A novel method of exposing the aggregate on vertically cast in place structural concrete has recently been developed in Texas. Using this technique, a concrete contractors can achieve a decorative architectural finish on virtually any cast in place wall, column, or beam.
The process calls for attaching a screen barrier to the reinforcing steel and vibrating a select facing aggregate into place between the outside form and the wire barrier. This aggregate is carefully graded and then thoroughly dampened at least an hour before being placed in the form. A rich concrete mix is placed into the center of the form. High frequency spud vibrators are used to consolidate the concrete and "push" the mortar paste through the loose decorative face aggregate. Formwork is stripped as soon as possible and the surface is sandblasted to expose the aggregate. After sandblasting, the wall is sealed with a clear acrylic which also brings out the color of stones.