Note: Descriptions are shown in the official language in which they were submitted.
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CONCRETE MIX COUNTERTOP PRODUCTION AND PRODUCTS
Background of the Invention
1. Field of the Invention
The invention relates to countertop production and then also the resultant
countertop as a product.
2. Prior Art
The following discussion considers the counter and/or countertop production
from the context of remodeling jobs. This is done so not for limiting the
invention but
for convenience only in this discussion because the inventor's experience is
predominantly in this context. However, the issues discussed below apply
comparably
to new construction as well.
That said, a homeowner's remodeling options from the prior art have to date
included FORMICA , CORIAN , tile, marble, granite and chemically-stained
concrete.
FORMICA is the lowest cost option, partly because countertops are simply
resurfaced rather than having the counter totally refurbished. In that
fashion,
FORMICA is simply used cover over the original countertop, which of course
eliminates the work of tearing out the counter. The shortcomings of FORMICA
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include its vulnerability to being marked by scratches as well as bums. Also,
FORMICA does not really achieve a high-end classic look.
CORIAN is an improvement over FORMICA toward achieving a high-end
decorative look, but as can be expected, it is costlier because of that.
Typically a
remodeling job with CORIAN requires tearing off and junking the original
counter,
which includes tearing off the wood or MDF (or whatever) substrate. CORIAN
has
to be ordered according to measurements taken on the job-site, and then
produced in
slabs at fabrication sites remote from the job-site, not deliverable to the
job-site until
factory-ready. Only then, after delivery, can the CORIAN slabs be installed.
During
remodeling jobs, homeowners may have to wait weeks after the pre-existing
counter is
torn down and measurements are taken before the job can be completed, all
because of
waiting on delivery from the factory. Since CORIAN slabs are set in tile
fashion next
to one another, there are consequently seams. Typically seams between CORIAN
slabs are grouted or caulked. CORIAN generally lasts better than FORMICA
because it is not as vulnerable to being marked by scratches or burns.
Nevertheless, the
grouted seams between CORIAN slabs have to be properly sealed and perhaps re-
sealed, and even then cared for and looked after as time extends.
Tile has all kinds of inherent issues involved with it. A remodeling job
requires
tearing off all the original counter, which includes its substrate, because
the substrate
has to be replaced with a fresh and clean, hardy backer-board for supporting
the tile.
Hence, the workers or installers have to tear out the original counter, build
a new
substrate, trowel on a thin undercoat, lay in the tile pieces, and then let
things dry.
After drying, the seams are grouted, let dry, sealed, let dry, re-sealed and
then perhaps
the job is done. The tile look has had and likely always will have its ardent
fans.
Nevertheless, common shortcomings with aging tile counters include shrinkage
of
grout in one seam or another (of the usually quite extensive interlaced
network of such
seams), or else the wiggling loose of a lone piece of tile in its socket, it
somehow (as is
commonplace over time) having loosened free from its undercoat and grout
anchorage.
Marble and granite produce a look for counters that can flat out awe and
amaze,
yet as expected there is a corresponding cost for that. Replacement jobs with
marble
and granite follow a fairly similar procedure as with CORIAN . Briefly, the
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procedure is messy and slow. The homeowner not able to live in all of the
kitchen for
at least a week. Again, the pre-existing counter has to be torn out,
measurements have
to be taken at the job-site, then slabs have to be ordered from remote shops
where the
slabs are sized and finished. The pre-existing counter is usually torn off
right down to
the cabinet top, which includes tearing off the substrate. From the time the
tear-off job
starts and until the job is completed, the whole remodeling job can take a
week or two.
The slabs have to be received at the site, installed, the seams have to be
grouted or
otherwise caulked. And then the slabs-and-seams have to be sealed and re-
sealed.
Although the public is more widely informed about this as a shortcoming of
marble's,
it is news to many that granite can be marred by scratches or stains. Hence
granite and
marble alike require some delicacy in use and periodic re-application of
sealant over
time.
In addition to all the above options, the prior art includes concrete
counter/countertops. There are two significantly different approaches for
doing a
concrete job. One approach involves pouring the concrete in-place, typically
right on
top of the pre-existing countertop. Workers build low dams around the edges.
