Method for the aesthetic surface treatment of a monolithic concrete floor and product of the method

Abstract

This invention relates generally to a method for forming a concrete floor as a monolithic unit, wherein a wet concrete mix is deposited and worked to achieve a generally uniform flatness of concrete and adding to the top layer thereof a decorative aggregate material. Subsequently, the surface of the concrete is worked, allowed to partially cure and then ground and polished to substantially remove surface irregularities and reveal the decorative aggregate. The floor surface may then be coated with a sealant to achieve a terrazzo-like appearance.

1 . A method for providing an integrated ornamental surface on a monolithic concrete floor concurrent with the pouring and finishing of the concrete floor, comprising:
 contiguously pouring concrete throughout the region of the concrete floor to form a monolithic concrete layer;   before the poured monolithic concrete layer hardens, consistently disbursing decorative aggregate over the surface of the monolithic concrete layer;   integrating the disbursed decorative aggregate into only an upper surface of the monolithic concrete layer;   partially curing the monolithic concrete layer with the integrated aggregate;   uniformly grinding only the upper surface of the partially cured concrete to produce a flat surface and thereby removing a layer of generally uniform thickness from the upper surface, including some of both the partially cured concrete and the integrated aggregate material embedded therein, at least until remaining ground aggregate is exposed uniformly over the flat surface; wherein uniformly grinding includes a series of grinding operations;   fully curing the concrete with the integrated aggregate; and then   polishing the upper surface with the integrated aggregate to produce a smooth surface on the monolithic concrete floor.   
   
   
       2 . The method according to  claim 1  wherein partially curing the monolithic concrete layer includes waiting at least about three days and no more than about seven days. 
   
   
       3 . The method according to  claim 1 , wherein uniformly grinding further comprises a rough pass using a grit in the range of about 10-24. 
   
   
       4 . The method according to  claim 1 , wherein uniformly grinding further comprises at least three passes. 
   
   
       5 . The method according to  claim 4 , wherein uniformly grinding further comprises altering the grinding operation for each pass. 
   
   
       6 . The method according to  claim 5 , wherein altering the grinding operation includes using progressively finer grits on successive passes. 
   
   
       7 . The method according to  claim 5 , wherein altering the grinding operation includes altering the direction of travel between successive passes. 
   
   
       8 . The method according to  claim 5 , further including removing particulate loosened during a pass. 
   
   
       9 . The method according to  claim 1 , further including applying a skim coat of grout-like material over the entire surface. 
   
   
       10 . The method according to  claim 1  wherein the decorative aggregate is selected from the group consisting of:
 stone;   marble;   porcelain;   granite;   glass;   calcareous formations;   shells;   aluminum;   zinc;   brass;   copper;   plastic; and   manufactured objects.   
   
   
       11 . The method according to  claim 1 , wherein disbursing the decorative aggregate is accomplished using a mechanical device. 
   
   
       12 . The method according to  claim 1 , wherein fully curing includes waiting up to about 28 days from when the concrete was poured. 
   
   
       13 . The method according to  claim 1 , further including sealing the upper surface using a concrete sealer/hardener. 
   
   
       14 . The method according to  claim 1 , further including applying a compound to the upper surface that interacts with the concrete and fills any microscopic pores remaining within the upper surface. 
   
   
       15 . The method according to  claim 14 , wherein the compound is a silicate-based compound. 
   
   
       16 . The method according to  claim 1 , further including applying a hardening/densifying compound to the upper surface. 
   
   
       17 . The method according to  claim 16 , wherein the hardening/densifying compound is diluted before application to the upper surface.