FR2734300A1 - FLOORING BASED ON CRUSHED STONES INCLUDED ON THE SURFACE IN A RESIN - Google Patents

Abstract

The subject of the invention is a process for producing a floor covering based on crushed stones encrusted in a resin, characterized in that it essentially comprises the steps consisting in: preparing a lean mortar from crushed stones and resin in such a proportion that the mortar gives a coating of cavernous appearance; applying to the floor to be coated a resin primer having the same composition as in step a); applying the lean mortar prepared in step a) immediately after carrying out step b); equalize if necessary; let dry; sand if necessary; partially blocking the pores of the coating being produced with an inert powder material so that the coating has a cavernous appearance on the surface; masticating the cavernous coating with the resin chosen for the exterior face of the coating; sand; if necessary, putty again with the resin used in step h) but solvated to eliminate the few air holes that may be present and sand again.

Description

The invention relates to floor coverings based on

  of crushed stones encrusted in a resin.

  The realization of floor coverings from a mortar based on synthetic resin and crushed stones from 5 mm to a few cm in diameter is a well known field. However, the use of this type of process is limited due to the high consumption of resin

that it generates.

  The object of the invention is to develop a more economical process, that is to say using less resin, while providing a coating having the same appearance and the same performance as the coatings of this type.

type achieved so far.

  According to the invention, we had the idea of carrying out the coating in several stages, which makes it possible to fill only on the surface the spaces between the pieces of stone with resin, and therefore to save the latter substantially. The subject of the invention is a process for producing a floor covering based on crushed stones embedded in a resin, characterized in that it essentially comprises the steps consisting in: a) preparing a lean mortar from crushed stones and resin in a proportion such that the mortar gives a coating of cavernous appearance; b) apply to the floor to be coated a resin primer having the same composition as in step a); c) apply the lean mortar prepared in step a) immediately after performing step b); d) equalize if necessary; e) allow to dry; f) sand if necessary; g) partially plugging the pores of the coating in progress with an inert powder material so that the coating has a cavernous appearance on the surface; h) puttying the cavernous coating with the resin chosen for the exterior face of the coating; i) sand; j) if necessary, chew again with the resin used in step h) but solvated to remove any air holes that may be present and sand

again.

  The quantity of resin used in step a) is preferably such that it is sufficient to coat the pieces of stone with a thin layer of resin and the

keep them glued together.

  The resin used in steps a) and b) can be

  in particular an epoxy, polyurethane or methacrylate resin.

  The inert material used to partially block the pores of the coating in step g) is

  example of fine sand or rubber powder.

  The puttying resin used in steps h) and j), identical to or different from the resin used in steps a) and b), can in particular be an epoxy, polyurethane or methacrylate resin, colored or not. This resin can advantageously be added with powder of

rubber, especially colored.

  The method according to the invention may also include the additional step of applying a protective varnish, in particular of the polyurethane type

aliphatic.

  The laying technique used being the agglomeration of crushed stones coated with a thin layer of resin to keep them glued together, there is no need to perform leveling. The applied mixture

  corrects the planimetry defects of the support.

  The following example is intended to illustrate and

explain the invention better.

  In this example, the resin chosen is an epoxy resin. Apply an epoxy primer of the same composition as that chosen to agglomerate the crushed stones. On the primer just put in place over a width of about 50 cm, apply the stone-resin mixture (lean mortar) in a proportion by weight of about 100: 7 for crushed stones 5 to 10 mm in diameter on a height from 12 to 15 mm approximately. We level out with the trowel by making up for the defects in the support. After drying for 12 to 24 hours, depending on the ambient temperature and humidity, sanding is done with a grinding wheel or a coarse abrasive belt until a smooth appearance and tightness are obtained.

regular stones.

  We then put fine sand, and / or advantageously rubber powder recovered on the stone covering, which is brought into the pores using a polishing machine provided with a masticating rubber tray, thus forcing the powder to descend into the pores. Then replace the rubber tray with a brush allowing the powders to penetrate more deeply and leave a cavernous appearance on the surface for 2 to 3 mm. The

  any excess powder is swept away.

  Then puttying is done using an epoxy resin, colored or not, with a squeegee or a scraper, removing as much resin on the stones

to limit sanding.

  Sanding is carried out either with a grinding wheel with fine grains, increasing the water supply to avoid heating the resin and fouling the grinding wheels, or with an abrasive belt. We chew with the same resin, but solvated,

  the few air holes still present.

  A new fine sanding is carried out and a protective varnish of the aliphatic polyurethane type is used to protect the floor covering from yellowing.

Claims (9)

  1. A method of producing a floor covering based on crushed stones embedded in a resin, characterized in that it essentially comprises the steps consisting in: a) preparing a lean mortar from crushed stones and resin in a proportion such that the mortar gives a coating of cavernous appearance; b) apply to the floor to be coated a resin primer having the same composition as in step a); c) apply the lean mortar prepared in step a) immediately after performing step b); d) equalize if necessary; e) allow to dry; f) sand if necessary; g) partially plugging the pores of the coating in progress with an inert powder material so that the coating has a cavernous appearance on the surface; h) puttying the cavernous coating with the resin chosen for the external face of the coating; i) sand; j) if necessary, chew again with the resin used in step h) but solvated to remove any air holes that may be present and sand again.   2. Method according to claim 1, characterized in that the amount of resin used in step a) is such that it is sufficient to coat the pieces of stone with a thin layer of resin and keep them glued between them.   3. Method according to claim 1 or 2, characterized in that the resin used in steps a) and b)   is an epoxy, polyurethane or methacrylate resin.   4. Method according to any one of   claims 1 to 3, characterized in that the material   inert material used to partially clog the pores of the coating in step g) is fine sand or rubber powder. 5. Method according to any one of claims 1 to 4, characterized in that the puttying resin used in steps h) and j), identical to or different from the resin used in steps a) and b) is a   epoxy, polyurethane or methacrylate resin.   6. Method according to any one of   Claims 1 to 5, characterized in that the   putty used in steps a) and b) is added with   rubber powder, especially colored.   7. Method according to any one of   Claims 1 to 6, characterized in that it comprises   the additional step of applying a varnish of   protection, in particular of aliphatic polyurethane type.   8. Method according to any one of   Claims 1 to 7, characterized in that the   lean mortar in a weight proportion of approximately 100: 7 for crushed stones 5 to 10 mm in diameter on a height from 12 to 15 mm approximately.   9. Method according to any one of   Claims 1 to 8, characterized in that, in step g),   the cavernous appearance on the surface has a height of 2 to 3 mm.