U.S. patent application number 14/019419 was filed with the patent office on 2014-01-02 for decorative aggregate concrete surface preparation process.
The applicant listed for this patent is Single Eagle, Inc. dba Concrete Contractors Interstate. Invention is credited to Jay E. Peterson, Ricardo Vasquez, JR..
Application Number | 20140000214 14/019419 |
Document ID | / |
Family ID | 41265737 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140000214 |
Kind Code |
A1 |
Vasquez, JR.; Ricardo ; et
al. |
January 2, 2014 |
DECORATIVE AGGREGATE CONCRETE SURFACE PREPARATION PROCESS
Abstract
The present invention is directed to a process of creating a
decorative aggregate concrete surface. The preparation includes
washed decorative aggregate surfaces using a variety of decorative
aggregate materials imbedded within a standard concrete mix having
a one inch maximum aggregate. A 6-mil polypropylene sheet Visqueen
material covered with a two-inch layer of sand is used directly
below the concrete to retard the curing time. Roller tamping is
used to move the large aggregate below the surface of the concrete
material. Power brushes are then used to expose the decorative
aggregate prior to the final process of applying a densifing
sealer. This process has been designed to reduce installation time,
as well as overall labor and material costs.
Inventors: |
Vasquez, JR.; Ricardo;
(Escondido, CA) ; Peterson; Jay E.; (Oceanside,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Single Eagle, Inc. dba Concrete Contractors Interstate |
Poway |
CA |
US |
|
|
Family ID: |
41265737 |
Appl. No.: |
14/019419 |
Filed: |
September 5, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12436561 |
May 6, 2009 |
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14019419 |
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Current U.S.
Class: |
52/741.11 |
Current CPC
Class: |
C04B 41/009 20130101;
C04B 41/5323 20130101; C04B 41/009 20130101; C04B 41/72 20130101;
E04B 1/16 20130101; E01C 7/142 20130101; B28B 19/0007 20130101;
C04B 28/02 20130101 |
Class at
Publication: |
52/741.11 |
International
Class: |
E04B 1/16 20060101
E04B001/16 |
Claims
1. A decorative aggregate concrete surface preparation process for
concrete poured to a ground installation, comprising the steps of:
(a) preparing the sub grade soil and applying a suggested 2 inch
layer of road base material; (b) laying down a 6 mil. polypropylene
Visqueen moisture barrier over the prepared surface and adding a 2
inch layer of washed sand; (c) installing concrete forms as
required and installing reinforcement bars; (d) pouring concrete to
a minimum specification of about 3000 psi; (e) screeding the
concrete surface to the required thickness below the top edge of
any form material and roller tamping the concrete surface; (f)
spreading a layer of decorative aggregate over designated surface
areas followed by a primary floating and secondary floating of
concrete surface before trowel finishing; (g) applying a surface
retardant; (h) washing and power brushing concrete surface to
expose decorative aggregate, then curing concrete for about 28 days
before a final washing and power brushing of concrete surface; and
(i) applying a densifying sealer to the exposed decorative concrete
surface.
2. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of spreading a layer of decorative aggregate
followed by a primary floating and secondary floating of concrete
surface before trowel finishing is repeated as necessary.
3. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of pouring concrete to a minimum specification of
about 3000 psi, further includes the step of pouring concrete to a
minimum specification of about 3000 psi to about 5000 psi as
required.
4. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of spreading a layer of decorative aggregate over
designated surface areas includes spreading natural and synthetic
decorative aggregate materials including glass, shells, rock,
metals, plastics, rubber, organic materials, inorganic materials,
chemically inert particulates, and chemically active
particulates.
5. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of primary floating and secondary floating of
concrete surface before trowel finishing includes the step of
floating by hand.
6. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of primary floating and secondary floating of
concrete surface before trowel finishing includes the step of
floating by hand using a wood, resin or magnesium float.
7. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of applying a surface retardant includes the step
of applying a surface retardant employing a surface retarder
consisting of propylene glycol and citric acid.
8. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of applying a densifying sealer to the exposed
decorative concrete surface includes the step of applying a
densifying sealer to the exposed decorative concrete surface
wherein said densifying sealer includes lithium silicate or lithium
quartz.
9. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of washing and power brushing includes the step
of washing and power brushing after a period of four to twenty four
hours following the application of a surface retarder.
10. The decorative aggregate concrete surface preparation process
for concrete poured to a ground installation, according to claim 1,
wherein said step of applying a densifying sealer is followed by
application of an enhancing sealer to bring out the vibrant color
of the decorative aggregate.
Description
FIELD OF THE INVENTION
[0001] This patent application is directed to the surface
preparation of concrete slabs. More particularly to the
incorporation of a washed decorative aggregate surface using a
variety of decorative aggregate materials imbedded within standard
concrete mix having an aggregate size which will vary from
1/8.sup.th inch or less to as much as 1 to 2 inches or more,
greatly reducing installation time, labor and material costs.
BACKGROUND OF THE INVENTION
[0002] Exposed aggregate surfaces on concrete have been used for
many years with a wide variety of patents filed to fulfill the
specific needs of this application. The use of an exposed aggregate
surface not only provides a unique decorative surface, it also
provides wide variety of other benefits. Exposed aggregate can
provide an abrasive, slip resistant surface as well as a smooth
very decorative surface. It can also provide a surface with better
wear resistance to heavy traffic.
[0003] Standard concrete usually comprises coarse aggregate, fine
aggregate, cement, additives and water. Varieties of other concrete
mixes are available, including a pea gravel (small stone) mix with
additional additives available at a higher price. The standard
concrete with a coarse aggregate mix is normally used because it
provides a stronger product at a lower cost. The coarse aggregate
can vary in nature and size up to one inch and often an ornamental
aggregate is used as a topping to be exposed on surface. This
process is called decorative or surface seeded aggregate. The
exposure of the decorative or seeded aggregate is achieved by
applying a curing retarder to the concrete surface that will slow
the curing process after applying the decorative or seeded
aggregate to the surface. The decorative or seeded aggregate is
worked to the surface by several different processes. When the
concrete has cured the surface to be exposed is brushed or
otherwise abraded to remove the cement and fine aggregate between
the coarser materials leaving the decorative aggregate surface
exposed.
[0004] After the concrete has cured, a variety of processes can be
used to give different surface textures. Without the addition of
decorative or seeded aggregate surfacing materials, the coarse
aggregate in the concrete surfaces can be too abrasive due to the
nature of the standard concrete stones. Most existing processes
call for the use of special concrete mixes, usually pea gravel mix
with special additives that is more expensive per yard. Various
arrangements and processes have been proposed in the past for
accomplishing this process of providing a decorative and durable
concrete surface, but they tend to add a great deal more work to
install and a good deal of added expense. There is a growing need
for reducing the installation time and costs involved in this
process.
[0005] Numerous innovations for creating an exposed aggregate
surface have been provided in the prior art that are described as
follows. Even though these innovations may be suitable for the
specific individual purposes to which they address, they differ
from the present design as hereinafter contrasted. The following is
a summary of those prior art patents most relevant to this
application at hand, as well as a description outlining the
difference between the features of the decorative aggregate
concrete surface preparation and the prior art.
[0006] U.S. Pat. No. 2,296,453 of George J. Saffert describes a
method of molding concrete products. It is the object of this
invention to provide a method of forming concrete slabs having the
exposed aggregate surface uppermost in the mold. The slabs do not
need to be turned over before the cement film on the face surface
is removed.
[0007] This patent describes a method for molding concrete products
such as panels. It has not been intended for the procedure of
constructing permanent concrete surfaces, such as floors and
sidewalks. There is no use of 6-mil poly (Visqueen)) with two
inches of sand on top, under the entire surface of the concrete, to
be used as a moisture barrier to slow the curing time, specified in
this patent. This patent indicates the early uses of the exposed
aggregate surfaces in the building industry.
[0008] U.S. Pat. No. 4,496,504 of Thomas W. Steenson et al. This
invention relates to a method for making a cast concrete panel with
the coarse aggregate of the concrete exposed on one face and to a
concrete finishing machine. The general process is to pour wet
concrete into the form, compact the concrete with a vibrating
screed and then level it with roller screeds. In some cases, ribs
are formed in the upper surface of the concrete for an ornamental
effect.
