Method and forming, installing and a system for attaching a pre-fabricated pavement slab to a subbase and the pre-fabricated pavement slab so formed

• US 6,663,315 B2
• Filed: 12/10/2001
• Issued: 12/16/2003
• Est. Priority Date: 09/05/2000
• Status: Expired due to Term

• Current Assignee: The Fort Miller Company Incorporated (The Fort Miller Group, Inc.)
• Original Assignee: The Fort Miller Company Incorporated (The Fort Miller Group, Inc.)
• Inventors: Smith, Peter J.
• Primary Examiner(s): Miller, William L.
• Assistant Examiner(s): MITCHELL, KATHERINE W
• Application Number:
  US10/013,761
• Publication Number:
  US 20020044826A1
• Time in Patent Office: 736 Days
• Field of Search: 249/2, 249/13, 249/188, 249/192, 404/72, 404/75, 404/18, 404/34, 404/39, 404/40, 404/41, 404/31, 404/60, 404/69, 404/261, 404/35, 404/37, 404/47, 404/49, 404/50, 404/51, 404/52, 404/61, 525/74, 523/93, 526/00, 525/96, 526/07
• US Class Current: 404/40
• CPC Class Codes: E01C 11/005 Methods or materials for repairing pavings E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00
• CPC Class Codes: E01C 23/10 for raising or levelling sunken paving; for filling voids under paving; for introducing material into substructure consolidating soil in general E02D3/12
• CPC Class Codes: E01C 5/08 Reinforced units with steel frames with metal upper or under layers E01C5/22
• CPC Class Codes: E01C 5/10 Prestressed reinforced units ; Prestressed coverings from reinforced or non-reinforced units prestressed concrete coverings E01C7/16

Abstract

A pre-fabricated pavement slab having a binder distribution system and an interconnection system formed for attachment of the bottom surface of the slab, wherein both the binder distribution system and the interconnection system are accessible from the top surface of the slab, such that the binder material may be injected into the binder distribution and interconnection systems from the top surface of the slab.

Claims

1. A method of fabricating a prefabricated pavement slab with an area bounded by ends and sides comprising:

providing a form for defining a binder distribution system within a bottom surface of the prefabricated pavement slab, wherein the binder distribution system does not allow a binder to be distributed beyond the area;

providing within the form at least one surface for defining a raised slot;

providing within the binder distribution system at least one surface for defining a raised channel that is independent from the raised slot;

providing within the form at least one surface for defining a port extending from the raised slot to a top surface of the prefabricated pavement slab;

providing within the form at least one surface for defining a port extending from the raiscd channel to the top surface of the prefabricated pavement slab;

pouring a pavement material into the form; and

incorporating a plurality of interconnections within a first end of the prefabricated pavement slab.

2. The method of claim 1 further comprising, providing within the form a surface for defining a plurality of mating interconnection slots in a second end of the slab.

3. The method of claim 1, wherein said plurality of interconnections comprise reinforcement rods.

4. The method of claim 1, wherein the pavement material comprises a cementitious material.

5. The method of claim 1 further comprising, providing within the form at least one surface for defining a rounded top section on the raised slot and at least one surface for defining a shear pin along a side of the raised slot.

6. The method of claim 1 a surface to form, wherein the raised slot has a top width greater than a base width.

7. A method of fabricating a prefabricated pavement slab with an area bounded by ends and sides comprising;

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab wherein said binder distribution system does not allow a binder to be distributed beyond said area, said form further having at least a second surface for defining an interconnection slot within the bottom surface of the prefabricated pavement slab; and

pouring a pavement material into the form.

8. The method of claim 7, wherein the at least first surface is a raised surface.

9. The method of claim 7, wherein the at least second surface is a raised surface.

10. The method of claim 7 further comprising, providing within the form at least one surface form for defining a port extending from the interconnection slot to a top surface of the slab.

11. The method of claim 7 further comprising, providing within the form at least one surface for defining a port extending from the binder distribution system to a top surface of the slab.

12. A method of fabricating a prefabricated pavement slab comprising:

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab and at least a second surface for defining an interconnection slot within a first side of the slab wherein said interconnection slot does not extend to a second side of the slab, wherein said interconnection slot includes a rounded top section and a shear pin along a side of the interconnection slot; and

pouring a pavement material into the form.

