U.S. patent application number 12/463748 was filed with the patent office on 2009-09-10 for road repair systems.
This patent application is currently assigned to Roads Europe Ltd.. Invention is credited to Mark Richard Jones.
Application Number | 20090226254 12/463748 |
Document ID | / |
Family ID | 9942434 |
Filed Date | 2009-09-10 |
United States Patent
Application |
20090226254 |
Kind Code |
A1 |
Jones; Mark Richard |
September 10, 2009 |
ROAD REPAIR SYSTEMS
Abstract
A range of various sized attachments of infrared heaters powered
by liquid petroleum gas (LPG) for installation to a number of
different styles of vehicles. These infrared heaters are designed
to heat asphalt and other road and structure surfaces for
subsequent repair. The vehicles may be an adaptation to existing
designs of medium to heavy road going flat bed trucks or to various
types of construction loaders. The attachments to construction
loaders may be installed as adaptions to front end loader
quick-change systems or back hoe bucket mount positions. The whole
attachment and its support operating and control assembly may be
easily removed for addition to other vehicles of similar types.
With the area heated to an appropriate temperature to release the
bound surface structure it can then be raked and combined with
minimal amounts of new surface fill if required to the previously
damaged area. A rejuvenating liquid is then sprayed onto the mix,
prior to compaction to provide a fast, economic, quiet and more
environmentally friendly means of road repair than traditional
methodology.
Inventors: |
Jones; Mark Richard; (Lincs,
GB) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST, SUITE 210
PONTIAC
MI
48342
US
|
Assignee: |
Roads Europe Ltd.
|
Family ID: |
9942434 |
Appl. No.: |
12/463748 |
Filed: |
May 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10524678 |
Jan 12, 2006 |
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PCT/EP2003/009144 |
Aug 14, 2003 |
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12463748 |
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Current U.S.
Class: |
404/77 ;
404/95 |
Current CPC
Class: |
E01C 23/14 20130101;
E01C 23/065 20130101 |
Class at
Publication: |
404/77 ;
404/95 |
International
Class: |
E01C 7/06 20060101
E01C007/06; E01C 23/14 20060101 E01C023/14 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 16, 2002 |
GB |
GB 0219088.2 |
Claims
1-20. (canceled)
21. An asphalt surface repair apparatus comprising: a vehicle road
repair system that includes a heating gas source; at least one gas
fired heater carried by the vehicle and adapted to be moved towards
and away from the surface to be repaired comprising: a downwardly
facing metal fabric heater blanket and adapted to face the surface
to be repaired which supplies heat by burning a mixture of
combustible gas and air on the downwardly facing surface; wherein
gas is supplied from the heating gas source and pre-mixed with air
and the mixture is passed through the metal fabric heater blanket
and is ignited on the downwardly facing surface of the blanket
facing the surface to be repaired and a control system is provided
to control the duration of heating to enable re-use of existing
asphalt.
22. An asphalt surface repair apparatus according to claim 21,
wherein the heater is capable of heating the surface to be repaired
to a depth of about 10 mm to about 100 mm to an average temperature
of about 50.degree. C. to about 200.degree. C. for from about 5 to
about 20 minutes.
23. The apparatus of claim 21, wherein the heater is mounted to the
rear portion of the vehicle for pivotal articulation relative to an
adjoining structure of the vehicle for moving the at least one
heater towards and away from the surface to be repaired.
24. The apparatus of claim 21, wherein the control system turning
on and is located on the heater.
25. The apparatus of claim 21, further comprising a sensor for
sensing the distance between the heater and the surface to be
repaired so that the control system activates the heater when the
sensor senses the heater is approximate to the surface to be
repaired.
26. The apparatus of claim 21, wherein the vehicle further
comprises a storage compartment for storing tools and equipment, a
compaction roller, or both.
27. The apparatus of claim 21, wherein the heater is controlled to
produce an infrared output having a medium wave output that
prevents burning of the asphalt surface.
