Methods of making concrete runways, roads, highways and slabs on grade

• US 8,636,941 B1
• Filed: 09/25/2012
• Issued: 01/28/2014
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): SCHIFFMAN, BENJAMIN A
• Application Number:
  US13/626,622
• Time in Patent Office: 490 Days
• Field of Search: None
• US Class Current: 264/333
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/0075 for road construction
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/08 Slag cements
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: E01C 11/18 for cement concrete pavings prefabricated reinforced units E01C5/08
• CPC Class Codes: E01C 23/03 Arrangements for curing paving; Devices for applying curing means; Devices for laying prefabricated underlay, e.g. sheets, membranes reinforcing elements E01C23/04; Protecting paving under construction or while curing, e.g. use of tents road barriers E01F13/00
• CPC Class Codes: E01C 3/06 Methods or arrangements for protecting foundations from destructive influences of moisture, frost or vibration heating devices E01C11/26; draining the subbase of roads E01F5/00
• CPC Class Codes: E01C 7/14 Concrete paving from concrete prepared in situ E01C7/12; small individual units from concrete cast in situ E01C9/001; arrangement or construction of joints E01C11/04; reinforcements E01C11/18
• CPC Class Codes: E01C 7/142 Mixtures or their components, e.g. aggregate E01C7/147, E01C7/355 take precedence; different layers of different composition E01C7/14
• CPC Class Codes: E01C 7/36 by subjecting soil to stabilisation E01C7/06 takes precedence; foundations E01C3/04; soil conditioning or soil stabilising materials C09K17/00; soil stabilisation devices for road construction E01C21/00
• CPC Class Codes: E01C 9/00 Special pavings specially adapted for playgrounds or sports grounds E01C13/00, for footpaths, sidewalks or cycle tracks E01C15/00; Pavings for special parts of roads or airfields pavement lights E01C17/00; manholes or like covers or frames E02D29/14
• CPC Class Codes: E01C 9/001 Paving elements formed in situ; Permanent shutterings therefor removable shutterings E01C19/502; moulding machines therefor E01C19/508; Inlays or reinforcements which divide the cast material in a great number of individual units reinforcement girders which do not break the cohesion of the covering material E01C11/16, E01C11/185
• CPC Class Codes: E04G 13/00 Falsework, forms, or shutterings for particular parts of buildings, e.g. stairs, steps, cornices, balconies foundations, sills E04G11/365 takes precedence; flat foundations, e.g. with lost forms E02D27/01; removable forms or shutterings for road-building purposes E01C19/50
• CPC Class Codes: E04G 21/246 specially adapted for curing concrete in situ, e.g. by covering it with protective sheets
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y02W 90/00 Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

The invention comprises a method of forming a slab on grade. The method comprises placing a first layer of insulating material horizontally on the ground and placing plastic concrete for a slab on grade on the first layer of insulating material. The plastic concrete is then formed into a desired shape having a top and sides. A second layer of insulating material is placed on the top of the plastic concrete and the first and second layers of insulating material are left in place until the concrete is at least partially cured. The second layer of insulating material is then removed. The product made by the method is also disclosed. A slab on grade is also disclosed.

Claims

1. A method comprising:

placing a first layer of insulating material horizontally on the ground;

placing plastic concrete cementitious-based material for a slab on grade on the first layer of insulating material;

wherein the cementitious-based material comprises;

aggregate;

cementitious material, wherein the cementitious material consists essentially of approximately 30% to approximately 80% by weight portland cement, approximately 0% to approximately 50% by weight slag cement, and 20% to approximately 50% by weight fly ash; and

water sufficient to hydrate the cementitious-based material;

forming the plastic cementitious-based material into a desired shape having a top and sides;

placing a second layer of insulating material on the top of the plastic cementitious-based material;

leaving the first and second layers of insulating material in place until the cementitious-based material is at least partially cured; and

removing the second layer of insulating material.

2. The method of claim 1 further comprising placing the second layer of insulating material on the sides of the plastic cementitious-based material.

3. The method of claim 1, wherein the first layer of insulating material is polymeric foam.

4. The method of claim 1, wherein the first layer of insulating material has an R-value of greater than 1.5.

5. The method of claim 1, wherein the first layer of insulating material has an R-value of greater than 4.

6. The method of claim 1, wherein the first layer of insulating material is a radiant heat reflective material and conductive heat insulating material.

7. The method of claim 1, wherein the first layer of insulating material is a refractory insulating material.

8. The method of claim 1, wherein the second layer of insulating material is polymeric foam.

9. The method of claim 1, wherein the second layer of insulating material has an R-value of greater than 1.5.

10. The method of claim 1, wherein the second layer of insulating material has an R-value of greater than 4.

11. The method of claim 1, wherein the second layer of insulating material is a radiant heat reflective material and conductive heat insulating material.

12. The method of claim 1, wherein the second layer of insulating material is a refractory insulating material.

13. The method of claim 1, wherein the curing cementitious material consists essentially of:

approximately 30% to approximately 80% by weight portland cement; and

at least one of approximately 20% to approximately 50% by weight slag cement or 20% to approximately 50% by weight fly ash.

14. The product of claim 13, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 1 to 1 to 1.

15. The product of claim 13, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.85-1.15:

0.85-1.15;

0.85-1.15.

16. The product of claim 13, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.9-1.1:

0.9-1.1;

0.9-1.1.

17. The product of claim 13, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.95-1.05:

0.95-1.05;

0.95-1.05.

18. A method comprising:

placing a quantity of plastic cementitious-based material between a first horizontal layer of insulating material and a second horizontal layer of insulating material;

wherein the cementitious-based material comprises;

aggregate;

cementitious material, wherein the cementitious material consists essentially of approximately 30% to approximately 80% by weight portland cement, approximately 0% to approximately 50% by weight slag cement, and 20% to approximately 50% by weight fly ash; and

water sufficient to hydrate the cementitious-based material;

allowing the plastic cementitious-based material to at least partially cure; and

removing one of the first or second horizontal layers of insulating material.

19. The method of claim 18, wherein the first and second layers of insulating material have an R-value of greater than 1.5.

20. The method of claim 18, wherein the curing cementitious-based material consists essentially of:

approximately 30% to approximately 80% by weight portland cement; and

at least one of approximately 20% to approximately 50% by weight slag cement or 20% to approximately 50% by weight fly ash.

21. The product of claim 20, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 1 to 1 to 1.

22. The product of claim 20, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.85-1.15:

0.85-1.15;

0.85-1.15.

23. The product of claim 20, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.9-1.1:

0.9-1.1;

0.9-1.1.

24. The product of claim 20, wherein the weight ratio of portland cement to slag cement to fly ash is approximately 0.95-1.05:

0.95-1.05;

0.95-1.05.