Abstract: The present invention is a contoured wall and method for creating the contour and appearance of a wall formed from individual assembled units such as stones. The wall is formed from a plurality of mating form liners each having a reciprocal contoured surface to that of the desired stone wall. The wall is formed from hardenable construction material such as concrete poured between two mold members with the form liners attached to at least one of the mold members. Each of the form liners has a lateral relief mold face adapted to provide a molded surface having the contour of a stone wall. Each lateral relief mold face of the form liners has a latticework non-linear mortar-forming interlocking portion surrounding stone-forming recessed portions. The form liners ar positionable in a plurality of arrangements wherein the interlocking portions and recessed portions along the mating edge of each form liner mate along the mating edge of the adjacent form liner to form a continuous lateral relief mold face.

Abstract: A concrete conduit is completely encased within a shell of a plastic resin such as polyethylene. The plastic shell functions to insulate the concrete conduit from mechanical shocks thereby preventing breakage and cracking of the conduit. The shell also effectively provides an impermeable barrier for water vapor and a smooth, relatively frictionless, surface for receiving electric cables, wires and the like. The conduit is made by preforming the shell, for example by rotational molding, and filling the shell with pourable cement through a filler hole in the shell. The filler hole can then be closed with a plug of the resin used to form the shell.

Abstract: A process for preparing cast articles includes preparing a primary mold of a flexible resilient bag-shaped membrane, disposing casting material in a flowable state into the primary mold and allowing the casting material to harden. Optionally, a relatively fixed secondary mold or a combination of relatively fixed secondary molds can be used adjacent the outside of the primary mold to impart a predetermined shape to portions of the cast object. A continuous ultra-smooth surface is created on the cast objects duplicating the surface of smooth naturally weathered stone.

Abstract: A secondary containment structure formed of a slurry infiltrated fiber concrete composite is used above ground or underground to enclose material storage containers and to safely contain any materials leaked from the container. The structure is a hollow configuration having a bottom wall, at least one side wall, and a removable top wall. The interior volume of the structure exceeds the volume capacity of the container which is enclosed therein. The bottom wall is sloped to facilitate drainage of any liquid leaked from the container and the top wall may have covered apertures to allow access to the container.

Abstract: The method includes mixing (100) degradable consumable cores (11) with a liquid coating composition (20) including an aqueous solvent (21), a hydrosoluble resin (22) and an anti-agglomerant additive (23), drying (200) the coated cores so as to obtain free balls (12) with a substrate film (2), mixing (300) these balls (12) first of all with a liquid covering substance (30) including a synthetic base product (31) and optionally an auxiliary product (32), then with an anti-agglutinant adjuvant (33), drying (400) the covered balls so as to obtain free ball structures (13) with a covering layer (3), and stoving (500) these ball structures so as to harden their covering layer and degrade the cores and thereby obtain hollow spherules (10). Application in the manufacture of intermediate products for producing in particular energy absorbers.

Abstract: A method of repairing an underground large-diameter pipe having an inner surface includes first supporting with props inside the pipe spaced inward from its inner surface a lining having a shape conforming to that of the inner surface and then injecting a hardenable mass into the space between the inner surface and the lining and substantially completely filling this space with the mass. The mass is then cured and the props are removed. Then the cycle can be repeated for the next lining section. The lining is made of a durable synthetic resin, polyvinylchloride or high-density polyethylene.

Abstract: A method for forming hollow concrete structures or shells in which the top, bottom and sides are formed into an integral unitary structure by rotating an assembly of reinforcing members to enable the concrete forming the top, bottom and side to each be finished in a substantially horizontal position with a minimum of forms. Openings for doors and windows may be formed by using suitable blanks that are prepositioned prior to pouring the concrete. Also, suitable end closure members can also be formed in a flat or horizontal position inside the unitary structure for subsequent erection in a vertical position.

Abstract: A pre-cast terrazzo panel having detailed, multicolor designs therein constituted by background and inlay designs of different colors includes inlay and background colors which are integral with no surface difference between the inlay and the background.

Abstract: A method for manufacturing a panel in which a base sheet having adhesive or all or selected parts of a surface thereof. Small stones are applied to the base sheet and a water absorbing polymer is also applied. A hardening material, such as center, is spread over the stones and the polymer. The polymer absorbs the water of the cement and expands. It is thereafter washed off or allowed to evaporate.

