U.S. patent application number 12/661976 was filed with the patent office on 2011-03-17 for reinforced pervious concrete.
Invention is credited to Jon Dennis Sader.
Application Number | 20110064517 12/661976 |
Document ID | / |
Family ID | 42781349 |
Filed Date | 2011-03-17 |
United States Patent
Application |
20110064517 |
Kind Code |
A1 |
Sader; Jon Dennis |
March 17, 2011 |
Reinforced pervious concrete
Abstract
A pavement such as a road, driveway, sidewalk, parking lot or
the like, formed with pervious concrete material and one or more
basalt reinforcing members embedded in or positioned below the
pervious concrete material. The one or more basalt reinforcing
members add structural rigidity to the pervious concrete, making
the pervious concrete capable or supporting loads as normally
experienced on pavements. The one or more basalt reinforcing
members may be basalt rebar rods, or basalt rebar rods having a
Figure-Eight shape, or a mesh made of basalt strands. In one
example, the pavement may also include a layer of filtration fabric
positioned below the basalt reinforcing members. Various methods
are described for forming pavements, roads, driveways, sidewalks,
parking lots or the like. Such a pavement allows water or moisture
to pass through the surface of the pavement and be filtered. Such a
pavement reduces flooding and the need for complex storm drainage
systems adjacent to the pavement.
Inventors: |
Sader; Jon Dennis;
(Franklin, MI) |
Family ID: |
42781349 |
Appl. No.: |
12/661976 |
Filed: |
March 25, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61211396 |
Mar 25, 2009 |
|
|
|
Current U.S.
Class: |
404/28 ;
404/82 |
Current CPC
Class: |
E01C 7/142 20130101;
Y02A 10/30 20180101; E01C 11/226 20130101; E01C 7/145 20130101;
Y02A 30/32 20180101; Y02A 10/395 20180101; Y02A 30/30 20180101 |
Class at
Publication: |
404/28 ;
404/82 |
International
Class: |
E01C 5/12 20060101
E01C005/12; E01C 19/00 20060101 E01C019/00 |
Claims
1. A pavement, comprising: pervious concrete material; and one or
more basalt reinforcing members embedded in the pervious concrete
material.
2. The pavement of claim 1, wherein the one or more basalt
reinforcing members are basalt rebar rods.
3. The pavement of claim 1, wherein the one or more basalt
reinforcing members are basalt rebar rods having a Figure-Eight
shape.
4. The pavement of claim 1, wherein the one or more basalt
reinforcing members are a mesh made of basalt strands.
5. The pavement of claim 1, further comprising a layer of
filtration fabric positioned below the basalt reinforcing
members.
6. The pavement of claim 1, further comprising: a compacted soil
layer; a layer of filtration fabric positioned above the compacted
soil layer; and a layer of course aggregate material positioned
above the layer of filtration fabric.
7. The pavement of claim 6, wherein the one or more basalt
reinforcing members are positioned above the layer of course
aggregate material.
8. The pavement of claim 7, wherein the pervious concrete material
forms the upper surface of the pavement.
9. The pavement of claim 1, wherein the one or more basalt
reinforcing members are positioned approximately two inches or more
above the bottom of the pervious concrete material.
10. The pavement of claim 1, wherein the pavement is a road.
11. The pavement of claim 1, wherein the pavement is a parking
lot.
12. The pavement of claim 1, wherein the pavement is a
driveway.
13. The pavement of claim 1, wherein the pavement is a
sidewalk.
14. A method for forming a road, comprising: compacting a sub-base
layer; installing a filtration fabric above the sub-base layer;
installing a layer of aggregate material above the filtration
fabric; positioning one or more basalt rebar reinforcement members
above the layer of aggregate material; and pouring a layer of wet
pervious concrete material above the one or more basalt rebar
reinforcement members.
15. The method of claim 14, further comprising: leveling said layer
of wet pervious concrete; and compacting said layer of wet pervious
concrete.
16. The method of claim 14, further comprising curing said layer of
pervious concrete.
