Method of forming a non-skid surfaced structure

The present invention defines methods of forming a non-skid surface on a base member, wherein the base member may consist of a wood, plastic, metal or concrete surface structure. One method includes applying one or more coats or layers of epoxy resin to one surface of a wood base member. After the epoxy resin is set, a first coat of polyurethane is applied thereover at a thickness determined by the size of the grit material that is disseminated in the first coat of polyurethane, whereby the upper portion of the grit is exposed so as to be covered by a second polyurethane coat applied over the first coat of polyurethane, the grit being locked within and between the two coats of polyurethane. An additional method includes the step of affixing a fiber/cement panel to the base member and applying the first polyurethane coat to the surface of the fiber/cement panel, followed thereafter by the grit and the second coat of polyurethane, whereby a non-skid surface is established thereon.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to a structural panel or base member, and more 
particularly to a base member formed from plywood, metal or plastic that 
is processed so as to establish a unique method of forming a non-skid 
surface, wherein the finished produce provides a weatherproof and 
wear-resistant, non-skid-surfaced structure for areas subjected to heavy 
foot traffic and are generally exposed to damp, wet environments. 
2. Description of the Prior Art 
The invention as disclosed herein is particularly suitable for solving 
various and difficult problems associated with surface structures which 
are designed for heavy pedestrian traffic, especially with respect to 
those surfaces associated with marine-dock systems and their surrounding 
structures. Several types of walking surfaces have been employed for this 
purpose, but with limited success. At present, there are two widely used 
surface materials, one being made from wood products and the other being 
constructed from relatively thin concrete or cement slabs. Wood surfaces 
are generally formed from a multiplicity of juxtaposed plank members 
positioned transversely across the deck or walkway. 
A dock structure or walkway formed from cement slabs is usually defined by 
elongated, rectangular slab members having a thickness of from one to two 
inches. Even though cement surfaces are becoming more popular over wood 
surfaces in the construction of marinas and related floating-dock 
structures, there are two inherent problems that prevail. One of these is 
that concrete slabs are very heavy and add considerable weight to an 
already large and heavy structure, making them cumbersome and difficult to 
handle; and the other is that cement slabs used for dock fingers and 
walkways are not resilient, and have a tendency to crack when subjected to 
twisting and flexing in turbulent water caused by adverse weather 
conditions. 
Hence, it can be readily understood from the following disclosure of the 
present invention that, when the end product thereof is employed, the 
above-mentioned problems are overcome. 
SUMMARY AND OBJECTS OF THE INVENTION 
The present invention has for an important object to provide a new and 
unique method of forming a non-skid-surfaced structure that can be readily 
employed as a structural walkway or decking for marinas and like areas. 
Another object of the present invention is to provide a method of forming a 
non-skid-surfaced wood, metal or plastic structure that is lightweight and 
wear-resistant, and capable of allowing heavy pedestrian traffic, while 
eliminating the above-mentioned problems that are inherent in the known 
surface structures. 
Still another object of the invention is to provide a non-skid, plywood, 
panel structure that is lightweight, durable and resilient, so that it can 
flex without cracking. 
A further object of the invention is to provide a non-skid-surfaced, metal 
base member defining a tile-like structure that is lightweight and 
durable. 
Yet a further object of the present invention is to provide a 
non-skid-surfaced,plastic base member defining a tile-like structure that 
is also lightweight and durable, and allows complete flexibility of the 
tile without causing cracking or peeling of the non-skid surface. 
A still further object of the invention is to provide a non-skid-surfaced, 
base member wherein the upper surface of the base member is formed having 
a crown to allow for drainage of liquids, rainwater, etc. 
Another object of the invention is to provide a non-skid-surfaced plywood 
structure wherein the plywood is sealed on at least one surface by 
applying a low-viscosity coat of catalyzed epoxy resin which is allowed to 
soak into the wood fibers. Immediately following the first application, a 
second coat of thickened epoxy resin of approximately 20 to 30 mils is 
applied. This coat is allowed to dry for approximately one hour, whereupon 
a third or intermediate coat of pigmented polyurethane is then applied to 
the epoxy surface. While this third or intermediate coat is still quite 
wet, and before it develops a skin, a very hard grit material such as 
aluminum oxide is evenly broadcast over the wet surface. The grit is 
provided with the proper coarseness so as to establish a sandpaper-like 
surface. In order to establish a positive restraint, a finish coat or 
layer is applied over the grit particles and the intermediate coat, thus 
preventing the loosely embedded particles from separating from the base 
member. 
