Method of manufacturing molded products having surface designs

Abstract

A method of manufacturing molded concrete products including, but not limited to, precast concrete panels having at least one decorative design on the surface(s) of such panels. At least one chemical cement retarder to a substrate. Thereafter, a stencil pattern embodying a desired pattern is placed on the retarder-laden substrate and secured in place. The substrate with the affixed stencil is then placed in a casting bed and secured from movement within such casting bed. Concrete mixed to desired specifications is poured or otherwise introduced into the casting bed. If colored panels are desired, colored aggregates can be added to the concrete by replacing portions of certain fine aggregates normally found in concrete with colored aggregates. The concrete in the casting bed is allowed to harden, thereby forming a concrete panel in the casting bed. The concrete panel is lifted from the casting bed and the retarder-laden substrate is then removed from the panel. The mortar from the area of the panel contacting the retarder can be selectively washed away from the concrete panel. Although such washing can be performed using any number of different methods, in the preferred embodiment such mortar is washed away using a water hose or pressure washer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a schematic view of cement retarding agent being applied to a substrate.

FIG. 2 depicts a schematic view of a stencil being applied to a retarder-laden substrate.

FIG. 2 a depicts a cross-sectional view of the stencil of FIG. 2 taken along line 2-2

FIG. 3 depicts a schematic view of a retarder-laden substrate and stencil being loaded within a casting bed.

FIG. 4 depicts a schematic view of wet concrete being introduced into a casting bed.

FIG. 5 depicts a schematic view of forms being removed from a casting bed.

FIG. 6 depicts a schematic view of a molded concrete panel being suspended after being lifted from a casting bed.

FIG. 7 depicts washing of at least one surface of a suspended concrete panel.

Claims

1. A method of manufacturing molded concrete products comprising: a. securing a stencil to a substrate having at least one cement retarder disposed thereon;b. placing said substrate and stencil in a casting bed;c. introducing a concrete mixture in said casting bed, wherein said concrete mixture at least partially covers said substrate and stencil;d. allowing said concrete mixture to solidify;e. extracting said solidified concrete from said bed; andf. removing mortar from areas of said concrete exposed to said at least one cement retarder.

2. The method of claim 1, wherein mortar is removed from areas of said concrete exposed to said at least one cement retarder by washing said concrete with pressurized fluid.

3. The method of claim 1, wherein said substrate is paper.

4. The method of claim 1, wherein said concrete mixture includes colored aggregates.

5. The method of claim 1, wherein said stencil has a thickness of at least 0.125 inches.

6. The method of claim 1, wherein said stencil has an adhesive backing.

7. A method of manufacturing molded concrete products comprising: a. applying at least one cement retarder to a substrate;b. securing a stencil to said substrate;c. placing said substrate and stencil in a casting bed;d. placing at least one reinforcing member in said casting bed;e. introducing a concrete mixture in said casting bed, wherein said concrete mixture at least partially covers said substrate and stencil;f. allowing said concrete mixture to solidify;g. extracting said solidified concrete from said bed; andh. removing mortar from areas of said concrete exposed to said at least one cement retarder.

8. The method of claim 7, wherein mortar is removed from areas of said concrete exposed to said at least one cement retarder by washing said concrete with pressurized fluid.

9. The method of claim 7, wherein said substrate is paper.

10. The method of claim 7, wherein said concrete mixture includes colored aggregates.

11. The method of claim 7, wherein said stencil has a thickness of at least 0.125 inches.

12. The method of claim 7, wherein said stencil has an adhesive backing.