U.S. patent application number 12/970044 was filed with the patent office on 2011-04-14 for method of forming surface seeded particulate.
Invention is credited to Lee A. Shaw, Ronald D. Shaw.
Application Number | 20110085858 12/970044 |
Document ID | / |
Family ID | 36180929 |
Filed Date | 2011-04-14 |
United States Patent
Application |
20110085858 |
Kind Code |
A1 |
Shaw; Lee A. ; et
al. |
April 14, 2011 |
METHOD OF FORMING SURFACE SEEDED PARTICULATE
Abstract
An improved surface seeded exposed particulate concrete and
method of making the improved surface seeded exposed particulate
concrete is disclosed. Small particulate is sprayed over the upper
surface of the concrete. The particulate may be sprayed using a
material sprayer. The particulate may be uniformly sprayed to
distances exceeding twenty feet. The particulate is mixed into a
cement paste derived from the concrete mixture using floats. A
surface retarder is then applied to cover the concrete surface.
Subsequently, any surface film is washed from the surface of the
concrete and the concrete is cured. The result is a surface seeded
particulate with an exposed surface that is flat and is suitable
for high traffic areas. The resultant surface may resemble stone,
granite or marble.
Inventors: |
Shaw; Lee A.; (Newport
Beach, CA) ; Shaw; Ronald D.; (Corona del Mar,
CA) |
Family ID: |
36180929 |
Appl. No.: |
12/970044 |
Filed: |
December 16, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12686743 |
Jan 13, 2010 |
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12970044 |
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12009208 |
Jan 17, 2008 |
7670081 |
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12686743 |
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11642325 |
Dec 20, 2006 |
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12009208 |
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11295067 |
Dec 6, 2005 |
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11642325 |
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10653671 |
Sep 2, 2003 |
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11295067 |
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10058912 |
Jan 28, 2002 |
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10653671 |
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Current U.S.
Class: |
404/76 |
Current CPC
Class: |
C04B 41/009 20130101;
C04B 28/02 20130101; E04F 15/12 20130101; C04B 28/02 20130101; C04B
41/009 20130101; E01C 7/351 20130101; C04B 41/5323 20130101; C04B
28/02 20130101; C04B 41/72 20130101; C04B 14/22 20130101; C04B
14/06 20130101; C04B 14/28 20130101; C04B 20/0076 20130101; C04B
41/53 20130101 |
Class at
Publication: |
404/76 |
International
Class: |
E01C 7/32 20060101
E01C007/32 |
Claims
1-32. (canceled)
33. A method of producing surface seeded exposed particulate
concrete utilizing a material spraying device to enable spraying of
particulate at distances greater than ten feet from a sprayer, the
concrete generally covering a large surface area greater than
10'.times.10' and having a generally flat exposed particulate
surface suitable for flooring applications, the method comprising:
a) providing particulate having a mean diameter size less than
3/8''; b) preparing a subgrade to a desired grade; c) pouring a
concrete mixture over the subgrade, the concrete mixture defining a
generally horizontal upper surface; d) while the concrete is
uncured and the material spraying device is remote from the upper
surface to be sprayed, continuously spraying the quantity of
particulate with the material spraying device through air upon the
upper surface of concrete mixture until the large surface area
greater than 10'.times.10' is covered with particulate; e)
distributing the provided particulate upon the upper surface of the
concrete mixture with the material spraying device wherein a level
of uniformity of the distributed particulate is greater for the
material spray gun than by shovel when particulate is distributed
over the wide surface area greater than 10'.times.10'; and f)
curing the concrete mixture to form the surface seeded particulate
concrete.
34. A surface seeded exposed particulate concrete product formed by
the method of claim 33.
35. The method of claim 33 wherein at least some of the
particulates are visibly exposed.
36. The method of claim 33 wherein the spraying step comprises the
step of continuously spraying the quantity of particulate through
air upon the upper surface of the concrete mixture greater than ten
feet from the sprayer utilizing a continuous material spraying
device.
37. The method of claim 33 wherein the spraying step is performed
with a motor driven material spraying device.
38. The method of claim 33 wherein the spraying step comprises the
step of continuously spraying the quantity of particulate with the
material spraying device until the quantity of particulate evenly
covers more than the 10'.times.10' concrete surface area.