[0009] This patent also describes a method of exposing aggregate in
a poured concrete panel. This process uses a unique roller screed
rotating in a direction to push excess surface concrete in advance
of the screed roller, lifting coarse aggregate towards the upper
surface. A unique device using aggregate lifting arms rotating in
front of the screed roller lifts the coarse aggregate to the
surface. This patent does not incorporate the application of
decorative or seeded aggregate. There is no use of 6-mil poly
(Visqueen) with two inches of sand on top, under the entire surface
of the concrete, to be used as a moisture barrier specified in this
patent.
[0010] U.S. Pat. No. 4,748,788 of Ronald D. Shaw et al. describes
an improved surface seeded exposed aggregate concrete and method of
use is disclosed characterized by use of small, rounded aggregate,
preferably sand, being broadcast over the upper surface of the
concrete. The broadcast aggregate is mixed into the cement paste
derived from the concrete matrix by magnesium hand floats and
finished by hand sponging. A surface retarder and vapor barrier is
then applied to cover the concrete surface for approximately four
to twenty four hours. Subsequently, any surface film is washed from
the surface of the concrete and the concrete is cured by fogging or
soaker hose. Approximately thirty days later, the surface residue
is removed from the concrete with a stem/acid wash providing an
exposed aggregate concrete having extreme flatness and high wear
resistance suitable for high traffic areas and improved aesthetics
resembling stone, granite or marble.
[0011] This patent describes an improved surface seeded exposed
aggregate concrete and method. This is a 3/8 inch pea gravel mix,
which requires more cement to meet the similar strength
requirements, thus adding additional cost to the process. They
suggest that you do not tamp the concrete. There is no use of 6-mil
poly (Visqueen) with two inches of sand on top, under the entire
surface of the concrete as a moisture barrier to slow the curing
time, specified in this patent. This procedure requires the
addition of Monterey Aquarium grade course sand be added to the
surface prior to seeding aggregates to provide an even paste. Hand
sponging is required along with water cure applications. Elmore
surface hardener is used and covering the surface with Poly
(Visqueen) is required. Hand brushing is required and no densifing
sealers are used as a final step.
[0012] U.S. Pat. No. 5,441,677 of David L. Phillips, Sr. a method
of fabricating a concrete floor having an autogenously hard high
gloss finish that does not require further coatings includes
pouring a designed concrete mix to establish a slab having an upper
surface slightly below the level determined for the finished floor.
A finishing floor surface layer is created by applying an amount of
a dry shake dressing material containing quartz crystals and a
coloring agent, but no coarse aggregate, to the upper surface of
the slab. Then floating the surface until the finishing layer
reaches predetermined amount, which cures to form a generally
monolithic structure with the slab but having a higher compressive
strength when fully cured. Necessary expansion joints are provided.
The floor is coated with a curing sealer and allowed to cure for
approximately 30 days, or until it reaches a predetermined
compressive strength. The sealer material is removed and the
expansion joints are sealed. The upper surface is then mechanically
sanded and polished until a predetermined level of shine or gloss
is achieved in the floor surface layer itself.
[0013] This patent describes a method of fabricating a concrete
floor having an autogenously hard high gloss finish. There is no
use of 6-mil poly (Visqueen) with two inches of sand on top, under
the entire surface of the concrete used as a moisture barrier to
slow the curing time specified in this patent. This patent uses a
purchased dry shake dressing material such as Master Builders
Colorcron.RTM., containing a mixture of Portland cement, silicon
and crystalline quartz and optionally containing a color pigment.
This patent uses a special custom mix concrete, which adds to the
expense of the procedure and a time consuming sanding process to
achieve a high gloss finish on the surface of the finished product.
No densifing sealer is applied at the end of the curing time.
