Decorative concrete with uniform surface and method of forming the same

Abstract

A decorative concrete with a very uniform finish surface and a method of fabricating the same is disclosed. A concrete mixture is poured over a subgrade which defines an exposed surface. The exposed surface is finished with any of several techniques, and the surface is then worked with an abrasive material, and additional techniques are used to color and seal the concrete.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]Not ApplicableSTATEMENT RE: FEDERALLY SPONSORED RESEARCH / DEVELOPMENT[0002]Not ApplicableBACKGROUNDField Of The Invention[0003]The present invention relates in general to concrete products, and more particularly, to a method of creating decorative concrete with a highly uniform surface and the method of forming the same.Description Of The Related Art[0004]As is well known in the building and construction trade, concrete is extensively utilized as a building material for commercial and residential applications. In this regard, due to its durability, water resistance, and cost economy, concrete has gained widespread use. With this widespread use, there is a demand for decorative concrete that possesses improved aesthetics such as a highly uniform surface.[0005]Although numerous methods of concrete finishing have been developed in prior art, such as salt finish, broom finish, and form pressed finish (i.e. stamp concrete), the use of such conv...

AI Technical Summary

Benefits of technology

[0010]After the concrete has hardened, the method utilizes an abrasive, such as a low grit sandpaper, which is applied to the top surface of the concrete. Preferably the sandpaper comprises a twenty grit sanding disc which may be mechanically or manually run over the top surface of the concrete. Although intuitively the application of a low grit sandpaper on the top surface of the concrete would seem to make the top surface of the concrete uneven and / or rough, the applicant has found that it actually evens out the sand particles creating a more uniform finish on the top surface of the concrete.

[0011]Following the abrasive sanding application, the top surface of the concrete may optionally be provided with conventional surface treatment, such as concrete stain and / or concrete sealers as desired. The method of the present invention can be utilized for both new concrete installations and is suitable for use on nearly all concrete finishing techniques, such as brooming finish, hand trowel finish, sand blast finish, stamp concrete finish, or acid wash finishes. Further, the present invention is additionally suitable for use on existing concrete installations as a retrofit application to improve the uniformity and aesthetics of the top surface of existing concrete installations.

Problems solved by technology

Although numerous methods of concrete finishing have been developed in prior art, such as salt finish, broom finish, and form pressed finish (i.e. stamp concrete), the use of such conventional techniques have typically failed to provide the desired result, i.e. aesthetics, of the resultant concrete surface to be highly uniform.

In this regard, although techniques have been developed to provide a more uniform concrete, such attempts have been generally difficult or costly to install.

Further, such prior art methods have typically focused on working the concrete before hardening by surface treating the concrete with additional material while the concrete is still in a plastic state.

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