Method for producing replicated paving stone
OwnerMichael Loweinventor
Life of this patent
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Abstract
A method of producing replicated paving stone including a base having a shaded and stratified layered upper surface with a plurality of simulated grout lines formed therein including the steps of preparing a cementitious mortar, applying a release agent to the interior of a forming mold, pouring the cementitious mortar into the forming mold, leveling the mortar, vibrating the forming mold and cementitious mortar therein, allowing the cementitious mortar to cure forming a base with an upper surface, releasing the base from the forming mold, applying an acid stain to the base, allowing the acid stain to etch the base to shade the upper surface, accenting the plurality of simulated grout lines with a pigment and sealing the replicated paving stone with an acrylic polymer sealer.
Claims3
A method for producing a replicated stone including a shaded irregular upper decorative surface comprising the following steps:
- (a) preparing a cementitious mortar;
- (b) applying a hydrophobic release agent including a pigment to an interior of a flexible block forming mold having a plurality of recesses to form a corresponding plurality of individual replicated stones before pouring the cementitious mortar into the flexible block forming mold to stain the cementitious mortar;
- (c) pouring the cementitious mortar into the flexible block forming mold;
- (d) vibrating the flexible block forming mold and cementitious mortar causing finer or smaller sand and aggregate particles to migrate to an irregular bottom to form a relatively nonporous upper decorative surface;
- (e) allowing the cementitious mortar to cure forming a replicated stone;
- (f) releasing the replicated stone from the flexible block forming mold;
- (g) applying an acid stain comprising an acid and pigment to the upper decorative surface;
- (h) allowing the acid stain to etch into the upper decorative surface causing the pigment to diffuse into the upper decorative surface to create a secondary random irregular variegated pattern therein;
- (i) sealing the upper decorative surface with a sealer.
Dependencies are inferred from the claim text.