Concrete for the pour is mixed in a wheelbarrow or else brought in by a truck
that
backs up to a window to pump it in. Either way, concrete is poured onto the
dammed
up counter. Indeed, since concrete is typically poured in to a depth at
minimum of
about two inches (-5 cm), it often makes sense to have a truck brought to the
job-site
and pump it in from there.
Generally a homeowner would desire the concrete countertop to be seamless,
but experienced contractors sometimes put in seams to break up certain
expansive
spreads because otherwise shrinkage during drying will cause cracks. The
concrete is
allowed to harden part way to full cure (ie., about a day or two) before
workers grout
seams. The homeowner is asked to live lightly in the kitchen during the month
(ie.,
twenty-eight days) it takes for the concrete to reach full cure. That is, the
homeowner
is advised not to spill out juice or grease -- or anything stain-causing --
onto the curing
concrete. Only after full cure is it prudent to start grinding and polishing
radiuses, in
fact polishing over the whole pour. Then after that detail work is completed,
the
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workers can at that time undertake the steps of stain, seal and re-seal and so
on until
done.
For all the all time and trouble (and mess), concrete countertops are capable
of
being rendered into truly awesome and attention-stopping structures. They are
also,
however, massive. They look like, and are, relatively thick slabs of concrete
rendered
as counters.
In contrast to the foregoing, the significantly different other approach to
doing a
concrete counter involves pouring concrete slabs at remote sites and then,
after the
month long cure (as well as staining and sealing process), delivering the
slabs to the
site for final installation. At some original time, workers tear out the pre-
existing
counter, take measurements for the concrete-slab replacement, return to their
remote
shop and build molds for the separate slabs. Concrete is then poured into the
molds
and allowed to cure. After curing, the separate slabs are extracted and
flipped over
from their top-side-down orientation in the molds, and then polished, stained,
sealed
and re-sealed and so on, in the shop. Ultimately the completed slabs are
delivered to
the job-site, laid in-place, and grouted together to fill in the seams between
the separate
slabs.
By either approach to doing concrete jobs, homeowners typically face a month
long ordeal during which their kitchen is substantially knocked out of
service. In spite
of that, many do put up with the inconvenience of mess and time because as
said,
concrete counters can be admired as awesome. For better or worse, concrete
counters
are massive things too.
What is needed is an improvement which overcomes various shortcomings of
the various prior art options.
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Summary of the Invention
It is an object of the invention to produce polymer-modified concrete
countertop overlays so that practitioners of the inventive method can pour in
a casting
compound of such in a very thin pour, rather than in the fashion of the
massive
concrete-slab counters of the prior art.
It is another object of the invention that the foregoing thinly-poured polymer-
modified countertop overlays provide excellent flexural strength compared to
prior art
concrete-slab countertops, as well as cure in a fraction of the time normally
required for
straight concrete.
It is an additional object of the invention to provide edging forms for giving
shape to the edges of the polymer-modified concrete countertop overlays, which
because of the thin pour of such, the inventive overlays can consequently be
compact,
lightweight, easily shaped by profile-shaping machine, deformable for coursing
along
not just straight lines but gentle curves too, whereby the total appearance of
the end-
product countertop overlay is not massive as the prior art knows in connection
with
straight concrete overlays, but lightweight, classic.
It is a further object of the invention to improve the way in which the stain
and
seal coats are applied in order to achieve and lock-in one-of-a-kind looks.
It is an alternate object of the invention that the remodeling jobs for
producing
the foregoing enhanced countertops can usually be completed in four to five
days. In
fact, with remodeling jobs that start with FORMICA countertops among others,
the
inventive polymer-modified concrete countertop overlay can be applied directly
on top
of the FORMICA .
A number of additional features and objects will be apparent in connection
with
the following discussion of the preferred embodiments and examples with
reference to
the drawings.
