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.

1 . 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 and having a generally flat exposed particulate surface suitable for flooring applications, the method comprising: 
 a) preparing a subgrade to a desired grade;    b) pouring a concrete mixture over the subgrade;    c) screeding the concrete mixture to a desired grade and forming a top surface thereof;    d) finishing the top surface of the concrete mixture with a float to seal the top surface and disposing 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;    e) spraying a quantity of the particulate through air uniformly upon the upper surface of cement/fines concrete paste greater than ten feet from the sprayer utilizing the spraying device;    f) mixing the quantity of particulate 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;    g) applying a surface retarder uniformly over the exposed surface of the surface-concentrated particulate and cement/fines concrete paste;    h) washing surface films from the exposed surface;    i) curing the concrete mixture and paste to form a cured mixture and a cured paste; and    j) washing the exposed surface to remove surface residue therefrom.    
   
   
       2 . The method of  claim 1  wherein the exposed particulate surface comprises a material reactable with a hydrolyzed alkali silica to form an insoluble silicate structure.  
   
   
       3 . The method of  claim 2  further comprising after said washing the exposed surface, applying a chemical treatment of hydrolyzed alkali silica solution uniformly over the exposed surface in a quantity sufficient to penetrate only the depth of the surface-concentrated particulate and cement/fines concrete paste.  
   
   
       4 . The method of  claim 3  wherein the hydrolyzed alkali silica is a hydrolyzed lithium quartz solution.  
   
   
       5 . The method of  claim 3  wherein said applying of chemical treatment causes 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.  
   
   
       6 . The method of  claim 2  wherein the particulate comprises glass.  
   
   
       7 . The method of  claim 2  wherein the particulate comprises organic materials.  
   
   
       8 . The method of  claim 7  wherein the organic material comprises sea shells.  
   
   
       9 . The method of  claim 1  wherein the particulate comprises coarse sand.  
   
   
       10 . The method of  claim 9  wherein the particulate comprises Monterey Aquarium coarse sand.  
   
   
       11 . The method of  claim 1  wherein the particulate has a mean diameter size of less than three-eights of one inch.  
   
   
       12 . The method of  claim 1  wherein said spraying device is a material gun.  
   
   
       13 . The method of  claim 1  wherein said spraying uniformly sprays the quantity of particulate.  
   
   
       14 . The method of  claim 1  wherein said spraying includes spraying some of the quantity of particulate a distance of at least twenty feet.  
   
   
       15 . The method of  claim 1  wherein said applying of the surface retarder causes penetration of the surface retarder into the upper surface of the concrete mixture through a distance greater than the mean diameter of the particulate.  
   
   
       16 . The method of  claim 1  wherein the particulate is sprayed over the upper surface of the concrete mixture at an approximate rate of one pound per square foot of concrete mixture.  
   
   
       17 . The method of  claim 1  wherein said mixing comprises using a float in a circular motion to cover the particulate with the cement/fines concrete paste.  
   
   
       18 . The method of  claim 1  wherein between said mixing and said applying the surface retarder, the method further comprises sponging in a circular motion any areas of the upper surface of the concrete mixture.  
   
   
       19 . The method of  claim 1  wherein said washing of surface film comprises: 
 (i) applying water to the upper surface of the concrete mixture; and    (ii) lightly brushing the upper surface of the concrete mixture.    
   
   
       20 . The method of  claim 19  wherein said lightly brushing removes no more than five percent of the particulate from the upper surface of the concrete mixture.  
   
   
       21 . The method of  claim 1  wherein said washing of the upper surface of the concrete mixture to remove surface residue therefrom comprises washing the upper surface of the concrete with a mixture of water and muriatic acid.  
   
   
       22 . The method of  claim 1  wherein between said applying of the surface retarder and said washing surface film, the method further comprises covering the upper surface of the concrete mixture with a vapor barrier.  
   
   
       23 . The method of  claim 22  wherein said covering the upper surface of the concrete mixture with a vapor barrier extends for a period of two to twenty-four hours.  
   
   
       24 . The method of  claim 1  wherein said curing comprises curing the concrete mixture by use of a fogger.  
   
   
       25 . The method of  claim 1  wherein said curing comprises curing the concrete mixture by use of a soaker hose.  
   
   
       26 . The method of  claim 1  further comprising placing reinforcement means upon the prepared subgrade to be disposed within the poured concrete mixture.  
   