39. The method of claim 33 wherein the particulate is selected from
the group consisting of organic materials, seashells, course sand
and Monterey Aquarium course sand.
40. The method of claim 33 wherein the providing step includes the
step of providing particulate having a mean diameter size of about
1/8''.
41. A method of producing surface seeded exposed particulate
concrete utilizing a material spraying device to enable spraying of
particulate at distances greater than ten feet from a sprayer, the
concrete generally covering a large surface area greater than
10'.times.10' and having a generally flat horizontal exposed
particulate surface suitable for flooring applications, the method
comprising: a) providing particulate having a mean diameter size
less than 3/8''; b) preparing a subgrade to a desired grade; c)
pouring a concrete mixture over the subgrade, the concrete mixture
defining a generally horizontal upper surface; d) while the
concrete is uncured and the material spraying device is remote from
the upper surface to be sprayed, continuously spraying the quantity
of particulate with the material spraying device through air upon
the upper surface of concrete mixture until the large surface area
greater than 10'.times.10' is covered with particulate; e)
redirecting the material spraying device to uniformly distribute
the provided particulate upon the upper surface of the concrete
mixture with the material spraying device; and f) curing the
concrete mixture to form the surface seeded particulate
concrete.
42. The method of claim 41 wherein a level of uniformity of the
distributed particulate over the wide surface area greater than
10'.times.10' is equal to or greater than a level of uniformity
when the particulate is distributed by shovel over a small surface
area less than 10'.times.10'.
43. The method of claim 41 wherein the particulate is distributed
over the generally horizontal upper surface at a rate of
approximately one pound per square foot.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] (Not Applicable)
BACKGROUND OF THE INVENTION
[0003] The present invention relates in general to exposed
particulate concrete, and in particular to an improved method for
surface-seeding the particulates into the upper surface of the
concrete.
[0004] U.S. Pat. No. 4,748,788 entitled SURFACE SEEDED EXPOSED
AGGREGATE CONCRETE AND METHOD OF PRODUCING SAME, hereby
incorporated by reference in its entirety, discloses a surface
seeded exposed aggregate concrete characterized by the use of
small, rounded aggregate, such as sand, being broadcast over the
upper surface of concrete. The method disclosed results in a
reduction in the size of the aggregate exposed on the surface of
concrete compared to other prior art methods. The resultant surface
seeded exposed aggregate concrete exhibits an extremely flat
exposed aggregate surface suitable for extremely high traffic
flooring applications. Additionally, the surface texture and color
are able to approximate the surface color and texture of more
conventional flooring surfaces, such as stone, granite and
marble.
[0005] U.S. Pat. No. 6,033,146 entitled GLASS CHIP LITHOCRETE AND
METHOD OF USE OF SAME, hereby incorporated by reference in its
entirety, discloses a surface seeded exposed particulate concrete
and method for producing same. U.S. Pat. No. 6,033,146 improves
upon the surface seeded aggregate concrete and method of making
same disclosed in U.S. Pat. No. 4,748,788 by disclosing a method
that produces surface seeded particulate concrete that expands the
colors and surface texture appearances of concrete surfaces beyond
those disclosed in U.S. Pat. No. 4,748,788.
[0006] The patents described above produce surface seeded exposed
particulate concrete with desirable characteristics, as evidenced
by the use and extensive licensing of such products throughout the
United States. However, the application of the surface seeded
particulate is a timely process. Furthermore, uniformity of
application is difficult to achieve for large surface areas.
Typically, it is difficult to achieve a uniform application for
surface areas which require broadcasting of particulate beyond a
distance of ten feet from the broadcaster.
[0007] Accordingly, there is a need for an improved process for
surface-seeding of the particulate into the upper surface of a very
large concrete slab.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention specifically addresses and alleviates
the problems described above in treating large areas of poured
concrete with exposed particulates.
[0009] Aspects of the present invention may be regarded as a
surface seeded exposed particulate concrete product and a method of
forming the surface seeded exposed particulate concrete product.
The surface seeded exposed particulate concrete has a generally
flat exposed particulate surface suitable for flooring
applications. The particulate may be reactable with a hydrolyzed
alkali silica to form an insoluble silicate structure. For example,
such a particulate may comprise glass or organic materials, such as
sea shells. The alternate may also be a non-reactive particulate.
