Abstract: Disclosed are systems and methods which provide durable and substantially smooth surfaces comprised of a number of smaller pieces of surfacing material. For example, tiles of natural materials, such as marble or granite, are formed into larger unitary structures, wherein the surfaces of the tiles are substantially dead flat and the seams therebetween are diminished in size so as to minimize their visual impact. These unitary structures are preferably adapted to interconnection to thereby allow formation of substantially larger surfaces. Jig apparatus and methods for there use are disclosed for casting unitary structures of various shapes and configurations in such a manner that a dead flat surface with very little to zero lippage is provided.

Abstract: Disclosed are systems and methods which provide durable and substantially smooth surfaces comprised of a number of smaller pieces of surfacing material. For example, tiles of natural materials, such as marble or granite, are formed into larger unitary structures, wherein the surfaces of the tiles are substantially dead flat and the seams therebetween are diminished in size so as to minimize their visual impact. These unitary structures are preferably adapted to interconnection to thereby allow formation of substantially larger surfaces. Jig apparatus and methods for there use are disclosed for casting unitary structures of various shapes and configurations in such a manner that a dead flat surface with very little to zero lippage is provided.

Abstract: An artificial stone veneer product has a thin substrate covered by a stone veneer having a pitted, uneven surface having an appearance similar to travertine. To make the product, layers of polymer resin and particulate matter are applied to a substrate. A thin layer of polymer resin is first applied to the substrate, followed by a layer of fine particulate matter that at least partially settles into the resin, and the resin is allowed to set partially. Another layer of polymer resin is applied to the underlying layers in a nonuniform manner over the underlying layers, resulting in a moderately porous layer having randomly located voids of varying size and shape. A final layer of particulate matter is then applied over the polymer layer, and the resin is allowed to set completely. In an optional step, the surface of the final product is finished to smooth it, during which some of the larger particulate matter is dislodged and removed, enhancing the uneven rough appearance of the veneer.

Abstract: An artificial stone veneer product has a thin substrate covered by a stone veneer having a pitted, uneven surface having an appearance similar to travertine. To make the product, layers of polymer resin and particulate matter are applied to a substrate. A thin layer of polymer resin is first applied to the substrate, followed by a layer of fine particulate matter that at least partially settles into the resin, and the resin is allowed to set partially. Another layer of polymer resin is applied to the underlying layers in a manner that only partially covers the underlying layers. A final layer of particulate matter is then spread over the polymer layer, and the resin is allowed to set completely. In an optional step, the surface of the final product is finished to smooth it, during which some of the larger particulate matter is dislodged and removed, enhancing the uneven rough appearance of the veneer.