Decorative concrete and method of installing the same

Abstract

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:
 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 vibrating metal bull float to dispose a quantity of cement/fines paste derived from the concrete mixture at the exposed surface thereof; and   finishing the exposed surface of the concrete mixture with a decorative finishing tool, the decorative finishing tool having a blade with a visual and textural decorative pattern formed thereupon, the blade being configured to face the exposed surface of the concrete mixture and imprint the visual and textural decorative pattern upon the exposed surface.   
   
   
       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 via the vibrating metal bull float.   finishing the exposed surface of the concrete mixture with a decorative finishing tool, the decorative finishing tool having a blade with a visual and textural decorative pattern formed thereupon, the blade being configured to face the exposed surface of the concrete mixture and imprint the visual and textural decorative pattern upon the exposed surface;   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 the concrete mixture over the subgrade step further includes preparing the subgrade to a desired grade prior to pouring the concrete mixture thereover. 
   
   
       5 . The method of  claim 4  wherein the pouring the concrete mixture over the subgrade step further includes compacting the subgrade to approximately 90% compaction. 
   
   
       6 . The method of  claim 4  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.   
   
   
       7 . The method of  claim 1  wherein the finishing the exposed surface of the concrete mixture with a 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. 
   
   
       8 . The method of  claim 1  wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step includes the decorative finishing tool having a blade, the blade further comprising:
 a first opposing side having a handle; and   a second opposing side having 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.   
   
   
       9 . The method of  claim 8  wherein the second opposing side having a plurality of rods disposed thereupon, the rods being configured to form the visual and textural decorative pattern to imprint on the exposed surface of the concrete mixture. 
   
   
       10 . The method of  claim 9  wherein the rods are adhesively attached to the second opposing side of the blade. 
   
   
       11 . The method of  claim 9  wherein the rods are welded to the second opposing side of the blade. 
   
   
       12 . The method of  claim 9  wherein the second opposing side further includes a plurality of grooves formed thereupon, the grooves being positioned in accordance to the visual and textural decorative pattern; and the rods rigidly attached to the grooves. 
   
   
       13 . 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. 
   
   
       14 . 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. 
   
   
       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 honed stone. 
   
   
       16 . The method of  claim 1  wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step comprises the decorative finishing tool being a trowel, the trowel having a trowel blade with the visual and textural decorative pattern formed thereupon, the trowel blade being configured to face the exposed surface of the concrete mixture and imprint the visual and textural decorative pattern upon the exposed surface. 
   
   
       17 . The method of  claim 1  wherein the finishing the exposed surface of the concrete mixture with a decorative finishing tool step comprises the decorative finishing tool being a float, the float having a float blade with the visual and textural decorative pattern formed thereupon, the float blade being configured to face the exposed surface of the concrete mixture and imprint the visual and textural decorative pattern upon the exposed surface. 
   
   
       18 . A concrete product having a visual and textural design pattern formed by the method of  claim 1 .