Abstract: The method of forming a three-dimensional pattern, wherein a pattern forming mold formed from an expanded polyethylene is attached to the work surface where a desired pattern is to be formed, a surfacing material of a specific acrylic resin concrete is cast onto the work surface, the surfacing material is allowed to harden, and the mold is detached and removed from the work surface.

Abstract: A method of making a shell mould, particularly for a lost wax casting operation, includes the deposition of an adhesion agent on the pattern before the deposition of layers of ceramic material to build up the mould. The adhesion agent used is preferably a 3% solution of aminosilane in a solvent consisting of ethanol and ethyl acetate in amounts from 25% to 75% of the solvent. The method avoids the phenomenon of detachment at the pattern/ceramic interface.

Abstract: A depositing method of wall concrete, in which unset concrete is deposited in a form, includes the step of disposing a non-hygroscopic soft sheet which has a large number of hollow projections or ridges on an inner surface of the form being deformable when lateral pressure is applied thereto by the hardening of the concrete.

Abstract: Thermally and acoustically insulating, water-repellent, fire resistant, slab-shaped building components are formed by wetting a plurality of expanded polystyrene beads with water and water-soluble synthetic resin, to coat the beads adding an inert filler drying and/or polymerizing the resin and mixing the thus-coated beads with predetermined proportions of cement, sand, fluidifying additive and water and also stearate. The thus-obtained mixture is put into a slab-shaped form and reinforcing components are immersed in the form. The mixture is cured and a thus-formed slab-shaped element is withdrawn from the form.

Abstract: There is provided an apparatus for producing a paving block comprising a block substrate and a solid top layer selected from a tile-like layer and a cured cement mortar layer firmly bonded onto the upper surface of the block substrate. The apparatus comprises a mortar applicator (21) consisting essentially of a mortar container and a masking bottom board (23) having an opening (24) to be located on the back of a top layer (1-2) or the upper surface of a block substrate (1-1) during application of cement mortar thereon, a clamping plate (25) to be located on the top layer (1-2) placed on the block substrate (1-1) during bonding them, and a scraping frame (26) for scraping excess mortar remaining on the side surfaces of the bonded block. When the apparatus is used to produce a novel paving block comprising a block substrate and a solid top layer having a plane dimension smaller than the substrate, squeeze-out deposits (6) of the cement mortar (7) are further formed around the bonded top layer (1-2).

Abstract: A method and apparatus for constructing an above ground concrete encased storage tank. The apparatus has a support assembly that extends from the baseplate of a concrete form, that supports, elevates, and secures an inner storage tank from the form baseplate, so that the tank may be completely surrounded by concrete. The form has removable walls that may be pivotally attached to the baseplate and initially in a horizontal position. The support assembly has anchor bolts that extend through holes in the baseplate. The anchor bolts are screwed into anchor nuts that are attached to a pair of brackets. The anchor nuts and brackets are spaced from the baseplate by sleeves that fit over the threaded portions of the anchor bolts. The brackets are constructed to support the storage tank, which is placed in the form on top of the support assembly. The tank is then fastened to the support assembly.

Abstract: A method of sealing a concrete joint formed between a pair of concrete castings by creating an injection hole wherein a removable frame member can be attached to the bottom surface of the first concrete casting so as to form obtuse angles with the concrete casting surface. The other concrete casting is then cast around the frame member. The frame member is then removed to form the injection hole of the desired configuration, and sealing material can then be inserted into the injection hole for feeding into, and sealing of, the joint.

Abstract: Dry cementitious compositions and packages and methods for their application. The dry compositions do not have to be mixed with water but instead are poured, sprayed or troweled onto a substrate which contains water in an amount in excess of that necessary for the hydration of the cementitious materials. These compositions can be applied by layering, dropping through a conduit, or preferably, merely dropped into the water.

Abstract: A centrifugal molding method which can smooth the inner surface of the resin concrete layer of a resin concrete pipe or of a composite pipe having a resin concrete layer even without using any special sand conditioning mechanism and which is high in productivity includes producing a composite pipe having a resin concrete layer or producing a resin concrete pipe by moving an arm member of a pipe material feeding device forward and backward axially through a pipe forming outer mold rotating about an axis thereof and by feeding pipe materials from a discharge port formed in a front end of the arm member. The resin concrete layer is formed by feeding resin and aggregate to a mixing portion provided at the front end of the arm member through separate feed routes, mixing the two in the mixing portion and discharging the resulting mixed resin concrete material from the discharge port.