[0014] U.S. Pat. No. 6,016,635 of Lee A. Shaw et al. discloses an
improved method of producing surface seeded exposed aggregate
concrete upon a sub grade. The method comprises the initial step of
pouring a concrete mixture over the sub grade, which is followed by
the step of finishing the exposed surface defined by the concrete
mixture with a vibrating metal bull float to dispose a quantity of
cement/fines paste derived from the concrete mixture at the exposed
surface thereof. Thereafter, a quantity of aggregate is broadcast
upon the exposed surface of the concrete mixture and subsequently
mixed into the quantity of cement/fines paste thereof via the
vibrating metal bull float. The exposed surface of the concrete
mixture is then finished with a power trowel to facilitate an even
distribution of the quantity of aggregate within the quantity of
cement/fines paste, which is followed by the application of a
surface retarder to the exposed surface of the concrete mixture.
The exposed surface of the concrete mixture is then finished with
the power trowel to massage the surface retarder into the quantity
of cement/fines paste having the quantity of aggregate mixed
therein.
[0015] This patent discloses an improved method of producing
surface seeded exposed aggregate concrete upon a sub grade. There
is no use of 6-mil poly (Visqueen) with two inches of sand on top
under the entire surface of the concrete, to be used as a moisture
barrier to slow the curing time, specified in this patent. This mix
is a 3/8 inch pea gravel mix, which requires more cement to meet
the similar strengths thus additional cost, and they suggest that
you do not tamp. This procedure required mechanical floating and
the use of a power trowel. Elmore surface hardener is used. Hand
brushing is required and no densifing sealers are used as a final
step.
[0016] U.S. Pat. No. 6,033,146 of Lee A. Shaw et al. discloses a
surface seeded exposed particulate concrete method of use that
includes the use of small particulates, the particulates not
necessarily chemically inert in the concrete mixture. The
particulates are broadcast over the upper surface of the concrete,
and mixed into the cement paste derived from the concrete matrix by
floats and finished by hand sponging. A surface retarder and vapor
barrier are applied, and washing and curing operations follow. The
present invention adds a chemical treatment of hydrolyzed alkali
silica solution, preferably lithium quartz, penetrating the upper
surface of the concrete mixture with minerals and silicates within
the concrete mix. The resultant exposed particulate concrete has
extreme flatness and high wear resistance suitable for high-traffic
flooring applications, aesthetics resembling terrazzo or ceramic
tile at a fraction of the price, and the strength and resistance to
corrosion expected of concrete surfaces.
[0017] This patent describes a surface seeded exposed particulate
concrete method of use that includes the use of small particulates,
the particulates not necessarily chemically inert in the concrete
mixture. There is no use of 6-mil poly (Visqueen) with two inches
of sand on top under the entire surface of the concrete, to be used
as a moisture barrier to slow the curing time, specified in this
patent. This mix is a 3/8 inch pea gravel mix, which requires more
cement to meet the similar strengths thus additional cost, and they
suggest that you do not tamp. Hand sponging is required along with
water cure applications. Elmore surface hardener is used and
covering the surface with poly (Visqueen) is required. Hand
brushing is required and some densifing sealers are used as a final
step.
[0018] U.S. Pat. No. 7,322,772 of Lee A. Shaw et al. describes a
method and a surface seeded exposed aggregate concrete product are
provided that precisely simulate the appearance and qualities of
various types of natural quarried stone, such as granite, marble,
rhinestone, bluestone, and brownstone, to name a few.
Implementations of the present invention are characterized by the
use of fine sand and aggregate broadcast over the exposed surface
of poured concrete, which surface has been prepared to receive the
same. Subsequently, a surface retarder and finishing steps are
performed to produce the concrete product which assimilates the
characteristics and colors of natural quarried stone, such as
speckles, inclusions, flecks, graining, fractures, joints, knots,
crystallization patterns, streaks, weathering, etc.
[0019] This patent describes a method and a surface seeded exposed
aggregate concrete product, which precisely simulate the appearance
and qualities of various types of natural quarried stone. There is
no use of 6-mil poly (Visqueen) with two inches of sand on top
under the entire surface of the concrete, to be used as a moisture
barrier to slow the curing time, specified in this patent. This mix
is a 3/8 inch pea gravel mix, which requires more cement to meet
the similar strengths thus additional cost, and they suggest that
you do not tamp. The aggregate is applied pneumatically and
mechanical floating and troweling is required. Water curing
applications are also required. Elmore surface hardener is used and
hand brushing is required. Densifing sealers are used as a final
step.