28. The apparatus of claim 21, wherein the vehicle includes a
rejuvenating liquid source a hot new asphalt source and the
rejuvenating liquid source is positioned so that residual heat from
the hot new asphalt source is used to maintain the working
temperature of the rejuvenating liquid.
29. The apparatus of claim 21, wherein the vehicle includes a
column for suspending the at least one heater therefrom such that
the at least one heater may be moved towards and away from the
surface to be repaired.
30. The apparatus according to claim 21, wherein the knitted metal
fabric is of an iron chromium alloy.
31. The apparatus of claim 21 comprising: a vehicle for
transporting the heater and i) the vehicle includes a hot new
asphalt source; ii) the vehicle includes a rejuvenating liquid
source; iii) the vehicle includes a rejuvenating liquid dispenser;
iv) the vehicle includes a controller for controlling an on/off
operation of the at least one heater; v) the apparatus further
comprises a storage compartment for storing tools and equipment and
a compaction roller; and vi) the at least one heater includes a
control system located thereon for independent turning on and
turning off of the at least one heater.
32. A method for repairing an asphalt surface comprising the steps
of: a) heating the surface to be repaired by burning gas on the
downwardly facing surface of one or more knitted metal fabric
infrared heaters adapted to be moved towards and away from the
surface to be repaired, the heating being to a depth of about 10 mm
to about 100 mm from the surface to be repaired, wherein the
average heating temperature is from about 50 to about 200.degree.
C., and the heating is for from about 5 to about 20 minutes; b)
applying a timing control system across the heating cycle to
optimize the penetration of the heat into the asphalt to be
repaired; c) breaking up the heated surface to be repaired by
raking, scarifying, or both; d) compacting the surface to be
repaired; and e) cooling the surface to be repaired to harden the
asphalt.
33. The method of claim 32, wherein a rejuvenating liquid is
applied to the broken-up area.
34. The method of claim 32, further comprising the step of applying
pre-coated chippings on hot rolled asphalt and compacting into the
surface to give road texture.
35. The method of claim 34, further comprising the step of applying
a top coat of a sealer/binder to the surface to be repaired.
36. The method of claim 32, wherein the gas is supplied to a
vaporizer where it is mixed with air and the mixture passed through
the knitted metal fabric and is ignited on the downwardly facing
surface of the knitted metal fabric.
37. The method of claim 32, further comprising the steps of
applying a dusting of fine aggregate to the surface to be repaired
to provide initial skid resistance upon the surface to be repaired.
Description
[0001] The present invention relates to asphalt repair systems and
in particular to systems useful in the repair of roads.
[0002] Asphalt deteriorates because of oxidation and the constant
pounding of traffic, but it is the joints from old repairs that
become the Achilles heel as weather and water ingress and break up
the seal and adjacent asphalt. Considerable sums of money are spent
each year on routine maintenance and repair of carriages and
footways, and the utility companies also spend large sums making
effective repairs after their excavations. Furthermore, roads are
generally deteriorating.
[0003] Bituminous wearing courses such as asphalt are generally
composed of about 94% aggregate (gravel or sand) and about 6%
bitumen binder. The bitumen binder is composed of hydrocarbons and
has ionic properties, which serve to bind the sand and gravel
particles together.
[0004] Wearing courses deteriorate through oxidation of the
bituminous binder. The oxidation process reduces the ionic
properties of the bitumen, which in turn leads to release of the
aggregate. The oxidised binder loses its flexibility and the
surface shrinks and cracks. The effects of traffic and weather
(temperature changes and moisture) speed up this process. After
general release of material larger flaws appear which eventually
turn into potholes.
[0005] The oxidisation process accelerates other damage to the
wearing course and failure of joints especially from conventional
reinstatements, around ironwork and on trenchwork.
[0006] The traditional method for the repair of damaged or aged
asphalt and tarmacadam-wearing courses comprises the total removal
of an area and its replacement with new asphalt. The damaged area
and its surrounds may be removed by using noisy pneumatic or
hydraulic hand held or machine mounted breakers. In this
traditional method it is necessary to use expensive and very noisy
diamond saws to pre-cut the area to minimise additional damage and
to form a face to bond in the replacement material. The areas may
also be removed by more modern methods known as cold planing that
pulverizes the damaged asphalt.
