Layered architectural pervious concrete

Abstract

A layered architectural water pervious concrete is provided. The concrete assembly includes a first layer of water pervious concrete preferably having 15%-25% void space capable of channeling water to the ground and underlying water table. Poured upon the pervious concrete layer, is a non-pervious concrete layer. Joints are formed through the non-pervious concrete layer, which preferably penetrates into the pervious concrete layer at least inch. Water flows from the top surface of the concrete assembly through the joints and into the porous concrete layer for distribution to the ground below.

Claims

1. A method of producing a layered architectural pervious concrete, the method comprising the steps of: (a) preparing a subgrade for receipt of a poured concrete mixture; (b) pouring a pervious concrete mixture upon the subgrade to form a layer of pervious concrete and create a pervious concrete surface; (c) after the pervious concrete mixture has been poured upon the prepared subgrade, pouring an impervious concrete mixture upon the pervious concrete surface to form a layer of impervious concrete and create an exposed impervious concrete surface, and wherein the pouring of the impervious concrete mixture upon the pervious concrete surface is conducted while the pervious layer of concrete is still in a plastic state; and (d) forming one or more joints into the layer of impervious concrete with the one or more joints extending at least from the exposed impervious concrete surface to the pervious concrete surface.

2. The method of producing a layered architectural pervious concrete of claim 1 wherein the one or more joints extend at least inch into the layer of pervious concrete.

3. The method of producing a layered architectural pervious concrete of claim 1 wherein the one or more joints extend through the layer of pervious concrete and partially into the layer of pervious concrete but not all the way through the layer of pervious concrete.

4. The method of producing a layered architectural pervious concrete of claim 1 wherein the step of forming one or more joints includes sawing through the layer of impervious concrete.

5. The method of producing a layered architectural pervious concrete of claim 1 wherein the step of forming joints includes pre-molding joints through the layer of impervious concrete.

6. The method of producing a layered architectural pervious concrete of claim 1 wherein the pervious concrete has at least 5% voids.

7. The method of producing a layered architectural pervious concrete of claim 1 wherein the pervious concrete has at 10-30% voids.

8. The method of producing a layered architectural pervious concrete of claim 1 wherein the pervious concrete provides a water flow rate of at least 2 gallons per minute per square foot.

9. The method of producing a layered architectural pervious concrete of claim 1 further comprising the steps of: (a) broadcasting a decorative aggregate upon the exposed impervious concrete surface; (b) troweling the decorative aggregate into the exposed impervious concrete surface; and (c) exposing the decorative aggregate within the exposed impervious concrete surface.

Description

DETAILED DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective cross-sectional view of the various layers of a first embodiment of a layered architectural water pervious concrete of the present invention;

(2) FIG. 2 is a side cross-sectional view illustrating the various layers of an embodiment of a layered architectural water pervious concrete of the present invention wherein water has started to seep into the joints; and

(3) FIG. 3 is a side cross-sectional view illustrating the various layers of an embodiment of a layered architectural water pervious concrete of the present invention wherein water has seeped through the joints and into the pervious concrete, base-coarse layer, and into the subgrade below.

DETAILED DESCRIPTION OF THE INVENTION

(4) While the present invention is susceptible of embodiment of various forms, as shown in the drawings, hereinafter will be described the presently preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the invention and it is not intended to limit the invention to the specific embodiments illustrated.

(5) With reference to FIGS. 1-3, the concrete assembly 1 of the present invention includes a top layer of traditional non-pervious concrete 7. This layer of non-pervious concrete 7 has a preferred thickness of inch-6 inches, and a more preferred thickness of inch-4 inches. Advantageously, this non-pervious concrete 7 will provide 2500-4000 pounds per square inch p.s.i. compressive strength.

(6) Underneath the non-pervious concrete layer 7, the concrete assembly 1 includes a pervious concrete layer 5. Preferably, the pervious concrete layer 5 is 2-6 inches thick and has 5%-50% void space. Even more preferably, the pervious concrete 5 has 10%-35% void space capable of providing a water flow rate of 2-18 gallons per square foot per minute.