17. The method of claim 14, wherein the operation of positioning
one or more basalt rebar reinforcement members further comprises:
placing the one or more basalt rebar reinforcement members
approximately two or more inches above the layer of aggregate
material.
18. The method of claim 14, wherein the pouring operation includes
pouring a portion of said wet pervious concrete material below the
one or more basalt rebar reinforcement members, so that the wet
pervious concrete material embeds the one or more basalt rebar
reinforcement members.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit under 35
U.S.C. 119(e) to U.S. Provisional Patent Application No. 61/211,396
entitled "Reinforced Pervious Concrete" filed Mar. 25, 2009, the
disclosure of which is hereby incorporated by reference in its
entirety.
FIELD OF THE INVENTION
[0002] This invention relates to, in general, concrete for use in
surfaces or pavements such as roads, sidewalks, driveways, bridges,
and the like.
BACKGROUND
[0003] For decades, during significant rainstorms or snowmelt,
cities and towns have experienced flooding of roads, streets,
parking lots, etc. As recognized by the present inventor, what is
needed is a new concrete structure that can be used to build roads,
streets and other concrete structures while reducing flooding
risks.
SUMMARY
[0004] In light of the above and according to one broad aspect of
one embodiment of the invention, disclosed herein are new methods
and structures for forming concrete structures that can be used to
make roads, sidewalks and other pavements or infrastructures.
Specifically, embodiments of the invention utilize pervious
concrete material with basalt reinforcement members (basalt rebar
members, basalt mesh, or both) to form concrete structures or
pavements that can be used for construction of roads, sidewalks and
other concrete structures or infrastructure. Through the use of
embodiments of the present invention, the concrete structures or
pavements formed permit water and air to pass through the concrete
structures, which provides various benefits, such as reducing the
need for complex and expensive storm water runoff systems in flood
prone areas.
[0005] In accordance with another broad aspect of an embodiment of
the invention, disclosed herein is a pavement, comprising pervious
concrete material and one or more basalt reinforcing members
embedded in or positioned below the pervious concrete material. The
one or more basalt reinforcing members may be basalt rebar rods, or
basalt rebar rods having a Figure-Eight shape, or a mesh made of
basalt strands. The one or more basalt reinforcing members add
structural rigidity to the pervious concrete, making the pervious
concrete capable or supporting loads as normally experienced on
pavements. In one example, the pavement may also include a layer of
filtration fabric positioned below the basalt reinforcing
members.
[0006] In another embodiment of the present invention, the pavement
may include a compacted soil layer; a layer of filtration fabric
positioned above the compacted soil layer; and a layer of course
aggregate material positioned above the layer of filtration fabric.
The one or more basalt reinforcing members may be positioned above
the layer of course aggregate material. In one example, the
pervious concrete material forms the upper surface of the
pavement.
[0007] In another example of the invention, the one or more basalt
reinforcing members are positioned approximately two inches or more
above the bottom of the pervious concrete material. The pavement
may be used to form a road, parking lot, driveway, sidewalk or
other structure as disclosed herein, which allows water or moisture
to pass through the surface of the pavement and be filtered. Such a
pavement reduces flooding and the need for complex storm drainage
systems adjacent to the pavement.
[0008] In accordance with another broad aspect of an embodiment of
the invention, disclosed herein is a method for forming a road. In
one example of the invention, the method includes the operations of
compacting a sub-base layer; installing a filtration fabric above
the sub-base layer; installing a layer of aggregate material above
the filtration fabric; positioning one or more basalt rebar
reinforcement members above the layer of aggregate material; and
pouring a layer of wet pervious concrete material above the one or
more basalt rebar reinforcement members.