[0020] None of these previous efforts, however, provides the
benefits and savings derived by the decorative aggregate concrete
surface preparation described in this application. The present
design achieves its intended purposes, objects and advantages over
the prior art processes through a new, useful and unobvious
combination of method steps and component elements, at a reasonable
cost to provide, and by employing readily available materials.
[0021] In this respect, before explaining at least one embodiment
of the decorative aggregate concrete surface preparation in detail
it is to be understood that the design is not limited in its
application to the details of construction and to the arrangement,
of the components set forth in the following description or
illustrated in the drawings. The decorative aggregate concrete
surface preparation described herein is capable of other
embodiments and of being practiced and carried out in various ways.
In addition, it is to be understood that the phraseology and
terminology employed herein are for the purpose of description and
should not be regarded as limiting. As such, those skilled in the
art will appreciate that the conception, upon which this disclosure
is based, may readily be utilized as a basis for designing of other
methods and systems for carrying out the several purposes of the
present design. It is important, therefore, that the claims be
regarded as including such equivalent construction insofar as they
do not depart from the spirit and scope of the present
application.
SUMMARY OF THE INVENTION
[0022] The principal advantage of the decorative aggregate concrete
surface preparation is by using the standard concrete mix having a
one-inch maximum aggregate base material, it reduces the potential
for shrinkage and increases the adhesion potential for the smaller
aggregates.
[0023] Another advantage to the decorative aggregate concrete
surface preparation is by using a 6-mil poly (Visqueen) moisture
barrier, the moisture in the concrete mix is not allowed to quickly
dissipate into the sub base and surrounding soil extending the
curing time. This is extremely valuable in temperate climates.
[0024] Another advantage is, by using a roller tamp device, the
large aggregate of the standard concrete mix is moved down from the
surface.
[0025] Another advantage is by using a power brush to remove the
sediment from the decorative aggregate surface a great deal of time
and labor is saved.
[0026] Another advantage of the decorative aggregate concrete
surface is that when the densifing sealer is applied in the final
process at the end of the curing time, a better surface hardness,
enhanced aggregate adhesion, and exposed aggregate sealing is
achieved.
[0027] These together with other advantages of the decorative
aggregate concrete surface preparation, along with the various
features of novelty, which characterize the process, are pointed
out with particularity in the claims annexed to and forming a part
of this disclosure. For a better understanding of the decorative
aggregate concrete surface preparation, its operating advantages
and the specific objects attained by its uses, reference should be
made to the accompanying drawings and descriptive matter in which
there are illustrated the preferred embodiment of the decorative
aggregate concrete surface preparation.
[0028] For the installation of the decorative aggregate concrete
surface preparation, the propose grade shall be on a soils
compacted to a minimum of 90% and per city specifications. Sub
grade to be within a tenth of a foot, ready to receive required
base material. Sub base should be tested by a licensed certified
soils engineer to insure proper moister content and compaction has
been achieved it is suggested that a minimum of two inches of
approved sub base i.e., class II base, 3/4'' gravel or se 30 sand
be utilized, but is not required. A moisture barrier of 6-mil poly
(Visqueen) is laid over the sub base and covered with a layer of
two inches clean washed sand to be fine graded in place to allow
for the proper thickness of concrete. This provides a moisture
content that is essential for proper curing and hydration of the
proposed decorative aggregate concrete surface.
[0029] A minimum requirement of 3000-PSI standard concrete design
mix consisting of 1 inch minus concrete aggregate, including a
mid-range water reducer that meets ASTM C-494 Type A+F admixture
(such as MasterBuilders "Polyheed" or Euclids EUCON MR) are
required for this application process. Flyash can replace cement
content up to 15% but in no case will cement content exceed
61/2-sack concrete mix. The concrete mix should not exceed a
six-inch slump test. On occasion, virgin homopolymer-polypropylene
multi-filament fibers (such as Fibermesh 150) can be used for
increased durability.
