Decorative concrete and method of installing the same
View Patent ↗A decorative concrete product and method of making the same is provided. The concrete surface carries a unique textural and visual decorative pattern that is troweled over the uncured surface. The decorative pattern strategically conceals any imperfections in the concrete surface. A decorative finishing tool is utilized to create a unique and consistent pattern throughout the exposed surface of the concrete. Unique visual patterns may include any aesthetic design including wood grain, or lightly finished honed or cut stone. The decorative finishing tool may be configured so that varying textures and contours may consistently be imprinted throughout the concrete. Advantageously, the cured concrete retains the durability of a concrete surface while carrying a visually and texturally appealing appearance.
1. A method of imprinting a visual and textural decorative pattern upon a concrete surface, the method comprising the steps of:
providing a decorative finishing tool having a blade including a plurality of grooves and a plurality of pattern forming elements selectively positionable within respective ones of the grooves and collectively defining a visual and textural pattern;
pouring a concrete mixture defining an exposed surface when poured;
finishing the exposed surface of the concrete mixture to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof;
selectively configuring the decorative finishing tool by selectively positioning the plurality of pattern forming elements within respective ones of the grooves in accordance with a desired decorative pattern; and
finishing the exposed surface of the concrete mixture with the decorative finishing tool with the blade facing the exposed surface of the concrete mixture to imprint the visual and textural decorative pattern upon the exposed surface, at least a portion of the blade being disposed within the concrete mixture and moved within the concrete in a plane substantially parallel to the exposed surface to create the visual and textural decorative pattern with the concrete.
2. The method of claim 1 wherein after the first finishing step:
broadcasting a quantity of aggregate upon the exposed surface of the concrete mixture; and
mixing the quantity of aggregate into the quantity of cement/fines paste;
applying a surface retarder to the exposed surface of the concrete mixture; and
finishing the exposed surface of the concrete mixture with a finishing tool to massage the surface retarder into the exposed surface having the design pattern thereupon.
3. The method of claim 2 further comprising the steps of:
forming a vapor barrier on the exposed surface of the concrete mixture;
washing surface films from the exposed surface of the concrete mixture; curing the concrete mixture; and
washing the exposed surface of the concrete mixture to remove surface residue therefrom.
4. The method of claim 1 wherein the pouring step comprises a step of pouring the concrete mixture over a subgrade.
5. The method of claim 4 wherein the pouring the concrete mixture over the subgrade step further includes preparing the subgrade to a desired grade prior to pouring the concrete mixture thereover.
6. The method of claim 5 wherein the pouring the concrete mixture over the subgrade step further includes compacting the subgrade to approximately 90% compaction.
7. The method of claim 5 wherein the pouring the concrete mixture over the subgrade step further comprises the steps of:
placing a layer of sand upon the prepared subgrade;
placing reinforcement members upon the layer of sand; and
pouring the concrete mixture over the layer of sand and the reinforcement members such that the reinforcement members are encapsulated by the concrete mixture.
8. The method of claim 1 wherein the finishing step comprises the step of finishing the exposed surface of the concrete mixture with a vibrating metal bull float.
9. The method of claim 8 wherein the finishing the exposed surface of the concrete mixture with the vibrating metal bull float step includes screeding the concrete mixture to a desired grade prior to finishing the exposed surface thereof with the vibrating metal bull float.
10. The method of claim 1 wherein the blade of the finishing tool used in the finishing step further includes:
a first opposing side having a handle; and
a second opposing side having at least a portion of the visual and textural decorative pattern formed thereupon, the second opposing side facing the exposed surface of the concrete mixture and configured to imprint the visual and textural decorative pattern on the exposed surface.
11. The method of claim 10 wherein the plurality of pattern forming elements includes a plurality of rods disposable upon the second opposing side, the rods being configured to form the visual and textural decorative pattern to imprint on the exposed surface of the concrete mixture.
12. The method of claim 11 wherein the rods are adhesively attached to the second opposing side of the blade.
13. The method of claim 11 wherein the rods are welded to the second opposing side of the blade.
14. The method of claim 11 wherein the second opposing side further includes the plurality of grooves formed thereupon, the grooves being positioned in accordance with the visual and textural decorative pattern; and the rods rigidly attached to the grooves.
15. The method of claim 1 wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step includes the visual and textural pattern being wood grain.
16. The method of claim 1 wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step includes the visual and textural pattern being cut stone.
17. The method of claim 1 wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step includes the visual and textural pattern being honed stone.
18. The method of claim 1 wherein the finishing tool used in the finishing step comprises a trowel.
19. The method of claim 1 wherein the finishing tool used in the finishing step comprises a float.