Modular pavement system

• US 9,920,490 B2
• Filed: 05/16/2016
• Issued: 03/20/2018
• Est. Priority Date: 01/05/2016
• Status: Active Grant

• Current Assignee: Integrated Roadways LLC
• Original Assignee: Integrated Roadways LLC
• Inventors: Sylvester, Tim
• Primary Examiner(s): RISIC, ABIGAIL ANNE
• Application Number:
  US15/156,001
• Publication Number:
  US 20170191227A1
• Time in Patent Office: 673 Days
• CPC Class Codes: E01C 2201/167 by reinforcement or mesh
• CPC Class Codes: E01C 5/003 characterised by material or composition used for beds or joints; characterised by the way of laying
• CPC Class Codes: E01C 5/005 Individual couplings or spacer elements for joining the prefabricated units E01C5/10 takes precedence
• CPC Class Codes: E01C 5/08 Reinforced units with steel frames with metal upper or under layers E01C5/22
• CPC Class Codes: E01C 5/20 made of units of plastics, e.g. concrete with plastics, linoleumE01C5/18 takes precedence; of textiles made of synthetic fibres E01C5/008

Abstract

A prefabricated paving slab includes specialized combinations of substantially vertical passages and cavities to enable “drop in” installation. The paving slab may include retractable coupling rods aligned using spacers having seating surfaces and alignment surfaces. Cavities of the paving slab, each configured for receiving a coupling rod, preferably are arranged in orientation(s) and pattern(s) selected for receiving and transferring the stresses of loads travelling in a pre-determined direction.

Claims

1. A system for coupling a pavement slab to an adjacent receiving structure, the system comprising:

a substantially horizontal first cavity in the slab terminating along a side of the slab;

a substantially horizontal second cavity in the receiving structure terminating along a side of the receiving structure, the side of the receiving structure being positioned adjacent to the side of the slab;

a coupling rod having a first portion received within the first cavity and a second portion received within the second cavity; and

a spacer including a seating surface configured to receive a lower surface of the coupling rod and an alignment surface for positioning in alignment with a landmark segment of the slab;

the alignment surface including a projection and the landmark segment of the slab including a portion of a top surface of the slab having a shape complementary to the projection.

2. The system of claim 1, wherein the alignment surface is additionally configured to bear a load received from the coupling rod along the seating surface.

3. The system of claim 1, wherein the projection includes a nib.

4. The system of claim 1, wherein the seating surface includes a curved projection and the lower surface of the coupling rod is correspondingly curved.

5. The system of claim 1, wherein the spacer extends through a passage extending from a top of the first cavity and terminating at a top surface of the slab.

6. The system of claim 5, further comprising a second spacer for positioning in alignment with a second landmark segment of the receiving structure.

7. The system of claim 1, wherein the spacer is configured so that alignment of the alignment surface with the landmark segment of the slab creates a pre-determined degree of separation between the coupling rod and an inner surface of the first cavity.

8. The system of claim 7, wherein the first cavity and the coupling rod are substantially cylindrical, and wherein the pre-determined degree of separation is approximately one-half inch (½

″

).

9. A system for coupling a pavement slab to an adjacent receiving structure, the system comprising:

a substantially horizontal first cavity in the slab terminating along a side of the slab;

a substantially horizontal second cavity in the receiving structure terminating along a side of the receiving structure, the side of the receiving structure being positioned adjacent to the side of the slab;

a coupling rod having a first portion received within the first cavity and a second portion received within the second cavity;

a spacer including a seating surface configured to receive a lower surface of the coupling rod and an alignment surface for positioning in alignment with a landmark segment of the slab, the spacer extending through a passage extending from a top of the first cavity and terminating at a top surface of the slab; and

a second spacer for positioning in alignment with a second landmark segment of the receiving structure, the second spacer extending through a second passage extending from a top of the second cavity and terminating at a top surface of the receiving structure.

10. The system of claim 9, wherein each of the spacers is configured for manual vertical adjustment during installation for alignment with respective landmark segments.

11. The system of claim 10, wherein each of the landmark segments of the slab and of the receiving structure includes respectively the top surface of the slab and the top surface of the receiving structure.

12. The system of claim 10, the system further including a filler substantially occupying the first and second cavities following vertical adjustment of the spacers.

13. The system of claim 10, wherein the first cavity is configured to accommodate substantially the entire length of the coupling rod and the first passage is positioned along a lateral axis at least partially above a first end of the coupling rod in an installed, extended configuration.

14. The system of claim 13, further including a third passage positioned along a lateral axis at least partially above the first end of the coupling rod in a retracted, uninstalled configuration.

15. The system of claim 14, further comprising a flexible snake configured for insertion into the third passage to urge the coupling rod into the second cavity in a telescoping movement for the installed, extended configuration.

16. The system of claim 12, wherein the filler is grout.

17. The system of claim 15, wherein the second passage is positioned along a lateral axis at least partially above the second end of the coupling rod in the installed, extended configuration.

18. The system of claim 17, wherein the second cavity includes a stopping surface configured to resist further penetration into the receiving structure by the coupling rod in the installed, extended configuration.

19. A method for installing adjacent pavement slabs, the steps of the method comprising:

aligning a cavity terminating in a side of a first slab with a matching cavity terminating in a side of a receiving structure; and

adjusting the position of a coupling rod, the coupling rod being at least partially within the cavity and at least partially within the matching cavity;

wherein the adjustment of the position of the coupling rod includes manipulating a spacer to achieve a pre-determined degree of separation from a surface of at least one of the cavity and the matching cavity, the spacer having;

(A) a seating surface including a curved projection configured to receive a correspondingly curved lower surface of the coupling rod, the adjusting including positioning the lower surface of the coupling rod on the curved projection; and

(B) an alignment surface configured for positioning in alignment with a landmark segment of one of the first slab and the receiving structure to achieve the pre-determined degree of separation.

20. The method of claim 19, wherein the adjustment includes manipulating a second spacer.

21. The method of claim 20, wherein each of the spacers is configured for manual substantially vertical adjustment during installation.

22. The method of claim 19, further including the step of injecting a filler to substantially occupy the cavity and the matching cavity following completion of the adjustment of the coupling rod.

23. The method of claim 19, further including the step of extending, prior to the adjustment step, the coupling rod from the cavity into the matching cavity in a telescoping motion.

24. The method of claim 23, wherein the extension of the coupling rod is effected using a flexible snake applied to the coupling rod through a passage configured to permit the flexible snake to push the coupling rod.

25. The method of claim 19, further comprising the step of grouting a bottom surface of the first slab.

26. A method for installing adjacent pavement slabs, the steps of the method comprising:

aligning a cavity terminating in a side of a first slab with a matching cavity terminating in a side of a receiving structure; and

adjusting the position of a coupling rod, the coupling rod being at least partially within the cavity and at least partially within the matching cavity;

wherein—

the adjustment of the position of the coupling rod includes manipulating a spacer to achieve a pre-determined degree of separation from a surface of at least one of the cavity and the matching cavity,

the alignment surface includes a projection and the landmark segment includes a portion of a top surface of one of the first slab and the receiving structure, the manipulating including aligning the projection with the landmark segment to achieve the pre-determined degree of separation.

27. The method of claim 26, further including the step of resting the projection of the spacer on the landmark segment and injecting grout into the cavity.