[0030] Decorative aggregate material should be selected, and proper
portions determined to accommodate the desired finish. The
decorative aggregate material should be cleaned and washed prior to
installation. Note: that the aggregate size will vary from
1/8.sup.th inch or less to as much as 1 to 2 inches or more. The
mean average of 1/2 to 5/8 inch will be the normal application for
aggregates such as shells, glass or rock. The decorative aggregate
per square foot portions will vary based on the percentage of
coverage and decorative aggregate type selected. Various types of
aggregate such as glass, shells, rock, metals, plastics, rubber,
organic materials, or exposed particulates, not necessarily
chemically inert, in the concrete mixture will be utilized. One
pound to one and one half pounds per square foot is considered the
typical amount to achieve 100% surface coverage required. At least
25% additional materials should be figured and available on site to
assure the proper selected percentage of coverage. It should be
noted that the weight of any given seeded material may vary, and in
all likelihood will vary.
[0031] A minimum of #3 (3/8 inch) rebar should be placed at 18
inches on center in both directions (each way). The rebar should be
placed on adobe riser blocks within the middle thickness of the
proposed concrete slab. When joining two separate concrete pours
together, slip dowels are recommended. Appropriate expansion,
construction and control joints shall be installed at strategically
placed locations to minimize the potential for random cracking.
[0032] Prior to the spreading of the decorative aggregate all
personnel will be required to know their responsibility for the
concrete pour. A sufficient number of experienced place and finish
personnel will be designated for each concrete pour. The same crew
will be utilized for all required individual projects for
consistency of the finished product. It is important that during
the spreading process of the decorative aggregate the concrete is
to be left lower than adjacent edges of the forms. A rise in
concrete elevations will take place during the spreading of
decorative aggregates thus elevating the concrete surface to the
desired elevation required or to adjacent surfaces.
[0033] A roller tamp will be utilized to lightly bury the larger
aggregates no more than 3/8-1/2 of an inch below the decorative
aggregate surface when utilizing a 1 inch minus concrete mix
design. The mix designs may vary depending on the desired finish
and the type decorative aggregate selected.
[0034] The surface of the concrete should be floated with a wood,
resin or magnesium bull float and allow sufficient time for the
water to rise to the surface. The process of spreading the
decorative aggregate is required to start prior to bleed water
evaporation from the concrete. All edges are to be hand floated and
the appropriate edgers must be used at this time to insure the rock
in the concrete mix is pushed down to the proper elevation prior to
the spreading of aggregates.
[0035] Selected decorative aggregates to be spread should be
prepared and placed along the pour areas to be readily available
when the need arises. Spreading should be done in a uniform manner
with the designated crew to insure the proper and desired
consistency is achieved throughout the project. One lead person
will be responsible for the proper application of decorative
aggregate materials and desired surface finishes.
[0036] Once the spreading of the decorative aggregate has occurred,
the concrete surface should be floated with resin or magnesium
floats in a timely manner to imbed the materials to a depth
approximately 1/8 to 1/4 of an inch below the surface. Hand floats
must also be utilized to manipulate the embedment of the decorative
aggregate material into the surface with a circular motion using a
flat angle trowel position to insure proper embedment of the
decorative aggregate. Special care is required to eliminate the
potential for over-embedment of the decorative materials. In some
cases, lightly tamping may be required. The decorative aggregate
surface should be allowed to release any additional bleed waters
before finish trowels are applied.
[0037] All proper conventional finishing techniques should be
utilized and followed to give the concrete surface a once-over
smooth trowel finish and leave ready to receive the application of
the retarder. After the embedded decorative aggregate process has
been completed, the surface should only be toweled one time prior
to the application of the surface retarder. This process must be
completed exactly the same way on multiple concrete pour projects
to insure the same finish will be obtained.
[0038] A surface retarder consisting of propylene glycol, citric
acid and 5-cloro-2-methyl-2H-isothiazol-3-one (such as Grace Top
Cast 150.RTM. or a similar compound) shall be applied per
manufactures recommendations. Various grades of surface retarders
may be applied depending on the decorative aggregate type and
desired finish selected. Proper containment of surface wash should
be taken to abide to local, state and federal environmental laws.