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Brief Description of the Drawings
There are shown in the drawings certain exemplary embodiments of the
invention as presently preferred. It should be understood that the invention
is not
limited to the embodiments disclosed as examples, and is capable of variation
within
the scope of the appended claims. In the drawings,
FIGURE 1 is a perspective view of a prior art or subsisting kitchen countertop
before which remodeling work is undertaken to it by practitioners of a= method
of
producing polymer-modified concrete countertops in accordance with the
invention, to
obtain a polymer-modified concrete countertop product or overlay in accordance
with
the invention;
FIGURES 2 through 15 comprise a series views showing various steps or stages
along the way of an example execution of the method in accordance with the
invention
for polymer-modified concrete countertop production, to obtain a concrete mix
countertop overlay (or product) in accordance with the invention as shown by
FIGURE
16, wherein:
FIGURE 2 is a perspective view comparable to FIGURE 1 except showing a
stage where inter alia the subsisting countertop has been overlain with lath;
FIGURE 3 is an enlarged scale perspective view zooming in on the foreground
in FIGURE 2 and showing inter alia temporary attachment of sheet metal gutters
for
supporting temporary edging forms;
FIGURE 4 is an enlarged scale perspective view zooming in on the foreground
in FIGURE 3 and showing inter alia the insertion of the temporary edging forms
in the
gutters;
FIGURE 5 is a sectional elevational illustration showing a foam-block edging
form in accordance with the invention and showing inter alia a nail and washer
securing the edging form to the subsisting counter (or alternatively the
underlying
cabinet, although this is not shown), and as nailed through a fillet;
FIGURE 6 sectional elevational illustration comparable to FIGURE 5 except
showing an alternate method of temporarily attaching the foam-block edging
form in
place, namely wherein, as introduced in FIGURES 3 and 4, the edging form is
supported by a sheet metal gutter which in this view is secured by screws to
the
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underside of an overhang of the subsisting cabinet (or alternatively, an
overhang of the
subsisting counter, although this is not shown);
FIGURE 7 is an enlarged scale perspective view zooming in on the center of
FIGURE 2 and showing inter alia the opening that was left by the removal of
the sink
thereafter being rimmed by a temporarily-attached band of flexible material,
forming a
low flow check;
FIGURE 8 is a perspective view comparable to FIGURE 2 except showing inter
alia the pouring in of a casting compound over the lath;
FIGURE 9 is a perspective view comparable to FIGURE 8 except showing inter
alia the poured-in casting compound being troweled out to completely cover the
subsisting countertop as well as fill in all the cavity provided by the edging
forms;
FIGURE 10 is a perspective view comparable to FIGURE 1 except showing
inter alia the poured-in casting compound leveled out even with the low rises
of the
edging forms and flow checks, respectively;
FIGURE 11 is a perspective view comparable to FIGURE 9 except showing
inter alia a process for indenting a texture into the surface of the
hardening, but still
soft, casting compound;
FIGURE 12 is a perspective view from a vantage point a quarter-turn contra-
clockwise relative to FIGURE 11, showing inter alia the continuation of the
indenting
process, including the matching of the "fault-lines" across seams to disguise
any
repetitious pattern of such;
FIGURE 13 is a perspective view comparable to FIGURE 12 except showing
inter alia the edging forms and gutters removed from the work (concurrently,
the flow
checks would be removed as well although this is not shown);
FIGURE 14 is a perspective view comparable to FIGURE 13 except
diagrammatically showing inter alia application of sealant, or else a mixture
of sealant
and stain such that two jobs can be accomplished by one;
FIGURE 15 is a perspective view comparable to FIGURE 14 except showing
inter alia that the remodeling job is primarily done, inasmuch as that the
protective
plastic film and drop cloths can be removed at this time;
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FIGURE 16 is a perspective view comparable to FIGURE 1 except showing in
contrast the substantial completion of the remodeling job for installing the
polymer-
modified concrete countertop overlay in accordance with the invention, which
substantially changes the look of the subsisting countertop shown in FIGURE 1;
FIGURE 17 is an elevational section illustration comparable to either FIGURES
or 6 except showing another embodiment of foam-block edging form as well as
another embodiment of temporary support of the same;
FIGURE 18 is a front perspective view of an alternate embodiment of a
polymer-modified concrete countertop product in accordance with the invention,
and
one which includes curving edges that in part were enabled by the edging-form
support
of FIGURE 17;
FIGURE 19 is an enlarged scale side perspective view of the bar top of
FIGURE 18; and
FIGURE 20 is another perspective view of a polymer-modified concrete
countertop product in accordance with the invention except showing that the
creative
embellishments the invention affords are not just limited to texture and color
but also
allow fanciful and arbitrary designs as well.
