Composition and method for installing a simulated natural surface

Abstract

A method of producing a simulated natural surface, such as stone, tile, brick or wood planking uses all environmentally friendly components. First, a water-based polymer liquid is applied to the existing surface using a roller. Next, a self-leveling mixture of water, polymer, cement and sand is applied with minimal trowelling in order to spread the mixture evenly over the surface. The applied mixture settles in a self-leveling manner. When partially cured, a desired grout pattern is scored in the applied cementous mixture to create the desired pattern (i.e., brick, stone, tile, wood planking). Next, the entire surface is painted with a prime coat of an acrylic paint including the scored grout lines. Once the prime coat dries, shading containing an organic oxide pigment is applied using a sponge. Alternatively, a marble appearance is created by applying drops of ink or other liquid pigment to the self-leveling cementous layer while still wet, which allows the drops to bleed and create a natural marble veining appearance. Lastly, a water-based glaze is applied over the entire surface as a sealer.

1 . A method of producing a simulated natural surface over an existing surface comprising:
 providing a bonding agent comprising 40% polymer liquid and 60% water;   applying the bonding agent to the existing surface;   providing a second mixture comprising 20% polymer and 80% water;   providing a cementous mixture comprising 50% Portland cement and 50% sand;   combining and thoroughly mixing the second mixture and the cementous mixture to produce a self-leveling cementous mixture;   applying a layer of the self-leveling cementous mixture over the bonding agent previously applied to the existing surface;   applying at least one pigment of a desired color to the previously applied self-leveling cementous mixture prior to curing of the self-leveling cementous mixture;   allowing the self-leveling cementous mixture to fully cure; and   applying a water-based sealer over the self-leveling cementous mixture.   
   
   
       2 . The method as recited in  claim 1  comprising the further step of:
 scoring the applied layer of the self-leveling cementous mixture, prior to curing and prior to said step of applying at least one pigment, to create desired grout line patterns.   
   
   
       3 . The method as recited in  claim 2  wherein said step of applying said at least one pigment includes avoiding application of said at least one pigment to said scored grout lines. 
   
   
       4 . The method as recited in  claim 1  wherein said at least one pigment is an organic iron oxide. 
   
   
       5 . The method as recited in  claim 4  wherein said step of applying at least one pigment includes:
 applying said at least one pigment using a sponge without touching the scored grout lines.   
   
   
       6 . The method as recited in  claim 1  wherein said at least one pigment is ink. 
   
   
       7 . The method as recited in  claim 6  wherein said step of applying at least one pigment includes:
 applying drops of the ink at spaced, random locations throughout the layer of self-leveling cementous mixture while the self-leveling mixture is still wet and allowing the drops to bleed into the layer to create a marble veining appearance.   
   
   
       8 . The method as recited in  claim 1  wherein said polymer of said bonding agent is a masonry coating polymer. 
   
   
       9 . The method as recited in  claim 1  wherein said polymer of said second mixture is a masonry coating polymer. 
   
   
       10 . The method as recited in  claim 2  further comprising the step of:
 painting the entire cured surface of the self-leveling cementous mixture, including the scored grout line patterns, with a prime coat of acrylic paint.