If you’re wondering whether it’s possible to create a faux concrete wall, the answer is yes. In fact, this type of wall is more common on residential, commercial, and government properties. That’s because the manufacturing process for a precast concrete wall uses faux concrete.
Once made, these products are used for fences, garages, buildings, and other structures.
Is There Concrete in a Faux Concrete Wall?
The most important ingredient in a precast wall is the concrete base, so some concrete does go into the formula for creating faux concrete.
The National Precast Concrete Association (NPCA) certifies factories that manufacture precast concrete products. Before a plant can receive the certification, it must verify that the concrete it uses meets the NPCA’s requirements for quality.
It’s important to note that cement is an ingredient in concrete, so the NPCA restricts what types of cement are acceptable.
Typically, Portland Cement with a grade of 43 or 543 is acceptable. For precast cement used in areas where tornadoes and other harsh conditions may exist, the manufacturer must use stronger grades. In these situations, the manufacturer will use Portland Pozzolana or Portland Slag cement.
What Are the Other Basic Ingredients in Precast Concrete Wall Panels?
Another important ingredient in a faux concrete wall is water, which gets mixed with the concrete.
Two factors affect the use of water for this purpose. First, the amount of water will determine the strength and resilience of the finished wall. Additionally, testing for purity is necessary to ensure the water is free of contaminants. Impurities in the water can adversely affect the durability of the wall.
The manufacturer will add supplementary cementitious materials that come from industrial manufacturing byproducts and natural ingredients. This mixture is useful in improving the formula’s hydration properties.
Finally, aggregates go into the mixture to meet the customer’s design specifications. These materials help alter the color and texture of the faux concrete. In some cases in which the customer doesn’t have design preferences, aggregates may not go into the mixture. These materials are strictly used to meet unique preferences.
What Else Does The Faux Concrete Panels Creation Process Involve?
Once the mixture is complete and ready to get poured into the mold, the manufacturer will add other components. These pieces will help support and strengthen each wall panel, which will later get used in building the faux concrete wall. For example, reinforcing rebar will go into the mold for more durable support.
The manufacturer may also add steel tendons and joints to help dissipate tension and stress on the cement wall. Steel and polymeric fibers can add strength to the precast concrete when included in the mold. Certain structures, such as septic tanks, roofs, and retaining walls, may need waterproofing. An admixture would be included for this purpose.