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Detailed Description of the Preferred Embodiments
FIGURE 1 shows a prior art kitchen counter 50 at some original time before a
remodeling job on it is undertaken by practitioners of a polymer-modified
concrete
countertop production method in accordance with the invention. For sake of a
non-
limiting example, this prior art counter 50 has a countertop covering of
FORMICA
50T and serves as a representative of a prevalent type of counter 50 popularly
chosen
for a remodeling enhancement.
The kitchen counter 50 shown in FIGURE 1 serves as a non-limiting example
of an exemplary kitchen or bar or else bathroom countertop suitable for
enhancement
by the method in accordance with the invention, it further serving as an
example
without exclusion of other residential and commercial building countertop-like
structures suitable for enhancement by polymer-modified concrete countertop
productions in accordance with the invention. One aspect of the invention is
that the
inventive casting process can be administered directly on top of a subsisting,
pre-
existing countertop 50T or substrate 50S, without requiring the subsisting
countertop
50T or substrate 50S to be stripped down or torn off.
Whereas the advantages of the invention work advantageously on FORMICA
covered counters 50, it is not a prerequisite of the inventive method that the
pre-
existing counter 50 truly belong in a class of "prior art" counters. The
method in
accordance with the invention is suitably advantageous for administering to a
wide
variety of "subsisting" countertops 50T or substrates 50S, preferably ones
which are
particularly suitable for overlay by the inventive utilization of polymer-
modified
concrete/cementitious materials.
FIGURES 2 through 15 provides a series of "snapshots" of various stages of
completion of an example implementation of the method in accordance with the
invention, for producing a polymer-modified concrete countertop product or
overlay
100 in accordance with the invention as shown by for example and without
limitation
FIGURES 16 or 18.
FIGURE 2 shows preparation work in progress. The floor cabinets are covered
with plastic film 61 to protect against splatter, as have the walls adjoining
the
subsisting countertop. The low "back-splash" 63 shown in FIGURE 1 is removed
(and
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preferably discarded instead of re-installed afterwards). The overhead
cabinets might
be temporarily taken down so that they too avoid splatter on during the job.
Accessories likes sinks 64 and stoves and so on are temporarily removed or
moved out
of the way or protected by covering as well. Drop cloth is also preferably
stretched out
across the floor (not in view).
More significantly, the subsisting FORMICA covering 50T as well as its
underlying substrate (indicated as reference 50S in FIGURE 5) are left in
place. In
fact, the subsisting FORMICA covering 50T is utilized for purposes of the
invention
described more particularly next. The view shows that lath 105 is stretched
out over
the subsisting FORMICA covering 50T. It is preferred if the lath 105 is
either
expanded or woven metal mesh. The lath 105 is cut and trimmed to size for a
suitably
good fit.
The countertop 50T can be reckoned as delimited by edges 52 falling into one
of three or so categories. One category of edges includes those edges 521
bounded by
an adjoining, presently tangible vertical structure such as walls or back-
splashes.
Typically there is no need to check the flow of a casting compound at these
edges. A
second category of edges includes those edges 52+ bounded by an adjoining,
presently
intangible vertical constraint. One example of such is the opening 64' for the
removed
sink 64. Although the sink 64 itself is tangible, it is presently removed and
so the
constraint to not alter the size of its required opening 64' is a "presently
intangible"
constraint. Consequently, the flow of the casting compound typically must be
checked
from flowing across such a vertical constraint so that the compound will not,
in this
instance, shrink the size of the opening 64' so much so that re-installing the
sink is a
challenge. This category of "presently intangible" constraints also includes
bays
formed into the subsisting counter 50 (and underlying cabinetry) to allow the
sliding-in
of a closely fitting stove/oven appliance or the like, or else any other
reason determined
by the planners of the project.
A third category of edges, among other further categories not defined here,
include those edges 52 that are essentially free of any such of the foregoing
boundaries
or constraints. This third category of edges 52 affords opportunity to
construct the
inventive countertop overlay 100 with decorative embellishments such as and
without
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limitation edge profiles including protrusions 100E extending outboard from
the
subsisting counter 50's edge 52 as well including apron- or fascia-portions
100F.
FIGURE 2 shows that the lath 105 is folded down at these category three edges
52 for
at least a short length thereof.
