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 - 32 . (canceled) 
     
     
         33 . 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 greater than 10′×10′ and having a generally flat exposed particulate surface suitable for flooring applications, the method comprising:
 a) providing particulate having a mean diameter size less than ⅜″; 
 b) preparing a subgrade to a desired grade; 
 c) pouring a concrete mixture over the subgrade, the concrete mixture defining a generally horizontal upper surface; 
 d) while the concrete is uncured and the material spraying device is remote from the upper surface to be sprayed, continuously spraying the quantity of particulate with the material spraying device through air upon the upper surface of concrete mixture until the large surface area greater than 10′×10′ is covered with particulate; 
 e) distributing the provided particulate upon the upper surface of the concrete mixture with the material spraying device wherein a level of uniformity of the distributed particulate is greater for the material spray gun than by shovel when particulate is distributed over the wide surface area greater than 10′×10′; and 
 f) curing the concrete mixture to form the surface seeded particulate concrete. 
 
     
     
         34 . A surface seeded exposed particulate concrete product formed by the method of  claim 33 . 
     
     
         35 . The method of  claim 33  wherein at least some of the particulates are visibly exposed. 
     
     
         36 . The method of  claim 33  wherein the spraying step comprises the step of continuously spraying the quantity of particulate through air upon the upper surface of the concrete mixture greater than ten feet from the sprayer utilizing a continuous material spraying device. 
     
     
         37 . The method of  claim 33  wherein the spraying step is performed with a motor driven material spraying device. 
     
     
         38 . The method of  claim 33  wherein the spraying step comprises the step of continuously spraying the quantity of particulate with the material spraying device until the quantity of particulate evenly covers more than the 10′×10′ concrete surface area. 
     
     
         39 . The method of  claim 33  wherein the particulate is selected from the group consisting of organic materials, seashells, course sand and Monterey Aquarium course sand. 
     
     
         40 . The method of  claim 33  wherein the providing step includes the step of providing particulate having a mean diameter size of about ⅛″. 
     
     
         41 . 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 greater than 10′×10′ and having a generally flat horizontal exposed particulate surface suitable for flooring applications, the method comprising:
 a) providing particulate having a mean diameter size less than  3 / 8 ″; 
 b) preparing a subgrade to a desired grade; 
 c) pouring a concrete mixture over the subgrade, the concrete mixture defining a generally horizontal upper surface; 
 d) while the concrete is uncured and the material spraying device is remote from the upper surface to be sprayed, continuously spraying the quantity of particulate with the material spraying device through air upon the upper surface of concrete mixture until the large surface area greater than 10′×10′ is covered with particulate; 
 e) redirecting the material spraying device to uniformly distribute the provided particulate upon the upper surface of the concrete mixture with the material spraying device; and 
 f) curing the concrete mixture to form the surface seeded particulate concrete. 
 
     
     
         42 . The method of  claim 41  wherein a level of uniformity of the distributed particulate over the wide surface area greater than 10′×10′ is equal to or greater than a level of uniformity when the particulate is distributed by shovel over a small surface area less than 10′×10′. 
     
     
         43 . The method of  claim 41  wherein the particulate is distributed over the generally horizontal upper surface at a rate of approximately one pound per square foot.