A still further object of the invention is to provide a method of this 
character that can be used for forming a non-skid surface on a base 
structure that can be readily employed either as a permanent or a 
temporary walkway for pedestrian traffic at building sites, and for 
replacement and/or repair of worn walkways or decks that would otherwise 
need to be reconstructed. 
Other features, objects and advantages of the instant invention will be 
obvious to persons skilled in the art from the following detailed 
description of several embodiments, accompanied by the attached drawings, 
in which identical reference numerals will refer to like parts in the 
various views.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring more particularly to FIGS. 1 through 4, there are shown enlarged, 
cross-sectional views representing a non-skid-surfaced panel or base 
member 10 illustrated in such a manner as to indicate sequentially the 
several necessary steps for producing the non-skid-surfaced structure. 
As previously mentioned heretofore, there are several areas of application 
for which the present invention is well suited, even though its main 
purpose is to establish a non-skid decking in and about waterfront areas 
or related environments, and more particularly in connection with decking 
for marine-dock structures. However, it is readily apparent that, after 
understanding the end results of the present invention and its unique 
advantages, other uses for floorings, walkways, and even roadways, can be 
established. 
FIG. 1 shows a wood panel or base member 10 which is formed preferably from 
a plywood structure having a thickness of between 1/4" to 21/2", with a 
specification requiring 11/8" thick Grade CC exterior plywood panel which 
is pressure-preservative treated. 
It is important to note, however, that other wood products, such as planks, 
boards, etc., can be substituted for the plywood which is used in the 
description because it is considered to be the preferred embodiment of the 
present invention. 
The purpose of the particular method of forming the end product of the 
non-skid-surfaced structure is to provide a permament but flexible bonding 
between the wood base member 10 and the non-skid elements thereof. 
Accordingly, the first embodiment as shown in FIGS. 1 through 4 comprises 
a wood base member having preferably a generally rectangular 
configuration, and having the approximate dimensions of a typical 
4'.times.8' panel. It is contemplated templated that the base member be 
also formed with 12".times.12" tile. 
Once the wood base member is selected and defined, a coat of catalyzed 
epoxy resin 16 having a low viscosity is applied to the upper surface 18 
of the base member 10. In other words, a catalyzed epoxy resin, indicated 
by the dots 16, must be applied in a thin liquid state, so as to penetrate 
within the surfaces 18, thus soaking into the wood fibers and readily 
sealing the surfaces thereof. 
The next step is to immediately apply a second coat of the same type of 
catalyzed epoxy resin. However, this second coat 22 is much thicker in 
viscosity and is formed having a thickness of between 10 to 30 mils. In 
order to aid in the bonding strength of epoxy layer 22, there is added 
thereto a sufficient amount of ground fiberglass (cabosil) which moreover 
provides a controlled viscosity of the epoxy resin. The second coat 22 is 
applied only to surface 18, which defines the upper or outer surface, and 
is then allowed to harden together with the first thin coat 16. Thus, a 
very strong bond is established between the second thick coat 22 and the 
saturated wood fibers on surface 18. The time required for the hardening 
of the second coat 22 can vary, but generally it takes about one hour to 
dry hard under normal, ambient, room temperature, although the base member 
at this time can, if desired, be subjected to a predetermined controlled 
temperature, whereby the hardening time will be set under a selective 
temperature-controlled environment. 
After the hardening of second coat 22, the surface thereof is roughened by 
any suitable means such as sanding, and a third coat 24 is then applied. 
This coat is preferably a pigmented polyurethane material that is spread 
or rolled over coat 22 and is applied having a thickness of between 10 to 
40 mils, but preferably 30 mils, and having a viscosity of between 1100 
and 1400 centipoise. The thickness of this coat is normally determined by 
the size and type of abrasive material that is combined therewith, the 
grit size being between No. 30 and No. 60. That is, while the polyurethane 
coat 24 is still very wet, and before it develops a skin-like surface, an 
overlay of very hard grit material 26 is evenly spread or disseminated 
over the wet layer of polyurethane. It is preferred that grit 26 be a No. 