For example, a non-reactive particulate may comprise coarse sand,
such as Monterey Aquarium coarse sand.
[0010] The method begins by preparing a subgrade to a desired
grade. A concrete mixture is poured over the subgrade. The concrete
mixture is screeded to a desired grade which forms a top surface
thereof. The top surface of the concrete mixture is finished with a
float to seal the top surface and dispose a quantity of
cement/fines derived from the concrete mixture at the top surface
of the concrete mixture to form an upper surface of cement/fines
concrete paste. A quantity of particulate is sprayed upon the upper
surface of cement/fines concrete paste. A quantity of particulate
is mixed into the cement/fines concrete paste with a float to form
an exposed surface of a depth of a mixture of surface-concentrated
particulate and cement/fines concrete paste. A surface retarder is
applied uniformly over the exposed surface of the
surface-concentrated particulate and cement/fines concrete paste.
Surface films are washed from the exposed surface. The concrete
mixture and paste are cured to form a cured mixture and a cured
paste. The exposed surface is then washed to remove surface residue
therefrom.
[0011] If the particulate is reactable with a hydrolyzed alkali
silica, after the exposed surface is washed, a chemical treatment
of hydrolyzed alkali silica solution is applied uniformly over the
exposed surface in a quantity sufficient to penetrate only the
depth of the surface-concentrated particulate and cement/fines
concrete paste. The hydrolyzed alkali silica used with particulates
may be a hydrolyzed lithium quartz solution. Applying of chemical
treatment may cause penetration of the hydrolyzed alkali metal and
silica compound into the upper surface of the concrete mixture
through a distance greater than the mean diameter of the
particulate.
[0012] Preferably, the particulate has a mean diameter of less than
three-eighths of one inch.
[0013] The spraying the quantity of particulate is accomplished
using a material gun. The spraying uniformly sprays the quantity of
particulate. The spraying includes spraying some of the quantity of
particulate a distance of at least twenty feet.
[0014] Applying of the surface retarder may cause penetration of
the surface retarder into the upper surface of the concrete mixture
through a distance greater than the mean diameter of the
particulate.
[0015] The particulate may be sprayed over the upper surface of the
concrete mixture at an approximate rate of one pound per square
foot of concrete mixture.
[0016] Mixing may comprise using a float in a circular motion to
cover the particulate with the cement/fines concrete paste.
[0017] The method may include sponging in a circular motion any
areas of the upper surface of the concrete mixture after the mixing
and before the applying of the surface retarder.
[0018] The washing of surface film may include applying water to
the upper surface of the concrete mixture and lightly brushing the
upper surface of the concrete mixture. Preferably, the lightly
brushing removes no more than five percent of the particulate from
the upper surface of the concrete mixture.
[0019] The washing of the upper surface of the concrete mixture to
remove surface residue therefrom may comprise washing the upper
surface of the concrete with a mixture of water and muriatic
acid.
[0020] The method may include covering the upper surface of the
concrete mixture with a vapor barrier after applying of the surface
retarder and before washing surface film. The covering the upper
surface of the concrete mixture with a vapor barrier may extend for
a period of two to twenty-four hours.
[0021] The curing may comprise curing the concrete mixture by use
of a logger or curing the concrete mixture by use of a soaker
hose.
[0022] Reinforcement means may be placed upon the prepared subgrade
to be disposed within the poured concrete mixture.
[0023] The pouring may comprise mixing the concrete mixture with a
color additive.
[0024] After the curing, the method may include altering the
surface roughness of the upper surface of the concrete mixture.
[0025] Prior to spraying particulates, the method may include
washing with potable water and air drying the particulates.
