U.S. patent application number 11/670538 was filed with the patent office on 2008-08-07 for method of making an asphalt coating.
Invention is credited to John Joseph Lombard.
Application Number | 20080184661 11/670538 |
Document ID | / |
Family ID | 39671592 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080184661 |
Kind Code |
A1 |
Lombard; John Joseph |
August 7, 2008 |
METHOD OF MAKING AN ASPHALT COATING
Abstract
The present invention involves the recycling of asphalt based
roofing materials by comminuting the roofing material and
subsequently separating a rock component from an asphalt component
of the roofing material. The asphaltic component is separated into
a feed stream having a mesh size of less than about 50 mesh while
the rock component is separated into a feed stream having rocks in
the size of 10 mesh or larger. A portion of the comminuted material
may be recycled back for additional comminuting. The separated
asphaltic component is placed in contact with the solvent to
dissolve the asphalt in the asphaltic component providing a mixture
of filler, fiber and dissolved asphalt. The liquid may then be
applied to a surface of a wall to form a substantially continuous
solidified film on the wall to provide waterproofing and an air
barrier.
Inventors: |
Lombard; John Joseph; (St.
Louis, MO) |
Correspondence
Address: |
HUSCH BLACKWELL SANDERS LLP
720 OLIVE STREET, SUITE 2400
ST. LOUIS
MO
63101
US
|
Family ID: |
39671592 |
Appl. No.: |
11/670538 |
Filed: |
February 2, 2007 |
Current U.S.
Class: |
52/745.19 ;
52/515; 52/741.4 |
Current CPC
Class: |
E04D 7/00 20130101; C09D
195/00 20130101; C08J 3/02 20130101; C08J 2395/00 20130101 |
Class at
Publication: |
52/745.19 ;
52/741.4; 52/515 |
International
Class: |
E04F 21/02 20060101
E04F021/02 |
Claims
1. A method of applying an asphalt coating: a) comminuting roofing
material containing asphalt and rock particles; b) separating rock
from the comminuted roofing material to provide an asphaltic
component containing less than about 20% by weight rock larger than
about 10 mesh in size; c) forming said asphaltic component into a
liquid material; and d) applying the liquid material to a surface
to form a substantially continuous water resistant coating.
2. The method of claim 1 wherein the asphaltic component containing
less than about 10% by weight of rock larger than about 10 mesh in
size and said asphaltic component containing fibrous filler.
3. The method of claim 2 wherein the asphaltic component being in
particulate form with at least about 80% by weight being of a mesh
size of less than about 50 mesh prior to forming the liquid
material therewith.
4. The method of claim 3 wherein the liquid is formed by dissolving
an asphalt portion of the asphaltic component with solvent.
5. The method of claim 4 wherein the solvent including at least one
of kerosene, biodiesel and naptha.
6. The method of claim 4 wherein the applying of the liquid
material being by at least one of spraying, rolling or
brushing.
7. The method of claim 1 wherein the comminuting is done at least
partially by grinding with a hammermill.
8. The method of claim 7 wherein the hammermill having a plurality
of output streams including first and second output streams, at
least one of the output streams being separated into an asphalt
component stream and a rock component stream.
9. The method of claim 8 wherein the first output stream being a
return stream and the method further including returning the first
output stream to the comminuting step.
10. The method of claim 9 wherein the second stream including
asphaltic component and rock, and the method further including
separating the rock from the asphaltic component with the separated
asphalt component having a mesh size of less than about 50.
11. The method of claim 10 wherein the plurality of output streams
including a third output stream including asphaltic component fines
removed by an air stream.
12. The method of claim 11 wherein the asphaltic component after
the separating step including fibers, mineral filler and
asphalt.
13. The method of claim 12 wherein the liquid being applied to a
concrete wall surface.
14. The method of claim 12 wherein the liquid being applied to a
polymeric foam/concrete composite wall surface.
15. The method of claim 14 wherein liquid contacting the polymeric
foam.
16. The method of claim 15 wherein the composite wall being a
building wall above grade.
17. The method of claim 3 wherein the liquid is formed by heating
the asphaltic component.
18. The method of claim 17 wherein the liquid asphaltic component
is applied to a roof to form the coating.
19. The method of claim 18 wherein at least a portion of the
separated rock is applied to the coating for adhesion to the
coating.