Abstract: A method for producing concrete paving stones includes slidably mounting paving stone molds in a vertical row in a rack; sliding one mold to a different depth in the rack; filling the mold with concrete; sliding the mold to its original position; and filling the other molds in a similar manner.

Abstract: The components forming the layers of a composite pipe are successively introduced into a rotary drum (1). Initially, a plastic reinforcing lyaer (8), including a fiber reinforcement, is introduced into the drum, the ends of the drum (1) being bounded by rings. A concrete core layer (16) is then introduced and the length of the core layer (16) is shortened relative to that of the drum (1) by shaping rings fixed to the drum ends. The shaping rings are then replaced by other shaping rings (20, 21) so that, on either side of the core layer (16), two annular spaces (22, 23) are formed which are filled by a socket material (24, 25) of the same composite as the reinforcing layer (8). Thus, at one pipe end a socket end (28) is formed and at the other pipe end a spigot end (30) is formed, each such end being located within the composite pipe wall thickness. After introducing a second reinforcing layer (26), the production of the composite pipe is completed.

Abstract: An apparatus and a proces for the manufacture, by the extrusion method, of roof covering plates having at their underside a transverse flange shaped thereto. At a filling station cavities in the pallets corresponding to the transverse flange, are first filled with a hardenable plastic material such as fresh concrete, and said material is then compacted at at least one compacting station. Thereafter, a continuous layer of the material is deposited at a depositing station. The material is finally processed to roof covering plates.

Abstract: Decorative interior molding is molded from a slurry of gypsum, water, perlite, and a foaming agent. The slurry is surrounded by paper, cured, and dried.

Abstract: Procedure for the construction of a concrete shaft for a platform or similar structure, where one of several of the shafts will be outfitted with relatively much equipment. The shafts are constructed of prefabricated sections which are consecutively installed butt-in-butt on top of each other and which are left in the shaft as an internal fully shaped shaft component, as the sections internally contain associated equipment and externally feature bodies for the installation of easily removable formwork elements, preferably easily mountable slipforms, while the space between the formwork elements and a prefabricated section is filled with reinforcement and concrete. The formwork elements, after the hardening of poured concrete, by a per se known procedure, are moved to a higher level.

Abstract: A method of manufacturing and using a resinous concrete in the production of forming tools for stamping, trimming and other treatments of sheet metal parts. The process includes first mixing at least one resin and hardening agent and then adding a siliceous pulverulent grain filler so that the gravimetric ratio between the resin and hardening agent and the filler when mixed for a time depending on the working temperature at a work site will result in a mixture of filler grains and resin essentially free of macromolecules and having remaining spaces between the grains filled with the essentially macromolecular free resin thereby eliminating the formation of bending bridges. The final mixture is then poured into a casing containing working parts and moulding elements to create forming tools useable after the mixture polymerizes.

Abstract: A concrete pipe is produced by introducing a wet concrete mass into a pipe form to produce a cylindrical mass having an inner wall, compacting the cylindrical concrete mass by applying pressing rollers to the inner wall, smoothing the inner wall of the compacted cylindrical concrete mass, and applying a liquid impregnation medium to the inner wall under pressure after the concrete mass has been compacted, the inner wall has been partially smoothed and the concrete mass is still damp. The pressure is sufficient to cause the impregnation medium to permeate the damp concrete mass to a depth of at least 10 mm.

Abstract: A novel process for preparing a pre-cast terrazzo panel having detailed, multicolor designs therein constituted by background and inlay designs of different colors. The inlay and background colors are integral with no surface difference between the inlay and the background. The process involves the steps of (a) providing a pre-cast unpolished terrazzo panel with a first background color; (b) cutting out an inlay pattern or design in the terrazzo panel to create a silhouette cut-out panel; (c) placing the cut-out panel in a mold, pouring a blend of a second color comprising a binder and aggregate into the cut-out and curing the blend to create a cured inlay of a second color in the panel; (d) repeating steps (b) and (c) as often as desired with blends having colors the same or different from the first and second colors; and (e) polishing the resulting panel to produce a terrazzo panel having a plurality of colors.

