Processes for producing monolithic architectural cementitious structures having decorative aggregate-containing cementitious surfaces

A process for producing a monolithic architectural cementitious structure having a decorative aggregate-containing cementitious surface comprising:

• a. forming a freshly poured cementitious base that is free of decorative aggregate;
• b. preparing a decorative aggregate-containing cementitious slurry having at least decorative aggregate and cementitious matrix composition operable for forming a monolithic structure when applied to the freshly poured cementitious base and simultaneously cured therewith;
• c. pouring an amount of the decorative aggregate-containing cementitious slurry having a slump between about 3 inches and about 5 inches on the freshly poured cementitious base within a period of time after forming the freshly poured cementitious base, effective for forming a monolithic structure, when simultaneously cured with the freshly poured cementitious base, wherein said period of time is between about one minute and about 3 hours from the time of completing the pouring of the freshly poured cementitious base,
• the amount of the decorative aggregate-containing cementitious slurry producing a decorative aggregate-containing cementitious layer having a thickness operable, when cured, for permanently securing the decorative aggregate therein,
• at least a portion of the decorative aggregate forming a portion of a surface of the decorative aggregate-containing cementitious layer;
• and
• d. simultaneously curing
• i. the decorative aggregate-containing cementitious slurry poured on the freshly poured cementitious base, with
• ii. the freshly poured cementitious base, for a period of time effective for producing the monolithic architectural cementitious structure having the decorative aggregate-containing cementitious surface, and wherein there is no cold joint between the decorative aggregate-containing cementitious layer and the cementitious base.

A process for producing a monolithic architectural cementitious structure having a decorative aggregate-containing cementitious surface comprising:

• a. forming a freshly poured cementitious base that is free of decorative aggregate and has a thickness of at least about 3 inches;
• b. preparing a decorative aggregate-containing cementitious slurry having a slump between about 3 inches and about 5 inches, and having at least decorative aggregate and cementitious matrix composition operable for forming a monolithic structure when applied to the freshly poured cementitious base and simultaneously cured therewith, wherein the decorative aggregate has a size of between about {fraction (1/32)} inch and about ½ inch;
• c. pouring an amount of the decorative aggregate-containing cementitious slurry on the freshly poured cementitious base within a period of time after forming the freshly poured cementitious base, effective for forming a monolithic structure, when simultaneously cured with the freshly poured cementitious base,
• the amount of the decorative aggregate-containing cementitious slurry producing a decorative aggregate-containing cementitious layer having a thickness operable, when cured, for permanently securing the decorative aggregate therein, and a thickness of at least about {fraction (1/16)} inch,
• at least a portion of the decorative aggregate forming a portion of a surface of the decorative aggregate-containing cementitious layer;
• and
• d. simultaneously curing
• i. the decorative aggregate-containing cementitious slurry poured on the freshly poured cementitious base, with
• ii. the freshly poured cementitious base, for a period of time effective for producing the monolithic architectural cementitious structure having the decorative aggregate-containing cementitious surface.