Surface seeded exposed aggregate concrete and method of producing same

• US 4,748,788 A
• Filed: 07/01/1987
• Issued: 06/07/1988
• Est. Priority Date: 07/01/1987
• Status: Expired due to Term

• Current Assignee: Shaw Craftsman Concrete, LLC
• Original Assignee: Lee A. Shaw, Leroy E. Shaw, Ronald D. Shaw
• Inventors: Shaw, LeRoy E., Shaw, Lee A., Shaw, Ronald D.
• Primary Examiner(s): Raduazo, Henry E.
• Assistant Examiner(s): Smith, Creighton
• Application Number:
  US07/069,385
• Time in Patent Office: 342 Days
• Field of Search: 52/741, 52/742, 52/315, 264/31, 264/82, 264/256, 264/333, 264/DIG. 43
• US Class Current: 52/741.11
• CPC Class Codes: C04B 41/5323 to make grain visible, e.g. for obtaining exposed aggregate concrete
• CPC Class Codes: E04F 15/12 Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo gypsum floorsinorganic or bituminous masses C04B; organic plastic masses C08L
• CPC Class Codes: E04F 21/24 of masses made in situ, e.g. smoothing tools E04F21/04 takes precedence; finishing of concrete roads or pavings E01C19/40; devices for levelling concrete floors E04G21/10; devices for solidifying concrete floors by vibrating E04G21/066

Abstract

An improved surface seeded exposed aggregate concrete and method of use is disclosed characterized by use of small, rounded aggregate, preferably sand, being broadcast over the upper surface of the concrete. The broadcast aggregate is mixed into the cement paste derived from the concrete matrix by magnesium hand floats and finished by hand sponging. A surface retarder and vapor barrier is than applied to cover the concrete surface for approximately four to twenty four hours. Subsequently, any surface film is washed from the surface of the concrete and the concrete is cured by fogging or soaker hose. Approximately thirty days later, the surface residue is removed from the concrete with a stem/acid wash providing an exposed aggregate concrete having extreme flatness and high wear resistance suitable for high traffic areas and improved asthetics resembling stone, granite or marble.

Claims

1. A method of producing surface seeded exposed aggregate concrete having a generally flat exposed aggregate surface suitable for flooring applications comprising the steps of:

preparing the subgrade to a desired grade;

pouring a concrete mixture over said subgrade;

screeding said concrete mixture to a desired grade;

finishing the upper surface of said concrete mixture with a magnesium bull float to seal said upper surface and dispose a quantity of cement/fines paste derived from said concrete mixture at said upper surface of said concrete mixture;

broadcasting a quantity of aggregate having a mean diameter size of less than three-eights of one inch upon said upper surface of said concrete mixture;

mixing said quantity of aggregate into said quantity of cement/fines paste with a magnesium hand float;

applying a surface retarder uniformly over said upper surface of said concrete mixture;

washing surface films from said upper surface of said concrete mixture;

curing said concrete mixture; and

washing said upper surface of said concrete mixture to remove surface residue therefrom.

2. The method of claim 1 wherein said applying of said surface retarder causes penetration of said surface retarder into said upper surface of said concrete mixture through a distance greater than the mean diameter of said aggregate.

3. The method of claim 2 wherein said aggregate comprises coarse sand.

4. The method of claim 3 wherein said aggregate comprises Monterey Aquarium coarse sand.

5. The method of claim 4 wherein said Monterey Aquarium coarse sand is broadcast over the upper surface of said concrete mixture at an approximate rate of one pound per square foot of concrete mixture.

6. The method of claim 4 wherein said mixing step comprises using a magnesium hand float in a circular motion to cover said aggregate with said cement/fines paste.

7. The method of claim 6 wherein between said mixing and said applying said surface retarder steps, said method comprises the further step of:

sponging in a circular motion any areas of said upper surface of said concrete mixture.

8. The method of claim 7 wherein said washing of surface film comprises the steps of applying water to said upper surface of said concrete mixture and lightly brushing said upper surface of said concrete mixture.

9. The method of claim 8 wherein said lightly brushing step removes no more than five percent of said aggregate from said upper surface of said concrete mixture.

10. The method of claim 9 wherein between said applying of said surface retarder and said washing surface film step said method comprises the further step of covering said upper surface of said concrete mixture with a vapor barrier.

11. The method of claim 10 wherein said washing of said upper surface of said concrete mixture to remove surface residue therefrom comprises washing said upper surface of said concrete with a mixture of water and muriatic acid.

12. The method of claim 10 wherein said covering said upper surface of said concrete mixture with a vapor barrier extends for a period of three to twenty-four hours.

13. The method of claim 12 wherein said curing step comprises curing said concrete mixture by use of a fogger.

14. The method of claim 13 wherein said curing step comprises curing said concrete mixture by use of a soaker hose.

15. The method of claim 12 wherein said preparing of the subgrade comprises compacting the subgrade to approximately ninety percent compaction.

16. The method of claim 15 wherein said preparing of the subgrade further comprises the step of placing a layer of sand between said subgrade and said poured concrete mixture.

17. The method of claim 16 comprising the further step of placing reinforcement means upon said prepared subgrade to be disposed within said poured concrete mixture.

18. The method of claim 17 wherein said pouring step comprises the further step of mixing said concrete mixture with a color additive.

19. A surface seeded exposed aggregate concrete product formed by the method of claim 18.