[0009] In another example, the method may also include leveling
said layer of wet pervious concrete, and compacting said layer of
wet pervious concrete. In another embodiment, the method may also
include curing said layer of pervious concrete. The method may also
include placing the one or more basalt rebar reinforcement members
approximately two or more inches above the layer of aggregate
material, and in another example, the method may include pouring a
portion of said wet pervious concrete material below the one or
more basalt rebar reinforcement members, so that the wet pervious
concrete material embeds the one or more basalt rebar reinforcement
members. In this manner, a road can be formed which allows water or
moisture to pass through the road and be filtered, thereby reducing
flash flooding and reducing or eliminating the need for complex
storm drainage systems adjacent to the road.
[0010] The foregoing and other useful features and advantages of
the invention will be apparent from the following more particular
description of a various embodiments of the invention as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an example of a reinforced concrete
structure including pervious concrete material and basalt rebar
members, in accordance with one embodiment of the present
invention.
[0012] FIG. 2 illustrates an example of a reinforced concrete
structure including pervious concrete material and a basalt mesh,
in accordance with one embodiment of the present invention.
[0013] FIG. 3 illustrates a conventional road using impervious
concrete and storm water drains.
[0014] FIG. 4 illustrates an example of a road made using an
embodiment of the present invention having pervious concrete and
without storm water drains.
[0015] FIG. 5 illustrates a conventional parking lot using
impervious concrete and storm water pipes.
[0016] FIG. 6 illustrates an example of a parking lot made using an
embodiment of the present invention having pervious concrete and
without storm water pipes.
[0017] FIG. 7 illustrates an example of a sidewalk made using an
embodiment of the present invention having pervious concrete.
[0018] FIG. 8 illustrates a conventional sidewalk tree grate using
impervious concrete.
[0019] FIG. 9 illustrates an example of a sidewalk tree grate made
using an embodiment of the present invention having pervious
concrete, where the size of the tree grate can be smaller when
compared with the tree grate of FIG. 8.
[0020] FIG. 10 illustrates an example of a basalt rebar rod or
member, in accordance with one embodiment of the present
invention.
[0021] FIG. 11 illustrates a cutaway view of an example of a
reinforced concrete surface including pervious concrete material
and basalt rebar members, in accordance with one embodiment of the
present invention.
[0022] FIG. 12 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 11, in accordance with one
embodiment of the present invention.
[0023] FIG. 13 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 11, in accordance with one
embodiment of the present invention.
[0024] FIG. 14 illustrates an example of a process for forming a
pavement with pervious concrete and basalt rebar, in accordance
with an example of the present invention.
[0025] FIG. 15 illustrates an example of a basalt rebar rod or
member having a "Figure Eight" shape, in accordance with one
embodiment of the present invention.
[0026] FIG. 16 illustrates a cutaway view of an example of a
reinforced concrete surface including pervious concrete material
and basalt rebar members having "Figure Eight" shapes, in
accordance with one embodiment of the present invention.
[0027] FIG. 17 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 16, in accordance with one
embodiment of the present invention.
[0028] FIG. 18 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 16, in accordance with one
embodiment of the present invention.
[0029] FIG. 19 illustrates an example of a process for forming a
pavement with pervious concrete and basalt rebar members having
"Figure Eight" shapes, in accordance with an example of the present
invention.
[0030] FIG. 20 illustrates an example of a basalt mesh, in
accordance with one embodiment of the present invention.
[0031] FIG. 21 illustrates a cutaway view of an example of a
reinforced concrete surface including pervious concrete material
and basalt rebar mesh, in accordance with one embodiment of the
present invention.
[0032] FIG. 22 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 21, in accordance with one
embodiment of the present invention.
[0033] FIG. 23 illustrates a sectional view of the example of a
reinforced concrete surface of FIG. 21, in accordance with one
embodiment of the present invention.
[0034] FIG. 24 illustrates an example of a process for forming a
pavement with pervious concrete and basalt mesh, in accordance with
an example of the present invention.
[0035] FIG. 25 illustrates a representation of a sectional view of
an example of a road made using pervious concrete and basalt rebar,
wherein a pothole has developed.
[0036] FIG. 26 illustrates a representation of a sectional view of
an example of a road made using pervious concrete and basalt rebar,
wherein a pothole has been repaired.