When washing, it is recommended to use a floor maintainer (buffer)
with a stiff brush and ample amounts of water. Scrubbing should be
done until the desired finish is acquired. An acid solution may be
necessary prior to any sealing of the surface. One last buff wash
should be applied just prior to the sealing process.
[0039] Proper curing methods should be utilized and a 28-day curing
period is required prior to the application of a densifing sealer
that is required for this type of finish. The surface may be kept
moist to help the hydration process, but it is not necessarily
required because of the 6-mil poly (Visqueen) used as a moisture
barrier below the concrete.
[0040] After a 28-day curing period and final buff wash it is time
to apply a densifing sealer. It is highly recommended that a
densifying sealer be applied. The densifying sealer should consist
of lithium silicate such as Prosoco Consolideck LS or lithium
quartz such as Sinak HLQ-125. Once any of the referenced products
are applied, per manufacturer's recommendations, this will properly
densify and seal the exposed finish completing the decorative
aggregate concrete surface preparation process. If desired, an
enhancing sealer such as GlazeNSeal, Wet Look 2000, Westcoat SC70
or Schofield Cementone, may be applied to increase the color value,
and bring out the vibrant color of the seeded decorative aggregate
surface.
[0041] The foregoing has outlined rather broadly the more pertinent
and important features of the present decorative aggregate concrete
surface preparation in order that the detailed description of the
application that follows may be better understood so that the
present contribution to the art may be more fully appreciated.
Additional features of the process will be described hereinafter
which form the subject of the claims of this disclosure. It should
be appreciated by those skilled in the art that the conception and
the disclosed specific embodiment might be readily utilized as a
basis for modifying or developing other processes and methods for
carrying out the same purposes of the present invention. It should
also be realized by those skilled in the art that such equivalent
processes and methods do not depart from the spirit and scope of
this application as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The accompanying drawings that are incorporated in and form
a part of this specification, illustrate embodiments of the
decorative aggregate concrete surface preparation.
[0043] FIG. 1 depicts a perspective view of the decorative
aggregate concrete surface preparation process.
[0044] FIG. 2 depicts a block diagram of the decorative aggregate
concrete surface preparation process.
[0045] For a fuller understanding of the nature and advantages of
the decorative aggregate concrete surface preparation, reference
should be had to the following detailed description taken in
conjunction with the accompanying drawings which are incorporated
in and form a part of this specification, illustrate embodiments of
the design and together with the description, serve to explain the
principles of this application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] Referring now to the drawings, wherein similar parts of the
decorative aggregate concrete surface preparation 10 are identified
by like reference numerals, there is seen in FIG. 1 a perspective
view of the decorative aggregate concrete surface preparation 10
illustrating the varying layers of the process, as it applies to a
ground concrete installation. Above the existing soil 11 will be a
suggested layer of road base material 12 at the required thickness
compacted to a minimum of 90% compaction. A moisture barrier 14 of
6-mil poly (Visqueen) is layered over the road base material 12 and
covered with a layer of two inches clean washed sand 16 to be fine
graded in place to allow for the proper thickness of concrete 18.
The rebar mat 20 is placed on adobe risers 22 elevating the rebar
off the surface and not allowing any of the rebar mat 20 to extend
below the lower surface of the concrete. This is important because
if any of the metal surface of the rebar mat 20 is exposed the
rusting process will extend through out the rebar mat 20 quickly. A
minimum requirement of 3000 PSI standard concrete 18 design mix
consisting of 1 inch minus concrete aggregate 24, including water
reducing chemicals that are required for this application process
is illustrated over the rebar mat 20 with the decorative aggregate
surface 26 on the top.
[0047] FIG. 2 depicts a block diagram of the decorative aggregate
concrete surface preparation 10 illustrating the conventional
features of the process in dotted lines and the unique features of
the process in bold solid lines. For a podium deck or topping slab
concrete installation the sub grade soil prep, 6 mil poly and sand
are not required.
[0048] The first step of the installation process of the decorative
aggregate concrete surface preparation 10 will be the sub grade
soil preparation 36, when required, where the proposed grade shall
be on a soil compacted to a minimum of 90% and per city
specifications. Sub grade to be within a tenth of a foot ready to
receive required road base material 12. Next step 38 will be the
installation of a 2-inch suggested layer of road base material 12
tested by a licensed certified soils engineer to insure proper
moister content and that the proper compaction has been achieved.