[0007] The area is then filled with new material that then needs to
be compacted and sealed with overbanding or jointing sealant. The
removed asphalt is then transported away for disposal that is
normally for land-fill due to the limitations of current re-cycling
systems.
[0008] These conventional methods are not ideal in respect of
costs, safety, environment, sustainability and durability. Such
methods are described in U.S. Pat. No. 4,534,674 and German Patent
application 3906352 A1.
[0009] More recently Hot In-Place Recycling (HIR) techniques have
been developed for the effective repair of potholes, cracks and
sunken utility cuts in asphalt surfaces using an infrared heating
process. With the surface heated and raked it is then combined with
a rejuvenation liquid that will recycle the existing embrittled
asphalt. This enables a substantial reduction in repair costs. A
typical rejuvenating liquid for use in the method generally
comprises maltenes. Preferred liquids contain an emulsifier, a
heavy paraffinic distillate solvent extract, a heavy naphthenic
distillate solvent extract and water and is described in WO00/20689
optionally with other additives.
[0010] The Infrared HIR method comprises: heating the damaged area
with an infrared heating device; adding new material if required;
raking together; applying a liquid that rejuvenates the original
bitumen; and compacting the new combined material.
[0011] The HIR method can also include applying a topcoating liquid
to the repaired area that seals and binds the repair, or applying a
fine aggregate to provide skid resistance.
[0012] The present invention provides improved equipment for
performing the Infrared HIR techniques described above, comprising
a single vehicle road repair system with means for supplying
infrared heat to the surface to be repaired, means for storing and
supplying hot new asphalt, means for storing and supplying a
rejuvenation liquid, and means for storage and supply of gas for
heating.
[0013] In a first embodiment the vehicle may be a truck, fitted at
the rear with an infrared heater system that is adapted to be moved
towards and away from the surface to be repaired. The flatbed would
have fitted a hot box that contains replacement asphalt if
required, an adjacent tank containing rejuvenation liquid which may
use the hotbox residual heat to maintain a good working
temperature, and preferably a pump and lance for delivery of the
liquid to the desired location. In a preferred embodiment a small
waste container may be provided. A secure area is preferably
provided for hand tools and other equipment such as traffic control
signs, rakes and equipment. A tow bar may be fitted for towing a
trailer-mounted compaction roller.
[0014] In a preferred embodiment the infrared heating system is
hinged so that it may be folded up against the back of the truck
when not in use. It is further preferred that the heater be fitted
with a cover to protect the otherwise exposed heating surface.
[0015] Advantages over an existing vehicle such as the vehicles
manufactured by Ray-Tech Infrared Corp., as shown on their web
site, are:
[0016] 1. Built in tank, pump and delivery system, such as a spray
lance for storage and application of rejuvenation liquid.
[0017] 2. A tow bar for a trailer-mounted compaction roller and a
built in gas tank so avoiding the need for a hydraulic lifting arm
to load and unload the roller and large gas bottles.
[0018] 3. A secure enclosed area, for loose tools and equipment,
typically secured by a lockable sliding curtain securing the front
half of the vehicle's flatbed.
[0019] In a further preferment the heater blanket is made of
Fecralloy.RTM. which heats quickly and cools to ambient in less
than 5 seconds, providing significant safety advantages. The
blanket, whether of Fecralloy.RTM. or another suitable material may
be heated using LPG supplied through a vaporiser system.
[0020] In another embodiment the vehicle may be a tractor backhoe
or wheeled or skid-steer loader to which the equipment may be
quickly installed or removed. The attachment that forms the
infrared heater being fixed to the dipper arm (of a backhoe loader)
or the front loader quick change system (of a skid steer) so that
it may be moved towards and away from the surface to be repaired.