[0026] The subgrade may be prepared by compacting the subgrade to
approximately ninety percent compaction. Preparing the subgrade may
include placing a layer of sand between the subgrade and the poured
concrete mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These as well as other features of the present invention
will become more apparent upon reference to the drawings
wherein:
[0028] FIG. 1 is a partial cross-sectional view of the surface
seeded exposed particulate concrete of the present invention;
[0029] FIG. 2 is an enlarged partial perspective view. of the
concrete mixture having the exposed particulate thereon; and
[0030] FIG. 3 is a schematic flow diagram of the manipulative steps
utilized in producing the surface seeded exposed particulate
concrete of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring now to the drawings wherein the showings are for
purposes of illustrating preferred embodiments of the present
invention only, and not for purposes of limiting the same, the
surface seeded exposed particulate concrete and method of producing
the same is pictorially and schematically illustrated. The
particulate may be potentially reactive with the concrete mixture
16. For example, the particulate 18 may comprise glass, such as
silica glass, organic materials, such as sea shells of marine
animals and mollusk, and other various metals and composite
materials. Alternatively, the particulate 18 may be an aggregate
that does not react with the concrete mixture. For example, the
particulate may comprise coarse sand, such as Monterey Aquarium
(Grade) coarse sand. Preferably, the particulate is characterized
by having a mean average diameter size of approximately one-eighth
inch diameter. The particulate may possess a rounded external
surface configuration. Alternatively, the individual particulates
may have an angled external surface configuration.
[0032] As is conventional, the initial step in the method of the
present invention comprises the preparing of the subgrade to the
desired elevation and grade and the compacting of the same to
preferably 90% compaction. Subsequently, the subgrade 10 is covered
with a one inch minimum thick layer of clean, moist fill sand 12.
The fill sand 12 is not absolutely necessary, but it is highly
desirable to control the hydration process of the concrete.
Further, in order to increase the resultant strength of the
concrete and inhibit subsequent cracking, reinforcement wire mesh
or rebar 14 is positioned upon the bed of fill sand 12.
[0033] With the rebar 14 in place, a concrete mix or mixture 16 is
poured over the fill sand 12 and rebar 14 respectively, and as is
conventional is poured to approximately a three and one half to
four inch thickness. Although variations in the concrete mix 16 are
fully contemplated, preferably the mixture 16 comprises 70% sand
and 30% three-eighth inch mean diameter particulate combined with a
minimum of five sacks of cement, such as Portland cement per cubic
yard. Dependent upon individual preferences, various conventional
color mixtures may be added to the concrete mix.
[0034] The concrete surface is preferably struck off or screeded to
the desired level plane of the concrete surface. However, the mix
is preferably not tamped as is conventional, as Applicants have
found tamping brings up too many sand fines in most concrete mixes,
which would interfere with the subsequent surface seeding of the
exposed particulate thereupon. Rather, subsequent to screeding the
concrete surface, the surface is floated using a conventional bull
float, which may be manufactured of fiberglass, wood, magnesium, or
the like. Such floats are characterized by possessing an extremely
smooth surface which tends to seal the top surface of the concrete
mix 16 and bring out appropriate amounts of cement paste for the
subsequent steps of the present invention.
[0035] When the upper surface of the concrete mix 16 is still
plastic, small size exposed particulate 18 is sprayed over the top
surface of the concrete mix 16. An industrial sprayer, such as a
Goldblat material sprayer or a sand blaster may be used to spray
the exposed particulate. Use of such a spraying device allows for
the uniform placement of the particulate over large surface areas.
For example, the particulate can be uniformly sprayed for distances
of about twenty to twenty-four feet from the sprayer as compared to
traditional methods of broadcasting the particulate (e.g.,
manually) which can only achieve uniformity for a distance of about
eight to ten feet away from the person broadcasting the
particulate.
[0036] Depending on the particulate used, it may be desirable to
wash the particulate with potable water and air dry it prior to
spraying the particulate on the plastic concrete surface. The
particulate 18 should not initially depress below the top surface
of the concrete mix 16 but rather, should be sprayed solely to
cover the same.
[0037] After the spraying of the particulates 18, the particulates
are then floated into the plastic upper surface of the concrete mix
16 using floats, for example, a fiberglass, wood or magnesium
float. The mixing of the particulates 18 with the sand cement paste
is critical as it ensures that the particulates 18 are thoroughly
adhered or bonded to the top surface of the concrete mix 16 upon
resultant curing. Hand sponges may then be used in a rotary fashion
to further coat the surface seeded particulates 18 with the sand
cement paste of the concrete mix 16. The entire surface is then
finished with steel trowels.
