Background of Invention

This invention relates to a method for raakinga simulated stone, slate, wood or coral rock, wall, floor or roof.

In the applicant's prior patent U.S. 4,349,588 a method is described for making a simulated brick or tile wall or floor using cement, water-based adhesive and water-insoluble powdered pigment. The consecutive steps in that method consist of applying a mixture of the cement, water and water-based adhesive directly to a wall or floor, permitting partial setting, scoring selected indentations, permitting complete set, applying mortar into the indentations as a grout and then applying a clear water-resistant coating to the entire surface. Where color is desired a water insoluble powdered pigment is included in the initial mixture. In one variation, a clear coating is applied before applying the grout.

The method of the prior patent, while suitable for simulating brick or tile is not suitable for simulating stone, slate, wood or coral rock.

One object of the- resent invention is to provide a method for making simulated stone, slate, wood or roofing.

Other objects and advantages of this invention will be apparent from the description and claims which follow, taken together with the appended drawing.

Brief Description of Drawing

The steps of the method of this invention are shown in the drawing which illustrates the steps of the process in making a simulated stone floor .

Summary of Invention

The method of this invention comprises generally first applying a coating of polyvinyl acetate latex emulsion to the existing surface to be covered and allowing the coating to dry. A mortar mixture made from a mixture of cement, sand, water and modified acrylic resin is then applied by trowel or with a spray nozzle from a ^" hopper. The applied mortar mixture is permitted to partially set. Then, indentations in a selected design and/or desired surface texturing are made with appropriate tools to the partially set slurry. Excess material is then removed and the treated surface allowed to completely set and harden. After complete hardening, a first seal coating containing desired color or stain is applied. Alternately, a thin coat of the mortar mixture with shading color is applied, allowed to dry and then covered with a first clear seal coating. After the se ^' al coating is dry any grout that is reguired can then be applied. This is followed by a final clear seal coating. The seal coatings in all cases are water-resistant.

Specific Examples of Invention

The references to I, II, III, IV, IVA, V and VI are to the drawings .

Example 1. A simulated stone floor is prepared by the following steps:

A 50% solid aqueous dispersion of polyvynl acetate is applied to the surface to be covered and then allowed to dry. (I). After drying, a cement slurry is applied. (II) . Such a slurry typically consists of 5 gallons of water, 50 to 75 pounds of sand, 50 pounds of Portland cement and 1 1/2 pounds of a modified acrylic resin emulsion having a high solids content. An example of such a resin emulsion is a commercial acrylic emulsion which has a solids content of 53%, viscosity of 300 centipoises,

a specific gravity of 1.18 and a pH of 8.5. The slurry can be applied by either a trowel or a spraying apparatus. The depth of the slurry coating is in the range of 1/8 to one inch.

After the slurry coating is applied it is allowed to partially set, which typically takes two to three hours. When it is partially set, appropriate indentations according to a selected design and/or surface texturing are made with appropriate tools. (III). Thereafter, the excess materials are removed and the applied slurry allowed to completely harden.

After this, a water-resistant seal coat containing the desired color or colors is applied. (IV). Where desired one seal coat of one color may be applied to a seal coat of another color before complete drying of the first seal coat, thus permitting blending, streaking and other similar desired effects. After the seal coats have completely dried required grout is applied. (V). The final step comprises applying a clear water-resistant seal coat to the entire surface. (VI).

Example 2. A simulated stone floor is prepared by the steps described in Example 1, except that instead of applying water- resistant seal coats containing color to the completely hardened surface, a thin coat of slurry containing shading color is applied, allowed to dry and then covered with a clear water- resistant seal coat. (IVA) .

Example 3. Simulated wood is prepared by the same method as described in Example 1. The indentations are those which simulate the thin lines between wood planks. The texturing is much less than with suraulated stone and the color in the first seal coat can be wood stain. Color can also be added to the wood grout.