This attachment can also contain the associated gas bottles and
control systems. These control systems are preferably such that
they enable independent on/off control of each burner within the
heater. A separate attachment may be fitted to the rear of the
vehicle containing a hot box for new asphalt, an adjoining tank for
rejuvenation liquid that uses the hotbox residual heat to maintain
a good working temperature, and a spray lance for its application
to the raked area. With this system the area to be repaired may be
heated with the vehicle which is then moved quickly away to a
suitable position, the heated area is then raked so that the
rejuvenating liquid may be delivered to the prepared surface of the
area being repaired, prior to compaction.
[0021] Such attachments for tractor backhoe vehicles are a part of
the present invention.
[0022] The advantages of this invention when used in a skid-steer
solution over existing skid-steer attachments manufactured by
Ray-Tech Infrared Corp. are: [0023] 1. Built in tank, pump and
spray lance for storage and controlled application of warm
rejuvenation liquid. [0024] 2. Built in hotbox to enable
independence from a separate supply of hot asphalt when operating.
[0025] 3. In a preferred system the heater incorporates a more
robust heater blanket of Fecralloy.RTM. which heats quickly and
cools to ambient in less than 5 seconds. This provides significant
safety advantages.
[0026] The invention therefore provides more efficient, compact and
lightweight equipment that enables faster, quieter and more
economic method of repair of a wearing course using Infrared HIR
techniques.
[0027] The heating of the damaged area to be repaired may be
carried out using one or more LPG powered infrared heaters
depending on the size and shape of the area to be repaired. The
heating needs may be to depths of 10 mm to 100 mm from the surface.
The average temperature of the heated material should generally not
exceed 200.degree. C. and may be from 50 to 200.degree. C.,
preferably 100 to 200.degree. C. As with all carbon structures heat
increases oxidation, but since the infrared output of the infrared
attachment is selective at its medium wave output it does not
induce burning (which would destroy the binder's asphaltenes
permanently). The heating time may vary according to its structure
and dependant upon the surface temperature, wind chill factor and
whether the surface is damp, but may for example be from 5 to 20
minutes, typically 6 to 8 minutes.
[0028] Once heated, the damaged area is raked or scarified to mix
the highly oxidised top surface with the less oxidised sub-strata.
This also increases the surface area of the mix. Care must be taken
to leave an outer perimeter of the heated area unraked to allow
development of an efficient bonded joint when compacted.
[0029] The rejuvenating liquid may then be applied using the lance
provided. The composition of the rejuvenating liquid comprises
rejuvenating oils high in aromatics with high levels of polar
compounds. The oils in the rejuvenating liquid are preferably
emulsified with cationic slow set emulsifiers at higher than normal
levels to ensure not only a very storable and stable emulsion but
also to aid in a slow cure and break time.
[0030] The rejuvenating liquid preferably contains from 30 to 80
parts by weight in total of a heavy paraffin distillation solvent
extract and a heavy naphthenic distillate solvent extract, from 10
to 60 parts by weight of water, and from 1 to 5 parts by weight of
the emulsifier. More preferably, the liquid comprises from 60 to 65
parts by weight in total of the heavy paraffinic distillate solvent
extract and the heavy naphthenic distillate solvent extract, from
30 to 35 parts by weight of water and from 1 to 5 parts by weight
of the emulsifier.
[0031] New material may be needed if it is required to level the
patch to be repaired, i.e., the amount of material that has been
worn out of the surface. The material may also assist in knitting
of the joint. On hot rolled asphalt, precoated chippings are added
and compacted into the surface to give road texture. The material
is generally raked level and then compacted either by a vibrating
roller or compaction plate. A topcoat of a sealer/binder may also
be applied, or a dusting of fine aggregate (e.g. aluminium
silicate) may be added to ensure good initial skid resistance. Once
the surface has cooled and hardened, normally for a minimum of one
hour, it is capable of accepting traffic.
[0032] The advantages to using the apparatus of the present
invention over traditional methods are: [0033] 1. Reduced asphalt
costs since only material lost as a result of the damage is added:
in the conventional method it is also necessary to replace material
that is removed from around and beneath the damaged area.
