Method of fabricating decorative wall

A constructed wall structure and method of fabrication that replicates a wall formed by nature. The structure has a plurality of discrete layers, with each layer constructed of concrete and a decorative additive. Every layer has an interface with an adjacent layer to thereby form a plurality of interfaces wherein at least one, and preferably most or all, of the interfaces are non-level. Non-limiting examples of decorative additives are rocks, sea shells, colorants, and mixtures thereof. Methodology for fabricating the wall structure includes pouring a first concrete mixture into a substantially vertical form which can be constructed as a channel within a generally elongate mound of a naturally occurring material and thereafter permitting a top surface of the concrete mixture to assume a non-level configuration. Preferably, a joint forming material is placed on the top surface of this first concrete mixture. In like manner, a second concrete mixture is poured on top of the first layer and a joint forming material is included. Additional layers can be added, with the concrete mixtures preferably including decorative additives that are exteriorly visible. After form removal by removing the mound, the entire wall or individual layers thereof can be subjected to an exterior treatment to enhance appearance.

FIELD OF THE INVENTION 
The present invention relates in general to decorative walls such as for 
landscaping and the like, and in particular to fabrication of a decorative 
wall having a plurality of discrete layers replicating a natural image to 
portray a naturally occurring wall structure. 
BACKGROUND OF THE INVENTION 
Many of the most desirable sights around the world are those formed by 
events caused over many years by the action of nature. Especially 
noteworthy are rock and stone wall formations created by centuries of 
erosion by water, by volcanic actions, or by other natural phenomena that 
expose a vertical face plane revealing a series of layers that represent 
respectively different mineral deposits, sedimentary accumulations, 
fossilized precipitates, and other naturally assembled matter. Evidence of 
the appeal of these natural attractions is apparent in the number of 
tourists who visit such places as the Rocky Mountains, Bryce Canyon, and 
other similar destinations in the United States every year. 
While the pleasure of these attractions is formidable, on-going enjoyment 
for most people when their respective visitations are over is generally 
limited to viewing photographs of these naturally layered wall-like 
structures. Thus, and although such walls are naturally available at only 
relatively few locations where actual residence generally is not even 
available, it is believed that a bona fide replication of the appearance 
of such walls at sites selected by respective viewers is desirous. 
Accordingly, a primary object of the present invention is to fabricate a 
formed wall structure whose exteriorly visible vertical plane has a 
plurality of layers situated to replicate natural appearance. 
Another object of the present invention is to fabricate a formed wall 
structure with discrete layer separations. 
Yet another object of the present invention is to fabricate a formed wall 
structure wherein the plurality of layers differ from each other in 
appearance and can include visible shells, rocks, colorant, or other 
materials. 
Yet another object of the present invention is to fabricate a formed wall 
structure using naturally occurring material as structural framework for 
construction. 
These and other objects of the present invention will become apparent 
throughout the description thereof which now follows. 
SUMMARY OF THE INVENTION 
The present invention is a method of fabricating a formed wall structure 
comprising a plurality of discrete layers. Each of the layers of the 
structure comprises concrete, with at least one of such layers 
additionally comprising a decorative additive, and with each layer having 
an interface with an adjacent layer to thereby form a plurality of 
interfaces wherein at least one, and preferably most or all, of the 
plurality of interfaces are non-level. Non-limiting examples of decorative 
additives can be selected from the group consisting of rocks, sea shells, 
colorants, and mixtures thereof, while the exposed surface can be 
encompassed with a sealing material. 
The method for fabricating the formed wall structure as defined above 
comprises pouring a first quantity of a first concrete mixture into a 
substantially vertical form comprising two generally opposing walls and 
permitting a top surface of the first concrete mixture to assume a 
non-level configuration. This substantially vertical form can be 
constructed of a naturally occurring material preferably situated at a 
site to be occupied by the decorative wall. In particular, the natural 
material at the site is first formed into a generally elongate mound 
having a length and height substantially equal to that desired for a 
finished decorative wall. Thereafter, a channel is formed as by excavation 
within and along the length of the mound of material at a depth equal to 
that desired for the finished decorative wall. The channel thus functions 
as a structural form in which the decorative wall is constructed. 
Preferably, a joint forming material is placed on the top surface of the 
first concrete mixture poured into the channel as noted above to thereby 
form a first layer of the wall. In like manner, a second quantity of a 
second concrete mixture is poured on top of the first layer and permitted 
to assume a non-level configuration at its top surface. Once again, a 
joint forming material can be placed on the top to thereby complete 
formation of a second layer of the wall. One or more additional layers as 
desired can be added in the same way to thereby complete physical 
formation of the wall, with the concrete mixtures preferably including 
decorative additives that are exteriorly visible. After the layers of the 
wall have cured, the natural material is removed from both sides thereof 
and the entire wall or one or more individual layers thereof can be 
subjected to an exterior treatment such as etching, sand blasting, 
sponging, chipping, dusting on a color, applying a sealant, and 
combinations thereof. In this manner, aesthetically appealing wall 
structures can be provided for placement and enjoyment at critical sites 
for architectural as well as artistic functionality.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to FIGS. 1-3, a multi-layer decorative wall structure 10 such as 
for outdoor architectural decor is shown. The structure 10 has five 
decorative layers 12, 14, 16, 18, 20, topped with a finishing layer 21, 
each preferably separated from its next adjacent layer(s) by respective 
cold joints 22 preferably formed as later described with fiber mats 
coupled with vapor barriers. As is apparent, the respective tops 24 of 
each layer 12, 14, 16, 18, 20 are not level to thereby better replicate a 
naturally occurring wall structure with respect to its formation as such 
natural formation occurred over centuries. Decorative additives 
non-limitedly exemplified by sea shells 26 and rocks 28 appear 
respectively in layers 12, 16 to be exteriorly visible. Additionally, 
dust-on colorant as known in the art can be applied to one or more layers 
in one or more colors or color shades to further replicate a naturally 
occurring wall formation. 