[0037] FIG. 27 illustrates an example of a process for repairing a
pothole in a road formed with pervious concrete and basalt rebar,
in accordance with an example of the present invention.
DETAILED DESCRIPTION
[0038] Disclosed herein are new methods and structures for forming
concrete structures or reinforced pavements that can be used to
make roads, sidewalks and other infrastructures. Specifically,
embodiments of the invention utilize pervious concrete material
with basalt reinforcement members (basalt rebar members, basalt
mesh, or both) to form concrete structures or pavements that can be
used for construction of roads, sidewalks and other concrete
structures or infrastructure. Through the use of embodiments of the
present invention, the concrete structures formed permit water and
air to pass through the concrete structures, which provides various
benefits, such as reducing the need for complex and expensive storm
water runoff systems in flood prone areas.
[0039] By embedding basalt reinforcement members within pervious
concrete, the PSI rating level of the pervious concrete structure
formed is believed to be sufficient to withstand traffic loads and
other weight bearing loads because basalt reinforcement members
both reinforce the pervious concrete material and the basalt
reinforcement members can be exposed to water without rusting or
being weakened by rust over time. Through the use of pervious
concrete combined with one or more basalt reinforcement members,
roads and streets can be formed so that the amount of rainwater
runoff in flash flood prone areas is reduced. Instead, rainwater or
other moisture passes through the pervious concrete surface and
down below the grade of the concrete surface.
[0040] Through the use of embodiments of the present invention,
during rain or snow or other moisture conditions, the groundwater
aquifers can be more readily replenished because the water/moisture
passes through the pervious concrete to the aquifers located below
such pervious concrete. Moreover, through the use of embodiments of
the present invention, several environmental constraints typically
experienced by impervious or traditional concrete can be avoided or
minimized while serving many of the same purposes as standard
concrete. For instance, pervious concrete allows water to pass
through it and seep into the soil therefore becoming instrumental
in recharging groundwater and reducing large amounts of stormwater
runoff. Because pervious concrete allows water and air to pass
through the concrete structure, there is a large reduction in the
need for complex and expensive storm water runoff systems in flood
prone areas.
[0041] Many characteristics of basalt materials have been
recognized by the present inventor as useful when combined with
pervious concrete. Basalt is a naturally occurring volcanic rock
that employs a variety of benefits when compared to steel
reinforcement typically used for reinforced concrete. It is
believed that basalt materials have a higher tensile strength than
fiberglass or possibly steel. Basalt is a naturally occurring rock
which means it can resist rust or any type of corrosion and does
not absorb any amount of water. Basalt rebar is also about 1/4 of
the weight of steel rebar, which makes basalt rebar much easier to
transport and assemble on the job site. Also, basalt rebar can be
easily cut and shaped using common tools in the field.
[0042] FIG. 1 illustrates an embodiment of the invention, where a
concrete structure 50 is formed using pervious concrete 52 and one
or more basalt rebar members 54, the basalt rebar members 54
configured in a manner to impart structural rigidity and strength
to the concrete structure. In this example, the basalt rebar
members 54 are configured in a generally square matrix pattern, but
it is understood that the basalt rebar members 54 may be configured
in other different patterns and densities depending upon the
particular structure being built and the desired load bearing
characteristics. For complex structures, the basalt rebar members
54 can be molded in order to form or reinforce a desired
structure.
[0043] If desired, the basalt rebar members 54 may be temporarily
held together in a desired patters using coated wire twist ties,
also known as bar ties (not shown), which temporarily can affix
rebar members to one another. The bar ties can be, in one example,
16 gauge, 6 inch steel ties if desired.
[0044] FIG. 2 illustrates another embodiment of the invention,
where a concrete structure 60 is formed using pervious concrete 52
and a basalt mesh 62, the basalt mesh 62 provided to impart
structural rigidity and strength to the concrete structure. In one
example, the basalt mesh 62 may be obtained in rolls and has a
generally square matrix pattern, but it is understood that the
basalt mesh 62 may be configured in other different patterns,
densities and thicknesses depending upon the particular structure
being built and the desired load bearing characteristics.