(7) Still with reference to FIGS. 1-3, the concrete assembly 1 includes joints 9. The joints 9 penetrate entirely through the non-pervious concrete layer 7, and preferably extend at least partially into the pervious layer of concrete 5. Preferably, the joints 9 penetrate at least inch in depth into the pervious concrete layer 5. Even more preferably, the joints 9 penetrate inch-2 inches into the pervious concrete layer 5. Preferably the joints 9 are inch- 3/16 inch in width. The preferred joint is 3/16 inch in width. The concrete assembly 1 may include a single joint. However, it is preferred that the concrete assembly include a plurality of joints spaced in accordance with traditional concrete construction such as with spacing of 2 feet-10 feet. Furthermore, the joints 9 may be laid out in various configurations including, but not limited to, parallel, perpendicular grid, or diamond shaped configurations.

(8) Advantageously, the top non-pervious concrete layer 7 provides a pleasing decorative finish having increased strength and durability. With reference to FIGS. 2 and 3, the joints 9 act as channels to capture and divert water 11 from the surface of non-pervious concrete layer 7 to the pervious concrete layer 5. Meanwhile, the pervious concrete layer 5 provides a sufficiently strong support layer and sound dampening barrier while also channeling and distributing water 11 to the ground and underlying water table. Advantageously, the construction of the concrete assembly 1 of the present invention can be accomplished primarily utilizing known construction methods to accomplish a previously unknown structure providing previously unknown benefits. To prepare this concrete assembly 1, a subgrade 2 or formwork (not shown) is prepared. A formwork will utilize wood or metals to create a mold for receipt of a concrete mixture. Conversely, a traditional subgrade 2 is prepared by simply modifying the underlying elevation and grade of the ground. Preferably, the subgrade 2 is compacted, such as to 90%. Water 11 from the upper non-pervious concrete layer 7 and pervious concrete layer 5 may be distributed evenly through the subgrade 2 to the ground. Alternatively, the subgrade 2 may be excavated and/or compacted to divert water such as for collection. Though not necessary, the subgrade 2 may be covered by a layer of base-coarse material 3. Typical base-coarse materials may include sand, gravel and aggregates.

(9) The layer of pervious concrete 5 is poured upon the subgrade 2 and optional base-coarse materials 3. As explained above, the pervious concrete 5 has 5%-50% void space, and preferably 10%-35% void space, and still even more preferably, between 15%-25% voids. The void spaces are determined by carefully controlling the amounts of water and cementitious materials which are used to coat the aggregate particles. Preferably, little or no sand is utilized in the pervious concrete layer 5, but sufficient cementitious paste is utilized to coat and bind the aggregate particles to create a system of highly permeable, interconnected voids that allows the drainage of water 11. Though pervious concrete is capable of providing a water flow rate of 2-18 gallons per square foot per minute, a typical flow rate through pervious concrete 5 is 5 gallons per square foot per minute.

(10) Preferably, before the pervious concrete layer 5 has cured, the non-pervious concrete layer 7 is poured upon the pervious concrete layer 5. Though still in a plastic state, which may continue for up to 28 days after being poured, it is preferred that the pervious concrete layer 5 be allowed to cure sufficiently so as to properly set so as to not be compacted by the weight of the non-pervious concrete layer 7.

(11) Joints 9 are formed entirely through the non-pervious concrete layer 7 and partially into the pervious concrete layer 5. Typically the joints 9 may be installed utilizing tools such as saws or blades or the like when finishing the concrete's surface. However, where the concrete employs hard aggregates, such as coarse gravel, the joints 9 may be molded by utilizing mechanical spacers.

(12) The upper exposed surface of the non-porous concrete layer 7 may be modified to improve the surfaces aesthetics, texture or durability. To this end, color additives and/or color hardeners may be applied. Alternatively, traditional sealants may be utilized to seal the upper exposed surface. Furthermore, decorative aggregates may be utilized to provide improved aesthetics. Implementing each of these finishes can be determined by those skilled in the art.

(13) Once completed, the concrete assembly of the present invention provides an aesthetically superior construction with virtually invisible water channeling capabilities.

(14) While several particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Therefore, it is not intended that the invention be limited except by the following claims. Having described my invention in such terms as to enable a person skilled in the art to understand the invention, recreate the invention and practice it, and having presently identified the presently preferred embodiments thereof,