The lath 105 is attached simply by stapling it down, right through the
FORMICA . Typically it takes three to four hours on day one to complete this
much
work.
FIGURE 3 shows installation of sheet metal angles 90 which will support
edging forms (eg., such as indicated 1206 in FIGURE 6). The sheet metal angles
90
might measure about 1-e inches by 1-f inches (---4 cm by -5 cm) and are
screwed
temporarily to the bottom of the underlying cabinet 65's overhang 66 (if any,
see eg.
FIGURE 6). The sheet metal angles 90 serve as a temporary gutter. The edging
forms
1206 are slipped inside the gutters as shown better by FIGURE 6.
FIGURE 4 shows a enlarged scale view, relative to FIGURE 3, of edging forms
120 that are slipped inside the gutters 90 in order to eventually provide the
completed
countertop product with a decorative edging.
FIGURE 5 is a sectional illustration showing one edging form 1205 in
accordance with the invention. In this view, the casting compound 110A is
already
poured-in over the subsisting countertop 50T. Preferably the inventive edging
form
1205 is produced from an indefinitely long length of foam block- or bar-stock.
Such
foam bar-stock is preferably recessed in on one side to provide in relief
120R5 an
edging profile for the ultimate polymer-modified concrete countertop overlay
100. The
relief profile 120R5 may be formed in the foam bar-stock by any suitable means
including without limitation a router operation or like edge-profiler.
The inventive edging form 120R5 is attached directly or indirectly to the
subsisting counter 50 such that the edging form 120's outboard crown perimeter
120P
protrudes above the plane of the subsisting countertop 50T by a given measure,
or in
other words, a given rise 92. The given rise 92 measures preferably equal to,
but more
preferably at least greater than, the thickness of the pour of the casting
compound l 10A
as measured above the plane of the subsisting countertop 50T.
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Foam material is preferred for the edging forms for several reasons. These
include its adaptability to accept intricate reliefs 120R of edge profiles,
its flexibility to
produce gentle curves 100E19 in finished countertop overlays 10019 (see, eg.,
FIGURE
19), and its properties for releasing from cured polymer-modified
concrete/cementitious materials.
FIGURE 5 also shows nail and washer 93 securing the edging form 1205 to the
subsisting counter 50 (or alternatively, but not preferred, the underlying
cabinet 65,
although this is not shown), as nailed in this particular illustration through
a fillet 67.
In this particular embodiment, the relief profile 120R5 in the edging form
1205 both
defines the edge profile for the poured casting compound 1IOA as well as
accommodates the fillet 67. Although the edging form 1205 is shown temporarily
attached to the counter 50 by nail and washer 93, it is preferably not nailed
to the
underlying cabinet 65 so as not to leave a mark. It is preferred to produce
the relief
profiles 120R by edge-profiling machines in a shop off-site and then brought
to the job-
site on project day.
FIGURE 6 is comparable to FIGURE 5 except showing an alternate
embodiment of an edging form 1206 in accordance with the invention. The
inventive
edging forms 120 are amenable to being shaped with about any relief profile
120R
imaginable, especially relief profiles shaped-out by edge-profiling machines.
The
edging forms 120 are preferably used once and discarded. In FIGURE 6, it is
preferred
if the edging form 1206 is supported by the sheet metal gutter 90 mentioned
previously
in connection with FIGURES 3 and 4. Completion through this phase of the
project
generally takes another two hours on day one.
FIGURE 7 shows the following in connection with that category of edges 52 for
the subsisting counter 50 that encompass "presently intangible" vertical
constraints
(eg., edges 52+ in the "second" category, and in this view, surrounding the
opening 64'
for the removed sink 64). That is, such edges 52+ are preferably rimmed by a
temporarily-attached band of flexible plastic 96, which forms a flow check.
That is, the
flow of the casting compound 1IOA must be checked from spilling over the edge
of the
sink opening 64' so that the casting compound 11OA will not, in this instance,
shrink
the size of the opening 64' so that the sink 64 cannot be comfortably re-
installed. The
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flexible flow-check band 96 is preferably attached temporarily by brads,
nails, staples
or the like. The flow check 96 is arranged to protrude above the plane of the
subsisting
countertop 50T by a given rise (eg., compare 92 in FIGURE 5) that measures
(like the
case with the edging forms 120) preferably equal to, but more preferably at
least
greater than, the thickness of the pour of the casting compound 11 OA as
measured
above the plane of the subsisting countertop 50T. This completes day one on
the job.
