System and method for improved plasters

Abstract

Systems and methods according to present principles enhance aspects of applied plaster coats. In particular, the materials include a synthetic substitute aggregate (SSA), added to a cementitious base coat, for a plastering step prior to application of stucco or acrylic synthetic finishes or finish coats. The addition of SSA to a pre-blended cementitious base coat creates a light weight product which in some implementations is highly advantageous for the plastering industry.

1 . A plaster product, comprising:
 a. a first aggregate including sand;   b. a synthetic substitute aggregate, the synthetic substitute aggregate weighing less than 55% by volume compared to the first aggregate; and   c. a binder;   d. such that the first aggregate constitutes between about 40 and 70% by weight of the plaster product, the synthetic substitute aggregate and the first aggregate occupy the same volume within the plaster product plus or minus 25%, and the binder constitutes between about 20 and 40% by weight of the plaster product.   
     
     
         2 . The plaster product of  claim 1 , wherein the synthetic substitute aggregate includes expanded polystyrene. 
     
     
         3 . The plaster product of  claim 1 , wherein the binder includes Portland cement. 
     
     
         4 . The plaster product of  claim 1 , wherein the binder further includes lime. 
     
     
         5 . The plaster product of  claim 1 , wherein the first aggregate is selected from the group consisting of: calcium carbonate, silica, quartz, and combinations thereof. 
     
     
         6 . The plaster product of  claim 1 , wherein an amount of the first aggregate and an amount of the synthetic substitute aggregate occupy equal volumes plus or minus 10%. 
     
     
         7 . The plaster product of  claim 6 , wherein an amount of the first aggregate and an amount of the synthetic substitute aggregate occupy equal volumes plus or minus 15%. 
     
     
         8 . The plaster product of  claim 7 , wherein an amount of the first aggregate and an amount of the synthetic substitute aggregate occupy equal volumes plus or minus 5%. 
     
     
         9 . The plaster product of  claim 1 , wherein an amount of the first aggregate is, by volume, between about 20% and 70% of an amount of the synthetic substitute aggregate. 
     
     
         10 . A method of making a plaster product, comprising:
 a. mixing together a first aggregate, a synthetic substitute aggregate, and a binder; and   b. disposing the mixture in a storage unit or bag.   
     
     
         11 . The method of  claim 10 , wherein the synthetic substitute aggregate includes expanded polystyrene. 
     
     
         12 . The method of  claim 10 , wherein the binder includes Portland cement. 
     
     
         13 . The method of  claim 10 , wherein the binder further includes lime. 
     
     
         14 . The method of  claim 10 , wherein the first aggregate is selected from the group consisting of: calcium carbonate, silica, quartz, and combinations thereof. 
     
     
         15 . The method of  claim 10 , wherein the mixing includes mixing an amount of the first aggregate with an equal volume, plus or minus 25%, of an amount of the synthetic substitute aggregate. 
     
     
         16 . The method of  claim 15 , wherein the mixing includes mixing an amount of the first aggregate with an equal volume, plus or minus 10%, of an amount of the synthetic substitute aggregate. 
     
     
         17 . The method of  claim 16 , wherein the mixing includes mixing an amount of the first aggregate with an equal volume, plus or minus 5%, of an amount of the synthetic substitute aggregate. 
     
     
         18 . The method of  claim 10 , wherein an amount of the first aggregate is, by volume, between about 20% and 70% of an amount of the synthetic substitute aggregate. 
     
     
         19 . The method of  claim 10 , wherein ratios of constituent components are such that the first aggregate constitutes between about 40 and 70% by weight of the plaster product and the binder constitutes between about 20 and 40% by weight of the plaster product. 
     
     
         20 . A product made by the method of  claim 10 .