What is Roughcasting?

Gravel is often used in thick slabs.

Roughcasting is a type of exterior finishing method used in building construction. In casting, small pebbles and gravel or other similar materials are mixed with concrete or plaster to finish the exterior surface of the walls. The material dries to a rough, durable finish that is often maintenance-free for decades. Roughcasting is often confused with pebbles, a process in which pebbles and stones are thrown against a soft cement finish.

A modified version of pig iron is often used in tunnel construction.

Although popular in home construction, rough plaster began as a type of finish for commercial, common, and exterior buildings. The practice of throwing stones or gravel against a wall during construction requires a keen eye. The goal is to throw gravel and other substances onto the wall to produce a smooth, even layer without leaving stains. Once dry, the finish is durable and requires very little maintenance.

In some areas of the world, rough construction includes the use of small seashells instead of sand or gravel. This gives a unique style to the houses facing the sea. Stain and color additives are also used in sand or gravel mixes to add a certain color to the home finish. While primarily used for exterior wall finishing, plaster is also a unique way to add flavor to an interior wall.

A modified version of sheetrock is used to waterproof basement walls in some areas. A sheet of plastic is affixed against a wall where plaster and a chemical mixture are sprayed onto the plastic. The surface dries to form an impermeable barrier. This type of waterproofing is often applied in tunnel construction. While effective, it is also an expensive means of solving a problem that is often better handled by much more common methods.

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A negative aspect of rough finishing is the difficulty of matching repair color and finish textures. In damaged areas, the new plaster is easily detected in the original finish. The time factor, as well as the weather the original finish is exposed to, is often extremely difficult to replicate when mixing a new batch of wallcovering. It is often necessary to remove the original finish and restore an entire wall.

One method used by builders to ensure an even thickness of plaster is applied is to use a wide board to press the finish smooth. When using the board, the finish is applied in the same thickness, pressing it outwards, as if it were a floating concrete floor. The uniformity of the wall finish gives it a final appearance.

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