Pause can be taken because everything is prepared for the pour of the casting
compound I10A.
FIGURE 8 begins what preferably is day two of the project. The preferred
casting compound 110A comprises a polymer-modified cementitious material that
hardens into polymer-modified concrete. Suitable sources for the starting
materials for
polymer-modified cementitious casting compounds include without limitation
Americrete of Temecula, California; Color Maker Floors LTD of Burnaby, B.C.,
Canada; Increte Systems of Odessa, Florida; The Quickrete Company of Atlanta,
Georgia; Super Stone, Inc., of Opa Locka, Florida; Surecrete Design Products,
Inc, of
Dade City, Florida; as well as Ultimate Concrete Resurfacing Systems, Inc., of
Naples
Florida.
These sources offer both containerized wet mixes for use fairly immediately
upon opening as well as dry mixes which are to be combined with something,
eg.,
water, to change them over into wet mixes suitable for pouring as a casting
compound.
In FIGURE 8, a batch container of the casting compound 110A is being poured in
onto
the lath/subsisting countertop 105/50T.
FIGURE 9 shows the poured-in casting compound 11 OA being troweled out to
completely cover up the subsisting countertop 50T to the depth set by the
"rise" (see,
eg., 92 in FIGURE 5) of the edging forms 120 and flow check 96 (not shown in
this
view), as well as descend down into and fill all profile reliefs provided by
the edging
forms 120.
FIGURE 10 shows the poured-in casting compound 110A all in place and
leveled. All bubbles/voids are collapsed/filled in by tapping on a trowel or
the like. To
get to this point on day two generally requires about one and one-half hours
(eg., ninety
minutes). Pause is taken for about an hour while the casting compound 110A is
left to
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set and partially harden. Excluding the apron portions (eg., fascia portions
I00F in
FIGURE 6), the web expanses IOOW of the poured-in casting compound 110A are
generally only about d-ths an inch thick (-S10 mm).
FIGURE 11 shows a process for indenting a texture into the surface of the
casting compound 11 OA. Rubber stamps 98 of the selected texture in relief are
coated
with a release compound. The release compound is in part a liquid release
agent,
various sources of which are generally the same as identified-above in
connection with
the polymer-modified cementitious starting materials for the casting compound,
combined with in other part a colored powder. The colored powder drops off
onto the
tacky surface of the poured-in casting compound 11OA. This is done so for
antique
purposes. The colored powder will darken the fault lines that get indented
into the
surface. Hence the rubber mats 98 are set onto the tacky surface, light
pressure is
preferably applied in the form of hand-patting to the extent desired to
achieve the
indentation of the fault lines as desired, and then removed.
FIGURE 12 shows continuation of the fault-line indenting process. The
indented casting compound 11 OA in the foreground will as yet fail to show the
results
of the antique coloration. In any event, the end of this process preferably
completes
day two, which in comparison to day one is a short day.
FIGURE 13 shows what preferably transpires on day three. The edging forms
120 and their gutters 90, as well as the flow checks 96 (none in view) are
removed this
day because the polymer-modified concrete 11OZ is sufficiently cured to allow
this as
well as what's planned for next, namely, the application of stain. At this
stage, the
edge profiles 100E are cleaned up of any residual foam material by light
sanding with
grit paper or steel wool, as well as to the flat surface expanses 100W of the
countertop
100 also, although in the alternative the flat surface expanses 100W of the
countertop
100 might be rubbed over by a brick or the like. This view shows completion of
the
step of staining the work in progress. Stain is optional. Alternatively,
practitioners of
the method in accordance with the invention can spray on acid and allow it to
blend in.
Regardless, any of these choices individually or in combination completes what
is
preferred for day three. It is the shortest day to date in accordance with the
preferred
practice of the inventive method, about a half a day. However, practitioners
of the
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inventive method preferably leave the work dry before much more should be
attempted.
FIGURE 14 shows what preferably is planned for day four, namely, application
of sealant. The sealant can either be a clear coat or it can be mixed with
stain as well.