Construction of the wall structure 10 is first exemplified in FIG. 5 
wherein two conventional, opposing, generally-parallel plywood boards 36, 
38 are provided to build a form 40 as known in the art between which the 
wall structure 10 is formed. Construction commences by pouring a first 
quantity of a first concrete mixture 12a into the form 40 to a variable 
depth averaging about two inches, but preferably with a non-level top 
surface 24a. The concrete mixture includes concrete along with a 
decorative additive here shown as sea shells 26 as earlier described, and 
such mixture can be mixed prior to pouring or it can be formulated during 
the pouring step by adding the decorative additive to the concrete as it 
is being poured into the form 40. Preferably, a cold-joint forming 
material 22 comprising a vapor barrier such as a plastic sheeting or 
Visqueen.RTM. 44 and standard fiber matting 46 (FIG. 4) is placed on the 
top surface 24a to enhance appearance of resulting layers through 
cold-joint formation. The layer 12 thus formed is allowed to at least 
partially set such that addition of a second layer there above will not 
cause significant disturbance of the top surface 24a. 
When appropriate, a second concrete mixture 14a is introduced into the form 
40 on top of the first layer 12 as shown. As with the concrete mixture 
12a, the mixture 14a includes concrete along with a decorative additive 
(e.g. a colorant as known in the art) as desired. Once again, the top 
surface 24b of the second concrete mixture 14a is permitted to assume a 
non-level configuration. Likewise as described above with respect to the 
first layer 12, a cold--joint forming material is positioned on the top 
surface 24b of the second concrete mixture 14a within the form 40. 
Thereafter, additional layers as desired can be formed as illustrated in 
FIG. 2 to thereby complete construction of the wall structure 10. If the 
wall structure 10 is to be used as a support for one or more items to be 
placed thereon as exemplified in FIG. 1, a flat cover piece 21, here shown 
as concrete, but which can be made of wood or other material, is formed 
over the structure 10 as shown. Construction of the wall structure 10 can 
be accomplished at the site of desired placement, or it can be constructed 
off-site in sections as required for size considerations and thereafter 
delivered to the location of ultimate placement. 
FIGS. 6-8 exemplify a wall construction methodology wherein a substantially 
vertical form 50 can be constructed of a naturally occurring material 52 
such as packed sand preferably situated at a site to be occupied by a 
multi-layer decorative wall structure 10a. In particular, the natural 
material 52 at the site is first formed into a generally elongate mound 54 
having a length and height substantially equal to that desired for a 
finished decorative wall 10a. Thereafter, a channel 56 is formed as by 
excavation within and along the length of the mound 54 of material 52 at a 
depth equal to that desired for the finished decorative wall 10a. The 
channel 56 thus functions as a structural form in which the decorative 
wall 10a is constructed. Just as in the construction of the wall 10 as 
described above in relation to the form 40, a first quantity of a first 
concrete mixture 12a is poured into the channel 56 to a variable depth 
averaging about two inches, but preferably with a non-level top surface. 
The concrete mixture 12a includes concrete along with an optional 
decorative additive as earlier described, and such mixture 12a can be 
mixed prior to pouring or it can be formulated during the pouring step by 
adding the decorative additive to the concrete as it is being poured into 
the channel 56. Preferably, a cold-joint forming material comprising a 
vapor barrier such as a plastic sheeting or Visqueen.RTM. and standard 
fiber matting as described above is placed on the top surface of each 
layer to enhance appearance of resulting layers through cold-joint 
formation. The layer 12 thus formed is allowed to at least partially set 
such that addition of a second layer there above will not cause 
significant disturbance of its top surface. 
As described above with respect to use of a plywood form 40, a second 
concrete mixture 14a is introduced into the channel 56 on top of the first 
layer 12 as shown to form a second layer 14. As with the concrete mixture 
12a, the mixture 14a includes concrete along with a decorative additive as 
desired. Once again, the top surface of the second concrete mixture 14a is 
permitted to assume a non-level configuration. Likewise as described above 
with respect to the first layer 12, a cold-joint forming material is 
positioned on the top surface of the second concrete mixture 14a within 
the channel 56. Thereafter, additional layers as desired can be formed as 
illustrated in FIGS. 7 and 8 to thereby complete construction of the wall 
structure 10a. A cover 21 can be placed on the top of the wall 10a as 
described above in relation to the wall 10. Upon complete curing, the 
material 52 of the mound 54 is removed to thereby leave the wall 10a in 
place as shown in FIG. 8 which depicts the earlier-standing mound 54 in 
phantom lines. As earlier described, the exterior of the wall 10a can be 
subjected to an exterior treatment to further enhance its appearance. 
As is apparent, the present invention provides a readily fabricated wall 
structure whose exteriorly visible vertical planes replicate the 
appearance of a naturally formed wall. While an illustrative and presently 
preferred embodiment of the invention has been described in detail herein, 
it is to be understood that the inventive concepts may be otherwise 
variously embodied and employed and that the appended claims are intended 
to be construed to include such variations except insofar as limited by 
the prior art.