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 architectural 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) while the sprayer is off of the upper surface to be sprayed, spraying a quantity of the particulate through air upon the upper surface of cement/fines concrete paste greater than ten feet from the sprayer utilizing the material 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 - 32 . (canceled)  
   
   
       33 . The method of  claim 1  wherein the particulate comprises glass, organic materials, seashells, course sand or Monterey Aquarium course sand.  
   
   
       34 . The method of  claim 1  wherein the particulate has a mean diameter size of less that ⅜ of one inch.  
   
   
       35 . The method of  claim 1  wherein the material spraying device is a directional material gun.  
   
   
       36 . The method of  claim 1  wherein said spraying includes spraying some of the quantity of particulate a distance of at least 20 feet.  
   
   
       37 . A surface seeded exposed particulate concrete product formed by the method of  claim 1.