Methods and apparatus for stabilization of surfaces

• US 9,499,716 B2
• Filed: 10/09/2014
• Issued: 11/22/2016
• Est. Priority Date: 06/10/2010
• Status: Active Grant

• Current Assignee: Polylast Systems, LLC
• Original Assignee: Polylast Systems, LLC
• Inventors: Laurence, Peter J.
• Primary Examiner(s): RISIC, ABIGAIL ANNE
• Application Number:
  US14/511,094
• Publication Number:
  US 20150023732A1
• Time in Patent Office: 775 Days
• Field of Search: 404/25, 404/26, 404/107, 404/108, 404/75
• US Class Current: 1/1
• CPC Class Codes: C08G 18/307 Atmospheric humidity
• CPC Class Codes: C08L 95/00 Compositions of bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: C09D 163/00 Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
• CPC Class Codes: C09D 175/04 Polyurethanes
• CPC Class Codes: C09J 175/04 Polyurethanes
• 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

Abstract

Various embodiments provide surface compositions and methods for repairing durable and/or load-bearing surfaces including roadway voids, manhole structures, and/or safety flooring. Compositions and methods may comprise utilizing a liquid binder, catalyst, and/or primer to provide durable, waterproof, and/or long-lasting surface compositions to dispose within the roadway voids and/or to coat flooring. The surface compositions may cure rapidly through an internal exothermic reaction process to form the repair and/or the safety flooring. In some embodiments, filler materials may be disposed within the liquid binders to provide elasticity, compression, slip resistance, heat transfer, reduced cure time, and/or a desired surface texture to the surface composition.

Claims

1. A surface composition for application to at least one of a roadway void and a flooring for traffic, the surface composition comprising:

a liquid binder comprising a polyurethane adapted to cure through an exothermic reaction process, wherein the cured liquid binder has an increased viscosity relative to the liquid binder prior to curing; and

a primer adapted to adhere to the cured liquid binder and the at least one of the roadway void and the flooring;

wherein the surface composition applied to the roadway void and the flooring is adapted to withstand wear from the traffic over the roadway void and the flooring.

2. The surface composition of claim 1, further comprising a filler material, wherein the filler material is mixed with the liquid binder.

3. The surface composition of claim 2, wherein the filler material comprises at least one of an aggregate material, rubber particles, asphalt particles, sand, ceramics, glass, marble, rock, and gravel particles.

4. The surface composition of claim 1, wherein the liquid binder comprises a first component comprising a polyol and a second component comprising an isocyanate, wherein the exothermic reaction is initiated upon at least one of:

(1) the mixing of the first component and the second component and (2) the exposure of the liquid binder to air.

5. The surface composition of claim 4, wherein the first component further comprises a catalyst.

6. The surface composition of claim 4, wherein the isocyanate comprises an aromatic isocyanate.

7. The surface composition of claim 1, further comprising an additive.

8. The surface composition of claim 7, wherein the additive comprises at least one of an antimicrobial composition, a surfactant, and a pigment.

9. The surface composition of claim 7, wherein the additive comprises an edge retention composition.

10. The surface composition of claim 1, wherein the primer comprises an epoxy.

11. A method for filling a roadway void comprising a cavity having a surface comprising the steps of:

applying a primer to at least a portion of the cavity surface;

filling the cavity with an amount of a liquid binder sufficient to be level with the roadway such that the liquid binder is in contact with and adheres to the primer,

wherein the liquid binder comprises polyurethane adapted to cure through an exothermic reaction process, and

wherein the cured liquid binder has an increased viscosity relative to the liquid binder prior to curing; and

allowing a sufficient amount of time for the liquid binder to cure before resuming traffic over the roadway.

12. The method of claim 11, wherein loose debris is removed from the cavity prior to applying the primer.

13. The method of claim 11, wherein standing water is removed from the cavity prior to applying the primer.

14. The method of claim 11, wherein the primer is applied to the cavity surface with at least one of a brush, roller, and a spray to coat the cavity surface.

15. The method of claim 11, wherein the primer comprises an epoxy.

16. The method of claim 11, wherein the liquid binder comprises a first component comprising a polyol and a catalyst and a second component comprising an isocyanate, wherein the exothermic reaction is initiated upon at least one of:

(1) the mixing of the first component and the second component and (2) the exposure of the liquid binder to air.

17. The method of claim 16, wherein the isocyanate is an aromatic isocyanate.

18. The method of claim 16, wherein the first component and the second component are mixed prior to filling the cavity.

19. The method of claim 11, further comprising mixing a filler material with the liquid binder prior to filling the cavity.

20. The method of claim 19, wherein the filler material comprises at least one of an aggregate material, rubber particles, asphalt particles, sand, ceramics, glass, marble, rock, and gravel particles.

21. The method of claim 11, wherein the time for the liquid binder to cure before traffic resumes is up to 20 minutes.

22. The method of claim 11, wherein the cavity is filled with the liquid binder within forty-eight hours of the application of the primer to the cavity surface.

23. A method for forming a safety flooring over a surface for at least one of human traffic and animal traffic comprising the steps of:

mixing a liquid binder with a filler material;

applying a mixture of the liquid binder and the filler material over the surface, wherein the liquid binder comprises polyurethane adapted to cure through an exothermic reaction process, and wherein the cured liquid binder has an increased viscosity relative to the liquid binder prior to curing; and

allowing a sufficient amount of time for the liquid binder to cure before resuming the at least one of the human traffic and the animal traffic over the surface.

24. The method of claim 23, wherein the filler material is adapted to provide slip resistance to the safety flooring.

25. The method of claim 23, wherein the filler material is adapted to provide compressibility to the safety flooring.

26. The method of claim 23, wherein the filler material is applied over a top surface of the liquid binder and adsorbs to the liquid binder prior to curing.

27. The method of claim 23, in which the step of curing the liquid binder comprises spraying the surface of the liquid binder with a catalyst.

28. The method of claim 23, wherein the liquid binder comprises a first component comprising a polyol and a second component comprising an isocyanate, wherein the exothermic reaction is initiated upon at least one of:

(1) the mixing of the first component and the second component and (2) the exposure of the liquid binder to air.

29. The method of claim 28, wherein the first component further comprises a catalyst.

30. The method of claim 28, wherein the isocyanate is an aromatic isocyanate.