Pavement repair system

• US 9,551,114 B2
• Filed: 05/06/2016
• Issued: 01/24/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: William B. Coe
• Original Assignee: William B. Coe
• Inventors: Coe, William B.
• Primary Examiner(s): Addie, Raymond W
• Application Number:
  US15/148,998
• Publication Number:
  US 20160251808A1
• Time in Patent Office: 263 Days
• Field of Search: 404/75, 404/77, 404/79, 404/95
• US Class Current: 1/1
• 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 19/002 Apparatus for preparing and placing the materials and for consolidating or finishing the paving
• CPC Class Codes: E01C 19/15 for laying-down uncoated stone or similar materials, or for striking-off or spreading same without compacting, e.g. for crushed rock base courses, sand cushions for paving E01C19/466 , E01C19/52 take precedence; distributing E01C19/20; laying down and rolling E01C19/482
• CPC Class Codes: E01C 23/00 Auxiliary devices or arrangements for constructing, repairing, reconditioning, or taking-up road or like surfaces apparatus for reconditioning of salvaged non-hydraulic compositions for- in plant recycling of salvaged bituminous mixtures E01C19/10
• 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 23/065 Recycling in place or on the road, i.e. hot or cold reprocessing of paving in situ or on the traffic surface, with or without adding virgin material or lifting of salvaged material; Repairs or resurfacing involving at least partial reprocessing of the existing paving in situ mixing of hydraulic cement concrete E01C19/025; apparatus for in-plant recycling E01C19/1004, E01C19/1036
• CPC Class Codes: E01C 23/14 for heating or drying foundation, paving, or materials thereon, e.g. paint E01C23/03 takes precedence; heating or drying devices incorporated in the paving E01C11/26; surface soil stabilisation by fusing, calcining or burning soil in situ E01C21/02; for street cleaning E01H1/08; melting snow or ice on surfacing E01H5/10
• CPC Class Codes: E01C 7/187 Repairing bituminous covers, e.g. regeneration of the covering material in situ, application of a new bituminous topping application of thin surface layers with other binders E01C7/35; repairing pavings in general E01C11/005
• CPC Class Codes: E01C 7/358 with a combination of two or more binders according to groups E01C7/351 - E01C7/356
• CPC Class Codes: H05B 3/0038 for industrial applications
• CPC Class Codes: H05B 6/48 Circuits

Abstract

A pavement repair system utilizes solid phase auto regenerative cohesion and homogenization by liquid asphalt oligopolymerization technologies. The system is suitable for use in repairing asphalt pavement, including pavement exhibiting a high degree of deterioration (as manifested in the presence of potholes, cracks, ruts, or the like) as well as pavement that has been subject to previous repair and may comprise a substantial amount of dirt and other debris (e.g., chipped road paint or other damaged or disturbed surfacing materials). A system utilizing homogenization by liquid asphalt oligopolymerization is suitable for rejuvenating or repairing aged asphalt, thereby improving properties of the paving material.

Claims

1. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1 nm to 10000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement, wherein the peak wavelength of the radiation is selected such that the radiation penetrates through and heats the road plating composition and the surface layer of the asphalt pavement to a depth of at least two inches from a topmost pavement surface, wherein a temperature differential throughout a top two inches of the pavement is 100°

F. or less, wherein a highest temperature in the top two inches of the pavement does not exceed 300°

F., and wherein a minimum temperature in the top two inches of the pavement is at least 200°

F.

2. The method of claim 1, wherein the road plating composition is from ⅛

inch to ½

inch thick.

3. The method of claim 1, further comprising installing a binder primer on the asphalt pavement prior to transferring the road plating composition.

4. The method of claim 1, further comprising installing a levelling course on the asphalt pavement prior to transferring the road plating composition.

5. The method of claim 1, further comprising subjecting the new wearing surface to vibratory compaction, whereby the irradiated road-plating composition is fused to the irradiated surface layer of the asphalt pavement.

6. The method of claim 1, wherein the road plating composition is in a form of a pre-manufactured roll or a sheet.

7. The method of claim 1, wherein the binder is an asphalt binder.

8. The method of claim 1, wherein the binder comprises at least one binder crosslink component selected from the group consisting of polyurethanes, isocyanates, bisphenol A-based liquid epoxy resins, and aliphatic glycol epoxy resins.

9. The method of claim 1, wherein the graded stone is coated with a 3-5 mil layer of binder.

10. The method of claim 1, wherein the binder comprises an elastomer.

11. The method of claim 10, wherein the elastomer is selected from the group consisting of a butyl rubber, a styrene-butadiene-styrene polymer, a styrene/acrylate copolymer, a chlorinated natural rubber, a thermoplastic, and a bioresin.

12. The method of claim 1, wherein the asphalt pavement comprises an asphaltene asphalt, and wherein the preselected peak wavelength is from 1000 nm to 4000 nm.

13. The method of claim 1, wherein the asphalt pavement comprises a maltene asphalt, and wherein the preselected peak wavelength is from 1000 nm to 10000 nm.

14. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1 nm to 10000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement, wherein the peak wavelength of the radiation is selected based on at least one criterion selected from the group consisting of absorbed wavelength quanta data related to a stone petrography of the asphalt pavement, an asphaltene/maltene content of the binder, and an average crack width by depth topography of the asphalt pavement.

15. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1 nm to 10000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement, wherein the peak wavelength of the radiation is selected based on data from exploratory testing conducted on representative portions of the surface of the asphalt pavement.

16. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1000 nm to 10000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement.

17. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone, the asphalt pavement comprising a granite rock; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 3000 nm to 5000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement.

18. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone, the asphalt pavement comprising a limestone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 3000 nm to 4000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement.

19. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone, the asphalt pavement comprising a sand; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 5000 nm to 8000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement.

20. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone;

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1 nm to 10000 nm; and

irradiating the road plating composition and the surface layer of the asphalt pavement with a radiation having a second preselected peak wavelength of from 2 mm to 5 mm,

whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement.

21. A method for providing an asphalt pavement with a new wearing surface, comprising:

transferring a road plating composition to a surface of an asphalt pavement, the road plating composition comprising a binder and graded stone; and

irradiating the road plating composition and a surface layer of the asphalt pavement with a radiation having a preselected peak wavelength of from 1 nm to 10000 nm, whereby the asphalt pavement is provided with a new wearing surface comprising the irradiated road plating composition atop the irradiated surface layer of the asphalt pavement, wherein the radiation is generated by an emitter, wherein the emitter comprises an emitter panel comprising a birefringent material through which an electromagnetic radiation generated by the emitter passes, wherein the birefringent material is a sheet of a micaceous material exhibiting biaxial birefringence.