[0045] Pervious concrete 52 is commercially available from many
concrete companies, such as Lafarge North America, Inc. Basalt
rebar and basalt mesh may be available from Raw Energy Materials,
Inc. of Pompano Beach, Fla. In one example, the basalt rebar
members 54 can be rods made of a unidirectional composite of basalt
fibers.
[0046] In one example, to construct a surface such as a road or
sidewalk or other concrete structure using an embodiment of the
present invention, after the sub-grades and sub-bases have been
prepared, one or more basalt reinforcement members (e.g., 54, 62)
are positioned along the surface as desired to achieve the required
structural integrity or PSI ratings. Pervious concrete material 52
is poured on top of such basalt reinforcement members, and the top
of the pervious concrete material is compacted (in one example, the
top half inch of pervious concrete material may be compacted). The
surface of the pervious concrete material can be covered with
plastic, ply, or a tarp to keep the pervious concrete moist during
curing which may take a number of days for the pervious concrete to
fully cure. In one example, joints between pervious concrete
members can be placed for instance, every twenty feet, and it is
believed that expansion joints would not be needed since pervious
concrete material does not expand or contract in the same manner as
impervious concrete. The plastic/ply/tarp also functions to keep
rainwater out of the pervious concrete material while the pervious
concrete material is curing.
[0047] Embodiments of the invention may be used to form roadways 70
(FIG. 4)(compare to FIG. 3 showing a conventional road 72 using
impervious concrete 74 with storm drain pipes); parking lots 80
(FIG. 6)(compare to FIG. 5 showing a conventional parking lot 82
with impervious concrete 72 and storm water pipes); sidewalks (FIG.
7); and sidewalks 90 with tree grates 91 (FIG. 9)(compare with FIG.
8 showing larger tree grates 94 used with conventional impervious
concrete 74). Other concrete structures may be built using
embodiments of the present invention, such as bridges or portions
of bridges, curbs, portions of sewer systems, retaining walls, or
any other concrete structures where it may be desirable to allow
water and air to pass through.
[0048] In one example of the present invention, pervious concrete
52 may be formed in a manner that is thicker in consistency
compared to regular concrete 74, as pervious concrete 52 can be
formed as a mixture of cement, coarse aggregates (i.e., 3/8''
gravel or limestone), water, and little or no sand. Pervious
concrete 52 may be formed so that it has a large volume (e.g.,
approximately 15-30%) of interconnected voids 100 (FIGS. 1-2)
allowing rainwater to percolate through the pervious concrete 52
into the underlying soil, with the tradeoff being that the larger
the voids 100, the lower the strength of the pervious concrete 52.
This filtration effect also helps to purify the water by capturing
pollutants as the water drains through the small voids 100 in the
pervious concrete 52 before it reaches a storm drain. Various mixes
of pervious concrete 52 materials are described in "Practical
Application of Pervious Concrete: Mix Designs That Are Workable" by
Rick Blackburn, Axim Italcementi Group (2006) (presentation from
National Ready Mixed Concrete Association Conference, available at
http://www.rmc-foundation.org); "Development of Mix Proportion for
Functional and Durable Pervious Concrete" by K. Wang, V. R.
Schaefer, J. T. Kevern, M. T. Suleiman, Iowa State University,
(2006) (presentation from National Ready Mixed Concrete Association
Conference, available at http://www.rmc-foundation.org); "Making
Pervious Concrete Placement Easy Using a Novel Admixture System" by
Mark Bury, Christine Mawby, and Dale Fisher, Degussa Admixtures,
Inc., (2006) (available at http://www.rmc-foundation.org); and
"Mix, Forms, and Admixtures" by Charles Wolfersberger, Charger
Enterprises Inc. (available at http://www.perviousconcrete.com),
the disclosures of which are hereby incorporated by reference. The
particulars of the mix used to create wet pervious concrete 52 will
depend on the loading requirements and other details of the
particular application. In one example, a pervious concrete mix
available from Lafarge North America Inc. may be used for street
paving and other applications.