Abstract: Iron pipe and other hollow articles are lined with a cementitious mortar containing a quantity of polymer particles and the pipe is rotated about its axis so as to stratify the mortar and develop a polymer rich inner surface that is subsequently cured, dried and heated to the polymer fusion temperature and then coated with a continuous layer of pure polymer.

Abstract: Concrete-type composite pipe is produced by rotating a drum mold while casting concrete thereinto to form a concrete layer of a uniform thickness using a centrifugal force exerted on the cast concrete, casting a mixture of hydrophilic resin and a hardener to form a corrosion protective resin layer on an inner surface of the formed concrete layer before the concrete layer starts to solidify, scattering aggregates or the like on the inner surface of the resin layer, accelerating the rotation to cause the aggregates or the like in the resin layer to form an intermediate layer, between the concrete layer and the corrosion protective layer, of resin, concrete, and coarse aggregates and stopping the rotation after the hardening of the corrosion protective layer.

Abstract: A wave-dissipating caission includes a box-shaped skeleton made up of ridge members, wherein wing members are provided. Each wing member is in the form of a trapezoid with one end thereof separated from other wing members, and an opposite end joined to other wing members. The method for producing the caisson includes the steps of providing a mold for a bottom plate portion of the caission, depositing reinforced concrete into the mold for forming the bottom plate portion, and installing a plurality of steel rods onto the bottom plate portion. The method for producing the caission further includes the step of erecting wing frames, right and left side frames, front and back frames, and an upper frame around the plurality of steel rods. Concrete is then deposited into the frames, thereby forming the caission within the frames. Then the frames are removed from the formed caission.

Abstract: Rammed building walls having an earth core and integral cement jackets are formed by placing a rectangular earth hopper within a rectangular wall moulding cavity that is defined by formwork members which are aligned with an underlying foundation. The hopper is filled with earth while outside of the moulding cavity and has a trapdoor as its bottom. The moulding cavity has a substantially greater width than the width of the hopper so that jacket cavities are formed on either side of the hopper. A pair of tiltable cement hoppers, filled with concrete or a sand and cement mix, are mounted on the earth hopper and are tiltably unloaded into the jacket cavities. The trapdoor is then released so that the earth slides downwardly and laterally, and the hoppers are lifted as a unit out of the moulding cavity while the earth fills a core cavity between the mix-filled jacket cavities. Both the earth and mix are then rammed simultaneously.

Abstract: A process for manufacturing stratified pieces, such as roof tiles and wall tiles, by sucessive and independent extrusion of mortars or concretes. In the process mortar is deposited on a limited part of the molds. The mortar is extruded and compacted, and some mortar is dislodged from cross strips in each zone of contact between two consecutive molds. Thereafter, complete sheets of mortar are shaped on the first layers, filling both the emptied cross strips and the limited sides, and lastly the thicknesses of the pieces are cut in their entirety in a vertical transversal plane at each zone of contact of the molds to form multiple layer tiles having homogeneous facing surfaces.

Abstract: A form assembly for casting a lining wall in an existing manhole includes a cylindrical lower form assembly, a circular horizontal form assembly, and a cylindrical upper form assembly. All three assemblies are formed of smaller segments which are assembled together within the manhole and which can be disassembled after the manhole has been repaired.

Abstract: A collection of sheet-metal, flanged, arcuate panels is provided which panels can be assembled in belts of generally circular cross-section commencing from the bottom of the manhole to provide a complete form structure for casting a concrete liner with a minimum thickness of about three inches and including openings created by sectional cylindrical inserts, all of which can be assembled, then disassembled after the concrete liner has set. An extensive variety of panels to accomodate different shapes of manholes includes panels for forming right conical belts, for forming offset conical belts, and for forming wedge-shaped belts to make transitions between vertical and tilted sections of the manhole. A key-panel for these various belts is provided to prevent capture of the panels by the poured concrete liners which includes a relatively narrow portion with vertical flanges fixed at an angle to one another which angle diverges toward the center of the form structure.

Abstract: The fracture-free paving block (1) comprises a cement block substrate (1-1) and a top solid layer (1-2), and is characterized in that the top layer is selected from a cured cement mortar layer and a tile-like layer firmly bonded to the substrate with cement mortar; the top layer is bonded to the block substrate with lateral margins (2) of 1 to 8 mm wide in horizontal distance (1.sub.5) from the peripheral edges of the substrate: and the vertical distance (1.sub.6) from the surface of the top layer to the peripheral edge of the substrate is 5 to 50 mm. The method for producing the paving block (1) having a tile-like top layer comprises applying adhesive cement mortar between the back of the top layer (1-2) and the upper surface of the substrate (1-1); placing the top layer on the substrate with the above-mentioned margins (2) of the substrate surface: and applying vibration and/or pressurization between the top layer and the substrate.

