Concrete runways, roads, highways and slabs on grade and methods of making same

• US 9,114,549 B2
• Filed: 01/28/2014
• Issued: 08/25/2015
• 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
• Application Number:
  US14/165,630
• Publication Number:
  US 20140312524A1
• Time in Patent Office: 574 Days
• Field of Search: None
• US Class Current: 1/1
• 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 a surface;

placing plastic cementitious-based material on the first layer of insulating material;

wherein the cementitious-based material comprises;

aggregate; and

cementitious material, wherein the cementitious material consists essentially of approximately 30% to approximately 80% by weight Portland cement and the remaining cementitious material comprising one or more supplementary cementitious materials selected from slag cement and fly ash;

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-base material; and

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

2. The method of claim 1, wherein the first and second layers of insulating material each have an R-value of at least 4.

3. The method of claim 1, wherein the first and second layers of insulating material each have an R-value of at least 8.

4. The method of claim 1, wherein the cementitious material consists essentially of approximately 30% to approximately 70% by weight portland cement.

5. The method of claim 1, wherein the cementitious material consists essentially of approximately 30% to approximately 60% by weight portland cement.

6. The method of claim 1, wherein the cementitious material consists essentially of approximately 30% to approximately 50% by weight portland cement.

7. A method comprising:

placing a first layer of insulating material horizontally on a surface;

placing plastic cementitious-based material on the first layer of insulating material;

wherein the cementitious-based material comprises;

aggregate; and

cementitious material, wherein the cementitious material consists essentially of approximately 30% to approximately 80% by weight portland cement and the remaining cementitious material comprising one or more supplementary cementitious materials selected from slag cement, fly ash, silica fume, rice husk ash, metakaolin, and other siliceous, aluminous or aluminosiliceous materials that react with calcium hydroxide in the presence of water

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; and

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

8. The method of claim 7, wherein the first and second layers of insulating material each have an R-value of at least 4.

9. The method of claim 7, wherein the first and second layers of insulating material each have an R-value of at least 8.

10. The method of claim 7, wherein the cementitious material consists essentially of approximately 30% to approximately 70% by weight portland cement.

11. The method of claim 7, wherein the cementitious material consists essentially of approximately 30% to approximately 60% by weight portland cement.

12. The method of claim 7, wherein the cementitious material consists essentially of approximately 30% to approximately 50% by weight portland cement.

13. A method comprising:

placing a first layer of insulating material horizontally on a surface;

placing plastic cementitious-based material on the first layer of insulating material;

wherein the cementitious-based material comprises;

aggregate; and

cementitious material, wherein the cementitious material consists essentially of approximately 30% to approximately 80% by weight portland cement and the remaining cementitious material comprising one or more pozzolanic materials;

forming the plastic concrete 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; and

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

14. The method of claim 13, wherein the first and second layers of insulating material each have an R-value of at least 4.

15. The method of claim 13, wherein the first and second layers of insulating material each have an R-value of at least 8.

16. The method of claim 13, wherein the cementitious material consists essentially of approximately 30% to approximately 70% by weight portland cement.

17. The method of claim 13, wherein the cementitious material consists essentially of approximately 30% to approximately 60% by weight portland cement.

18. The method of claim 13, wherein the cementitious material consists essentially of approximately 30% to approximately 50% by weight portland cement.

19. The method of claim 13, wherein the cementitious material further consists essentially of a filler material.

20. The method of claim 13, wherein the cementitious material further consists essentially of approximately 0.1% to approximately 10% by weight Wollastonite.