[0049] In one example, pervious concrete 52 may be delivered to a
job site in a conventional ready-mix concrete truck, and can be
poured within one hour of being initially mixed. Pervious concrete
52 may be poured into standard concrete forms using 2''.times.4''
wood forms or other conventional forms or related techniques, in
one example.
Formation of Roads, Sidewalks, Driveways, etc. using Pervious
Concrete and Basalt Rebar Reinforcement Rods
[0050] In one example, a surface or pavement 110 such as a road,
sidewalk, driveway, parking lot, or the like, can be formed using
pervious concrete 52 reinforced with basalt rebar 54. FIGS. 10-13
show an example of basalt rebar 54 and show sectional views of one
example of a pavement 110 formed in accordance with an embodiment
of the present invention, wherein the pavement 110 includes a
compacted soil layer 112, a geotextile filtration fabric layer 114,
a layer of course aggregate 116, one or more basalt rebar rods 54
with one or more support blocks 118, and a layer of pervious
concrete 52. A curb 119 may be made of pervious or impervious
concrete.
[0051] One example of a method of forming a pavement using pervious
concrete 52 and basalt rebar members 54 is illustrated in FIG. 14.
Referring to FIG. 14, at operation 120, the sub-soil that will be
underneath the pervious concrete is compacted, for instance using a
vibrating roller. In one example, the soil is moist, but free of
standing water, to aid in the compaction.
[0052] At operation 122, a non-woven, geotextile filtration fabric
114 is placed to cover the compacted soil and acts as a silt
catcher in use, when the water percolates into the soil below. The
geotextile fabric 114 also functions as a weed blocker to prevent
any unwanted growth that could disrupt the pervious concrete layer
52.
[0053] At operation 124, coarse aggregate material 116, such as
limestone, crushed glass, superheated clay, is placed on the
filtration fabric 114. In one example, more than 6'' of coarse
aggregate 116 is placed on top of the geotextile fabric 114 which
in use increase the storage capacity, as well as provide a
secondary filtration layer to capture pollutants before they enter
storm drains or compacted soil 112 below.
[0054] At operation 126, basalt rebar members 54 are placed on the
coarse aggregate 116. In one example, the basalt rebar members 54
are placed in 1'.times.1' grids covering the entire area where the
pervious concrete will be installed. The grid may be formed using
basalt rebar members 54 that are held together in the grid through
the use of wire ties. In one example, each basalt rebar rod 54 may
have a diameter of approximately 5/8'', although the dimensions of
the basalt rebar members will vary depending upon the needs of a
particular application. Concrete chairs or support blocks 118 may
be used to support the basalt rebar, for instance 2'' above the
layer of coarse aggregate 116. This will allow the rebar 54 to
become embedded in the pervious concrete 52 about 2-21/2'' from the
bottom of the pervious concrete layer. In one example, for each 8'
span of rebar, three chairs or support blocks can be evenly
installed underneath the rebar grid for support.
[0055] At operation 128, the pervious concrete 52 is poured over
the basalt rebar 54. In one example, the pervious concrete 52 is
poured such that there is a sufficient amount ready for compaction,
for example 6'' for sidewalks and driveways, 10-12'' for
streets/roadways.
[0056] At operation 130, the pervious concrete layer 52 is leveled
and compacted while still wet. In one example, a vibrating
mechanical screed is used to level off the pervious concrete 52,
wherein the screed is a flat board or tool used to smooth concrete
after it has been placed on a surface.
[0057] In one example, at least 1/2'' of the pervious concrete
layer 52 may be striked-off above the form to allow for compaction.
Operation 130 may also include compacting the pervious concrete,
for instance, through the use of a heavy steel roller to compact
the pervious concrete layer. This operation creates a pervious
concrete slab where the top approximately 11/2'' has smaller voids
to trap pollutants captured from substances like oil and grease.