Abstract: A process for producing improved gypsum models and molds of high duplication accuracy is provided. In the process, bundles of carbon fibers of specified length and amount having a sizing agent deposited thereon are treated to remove the sizing agent from the carbon fibers which are then separated into single fibers in water. A major part of hemihydrate gypsum (CaSO.sub.4.1/2H.sub.2 O) powder is then added to the carbon fibers dispersed in water to obtain a gypsum slurry having the carbon fibers uniformly dispersed therein. The slurry is then cast to obtain the models or molds.

Abstract: A method for making a water and fire resistant building material of a layered, shaped and hardened composition of one or more absorbant components, magnesia cement, chemically active fumed silica, alkali silicate, one or several inorganic fillers, one or several lignin sulphonates, eventually ethyl silicate, whereby the final product is built up of a two binder system, one of fumed silica, alkali silicate and optionally magnesium oxide and the other of magnesia cement and a lignin sulphonate salt. The method of producing the product includes forming a dual layered binder system having a very short press time.

Abstract: After a mortar layer is formed on the surface layer of placed concrete, an ultrasonic vibrator is caused to vibrate while being pressed against the mortar layer surface, and a thin surface layer is scraped off, obtaining a dense water-shielding layer. Mortar with a low water-cement ratio is spread onto the surface of the water-shielding layer, and adhesion between the mortar and the water-shielding layer is strengthened by using the ultrasonic vibrator. The pressing force of the ultrasonic vibrator is then increased to make the mortar and the water-shielding layer densely integrated together, thereby forming a hard concrete surface excelling in abrasion resistance.

Abstract: The wall of the pipe section comprises a plurality of superimposed layers, which are formed from plastic and inorganic materials. The layer of inorganic materials forms the central layer, whose wall portions are in each case connected by a connecting layer to a reinforcing layer. While the central layer ensures the dimensional rigidity of the pipe section, the two reinforcing layers, which are made from a fiber-reinforced plastic, ensure the strength of the pipe. This combination of different layers is an inexpensive solution, which only requires that amount of expensive plastic as is required for the strength of the pipe. Through applying a plastic protective layer to the outer circumference of the pipe and a protective layer to the inner circumference of the pipe, the durability of the pipe section is ensured.

Abstract: A method of constructing a swimming pool by laying a concrete shell of 80 mm thickness without any substantial reinforcement. A glass reinforced plastic of 5 mm thickness is then laid over the concrete once the concrete has cured. This particular combination between the fiberglass and the concrete shell allows the shell to crack and move in relation to the reinforced plastic layer, without transmitting any stresses to the reinforced plastic layer. This results in a pool which allows any stresses due to soil subsidence, movement, etc. to be transmitted to the concrete shell and not the reinforced plastic layer thereby leaving the plastic layer free of cracks.

Abstract: A masonry structure is made by setting up a prefabricated wire support structure having the shape of the structure to be made, assembling a first row of bricks on the lowermost horizontal section thereof, masking a plurality of brick of that row with an open top removable mortar molding form which is placed around a plurality of bricks and covering the tops of the bricks by filling the form with mortar and leveling it to provide a mortar filling layer between adjacent bricks of the run and a continuous mortar layer above the bricks.

Abstract: A protective layer is formed on concrete or mortar by coating a strippable paint on the inner surface of a mold, to form a strippable membrane. A transferring layer is then formed on the strippable membrane, and concrete or mortar is placed in the mold having the strippable membrane and the transferring layer. The concrete or mortar is cured in the mold. Then, the mold is removed from the cured concrete or mortar, thereby allowing the strippable membrane to transfer onto the surface of the cured concrete or mortar.

Abstract: A method of manufacturing corrosion-resistant concrete or mortar wherein a peelable film is formed on the inner surface of a formwork, and one or two paints of asphalt, tar, and thermosetting resin paints, or resin mortar using a thermosetting resin as a binder is coated on the peelable film. Concrete or mortar is molded using the formwork, and the formwork is removed after the concrete or mortar is cured, thereby transferring the corrosion-resistant film layer together with the peelable film onto the surface of the concrete or mortar.

