A new method of texturing concrete walls

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This sample concrete panel demonstrates the relief surface that was created by the arrangement of the Styrofoam strips that were nailed to the costing side of the form.

he architects commissioned to design an addition to the Unitarian Church of Spokane, Washington, faced a difficult problem. The original church building had been the private home of one of Spokanes wealthy early-day families, and was constructed of granite stone. Use of similar stone for the planned addition was prohibitive from a cost standpoint, and any other stone alternate would not harmonize with the granite exterior of the original building. Concrete was the logical building material to choose because of its economy and durability, but its smooth surface would give a look of modernity which was not in keeping with the older building or the spacious park-like setting landscaped so beautifully at the turn of the century. The architects, McClure and Adkison, with Moritz Kundig as associate, presented their problem to Spokanes craftsman-designer, Harold Balazs, with the suggestion that perhaps he could work out a method of producing textured concrete walls which would blend with the stone walls. The resulting beautiful and unique addition built to expand the facilities of the church was recently given an award of merit in the second annual design award program sponsored by the Spokane chapter, American Institute of Architects. Mr. Balazs had previously had remarkable success in casting a huge concrete figure of Christ for the exterior decorative object on a church building, using Styrofoam as the forming material. He therefore tested the theory of cutting Styrofoam planks into designed strips and fastening them inside a mold as a form lining. The textured concrete wall section which was produced proved that a design which would harmonize with the stone walls could be achieved by this method. The pattern which he eventually chose as most suitable for the purpose was one of rhythmic, wavy undulations in a vertical pattern to give an effect of greater height to the walls and to contrast with the horizontal curved beams which were part of the architects design. So pleased were the architects and the church building committee with the sample Mr. Balazs made to illustrate his design that

RIGHT: An interior shot clearly shows the interesting effect resulting from the form liners. Similar textured surfaces also served as the exposed outside walls, and harmonized beautifully with the adjacent older building of granite stone.

Harold Balazs, craftsman-designer, uses his band saw to cut through the Styrofoam planks on which he has sketched a pattern of wavy lines. Pieces later rotated 90 degrees and a similar wavy cutting technique was used.

they decided to use it for two of the interior walls, totalling 786 square feet, as well as for the three exterior walls, totalling 1170 square feet. In preparing the mold, Mr. Balazs first drew wavy lines in a rhythmic sequence on 9-foot by 16-inch by 4-inch Styrofoam planks, making four sections to each plank. He then cut along these lines with his band saw, cutting completely through the Styrofoam Next he rotated each piece individually 90 degrees and made wavy, undulating cuts to varying depths, but none closer than 34 of an inch from the bottom. As each piece was sawed, he marked it on the end so the pieces could be kept in correct order because each must fit snugly against the matching piece cut during the first operation. These pieces were then taken to the site where the inside forms for the walls had been placed. The Styrofoam pieces were attached lightly with finishing nails, and the entire surface was coated with form oil. Then the steel reinforcing was placed and the outside form put in place. Mix design called for 1 inch maximum size aggregate (ASTM C33-54 T) and Type I cement (ASTM C150). Five and one-half sacks of cement per cubic yard were mixed with six and one-half gallons of water to produce a fairly wet mix which would penetrate well into the designs in the mold. Because of inclement weather at the time of placing, 1 percent of calcium chloride was added. Air content of concrete was to be 412 percent or 112 percent per ASTM C260-54. Specifications called for a compressive strength of 3,000 psi at 28 days.

Within 48 hours the forms were removed, though the concrete was not completely cured. The styrofoam tends to absorb the moisture so that setting is quicker than under normal conditions. Removing the Styrofoam was a bit more difficult than had been anticipated because in the samples Mr. Balazs had made the forms had been laid fiat, thus allowing the form oil to work more effectively in keeping the Styrofoam from sticking to the concrete. The form oil tended to leech off when the walls were vibrated by the stinger to force the concrete into every portion of the cast. Mr. Balazs feels that the tilt-up technique would be advisable in any future use of this method of texturing concrete walls. Although the walls on this proj ect were filler walls, the same procedure could be used in making load-bearing walls. Other craftsmen can work out an unlimited number of designs because the material is extremely easy to work with, inexpensive, and versatile enough to lend itself to any desired pattern or treatment.

PUBLICATION #C620044
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