Edges near the forms may be compacted using a small, hand-held
press to prevent raveling of the edges.
[0058] After placement of the pervious concrete layer, at operation
132, a mist of water can be applied to the pervious concrete 52,
and the pervious concrete 52 may be protected by covering it with
plastic sheeting (e.g., a 6 mil polyethylene cover such as
Visqueen), and kept damp for 5 to 7 days until full hydration has
occurred in the pervious concrete. In one example, the curing
process begins within approximately ten minutes of the initial
placement of the pervious concrete layer 52, and continues for at
least 7 days. In one example of the invention, the pervious
concrete layer is believed to reach its maximum strength after 28
days of curing.
Formation of Roads, Sidewalks, Driveways, etc. using Pervious
Concrete and "Figure Eight" Shaped Basalt Rebar Reinforcement
Members
[0059] In another embodiment of the invention, a pavement surface
110 such as a road, sidewalk, driveway, parking lot, or other
surface can be formed using pervious concrete 52 with one or more
basalt rebar reinforcement members 140 that have a "Figure Eight"
shape. FIG. 15 shows and example of a basalt rebar member 140
having a "Figure Eight" shape, and FIGS. 16-18 show a sectional
view of one example of a pavement 110 formed in accordance with an
embodiment of the present invention, wherein the pavement includes
a compacted soil layer 112, a geotextile filtration fabric layer
114, a layer of course aggregate 116, one or more basalt rebar
"Figure Eight" members 140 with one or more support blocks 118, and
a layer of pervious concrete 52.
[0060] One example of a method for forming a pavement surface 110
using pervious concrete 52 with a reinforcement of basalt rebar
members 140 having a "Figure Eight" shape is illustrated in FIG.
19. Operations 141-143 can be similar to operations 110-124 of FIG.
14, in one example. At operation 141 of FIG. 19, the sub-soil that
will be underneath the pervious concrete is compacted, for instance
using a vibrating roller. In one example, the soil is moist, but
free of standing water, to aid in the compaction. At operation 142,
a non-woven, geotextile filtration fabric is placed to cover the
compacted soil and acts as a silt catcher in use, when the water
percolates into the soil below. The geotextile fabric also
functions as a weed blocker to prevent any unwanted growth that
could disrupt the pervious concrete layer. At operation 143, coarse
aggregate material, such as limestone, crushed glass, superheated
clay, is placed on the filtration fabric. In one example, more than
6'' of coarse aggregate is placed on top of the geotextile fabric
which in use increase the storage capacity, as well as provide a
secondary filtration layer to capture pollutants before they enter
storm drains or compacted soil below.
[0061] At operation 144, basalt rebar members 140 having "Figure
Eight" shapes are placed on the coarse aggregate. In one example,
these basalt rebar members 140 are placed in 1'.times.1' grids
covering the entire area where the pervious concrete will be
installed. The grid may be formed using basalt rebar members that
are held together in the grid through the use of wire tires. In one
example and as shown in FIG. 15, each basalt rebar member may have
multiple oval portions forming the "Figure Eight" shape, wherein
each oval portion is approximately 13'' in length and has two legs
(e.g., each 3/16'' diameter) separated by a distance of
approximately 1'', although the dimensions of the basalt rebar
member will vary depending upon the needs of a particular
application. Concrete chairs or support blocks may be used to
support the basalt rebar, for instance 2'' above the layer of
coarse aggregate. This will allow the rebar to become embedded in
the pervious concrete about 2-21/2'' from the bottom of the
pervious concrete layer. In one example, for each 8' span of rebar,
three chairs or support blocks can be evenly installed underneath
for support.
[0062] At operation 125, the pervious concrete is poured over the
shaped rebar. In one example, the pervious concrete is poured such
that there is a sufficient amount ready for compaction, for example
6'' for sidewalks and driveways, 10-12'' for streets/roadways.