Abstract: A method for making a steel/concrete tank is provided. A steel interior tank is pressurized during or after pouring of a concrete outer tank around a steel inner tank. Pressurization is commenced before the concrete has set, and is maintained until substantial setting of the concrete. The resulting structure is less susceptible than previous structures to cracking of the exterior concrete upon pressure-testing of the structure for leaks.

Abstract: A method for making floors for filters, particularly for filters including a granular filtrating material, wherein the method includes forming two stages. The first stage is made by casting in concrete or the equivalent, at least one carrier self-supporting element or pre-slab, formed with openings in which are housed elements, such as nozzles, for the introduction of fluids used for washing the filter. Then the second stage is formed, during which, once the carrier self-supporting elements have been put in position on the supports of the filter, concrete is cast in a single operation on this element or elements, in a quantity sufficient for reaching the required total thickness of the floor and thereby providing a slab which will receive the filter granular material.

Abstract: A process for manufacturing a multilayer building panel in which one layer s a main layer comprising a binder and a reinforcing additive, and another layer contains a binder and a reinforcement such as a mat includes depositing the various layers such that one layer is deposited with an excess of water for hardening, and another with a deficiency, so that the water is caused to migrate between layers and creates a transition layer providing a gradual and continuous transition in composition between the layers.

Abstract: A method of making a concrete block having decorative stones embedded in a surface thereof includes the steps of placing on a face plate a layer of stones which includes a plurality of spaced decorative surface stones and includes filler stones substantially smaller than the surface stones and disposed in the spaces between the surface stones, applying a cement mortar on the surface stones and filler stones, introducing concrete into a separate mold, inverting the face plate and placing it on top of the concrete in the mold, consolidating the concrete and assembling the concrete and the sruface stones by applying pressure and vibration, removing the mold and the face plate, and curing the resulting block without the mold.

Abstract: A process for the production of a multi-layer block by distribution of a mixture, the block being used for the production of agglomerated slabs of marble, granite, sand or in general stone, consists of weighing a predetermined amount of the mixture, mixing it to render it homogeneous, conveying the predetermined amount of homogeneous mixture into a mold provided with a vertically movable bottom, subjecting the mixture to a vibrating action by means of a vibrating plate, then lowering said predetermined amount of the mixture of a distance equal to the thickness of a new slab, covering the mixture with a sheet of impermeable material, repeating the operations until the mold is filled. A multi-layer block is formed, which is compacted and allowed to set. The block is separated into slabs corresponding to the sheets of impermeable material. The apparatus is also described.

Abstract: An instrument table having two features is disclosed. The first is a stable instrument bench that is constructed of sections of precast reinforced concrete. Each of these sections are then moisture sealed with a plastic coat or paint, then assembled using epoxy and bolts. The second element of the present invention is the replication of a precision surface on the table portion of an instrument bench.

Abstract: A process is disclosed for making a casting nozzle wherein gas can be blown out through the outlet of the nozzle to prevent the sticking of nonmetallic impurities to the nozzle during use. Reticulate organic filaments in the form, e.g., of a net are applied around a preformed inner cylindrical refractory body having a pouring hole therein. An outer cylinder body is then formed around the inner cylinder body including the organic filaments. The entire body is then fired, whereby the organic filaments carbonize and evaporate, leaving a network of gas-permeable reticulate holes in the body. An outlet is drilled or cut in the fired body through the gas-permeable holes to the pouring holes. Accordingly, when the nozzle is in use, a blowing gas can be provided through the reticulate holes to the nozzle outlet to prevent the sticking of nonmetallic impurities.

Abstract: The present invention relates to a method of forming the primary core of a concrete pipe. A steel cylinder is disposed vertically on the base of the pipe forming machine. A conventional rotary packerhead having a diameter less than the inner diameter of the steel cylinder is lowered concentrically to the bottom thereof. Concrete is then introduced within the steel cylinder through the upper end thereof. The packerhead is rotated to force the concrete into the annular gap between the packerhead and the steel cylinder. As the primary core is formed, the packerhead is raised and rotated while concrete is introduced within the steel cylinder, thereby forming a primary core consisting of a steel cylinder having an inner lining of concrete. In an alternative embodiment, the steel cylinder is completely embedded within the concrete.