Process for covering a substrate with a cementitious surface having a mottled, speckled appearance

A process for covering a non-cementitious base comprising:

• mixing cement and sand to form a first mixture;
• adding an aqueous solution of an adhesive resin to the first mixture to create a first liquid mortar having a low viscosity;
• mixing cement and sand to form a second mixture;
• adding an aqueous solution of an adhesive resin to the second mixture to create a second liquid mortar of higher viscosity than the first liquid mortar to prevent spreading over the surface of the cured contiguous cementitious coating;
• adding and mixing a contrasting pigment to at least one of the first and second mixtures such that one of the first and second mortars has a color which contrasts with the color of the other one of the first and second mortars;
• providing a non-cementitious base;
• applying the first liquid mortar to the non-cementitious base to create a contiguous cementitious coating thereon;
• allowing the contiguous cementitious coating to cure thereby forming a cementitious substrate;
• positioning and releasably securing strips of straight edge tape in the shape of grout lines between tile onto the cured surface of the contiguous cementitious substrate;
• applying the viscous second liquid mortar onto randomly spaced portions of the previously cured and taped contiguous cementitious substrate to create a noncontiguous thickened cementitious coating having a thickness of about 1/8 of an inch prior to troweling and having a high viscosity to prevent spreading of the second liquid mortar over the surface of the cured cementitious substrate;
• troweling the noncontiguous thickened cementitious coating to form a plurality of interconnecting and non-interconnecting, flattened and level plateaus partially covering the cementitious substrate;
• allowing the troweled noncontiguous coating to cure;
• and
• removing the tape releasably secured to the cementitious substrate to reveal the cementitious substrate partially covered with a flattened and shaped pattern over the cementitious substrate simulating a mottled, speckled ceramic tile and to reveal the cementitious substrate representing grout lines where the second mortar covered the tape to yield grout lines of the cementitious substrate simulating a plurality of mottled and speckled ceramic tiles.

A process for covering a non-cementitious base comprising:

• mixing cement and sand to form a first mixture;
• adding an aqueous solution of an adhesive resin to the first mixture to create a first liquid mortar having a low viscosity;
• mixing cement and sand to form a second mixture;
• adding an aqueous solution of an adhesive resin to the second mixture to create a second liquid mortar of higher viscosity than the first liquid mortar to prevent spreading over the surface of the cured contiguous cementitious coating;
• adding and mixing a contrasting pigment to at least one of the first and second mixtures such that one of the first and second mortars has a color which contrasts with the color of the other one of the first and second mortars;
• providing a non-cementitious base;
• applying the first liquid mortar to the non-cementitious base to create a contiguous cementitious coating thereon;
• allowing the contiguous cementitious coating to cure thereby forming a cementitious substrate;
• applying the viscous second liquid mortar onto randomly spaced portions of the previously cured contiguous cementitious substrate to create a noncontiguous thickened cementitious coating having a high viscosity to prevent spreading of the second liquid mortar over the surface of the cured cementitious substrate;
• troweling the noncontiguous thickened cementitious coating to a plurality of interconnecting and non-interconnecting, flattened and level plateaus partially covering the cementitious substrate;
• and
• allowing the troweled noncontiguous coating to cure to reveal the cementitious substrate partially covered with a flattened and shaped pattern over the cementitious substrate simulating a mottled, speckled ceramic appearance.

A process for covering a substrate with a cementitious simulated ceramic tile surface having a mottled, speckled appearance comprising:

• providing a contiguous cementitious substrate;
• positioning and releasably securing strips of straight edge tape in the shape of grout lines between tile onto the surface of the cementitious substrate;
• applying a second liquid mortar onto randomly spaced portions of the previously cured and taped contiguous cementitious substrate to create a noncontiguous thickened cementitious coating having a thickness of about 1/8 of an inch prior to troweling and having a high viscosity to prevent spreading of the second liquid mortar over the surface of the cementitious substrate;
• troweling the noncontiguous thickened cementitious coating to a plurality of interconnecting and non-interconnecting, flattened and level plateaus partially covering the cementitious substrate;
• allowing the troweled noncontiguous coating to cure;
• and
• removing the tape releasably secured to the cementitious substrate to reveal the cementitious substrate partially covered with a flattened and shaped pattern over the cementitious substrate simulating a mottled, speckled ceramic tile and to reveal the cementitious substrate representing grout lines where the second mortar covered the tape to yield grout lines of the cementitious substrate simulating a plurality of mottled and speckled ceramic tiles.