20. A method of building a structural exterior wall, said method
comprising: forming a wall at least partially of cast concrete,
said wall having an exterior surface; forming a liquid of ground
asphaltic roofing material by comminuting shingle material and
separating a rock component from an asphaltic component, said
asphaltic component having less than about 20% by weight rock
component, and dissolving the asphaltic component in an organic
solvent to form the liquid; applying a coating of the liquid to an
exterior surface of the wall; and allowing the coating to solidify
on the surface as a substantially continuous film.
21. A liquid coating material comprising: asphalt derived from
comminuted roofing material; an organic solvent in an amount
sufficient to make a liquid of the asphalt and solvent wherein
substantially all of the asphalt is in solution, said solution
having viscosity adequate for applying a coating to a surface that
when solidified forms a water impermeable substantially continuous
film; and fibers derived from the comminuted roofing material.
Description
BACKGROUND OF THE INVENTION
[0001] According to one report, Performance of Recycled Shingles
for Road Applications, Grodinsky, et al, September 2002, there are
approximately 7-9 million tons of old asphalt shingles removed from
existing buildings. Additionally, there are approximately 1/2-1
million tons of factory rejects and tab cut-outs generated each
year. An asphalt shingle can contain between 15-35%, by total
weight of shingle, asphalt in the asphaltic component. The
asphaltic component can also include fibrous material and mineral
filler.
[0002] There have been many attempts to utilize these scrap
shingles as a source of asphalt for road patch and driveway repair
materials. However, these attempts have met with varying degrees of
success. A shingle, may vary widely in composition and the asphalt
may also vary in composition. A shingle, by weight of shingle, may
have 15-35% asphalt, 5-15% felt, and 10-20% mineral filler in the
asphaltic component and 30-50% mineral granules as a coating on the
asphaltic component. The felt may be of an organic material and/or
fiberglass. One type of asphalt may be used to impregnate the felt
while another type may be used to coat the impregnated felt. The
filler may be powdered limestone. After making the felt base, one
side of the shingle, or a portion thereof, may be coated with the
mineral granules in the form of crushed rock that may be coated
with a paint or other colorant for color purposes.
[0003] In order to recycle a shingle, the shingle is first ground.
When the recycled shingle material is used for road patch, the
shingle may be entirely used in the road patch composition since
the road patch would normally contain rock and other particulate
fillers with the fibrous part not posing significant problems to
its use as a road patch material that could be described as a
highly viscous paste composite with the asphalt binding aggregate
rock together. The ground up shingles may also be used as an
additive to virgin asphalt based road material so long as its
weight percent in the mixture of asphalt material and recycle
materials doesn't exceed a certain upper limit, for example, about
5% by weight.
[0004] Some of the attempts to recycle shingles may be found
discussed in U.S. Pat. Nos. 5,340,391, 4,706,893, 6,588,973 and
5,938,130.
[0005] While the above patents disclose how to recycle asphalt
shingles for road materials, there is no disclosure on how to
produce a liquid coating using the asphalt from recycled shingles
for use as a water proofing and/or air flow barrier material that
can be applied in liquid form to form a continuous thin coating on
a surface such as a wall or roof surface.
[0006] There is thus a need for an improved method of recycling
shingles, or other roofing material, to produce a liquid coating
for cold or hot application.
SUMMARY OF THE INVENTION
[0007] The present invention involves the provision of a method of
coating a surface, for example a roof or a wall to form a
substantially continuous water and wind resistant coating. The
coating is asphalt based. The asphalt is derived from recycled
roofing material such as shingles. The shingle feed material is
comminuted to form particles. The particles will contain the
constituants of the roofing material and when rock granules are
included in the roofing material, the rock granules are separated
from the comminuted material. The asphalt based component of the
shingles is ground to a size of about 50 mesh or smaller. A portion
of the asphaltic material may be removed from the comminuting
device with an air flow filter system while the remainder of the
asphaltic material may be separated from the totality of the
roofing material by a physical separation method for example,
screening. Once the proper size particles are obtained, the
asphaltic particles are formed into a liquid as by dissolution or
heating. Large particles may be recycled back to the comminuting
device for further processing. The liquefied asphalt based material
may include the fibrous material included in the roofing material
for example, fiberglass and/or cellulous based fiber material. The
liquid asphaltic material containing the asphalt may then be
applied to a surface as by mopping, brushing, rolling or spraying.
The viscosity of the applied coating increases to form a permanent
bonded continuous and substantially water and air impermeable
coating on the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic illustration of a roofing material
reprocessing line.
[0009] FIG. 2 is a perspective view of one form of shingle.
[0010] FIG. 3 is a recycling process flow chart.