   
       27 . The method of  claim 1  wherein said pouring comprises mixing the concrete mixture with a color additive.  
   
   
       28 . The method of  claim 1  wherein after said curing the concrete mixture, the method further comprises altering the surface roughness of the upper surface of the concrete mixture.  
   
   
       29 . The method of  claim 1  wherein prior to said spraying the quantity of particulate, the method further comprises washing the quantity of particulate with potable water and air drying the quantity of particulate.  
   
   
       30 . The method of  claim 1  wherein said preparing the subgrade comprises compacting the subgrade to approximately ninety percent compaction.  
   
   
       31 . The method of  claim 1  wherein said preparing the subgrade further comprises placing a layer of sand between the subgrade and the poured concrete mixture.  
   
   
       32 . A surface seeded exposed particulate concrete product formed by the method of  claim 1 .  
   
   
       33 . The method of  claim 1  wherein the quantity of particulate in the spraying step is uniformly sprayed a distance greater than a distance uniformly sprayable with a square point shovel.  
   
   
       34 . The method of  claim 1  wherein the quantity of particulate in the spraying step is uniformly sprayed a distance greater than a distance uniformly sprayable with manual means.  
   
   
       35 . A method of producing a surface seeded exposed aggregate 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 and being prepared upon a subgrade, the method comprising the steps of: 
 a) pouring a concrete mixture over the subgrade, the concrete mixture defining an exposed surface when poured;    b) finishing the exposed surface of the concrete mixture with a bull float to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof;    c) broadcasting a quantity of aggregate upon the exposed surface of the concrete mixture;    d) mixing the quantity of aggregate with the quantity of cement/fines via the bull float;    e) finishing the exposed surface of the concrete mixture with a power trowel to facilitate an even distribution of the quantity of aggregate within the quantity of cement/fines paste;    f) applying a surface retarder to the exposed surface of the concrete mixture; and    g) finishing the exposed surface of the concrete mixture to massage the surface retarder into the quantity of cement/fines paste having the quantity of aggregate mixed therein.    
   
   
       36 . The method of  claim 35  wherein the quantity of aggregate in the broadcasting step is uniformly broadcasted on the exposed surface greater than ten feet from a broadcaster.  
   
   
       37 . The method of  claim 36  wherein the quantity of aggregate in the broadcasting step is uniformly broadcasted at least twenty feet.  
   
   
       38 . The method of  claim 35  wherein the quantity of aggregate in the broadcasting step is uniformly broadcasted a distance greater than a distance uniformly broadcastable with a square point shovel.  
   
   
       39 . The method of  claim 35  wherein the quantity of aggregate in the broadcasting step is uniformly broadcasted a distance greater than a distance uniformly broadcastable with manual means.  
   
   
       40 . The method of  claim 35  wherein finishing step (g) is accomplished with a broom.  
   
   
       41 . An improved method of producing a surface seeded exposed aggregate concrete upon a subgrade, the method including the steps of pouring a concrete mixture over the subgrade, the concrete mixture defining an exposed surface when poured; finishing the exposed surface of the concrete mixture with a bull float to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof; broadcasting a quantity of aggregate upon the exposed surface of the concrete mixture; mixing the quantity of aggregate with the quantity of cement/fines via the bull float; finishing the exposed surface of the concrete mixture with a power trowel to facilitate an even distribution of the quantity of aggregate within 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 to massage the surface retarder into the quantity of cement/fines paste having the quantity of aggregate mixed therein, wherein the improvement comprises: 
 utilizing a material spraying device to perform the broadcasting of the particulate, the spraying device enabling the spraying of particulate at distances of at least ten feet from a sprayer for covering large surface areas.    
   
   
       42 . The method of  claim 41  wherein the aggregate is uniformly broadcasted on the exposed surface greater than ten feet from a broadcaster.  
   
   
       43 . The method of  claim 41  wherein the quantity of aggregate is uniformly broadcasted at least twenty feet.  
   
   
       44 . The method of  claim 41  wherein the quantity of aggregate is uniformly broadcasted a distance greater than a distance uniformly broadcastable with a square point shovel.  
   
   
       45 . The method of  claim 41  wherein the quantity of aggregate in the broadcasting step is uniformly broadcasted a distance greater than a distance uniformly broadcastable with manual means.