13. A method of fabricating a prefabricated pavement slab comprising:

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab and at least a second surface for forming defining an interconnection slot within a first side of the slab wherein said interconnection slot does not extend to a second side of the slab, wherein said interconnection slot includes a rounded top section and a shear pin along a side of the interconnection slot; and

pouring a pavement material into the form.

14. A method of fabricating a prefabricated pavement slab comprising;

providing a form having a plurality of first surfaces for forming defining a plurality of first interconnection slots at a first edge of the slab and a plurality of second surfaces for forming defining a plurality of second interconnection slots at a second edge of the slab wherein said second edge is not parallel to said first edge of the slab, further wherein said plurality of first interconnection slots are open to a bottom surface of said prefabricated pavement slab and said plurality of first interconnection slots do not extend to the second edge of the slab; and

pouring a pavement material into the form.

15. The method of claim 14, wherein the first surface is a raised surface.

16. The method of claim 14, wherein the second surface is a raised surface.

17. The method of claim 14 further comprising, providing within the form at least one surface for defining a port extending from the plurality of first interconnection slots to a top surface of the slab.

18. The method of claim 14 further comprising, providing within the form at least one surface for defining a port extending from the plurality of second interconnection slots to a top surface of the slab.

19. A method of fabricating a prefabricated pavement slab comprising;

providing a form having at least one surface for defining an interconnection slot on the bottom surface of the slab such that the interconnection slot comprises a geometry that will prohibit a binder material that is placed in the interconnection slot from moving in a vertical direction thereby preventing the slab from moving in a vertical direction with respect to an adjacent slab, further wherein said interconnection slot does not extend an entire length of said bottom surface of the slab; and

pouring a pavement material into the form.

20. The method of claim 19, wherein the at least one surface is a raised surface.

21. The method of claim 19 further comprising, providing within the form at least one surface for defining a port extending from the interconnection slot to a top surface of the slab.

22. The method of claim 19 further comprising, providing within the form at least one surface for defining a rounded top section on the interconnection slot and at least one surface for defining a shear pin along a side of the interconnection slot.

23. The method of claim 19 further comprising, providing within the form a surface for defining the interconnection slot with a top width greater than a base width.

24. The method of claim 19 further comprising, attaching a compressible material to a bottom surface of said prefabricated pavement slab.

25. A method of forming a prefabricated pavement slab comprising:

providing a form having at least one void for defining a binder distribution system within a bottom surface of the prefabricated pavement slab wherein the binder distribution system includes at least one channel, said form further having at least one surface for defining at least one interconnection slot along an edge of the slab, wherein said at least one channel is independent and not parallel with said at least one interconnection slot; and

pouring a pavement material into the form.

26. The method of claim 25, wherein said at least one interconnection slot is shaped to prevent vertical movement of the slab with respect to an adjacent slab.

27. A method of fabricating a prefabricated pavement slab with an area bounded by the length and width, wherein said length exceeds about 13 feet, comprising;

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab wherein said binder distribution system does not allow a binder to be distributed beyond said area, said form further having at least a second surface for defining an interconnection slot within the bottom surface of the prefabricated pavement slab; and

pouring a pavement material into the form.

28. A method of fabricating a prefabricated pavement slab with an area bounded by the length and width, wherein said width exceeds about 9 feet, comprising;

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab wherein said binder distribution system does not allow a binder to be distributed beyond said area, said form further having at least a second surface for defining an interconnection slot within the bottom surface of the prefabricated pavement slab; and

pouring a pavement material into the form.

29. A method of fabricating a prefabricated pavement slab with an area bounded by the length and width, wherein a ratio of the width of the slab to the thickness of the slab is at least about 10:

1, comprising;

providing a form having at least a first surface for defining a binder distribution system within a bottom surface of the prefabricated pavement slab wherein said binder distribution system does not allow a binder to be distributed beyond said area, said form further having at least a second surface for defining an interconnection slot within the bottom surface of the prefabricated pavement slab; and

pouring a pavement material into the form.