DETAILED DESCRIPTION
[0011] The reference numeral 1 designates generally a schematic
apparatus for processing asphalt based roofing materials such as
shingles and/or roofing felt into a liquid coating composition for
use in applying to surfaces of walls or the like to provide
waterproofing and/or an airflow barrier. Generally, the apparatus 1
includes the use of an infeed transfer device designated generally
3 that feeds roofing material segments 4 such as asphalt based
shingles into a comminuting device 6. The comminuting device 6 is
operable for reducing the infeed materials into particles. The
particles from the comminuter 6 are separated by a separator 8 into
at least two output streams 12, 14, one principally containing the
asphaltic material and one principally containing the rock or
granule material contained in the roofing material. The separator 8
may also provide a third output stream 10 which would include those
particles too large for further use. The material in the third
output stream may be returned for further comminuting via a
suitable transfer system for additional comminuting. The separator
8 is operable to separate its input into at least two output
streams, one being the waste rock stream 12 and the other being the
stream 14 of the asphalt based material containing suspended solids
like filler and fibers (asphaltic material or component). A fines
extractor 16 is provided that is operable for extracting fines such
as fugitive dust size particles from portions of the apparatus 1 to
provide an output stream 18. The output streams 14, 18 can be
combined and liquefied as by dissolving in a device 20 by the
addition of a suitable solvent from a solvent container 22 to form
an asphalt based liquid. The streams 14, 18 may also be heated to
form a liquid as more fully discussed below. The dissolved material
is fed via an output stream 24 to a packaging line designated
generally 26 for dispensing the liquefied asphalt based material
into containers 28. The containers 28 may then be transferred to a
worksite 27 where the liquefied asphalt material is applied to a
wall 30 or the like to form a substantially continuous coating when
the liquefied material solidifies. The liquefied material may be
applied cold (ambient temperature) by spraying, brushing, rolling
or the like.
[0012] The infeed device 3 may be a vibratory conveyor. The infeed
device 3 preferably feeds the roofing material components 4 in a
relatively steady stream preferably at a throughput rate to not
overload the comminuter 6. Other forms of infeed devices may be
used instead of a vibratory conveyor. Further, additional infeed
devices 3 may be used. The use of a vibratory infeed device helps
keep the roofing material segments 4 separate during conveying and
discharge into the comminuter 6.
[0013] Preferred roofing material components 4 are shingles that
include an asphaltic component 29 that includes asphalt 31 that is
impregnated into and coats reinforcement 32. The reinforcement 32
may be a fibrous cellulous based paper or felt type material,
fiberglass mats or the like. Shingles typically have a rock
aggregate 33 component on a portion of one surface 34 of the
asphaltic component 29. The rock aggregate 33 may comprise up to
about 50% by weight of the roofing material components. The
reinforcement material 32 within the asphaltic component 29 can
comprise up to about 20% of the roofing material components by
weight. It is preferred that aged roofing material pieces be used
since they are more brittle and easier to comminute as by
mechanical grinding. The asphaltic component 29 may also include
filler material up to about 20% by weight which may be a mineral
such as powdered limestone or the like. Used shingles will have
typically become degraded during their life making them hard and
brittle. The degradation may occur by oxidation of the asphalt 31,
the loss of volatile light organic materials that were included in
the original asphalt 31, and may be degraded by ultraviolet light.
The asphalt 31 will thus vary in composition from aging and by
supplier and original composition. The asphalt 31 in shingles can
be in the range of between about 15-35% by total weight of the
roofing material components. While the included description is
directed to the use of asphalt shingles with rock aggregate, it is
to be understood that other asphalt based materials may be
included, for example, what is commonly referred to as roofing felt
or tar paper so long as there is sufficient asphalt contained in
the product which when combined with all products being processed
together, contains enough asphalt by weight to make a liquid for
coating walls or the like. Generally, the asphalt 31 component will
be approximately 50% by total weight of the asphaltic component 29
including the asphalt 31, reinforcement 32 and filler.
[0014] The comminuting device 6 is operable to grind the incoming
roofing material 4. Preferably, the comminuter 6 is a hammermill. A
suitable hammermill used had a 24 inch throat and a cylinder
diameter of 22 inches. This hammermill was operated at 2,000 rpm
and provided effective grinding of the incoming roofing material
segments 4. Other hammermills or types of grinders may be used. In
a preferred embodiment, the hammermill has an inlet throat 42 with
an infeed angle A for the plate forming the throat of at least
about 65 degrees from horizontal as seen in FIG. 1. This angle has
been found to provide good infeed of the roofing material segments
4 without hanging up in the throat 42. The infeed rate of roofing
material segments 4 will be determined by the size of the
hammermill and the desired output particle size and whether or not
multiple hammermills or other grinders will be used in sequence.