The following unique step 40 will be the application of the
moisture barrier 14 of a 6-mil poly (Visqueen) material over the
entire surface. Step 42 will be covering the moisture barrier 14
with a two-inch layer of clean washed sand 16 to be fine graded in
place allowing for the proper thickness of concrete 18. For podium
decks with waterproofing, this will satisfy the hydration process,
and the previous steps will be deleted. The following step 44 will
be the installation of the concrete forms 45 around the perimeter
of the desired area of the installation. Step 46 will be the
installation of the reinforcement 3/8 rebar mat 20 on adobe risers
22 or wire mesh as required. Step 48 will be the pouring of the
3000-PSI min., 1 inch or less aggregate 24 concrete material
18.
[0049] After pouring the concrete material 18 in place, step 50
will be to screed the concrete to the required thickness below top
edge of concrete forms 45. Step 52 of roller tamping the concrete
surface 28 will work the concrete aggregate 24 to the desired depth
below the concrete surface 28. The following step 54 of the primary
floating of the concrete surface 28 is done just prior to step 56
of spreading a layer of decorative aggregate 30 over designated
concrete surface 28. After spreading a layer of decorative
aggregate 30 over designated decorative aggregate surface 26 will
be step 58 of the secondary floating of concrete embedding
decorative aggregate 30 below the decorative aggregate surface 26.
It should be noted that steps 56 and/or 58 may need to be repeated
to achieve the desired finish based on the selected aggregate
material utilized. The aggregate size will vary from 1/8.sup.th
inch or less to as much as 1 to 2 inches or more.
[0050] The decorative aggregate surface 26 should be allowed to
release any additional bleed waters before finish trowels are
applied. All proper conventional finishing techniques should be
utilized and followed to give the decorative aggregate surface 26 a
once over smooth trowel finish and leave ready to receive the
application of the retarder. The step 60 of applying a trowel
finish to the decorative aggregate surface 26 will be followed by
step 62 of the application of a surface retarder, in an even
uniform pattern, to the decorative aggregate surface 26.
[0051] After a period of four to twenty four hours the decorative
aggregate surface 26 will have reached a relative hardness where
step 64 of washing and power brushing the decorative aggregate
surface 26 to expose decorative aggregate 30 may be accomplished.
When washing, it is recommended to use a floor maintainer (buffer)
with a stiff brush and ample amounts of water. Scrubbing should be
done until the desired finish is acquired. An acid solution may be
necessary prior to any sealing of the surface. One last buffing
wash should be applied just prior to the sealing process. Step 66
indicates a curing period of a minimum of 28 days before the step
68, the final wash and power brushing of the decorative aggregate
surface 26 and step 70, of the application of the densifing sealer
can be accomplished to complete the procedure of the decorative
aggregate concrete surface preparation 10. Finally, the application
of an optional enhancing sealer can be performed to achieve a
maximum vibrant color appearance of the decorative aggregate.
[0052] The decorative aggregate concrete surface preparation 10
shown in the drawings and described in detail herein disclose
arrangements of elements of particular construction and
configuration for illustrating preferred embodiments of structure
and method of operation of the present application. It is to be
understood, however, that elements of different construction and
configuration and other arrangements thereof, other than those
illustrated and described may be employed for providing a
decorative aggregate concrete surface preparation 10 in accordance
with the spirit of this disclosure, and such changes, alternations
and modifications as would occur to those skilled in the art are
considered to be within the scope of this design as broadly defined
in the appended claims.
[0053] Further, the purpose of the foregoing abstract is to enable
the U.S. Patent and Trademark Office and the public generally, and
especially the scientists, engineers and practitioners in the art
who are not familiar with patent or legal terms or phraseology, to
determine quickly from a cursory inspection the nature and essence
of the technical disclosure of the application. The abstract is
neither intended to define the invention of the application, which
is measured by the claims, nor is it intended to be limiting as to
the scope of the invention in any way.
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