Substantial cost savings arise due to avoiding the need to
transport the removed asphalt to land fill with its additional
charges. [0034] 2. The resulting repair is fully bonded with the
existing material by means of heat fusion. This eliminates or
reduces the problems of joint failures and the problem of `cold
shock` that occurs in the conventional method when hot sealant or
new material is added to cold asphalt to join the new material to
the old material. There is no pre-cutting of an edge to the old
surface, no need for any kind of overbanding or joint sealing
(notoriously short-lived), and no mixing of materials with
different expansion and contraction rates next to each other.
Furthermore, when the application of the topcoating is included in
the method of the invention, the surface is further bonded. [0035]
3. By recycling the existing surface there is far less new material
used, the process is very quiet, and its speed enables the roads to
be opened up far more quickly than would normally be the case. Due
to the lack of noise, roads may be repaired at night while traffic
is at its lightest with less disturbance to residents. [0036] 4.
This method of repair also eliminates the problems of `white
finger` caused by pneumatic and hydraulic hand held breakers, which
is a major problem to the construction industry, causing added
costs to all concerned. [0037] 5. Some 94% of the wearing course is
rock or sand and has an extremely long lifetime of many decades. Of
the 6% of the wearing course that is binder, only a small fraction
is degraded and the remainder (the predominant compounds being
asphaltenes) has a very long life span. By replacing only the
fraction of the aromatic oil component that is lost, the total
combined method of the invention is highly efficient in material
terms, and as a result effectively recreates the hydrocarbon
chain.
[0038] The invention is illustrated by reference to the
accompanying drawings in which:
[0039] FIG. 1 shows an apparatus consisting of a vehicle 1 to which
is attached a hot box 2 at the front of the vehicle and at the back
there is a dipper arm to which is attached a bank of infrared
heaters 3 in a manner that may be moved up and down towards the
road surface to heat the areas to be repaired.
[0040] FIG. 2 shows the composition of the hot box used in FIG. 1
showing compartments 4 and 5 for the rejuvenating liquid and a pipe
6, connected at one end to a pump 7 and at the other end to a lance
8 to provide the delivery system for the rejuvenating liquid.
[0041] FIG. 3 shows the attachment to the dipper arm 9 of the
vehicle of FIG. 1 on which are mounted the infrared heaters 10. The
attachment is also provided with an ON/OFF Sensor 11 so that the
heating can be controlled by the proximity to the road surface.
[0042] FIG. 4 shows a truck 12 according to the present invention
provided at the back with a bank of infrared heaters 13 which are
hinged so that they can be stored against the back of the truck
when not in use as shown in FIG. 4. The truck is also provided with
hot box and compartment 14 for the rejuvenating liquid and a pump
15, pipe 16 and lance 17 for delivery of the liquid. The truck may
also be provided with other compartments for example those shown at
18 and 19 for the storage of other useful equipment.
[0043] FIG. 5 is a plan view of the truck of FIG. 4 showing the
bank of infrared heaters moved downwards to be parallel to the road
in their operating mode.
[0044] FIG. 6 is a plan view of a preferred burner system which may
be used with the apparatus shown in FIGS. 1 to 3. FIG. 6 shows two
pairs of burners 20 and 21 mounted in an angle frame which is
preferably of steel. Four gas bottles 22 to 25 are located within
the assembly and the complete assembly is suspended from a central
column 26.
[0045] FIG. 7 is a side view showing how the gas bottles may be
mounted and held securely within the supporting frame 27 by
stirrups 28 and 29 which may conveniently be of the type used for
cargo restraint.
[0046] FIG. 8 shows how doors 30 and 31 may be provided (shown in
the open position in FIG. 8) for safety and security purposes. FIG.
8 also shows in more detail the central column which may be used to
suspend the heater assembly including a spherical plain thrust
bearing 32 which is tensioned with a compression spring 33 which
can act as a shock absorber.
[0047] In the operation of both systems illustrated, the damaged
area to be repaired is heated by the infrared system attached to
the vehicle, after which the area is then raked. The pump may then
be activated to deliver the rejuvenating liquid. The mix of heated
original asphalt plus new material if required may then be further
raked before being compacted by a vibrating roller or compaction
plate. Once leveled to the original surface profile it is ready to
accept traffic.
* * * * *