The comminuting device 6 has at least one output stream 45 from
feed device 44 which may be in the form of a bottom screw conveyor
or conveyor belt. Preferably the output stream 45 from feed device
44 is enclosed to prevent the escape of fugitive dust particles.
Preferably, the comminuter 6 and the feed device 44 are also
enclosed and operate under negative pressure via the fines
extractor device 16 for the extraction of the fines by air flow.
The extracted fines may be fed via the discharge 18 to the
dissolution apparatus 20. The fines extractor 16 may be a bag
filter or the like and its discharge 18 may also be a screw
conveyor or a belt conveyor preferably enclosed to reduce the
amount of dust emitted from the apparatus 1 used to conduct the
recycling process.
[0015] The separator 8 receives materials from the feed device 44
for separation into at least two streams and preferably at least
three streams. A first stream 12 from a discharge of separator 8 is
fed to a collection apparatus 46. The collection apparatus 46 is
operable for receiving the rock or grit component separated from
the asphaltic component 29 of the roofing material segments 4. The
separator 8 is preferably a screen separator although other types
of separating devices may be used, for example, centrifugal
separators or the like. The separator 8 separates particles of
about 10 mesh or larger and discharges those to the collector 46.
The output discharge stream 14 is preferably particles having a
mesh size of about 50 or less. Typically these latter smaller
particles will include the asphaltic component of the roofing
material segment 4. The fraction of particles between those
separated by the separator 8 to be discharged into streams 12 and
14 can be extracted and fed through a return conveyor device 10 for
subsequent comminuting in the device 6 if desired or treated as a
waste stream. Additionally, any very large particles that happen to
have been transferred to the separator 8 may also be discharged
back for subsequent comminuting via the discharge conveyor system
10. The rock collected at the collector 46 may be used for any
suitable purpose such as an aggregate in asphalt based road
material as is or may be subsequently ground as desired.
[0016] The asphaltic component 29 particles as derived from the
roofing material segments 4, from the fines extractor 16 and the
separator 8 may be combined and fed to an apparatus 20 for
dissolving the asphalt in the asphaltic component. The asphaltic
component 29 will contain the fine mineral filler if any is
present, which may be ground limestone, and the felt or fiberglass
material now in comminuted form and contained within the particles
of the asphaltic component 29. The dissolving of the asphalt in the
asphaltic component may be either done on a batch basis or a
continuous basis. By knowing the amount of asphalt 31 contained
within the asphaltic component 29 and the desired viscosity of the
coating material, the correct amount of solvent can be provided to
both dissolve the asphalt in the asphaltic component and provide a
predetermined viscosity in the liquid coating material. If desired,
once the asphalt 31 is dissolved, filtering of the liquified
asphaltic component may be effected to separate out some of the
fibrous component 32 from either the cellulose felt and/or
fiberglass mat. However, it has been found that by maintaining the
particle size as fed to the dissolution step below a maximum, the
fiber content in the liquid has not been a problem in making or
using the coating material. The fibers can be used as a bulk filler
or reinforcement in the coating and the filler material contained
within the asphaltic component 29 can be a bulk filler without
adversely affecting the functionality of the coating material or
the functionality of the solidified coating 55.
[0017] Preferred solvents are organic solvents and more preferably,
aromatic organic solvents. Such solvents can include naptha,
biodiesel and/or kerosene. The proper solvent will be determined by
both its ability to dissolve the asphalt in the asphaltic
component, and its appropriateness for release from the coating as
a volatile once it is applied. The solvent may also affect the
quality of the hardened or solidified coating to form a
substantially continuous film or membrane 55 coated on a surface 50
of a wall 30 or the like. Additionally, the solvent needs to be
acceptable for use at a particular type of worksite, be it an
inside site or an outside site. The amount of solvent is added as
needed, to provide the correct viscosity of the coating material to
be produced. If desired, a filtration device may be provided to
filter particulates such as rock, fiber or undissolved particles of
asphalt from the dissolved asphalt material or coating prior to its
being packaged in containers 28. The filtered particulates may be
returned for additional dissolving or may be a waste stream from
the process. The containerized coating material may then be stored
and/or shipped prior to use.
[0018] In use, the liquid coating material may be applied to a
surface 50 of a wall 30 that may be generally, vertically disposed.
