Method of Producing Limestone-Simulating Concrete

摘要

A new process for creating a decorative surface on a cast concrete tile. A mold is prepared by coating with mold release. An aggregate of water, coloring dye, sand, Portland cement, and preferably filler material such as pea gravel is pre-mixed. Baking soda is mixed with a significant volume of water to create a high-viscosity paste. The paste preferably has a high solid to liquid ratio so that it can be crumbled into baking soda clumps of various sizes. The dampened baking soda clumps are sprinkled randomly onto the bottom surface of the mold (which will bear against what becomes the top surface of the cast tile). The pre-mixed aggregate is then added to the mold. Once the aggregate is cured, the cast concrete tile is removed. The baking soda clumps create complex voids in the tile's upper surface, producing a surface texture similar to limestone.

主权项

1. A method of producing a concrete casting having a stone-mimicking surface, comprising:
a. providing a mold having a base, encircling side walls, and an open top; b. providing a mixed aggregate, including,
i. sand,ii. Portland cement,iii. coloring dye, andiv. water; c. providing a high-viscosity past of water infused baking soda wherein said paste includes a volumetric baking soda to water ratio such that said paste breaks apart into individual clumps having a size distribution between about 2 mm and about 25 mm; d. randomly distributing said baking soda clumps on said base of said mold; e. filling said mold with said aggregate; f. allowing said aggregate to harden into a solid, thereby forming said casting; and g. removing said casting from said mold.