Spraying Project-Artificial Cave Rock Formation

Artificial Cave Rock Formation – Spraying & Texturing Work

This project involved the construction and detailed surface finishing of a large-scale artificial cave rock structure, designed to replicate natural stone textures and stalactite formations for a themed environment. The structure is part of a larger attraction, requiring both aesthetic realism and structural durability.

The artificial rock face, including dramatic overhangs and vertical surfaces, demanded a consistent and efficient method for applying mortar onto metal mesh and concrete substrates. Due to the complex surface geometry and required volume of mortar, the use of a reliable and high-output spraying system was essential.

Machine Application: IMER Step 120

The IMER Step 120 screw-type mortar pump was selected for this job due to its ability to handle pre-mixed mortars and textured materials effectively. It is especially suitable for spraying onto vertical and overhead surfaces. The machine setup included:

• Integrated pan mixer for continuous on-site material preparation

• Consistent pressure output to ensure smooth and uninterrupted spray application

• Compact design and mobility suitable for maneuvering within the confined rockwork scaffold setup

• Reduced rebound and material wastage, even on complex carved surfaces

Spraying was conducted using a compressed air-assisted spray nozzle to control flow and direction, allowing the team to build up the desired thickness and detail required for realistic stalactite and cave wall effects.

Work Process & Results:

1. Surface Preparation: Metal mesh and structural frameworks were installed, forming the base of the rockwork.

2. Material Mixing: Special mortar was mixed on-site using the integrated pan mixer of the IMER Step 120, ensuring consistency.

3. Spraying Application: Mortar was sprayed layer by layer, building up surface textures with close attention to natural rock formation shapes.

4. Finishing Touches: After spraying, artisans manually carved and detailed the mortar while it was still workable to enhance realism.

   
   

The IMER Step 120 performed efficiently throughout the project, with minimal downtime and excellent control over spray consistency. The result was a visually striking, durable artificial cave formation that met both design and engineering expectations.