Hence two jobs can be accomplished by one in that the application of the
sealant can
concurrently accomplish application of stain. The sealant (with or without
stain) is
typically rolled out or spread with a paint pad. The preferred activities for
day four are
the shortest yet. Pause can be taken to consider why sealant can be applied
after two
days than twenty-eight (as required for concrete). The reasons are several.
The
countertop product 100 in accordance with the invention is thinner over its
major web
expanse 100W than comparable concrete-counter slabs from the prior art, as in,
for
comparison, a difference of about d-ths an inch (-10 mm) to about 1-'/z inches
(-40
mm). Also, polymer-modified concrete mixes are blended not only dry faster,
but also
dry twice as hard, resist better against shrinkage and hence cracking, and
have flexural
strength in addition.
FIGURE 15 shows another view of the end of the preferred day four. The
remodeling job is primarily done. The plastic film 61 cabinet protection as
well as the
drop cloths can be removed at this time but it is more usual to leave them on
for time
being. The work 100 is allowed to harden further. A customer who hires
professional
practitioners can be left with and entrusted to properly tear off the plastic
film without
the professionals having to return.
FIGURE 16 is a view comparable to FIGURE 1 except showing in contrast the
completion of the countertop overlay 100 remodeling job. The sink 64 is re-
installed
and otherwise the kitchen is ready for full use. The inventive polymer-
modified
concrete countertop overlay has 100 been preferably textured, antiqued,
stained and
sealed. Some seals leave a highly shined finish, others leave a more satin
(eg., dull)
finish.
Noteworthy things about the inventive method of production and product 100
are the following. The practitioners did not tear up the subsisting (eg.,
original) counter
50 or countertop 50T, as both were used in the condition they were found. The
enhanced countertop 100's dimension changes only slightly. It got only about d-
ths to
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about '/2 inch higher (-10 to -13 mm). The edges 100E only expanded by about
3/4-ths
an inch (- 19 mm).
FIGURE 17 is an elevational section illustration comparable to either FIGURES
or 6 except showing another embodiment of foam-block edging form 12017 as well
as
another embodiment of temporary support 91 of the same.
FIGURE 18 shows an alternate embodiment of a completed work 10019 in
accordance with the invention except utilizing various advantages afforded by
the
edging-form support structure 91 of FIGURE 17. Noteworthy things about this
view
are these. One, the resultant countertop edge 100E19 of the enhanced work
10019 is not
straight but shaped with curves producing a central lobe flanked by opposite
half lobes
(and as shown better by FIGURE 19). Remaining in FIGURE 18, the curving edges
100E19 of the work 10019 are made possible by the inherent flexibility of the
foam-
block edging forms (eg., 12017). That is, the foam-block edging forms 120 are
deformable to assume the curve desired if the curves are sufficiently gentle.
Otherwise,
miter cuts will have to be made and two pieces be mated together at a miter-
drawn
seam. Another noteworthy thing is that the front overhang of the work's edge
100E19 is
relatively substantial. Nevertheless the overhang is sufficiently strong
because
polymer-modified concrete mixes are stronger at supporting cantilevered
overhangs
than concrete alone. Indeed, polymer-modified concrete mixes generally have an
inherent although moderate amount of flexural strength, in contrast to
concrete, which
has none.
FIGURE 19 shows the counter top 10019 of FIGURE 18 from a vantage point to
better show the curving lines of the edges 100E19. Referencing back to FIGURE
17,
the wood or MDF substrate provides the real structural support for the
thinnest portions
of the inventive countertop product 10019. Nevertheless, polymer-modified
concrete
mixes are advantageous for this application in producing countertop overlays
10019
having such overhangs because the hardened material is lightweight and
provides
substantial flexural strength as sufficient to support the cantilevered
overhangs.
FIGURE 20 shows an expanse of the major flat portion of a polymer-modified
concrete countertop overlay 100 in accordance with the invention embellished
with not
only texture and color but as well with fanciful and/or arbitrary designs 100D
too.
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The invention having been disclosed in connection with the foregoing
variations
and examples, additional variations will now be apparent to persons skilled in
the art.
The invention is not intended to be limited to the variations specifically
mentioned, and
accordingly reference should be made to the appended claims rather than the
foregoing
discussion of preferred examples, to assess the scope of the invention in
which
exclusive rights are claimed.
