressing a second patterned surface into the second exposed surface.  
   
   
       42 . A method as recited in  claim 36 , wherein: 
 said first patterned surface is arcuate;    said first patterned surface having an axis of rotation substantially parallel to said first exposed surface; and    wherein advancing said first patterned surface along said concrete wall comprises rotating said first patterned surface about said axis so that successive portions of said first patterned surface impress successive exposed portions of said first exposed surface.    
   
   
       43 . A method as recited in  claim 42 , wherein: 
 said arcuate surface has a three dimensional pattern; and    wherein partially depressing a first patterned surface comprises rolling the arcuate surface along first exposed surface to create a three dimensional impression in the first exposed surface.    
   
   
       44 . A method as recited in  claim 40 , further comprising: 
 partially depressing a third patterned surface into a third exposed surface;    the third exposed surface being on the same side wall as the first exposed surface and oriented at an angle with respect to the first exposed surface.    
   
   
       45 . A method as recited in  claim 44 , further comprising: 
 partially depressing a fourth patterned surface into a fourth exposed surface;    the fourth exposed surface being on the same side wall as the second exposed surface and oriented at an angle with respect to the second exposed surface.    
   
   
       46 . A method as recited in  claim 36 , further comprising: 
 applying a release agent to the concrete wall prior to depressing the first patterned surface into the first exposed surface.    
   
   
       47 . A method as recited in  claim 36 , further comprising: 
 applying a plastic film to the concrete wall prior to depressing the first patterned surface into the first exposed surface.    
   
   
       48 . A method for impressing a pattern into a concrete wall emerging from a slip-form, the concrete wall having parallel opposing side walls and a top wall, said top wall spanning a transverse distance between said opposing side walls, comprising: 
 continuously impressing a three-dimensional pattern into successive portions of a first exposed surface of one of said opposing side walls emerging from the slip-form; and    engaging a second exposed surface opposite the first exposed surface while the first exposed surface is impressed with the three-dimensional pattern.    
   
   
       49 . A method as recited in  claim 48 , wherein engaging a second exposed surface comprises supporting the second exposed surface while the first exposed surface is being impressed with the three-dimensional pattern.  
   
   
       50 . A method as recited in  claim 49 , wherein the second exposed surface is supported with a side wall form extending adjacent to the second exposed surface and opposite to said first exposed surface.  
   
   
       51 . A method as recited in  claim 48 , wherein engaging a second exposed surface comprises impressing a three-dimensional pattern into the second exposed surface.  
   
   
       52 . A method as recited in  claim 48 , wherein the first exposed surface is impressed at the same rate as the formation of the wall emerging from the slip-form.  
   
   
       53 . A method as recited in  claim 48 , wherein continuously impressing a three-dimensional pattern comprises: 
 partially depressing a patterned surface into the first exposed surface; and    advancing said patterned surface along said concrete wall to impress successive portions of said first exposed surface with the patterned surface.    
   
   
       54 . A method as recited in  claim 53 , wherein: 
 said patterned surface comprises the periphery of an impression roller;    said impression roller having an axis of rotation substantially parallel to said first exposed surface; and    wherein advancing said patterned surface along said concrete wall comprises rotating said impression roller about said axis while maintaining engagement of said patterned surface with the first exposed surface so that successive portions of said patterned surface impress successive exposed portions of said first exposed surface.