46 size of aluminum oxide, whereby a 30-mil thickness to layer 24 would be 
achieved so as to allow the very sharp edges of the aluminum-oxide, 
sand-like particles to extend slightly above the surface of coat 24. Thus, 
the greater part of each grit particle is submerged and held in place by 
the proper thickness of the polyurethane material. It should be noted that 
other grit materials can also be used as an overlay under specific 
environmental conditions. Various materials such as silica sand and 
crushed walnut shells can be employed to provide a non-skid coating base. 
It is important to note that the grit substance 26 is disseminated over and 
in the polyurethane material, and is not physically secured within the 
second coat of epoxy layer 22. When grit particles 26 are supported in an 
epoxy base, such as at 22, they start to separate from the epoxy as it 
becomes brittle when exposed to ambient environmental conditions. Thus, 
the second coat of epoxy establishes a means by which the polyurethane 
coat 24 can be positively secured to the base member, particularly when 
the base member comprises a wood product, such as plywood. Polyurethane 
coat 24 further provides a means to protect the epoxy layer 22 from 
ultraviolet degredation. 
Due to extensive research, it was found that the surface tension of the 
first coat of polyurethane prevents some of the grit particles from 
sinking into the polyurethane coat far enough to be fixedly locked in 
place. Accordingly,a thin final coat or layer 28 of polyurethane is 
applied over the grit particles and polyurethane, so as to establish a 
positive securing means to prevent any of the grit particles 26 from 
separating from the structure. The finish coat 28 is thinly spread and has 
a viscosity of between 610 to 700 centipoises. This is clearly illustrated 
in the enlarged cross-sectional view of FIG. 5. The first coat of 
polyurethane 24 should have the proper thickness to cover only one-half to 
two-thirds of the grit particles, thus allowing the majority of the 
particles to settle and rest somewhat on epoxy layer 22. The finish coat 
is a much thinner layer which, when applied, covers layer 24 and 
encapsulates the remaining, upper, exposed portion of each grit particle. 
A second embodiment is disclosed in FIGS. 6 and 7, wherein a fiber/cement 
panel 30 having the same flat rectangular configuration as that of plywood 
panel 10 is placed over the second epoxy layer 22, thereby bonding 
opposing surface the fiber/cement panel to the plywood panel. The 
fiber/cement panel 30 is relatively thin and has a thickness of 
approximately 1/8". This panel generally consists of 36 percent Portland 
cement; 30 percent crushed limestone; 20 percent Possolan Volcanic ash; 
and 14 percent suitable fiber approximately 5/8" long. This particular 
composition is highly resistant to salt corrosion, has excellent chemical 
and fire resistance, and has resilient qualities to prevent cracking when 
subjected to constant movement, particularly when used as a walk surface 
on a floating-dock structure supported in a body of water, in which case 
the panels bend and twist to some extent. 
Accordingly, the following additional steps are required when the 
fiber/cement panel is employed: 
After applying the second coat of thicker cabosil-epoxy resin 22 to the 
plywood surface 18, this same thicker resin is also applied to the 
underside 29 of the fiber/cement panel 30. While both fiberglass-epoxy 
resin coats are still wet, the fiber/cement panel 30 is positioned over 
the plywood panel, allowing the two epoxies to commingle as one coating 
22a. 
At this time, the two attached panels 10 and 30 are placed in a press, 
whereby approximately 100 p.s.i. pressure is applied, thus forcing out the 
excess epoxy material and establishing a very thin bonding line between 
the two panels. 
Once this is accomplished, a first polyurethane coat 24 is applied to the 
upper surface 32 of panel 30. Again, the thickness of the coat is 
determined by the size and type of abrasive material that is applied 
thereafter. 
Accordingly, the polyurethane coat 24 is allowed to dry as previously 
described, at which time a second (finish) coat of polyurethane 35 is 
applied, so as to lock the abrasive particles in place. The second coat 
will further cover the grit surfaces to the level where only the top 
points of the grit are protruding from the surface, or the points might be 
slightly covered in the case of lower-lying grit particles. The second 
coat will trap any loose grit that, for some reason, might not be well 
fastened into the first coat. A second benefit is derived from employing a 
second finished polyurethane coat--which is that the color of the surface 
can be precisely controlled by selective pigmentation. 
The invention and its attendant advantages will be understood from the 
foregoing description; and it will be apparent that various changes may be 
made in the form, construction and arrangement of the parts of the 
invention without departing from the spirit and scope thereof or 
sacrificing its material advantages, the arrangement hereinbefore 
described being merely by way of example; and I do not wish to be 
restricted to the specific form shown or uses mentioned, except as defined 
in the accompanying claims.