[0038] When the resultant particulate 18 and concrete surface 16
has sufficiently set, such that a finger impression not in excess
of three-eighths of an inch deep is made upon manually pressing
with the fingertips thereupon, a conventional surface retarder,
preferably a citric acid based surface retarding agent, is spread
to uniformly cover the top surface of the concrete mix 16. The
surface retarder slows down the hydration process of the concrete
by penetrating the top surface of the concrete mix to a depth of
approximately one-eighth inch.
[0039] After the uniform coverage of the surface retarder thereon,
the top surface of the concrete mix 16 is covered with either a
plastic sheathing membrane or a liquid evaporation barrier,
maintained thereupon for a period of approximately two to
twenty-four hours. After about four hours, the surface can usually
support a workman without leaving an impression, and the sheathing
is removed and the top surface may be loosened with clean wet
sponges working in a circular fashion, revealing the top surface of
the embedded particulate 18. The surface is then washed with clean
water at low pressure and the heavy latentS removed with a soft
broom. The washing procedure and light bristle brushing preferably
removes no more than five percent of the particulate 18 from the
top surface of the concrete mix 16. Subsequent to the washing, the
concrete mix 16 is cured for a minimum of seven days with water
only by use of a conventional fogger or soaker hose. Craft paper or
liquid membrane cures may be used in place of water as job
conditions dictate. Preferably after curing for a minimum of seven
days, the surface is subject to conventional power washing using
3,000 PSI water pressure at a temperature of approximately
220.degree. F. A mixture of 10-50% muriatic acid is preferably
introduced into the hot water wash. The entire surface is then
flushed with clean hot water. Preferably 28 days after the initial
concrete placement, the surface is again washed with the high
pressure/hot water wash to remove any efflorescence or
discoloration from the surface. Sandblasting, acid etching or
grinding and polishing may also be used to create texture
variations on the surface.
[0040] If the particulate is reactable with a hydrolyzed alkali
silica to form an insoluble silicate structure, after the final
washing of the concrete, the top surface is treated with a
hydrolyzed alkali silica solution, preferably lithium quartz sealer
(approximately 12.5% lithium compound by volume). Other members of
the alkali family of metals which may be suitable include sodium,
potassium, rubidium, sesium, and francium. Other abundant silicone
containing materials which may be suitable include feldspars,
amphiboles or pyroxenes, and mica. The SINAK HLQ sealer is applied
in light even coats using a sprayer or brush to a surface having a
temperature between 50.degree.-100.degree. F. The hydrolyzed
lithium quartz sealer penetrates the top surface of the concrete
mix 16, again to a depth of approximately one-eighth of an inch.
The chemical treatment reacts with the mineral compounds or
silicious materials within the concrete mix. The reaction causes
formation of an insoluble silicate structure, which acts as a
protective barrier, reducing the permeability of the surface to
water. Applicant believes that minimizing the addition of moisture
over time minimizes the undesired expansion and cracking, even
given some chemical reaction in the concrete involving the
potentially reactive particulates. Applicant also believes that
minimizing the addition of moisture minimizes the scope of the
chemical reaction involving the non-inert particulates. Of course,
this chemical treatment may be omitted when non-reactive
particulates are used.
[0041] The resultant surface seeded exposed particulate concrete
besides exhibiting an extremely flat exposed particulate surface
suitable for pedestrian and vehicular paving applications, is also
not subject to deterioration from the chemical reaction from the
non-inert particulates and minerals and silicates found in the
concrete mix 16. The surface texture and color approximates
conventional flooring surfaces such as terrazzo, or ceramic tile,
and this resemblance may be further accentuated by cutting the
concrete surface into rectangular or irregular grids. The present
invention comprises a significant improvement in the art by
providing surface seeded exposed particulate concrete, wherein a
large variety of exposed particulates not necessarily chemically
inert may be introduced into the upper cement surface of the
concrete mixture.
[0042] Although the invention has been described with reference to
a specific embodiment, this description is not meant to be
construed in a limiting sense. Various modifications of the
disclosed embodiment as well as alternative embodiments of the
invention will become apparent to one skilled in the art upon
reference to the description to the invention. It is therefore
contemplated that the appended claims will cover any modifications
of. the embodiments that fall within the true scope of the
invention.
* * * * *