Surface seeded fine aggregate concrete simulating quarried stone
View Patent ↗A method of surface seeded fine aggregate to produce simulated quarried stone. The method comprises preparing a subgrade, pouring a concrete mixture over the subgrate, and broadcasting one of fine sand and aggregate over 5% to 60% of an exposed surface of the concrete mixture. Alternatively, both the fine sand and the aggregate can be broadcast over 5% to 60% of the exposed surface of the concrete mixture to obtain a desired aesthetic effect as provided by the quarried stone.
1. A method of seeding aggregate onto a surface, the method comprising the steps of:
preparing a subgrade;
pouring a concrete mixture over the subgrade, the concrete mixture defining an exposed surface;
broadcasting fine sand over 5% to 60% of the exposed surface of the concrete mixture while the concrete mixture is in a plastic state; and
broadcasting aggregate over 5% to 60% of the exposed surface of the concrete mixture after the fine sand has been broadcast, the aggregate being broadcast while the concrete mixture is in the plastic state, the fine sand and aggregate collectively simulating the appearance of quarried stone.
2. The method of surface seeded aggregate as claimed in claim 1 , wherein the step of preparing the subgrade further includes:
adding moist fill sand on a surface; and
positioning reinforcement members on the moist fill sand.
3. The method of surface seeded aggregate as claimed in claim 2 , wherein the moist fill sand is added with a thickness no less than 4 inches.
4. The method of surface seeded aggregate as claimed in claim 2 , wherein the reinforcement members include wire mesh or rebars.
5. The method of surface seeded aggregate as claimed in claim 1 , wherein the concrete mixture is poured to a thickness between about 3½ inches and about 4 inches.
6. The method of surface seeded aggregate as claimed in claim 1 , further comprising the step of finishing the exposed surface with a bull float after the concrete mixture is poured and before the fine sand is applied.
7. The method of surface seeded aggregate as claimed in claim 1 , wherein the fine sand is broadcast using a pneumatic device.
8. The method of surface seeded aggregate as claimed in claim 7 , wherein the aggregate is broadcast using a pneumatic device.
9. The method of surface seeded aggregate as claimed in claim 1 , wherein the exposed surface of the concrete mixture includes cement or fine paste, the method further comprising the step of mixing the fine sand or aggregate into cement or fine paste at the exposed surface of the concrete mixture after the fine sand or the aggregate is broadcast.
10. The method of surface seeded aggregate as claimed in claim 9 , further comprising using a power trowel to perform the step of mixing the fine sand or aggregate into the cement or fine paste at the exposed surface of the concrete mixture.
11. The method of surface seeded aggregate as claimed in claim 9 , further comprising a step of massaging a surface retarder to the exposed surface of the concrete mixture.
12. The method of surface seeded aggregate as claimed in claim 11 , further comprising a step of forming a vapor barrier on the exposed surface of the concrete mixture.
13. The method of surface seeded aggregate as claimed in claim 12 , wherein the vapor barrier is formed by applying a liquid chemical evaporation reducer to the exposed surface of the concrete mixture.
14. The method of surface seeded aggregate as claimed in claim 12 , wherein the vapor barrier is formed by covering the exposed surface of the concrete mixture by a predetermined length of visquene.
15. The method of surface seeded aggregate as claimed in claim 12 , wherein the vapor barrier is maintained on the exposed surface of the concrete mixture for a predetermined period of time.
16. The method of surface seeded aggregate as claimed in claim 15 , wherein the predetermined period of time includes two to twenty-four hours.
17. The method of surface seeded aggregate as claimed in claim 12 , further comprising a step of removing any surface films of the exposed surface of the concrete mixture.
18. The method of surface seeded aggregate as claimed in claim 17 , further comprising the step of curing the concrete mixture with water.
19. The method of surface seeded aggregate as claimed in claim 1 , wherein the aggregate includes glass, mica or other reactive aggregate, mineral, and a combination thereof.
20. A simulated quarried stone fabricated by a method of seeding aggregate onto a surface, the method comprising the steps of:
preparing a subgrade;
pouring a concrete mixture over the subgrade, the concrete mixture defining an exposed surface;
broadcasting fine sand over 5% to 60% of the exposed surface of the concrete mixture while the concrete mixture is in a plastic state; and
broadcasting aggregate over 5% to 60% of the exposed surface of the concrete mixture after the fine sand has been broadcast, the aggregate being broadcast while the concrete mixture is in the plastic state, the fine sand and aggregate collectively simulating the appearance of quarried stone.
21. The method of surface seeded aggregate as claimed in claim 20 , wherein the fine sand is broadcast using a pneumatic device.
22. A method of seeding aggregate onto a surface, the method comprising the steps of:
preparing a subgrade;
pouring a concrete mixture over the subgrade, the concrete mixture defining an exposed surface;
broadcasting aggregate over 5% to 60% of the exposed surface of the concrete mixture while the concrete mixture is in a plastic state; and
broadcasting fine sand over 5% to 60% of the exposed surface of the concrete mixture after the aggregate has been broadcast, the fine sand being broadcast while the concrete mixture is in the plastic state, the fine sand and aggregate collectively simulating the appearance of quarried stone.