Such walls 30 may include a poured or cast concrete wall or may be
a composite wall comprising a polymeric foam material 51, e.g.,
polystyrene foam, in combination with a concrete matrix or core 52
used to rigidify or reinforce the polymeric foam forms. Wall
construction is now being done with polymeric foam materials that
are used to form a wall precursor and cement paste is added to the
hollow spaces within the foam material to provide structural
rigidity and weight. Both cast concrete and foam walls may provide
leakage points, absorption, or porosity such that wind and water
may be drawn into or pass through the wall as by high winds, other
forms of pressure differentials, capillary action, and the like.
For example, home walls are being built now using the composite
concrete and foam forms and when these unfinished walls are coated
with an exterior coating, for example, stucco or the like, damage
may be done to the foam allowing water to migrate into the concrete
portion where mildew or other biological processes can occur. By
applying a substantially continuous film 55 of the coating material
to the exterior and then applying the wire mesh for stucco
adhesion, it has been found, that the water resistance of the foam
portion may be greatly increased. In fact, it has been surprisingly
found that the application of the above described coating, can pass
a standard water non-permeability test for waterproofing and wind
proofing for 14 days when the test only requires resistance for one
hour. Additionally, no problems have been encountered by adding the
metal mesh to the exterior of the asphalt coating for the
application of stucco or the like to the exterior wall surface 50.
Additionally, concrete walls may be coated, as is done today with
an asphalt based coating, particularly in those areas below grade
to provide waterproofing of concrete walls. Concrete walls are
prone to absorbing and maintaining high levels of water which can
be reduced by the application of the coating of the present
invention. The coating may be applied by pressurized spraying,
rolling as with a roller applicator or brushing as with a bristle
brush, mop or the like. The coating is then allowed to harden or
solidify.
[0019] A preferred viscosity of the coating is determined by
application method and conditions. It is preferred that the coating
have at least about 50% by weight asphalt before application and
more preferably at least 60% by weight asphalt after coating
application and solidifying. It is preferred that the coating be a
substantially continuous impermeable film after hardening. The
thickness of the coating is preferably in the range of between
about 1/16'' and about 3/8'' and more preferably in the range
between about 1/8'' and about 1/4''. The liquid coating or asphalt
stream 14 and fines 18 may also be used to make asphalt based road
material where the asphalt will coat and bind aggregate.
[0020] The process, is shown schematically in FIG. 3. The process
includes feeding 60 roofing materials 4 for comminuting 62 in a
suitable device 6 such as a hammermill. The comminuted materials
are fed to a device 8 for separating 63 the comminuted materials
into at least two streams when the roofing material includes rock
aggregate 33. The separation 63 separates the comminuted material
into a rock output stream 12 an asphaltic material stream 14 and
regrind coarse stream 10. Fines 18 may also be collected in the
comminuting step 62. The fines may include a significant portion of
asphalt. The asphalt stream 14 and fines 18 are fed for dissolving
67. Solvent is added 68 in a type and an amount to dissolve at
least substantially all of the asphalt material fed to the
dissolving step 67. The viscosity of the dissolved material and
solvent is selected for a particular type of coating wall to be
coated and the application method such as spraying, rolling or
brushing. An optional filtering 69 may be done on the coating
material from the dissolving step 67 if desired. The filtered out
material 70 at the filtering step 69 may be passed back to the
dissolving step 67 or to the comminuting step 62 depending upon
what is filtered out in the filtering step 69. The dissolved
coating material after filtering, can go to a packaging step 71 for
placing the dissolved materials (liquid coating material) in a
condition for storage and/or shipping after the packaging step 71,
the coating material is ready for application. A wall 30 is formed
72, and then coated 73 by spraying, brushing, rolling or the like
as discussed above. After coating 73, the coating material is
allowed to harden or solidify 74 as desired for the particular
application and wall construction. Typically, the solidified
coating 55 is then covered 74 as for example with a finish material
like stucco. Below grade, the solidified coating can be covered as
with back fill. The strength of the bond between the coating
material and the wall is such as to maintain the integrity of the
bond between the coating and the wall after back filling or other
covering as for example the application of the stucco or
siding.
