Decorative aggregate concrete surface preparation process

Abstract

The present invention is directed to a process of creating a decorative aggregate concrete surface. The preparation includes washed decorative aggregate surfaces using a variety of decorative aggregate materials imbedded within a standard concrete mix having a one inch maximum aggregate. A 6-mil polypropylene sheet Visqueen material covered with a two-inch layer of sand is used directly below the concrete to retard the curing time. Roller tamping is used to move the large aggregate below the surface of the concrete material. Power brushes are then used to expose the decorative aggregate prior to the final process of applying a densifing sealer. This process has been designed to reduce installation time, as well as overall labor and material costs.

We claim: 
     
         1 . A decorative aggregate concrete surface preparation process for concrete poured to a ground installation, comprising the steps of:
 (a) preparing the sub grade soil and applying a suggested 2 inch layer of road base material;   (b) laying down a 6 mil. polypropylene Visqueen moisture barrier over the prepared surface and adding a 2 inch layer of washed sand;   (c) installing concrete forms as required and installing reinforcement bars;   (d) pouring concrete to a minimum specification of about 3000 psi;   (e) screeding the concrete surface to the required thickness below the top edge of any form material and roller tamping the concrete surface;   (f) spreading a layer of decorative aggregate over designated surface areas followed by a primary floating and secondary floating of concrete surface before trowel finishing;   (g) applying a surface retardant;   (h) washing and power brushing concrete surface to expose decorative aggregate, then curing concrete for about 28 days before a final washing and power brushing of concrete surface; and   (i) applying a densifying sealer to the exposed decorative concrete surface.   
     
     
         2 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of spreading a layer of decorative aggregate followed by a primary floating and secondary floating of concrete surface before trowel finishing is repeated as necessary. 
     
     
         3 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of pouring concrete to a minimum specification of about 3000 psi, further includes the step of pouring concrete to a minimum specification of about 3000 psi to about 5000 psi as required. 
     
     
         4 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of spreading a layer of decorative aggregate over designated surface areas includes spreading natural and synthetic decorative aggregate materials including glass, shells, rock, metals, plastics, rubber, organic materials, inorganic materials, chemically inert particulates, and chemically active particulates. 
     
     
         5 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of primary floating and secondary floating of concrete surface before trowel finishing includes the step of floating by hand. 
     
     
         6 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of primary floating and secondary floating of concrete surface before trowel finishing includes the step of floating by hand using a wood, resin or magnesium float. 
     
     
         7 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of applying a surface retardant includes the step of applying a surface retardant employing a surface retarder consisting of propylene glycol and citric acid. 
     
     
         8 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of applying a densifying sealer to the exposed decorative concrete surface includes the step of applying a densifying sealer to the exposed decorative concrete surface wherein said densifying sealer includes lithium silicate or lithium quartz. 
     
     
         9 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of washing and power brushing includes the step of washing and power brushing after a period of four to twenty four hours following the application of a surface retarder. 
     
     
         10 . The decorative aggregate concrete surface preparation process for concrete poured to a ground installation, according to  claim 1 , wherein said step of applying a densifying sealer is followed by application of an enhancing sealer to bring out the vibrant color of the decorative aggregate.