Method of manufacturing molded products having surface designs

Abstract

A method of manufacturing molded concrete products including, but not limited to, precast concrete panels having at least one decorative design on the surface(s) of such panels. At least one chemical cement retarder to a substrate. Thereafter, a stencil pattern embodying a desired pattern is placed on the retarder-laden substrate and secured in place. The substrate with the affixed stencil is then placed in a casting bed and secured from movement within such casting bed. Concrete mixed to desired specifications is poured or otherwise introduced into the casting bed. If colored panels are desired, colored aggregates can be added to the concrete by replacing portions of certain fine aggregates normally found in concrete with colored aggregates. The concrete in the casting bed is allowed to harden, thereby forming a concrete panel in the casting bed. The concrete panel is lifted from the casting bed and the retarder-laden substrate is then removed from the panel. The mortar from the area of the panel contacting the retarder can be selectively washed away from the concrete panel. Although such washing can be performed using any number of different methods, in the preferred embodiment such mortar is washed away using a water hose or pressure washer.

Dependencies are inferred from the claim text.