[0021] In the forming of a building or a portion of a building, a
wall 30 and/or roof 80 are formed. The wall 30 and/or roof 80 will
have at least one exposed surface 50, 84 respectively. Preferably,
the liquid coating material of the present invention is
particularly useful for surfaces that are generally vertical. After
forming the wall, either by casting cement paste or by forming a
foam concrete composite wall or other type of wall, including wood
materials, the liquid coating of the present invention is applied
to one or more surfaces that need a waterproof or wind proof
barrier. The applied coating forms a substantially and continuous
and impermeable layer after the coating hardens. Hardening can be
by loss of the solvent material (or cooling as described below).
After the coating hardens, other coating or materials may be
applied, for example wire mesh followed by a stucco coating. For
below grade application, after the coating hardens or solidifies,
the excavation may be backfilled as disclosed. Preferably, the
surfaces to be coated are exterior surfaces however it is to be
understood that interior surfaces may be coated as well.
[0022] In a preferred embodiment, the asphalt component prior to
forming a liquid contains less than about 20% by weight rock larger
than about 10 mesh in size after the asphaltic component and the
rock component are separated from one another. More preferably, the
asphaltic component contains less than about 10% by weight of lock
larger than about 10 mesh. The asphaltic component 29 after
separation from the rock component is in particulate form with at
least about 80% by weight of the asphaltic component being of the
mesh size less than about 50 mesh prior to forming a liquid with
the asphalt component and more preferably less than about 10% by
weight.
[0023] Preferably, the liquid asphalt of the present invention, as
applied, is at least about 75%, more preferably at least about 80%
and most preferably at least about 90% by weight recycled asphalt
31.
[0024] FIGS. 1 and 3 show an alternate embodiment of the present
invention in broken lines to make a built-up roof. The streams 14,
18, instead of going to a dissolving 67 apparatus 26, may be
transferred after packaging 81 in ground form for liquefying by
heat 82 from heater 83. This alternate embodiment is particularly
well adapted for applying asphalt to a surface 84 of a roof 80
although other forms of surfaces such as the wall surface 50 may
also have a hot asphalt applied coating 87 applied thereto by an
applicator 89 such as a mop or sprayer. In addition to using the
recycled asphaltic component 29 with its fibrous filler and mineral
filler, the separated granules 33 may also be utilized for the
roofing coating 87. In the application of asphalt on a roof 80,
cover sections 88 such as plies or membranes of roofing material
are applied to the roof 80 with overlapping seam portions 90 as is
known in the art. The asphaltic material 29 is heated membranes 82
and applied 97, as by mopping onto the cover sections 88 and is
used to adhere overlapping portions of the cover sections 88
together at the seam portions 90. It has been found, that the use
of the present recycled asphaltic material 31, can be liquefied at
a temperature significantly less than the temperature of currently
applied roofing asphalt materials. The recycled asphalt can be
liquefied at a temperature of approximately 325.degree. F. to make
a flowable material while currently used asphalt requires a
temperature of approximately 375.degree. F. to make the asphalt
material flowable providing a method requiring less energy input
and lower temperatures with resulting safer working conditions
because of the lower temperature. Additionally, the coating 87
stays liquid longer and at a lower temperature for adhesion to
later applied rock granules. Typically, a roof has two applied
coatings of asphalt material, a first one to seal the cover and
provide a first coating. A second coating is then typically applied
onto which is applied 98 a coating of rock granules. The rock
granules can include, for example, aggregate such as pea gravel or
the like, and may be applied either individually or in combination
with the granule material 33. The total coating with rock may be 12
inch thick or thicker for a built-up roof. The rock granules can
include the separated granules 33 providing a recycle stream for
those granules which have been typically used as a filler in prior
art processes for making road patch material. The rock coated
asphalt is then allowed to solidify 100 by cooling adhering the
rock to the coating 87. The present invention permits the
utilization of the recycled asphalt at a high concentration as
discussed above, including a 100% recycled asphalt content.
Additionally, the contained fibrous material i.e., the felt and/or
fiberglass, may also be utilized in the coating material.
[0025] Thus, there has been shown and described several embodiments
of a novel invention. As is evident from the foregoing description,
certain aspects of the present invention are not limited by the
particular details of the examples illustrated herein, and it is
therefore contemplated that other modifications and applications,
or equivalents thereof, will occur to those skilled in the art. The
terms "having" and "including" and similar terms as used in the
foregoing specification are used in the sense of "optional" or "may
include" and not as "required". Many changes, modifications,
variations and other uses and applications of the present invention
will, however, become apparent to those skilled in the art after
considering the specification and the accompanying drawings. All
such changes, modifications, variations and other uses and
applications which do not depart from the spirit and scope of the
invention are deemed to be covered by the invention which is
limited only by the claims which follow.
* * * * *