Method for manufacturing and installing a textured tile flooring product

Abstract

A method for manufacturing and installing a textured cementitious tile flooring product, wherein sodium bicarbonate is used to texture the tile surface and a polyurethane caulking material provides flexible joints between tiles.

What is claimed is: 
     
         1 . A method of manufacturing a textured cementitious flooring product, comprising the steps of:
 (a) preparing a mold;   (b) preparing a cementitious material comprising reactive components;   (c) introducing a sodium bicarbonate layer onto an inner surface of the mold;   (d) introducing the cementitious material into the mold on top of the sodium bicarbonate layer to form a reaction interface between the sodium bicarbonate layer and the cementitious material;   (e) agitating the cementitious material to generate a randomly distributed reaction at the reaction interface to create a surface texture;   (f) allowing the cementitious material to harden into the flooring product having the surface texture; and   (g) removing the flooring product from the mold.   
     
     
         2 . The method of  claim 1 , wherein the mold is composed of a material selected from the group consisting of steel, rubber, plastic and polyvinyl chloride. 
     
     
         3 . The method of  claim 1 , wherein the reactive components are selected from the group consisting of Portland cement, metakaolin, fly ash and silica fume. 
     
     
         4 . The method of  claim 1 , further comprising a step of adding a strengthening agent to the cementitious material at step (b). 
     
     
         5 . The method of  claim 4 , wherein the strengthening agent is fibrous material. 
     
     
         6 . The method of  claim 1 , further comprising a step of adding a colouring agent to the cementitious material at step (b). 
     
     
         7 . The method of  claim 6 , wherein the colouring agent is a dye. 
     
     
         8 . The method of  claim 1 , further comprising a step of introducing a colouring agent on top of the sodium bicarbonate layer after step (c) but before step (d). 
     
     
         9 . The method of  claim 1 , further comprising a step of applying a releasing agent to the mold before step (d). 
     
     
         10 . The method of  claim 9 , wherein the releasing agent is oil. 
     
     
         11 . A method of installing a deck flooring product comprising at least two portions, the method comprising the steps of:
 (a) providing the portions of the flooring product;   (b) providing a substrate;   (c) applying adhesive to the substrate;   (d) installing the portions of the flooring product on top of the adhesive; and   (e) applying a polyurethane joint sealant between adjacent portions of the flooring product.   
     
     
         12 . The method of  claim 11 , wherein the adhesive is a polyurethane adhesive. 
     
     
         13 . The method of  claim 11 , wherein the polyurethane joint sealant is flexible. 
     
     
         14 . The method of  claim 11 , further comprising a step of installing a waterproof membrane on top of the adhesive after step (c) but before step (d), the portions of the flooring product then being installed directly on top of the waterproof membrane. 
     
     
         15 . The method of  claim 14 , further comprising a step of applying spaced apart and generally parallel adhesive strips on top of the waterproof membrane before installation of the portions of the flooring product thereon, the adhesive strips oriented in a direction of desired water drainage. 
     
     
         16 . The method of  claim 14 , further comprising a step of installing flashing over outer edges of the waterproof membrane before step (d). 
     
     
         17 . A method of installing a flooring product comprising at least two portions over radiant heat tubing, the method comprising the steps of:
 (a) providing the portions of the flooring product;   (b) providing a substrate;   (c) installing a reflective sheet on top of the substrate;   (d) installing a plurality of spaced apart spacers on top of the reflective sheet;   (e) installing radiant heat tubing on top of the reflective sheet and between the spacers;   (f) applying adhesive to upper surfaces of the spacers;   (g) installing the portions of the flooring product on top of the adhesive; and   (h) applying a polyurethane joint sealant between adjacent portions of the flooring product.   
     
     
         18 . The method of  claim 17 , wherein the reflective sheet is composed of aluminum foil. 
     
     
         19 . The method of  claim 17 , wherein the adhesive is a polyurethane adhesive. 
     
     
         20 . The method of  claim 17 , wherein the polyurethane joint sealant is flexible.