[0063] At operation 126, the pervious concrete layer is leveled and
compacted while still wet. In one example, a vibrating, mechanical
screed is used to level off the pervious concrete, wherein the
screed is a flat board or tool used to smooth concrete after it has
been placed on a surface. In one example, at least 1/2'' of the
pervious concrete layer may be striked-off above the form to allow
for compaction. Operation 126 may also include compacting the
pervious concrete, for instance, through the use of a heavy steel
roller to compact the pervious concrete layer. This operation
creates a pervious concrete slab where the top approximately 11/2''
has smaller voids to trap pollutants captured from substances like
oil and grease. Edges near the forms may be compacted using a
small, hand-held press to prevent raveling of the edges.
[0064] After placement of the pervious concrete layer, at operation
127, a mist of water can be applied to the pervious concrete, and
the pervious concrete may be protected by covering it with plastic
sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and
kept damp for 5 to 7 days until full hydration has occurred in the
pervious concrete. In one example, the curing process begins within
approximately ten minutes of the initial placement of the pervious
concrete layer, and continues for at least 7 days. In one example
of the invention, the pervious concrete layer is believed to reach
its maximum strength after 28 days of curing.
Formation of Roads, Sidewalks, Driveways, etc. using Pervious
Concrete and Basalt GeoMesh Reinforcement
[0065] In another embodiment of the invention, a pavement surface
110 such as a road, sidewalk, driveway, parking lot, or other
surface can be formed using pervious concrete 52 with a
reinforcement of basalt geomesh or mesh 150. FIGS. 20-23 show an
example of a basalt mesh 150, and show sectional views of one
example of a pavement formed in accordance with an embodiment of
the present invention, wherein the pavement 110 includes a
compacted soil layer 112, a geotextile filtration fabric layer 114,
a layer of course aggregate 116, a layer of basalt geomesh 150, and
a layer of pervious concrete 52.
[0066] One example of a method for forming a pavement surface using
pervious concrete 52 with a reinforcement of basalt geomesh 150 is
illustrated in FIG. 24. Operations 151-153 can be similar to
operations 120-124 of FIG. 14, in one example. At operation 151 of
FIG. 24, the sub-soil that will be underneath the pervious concrete
is compacted, for instance using a vibrating roller. In one
example, the soil is moist, but free of standing water, to aid in
the compaction. At operation 152, a non-woven, geotextile
filtration fabric is placed to cover the compacted soil and acts as
a silt catcher in use, when the water percolates into the soil
below. The geotextile fabric also functions as a weed blocker to
prevent any unwanted growth that could disrupt the pervious
concrete layer. At operation 153, coarse aggregate material, such
as such as limestone, crushed glass, superheated clay, is placed on
the filtration fabric. In one example, more than 6'' of coarse
aggregate is placed on top of the geotextile fabric which in use
increase the storage capacity, as well as provide a secondary
filtration layer to capture pollutants before they enter storm
drains or compacted soil below.
[0067] At operation 154, a basalt geomesh 150 is placed directly on
top of the coarse aggregate without the use of concrete chairs or
steel substitutes. In one example, a basalt geomesh 150 is a mesh
or basalt strands having a plurality of approximately 1'' by 1''
squares of basalt strands.
[0068] At operation 155, once the basalt geomesh 150 has been
installed over the coarse aggregate, pervious concrete is poured
over the geomesh 150 until the desired thickness of concrete has
been reached.
[0069] Operations 156-157 may be similar to operations 130-132 of
FIG. 14, in one example. In particular, at operation 156 of FIG.
24, the pervious concrete layer is leveled and compacted while
still wet. In one example, a vibrating, mechanical screed is used
to level off the pervious concrete, wherein the screed is a flat
board or tool used to smooth concrete after it has been placed on a
surface.
[0070] In one example, at least 1/2'' of the pervious concrete
layer may be striked-off above the form to allow for compaction.
Operation 156 may also include compacting the pervious concrete,
for instance, through the use of a heavy steel roller to compact
the pervious concrete layer. This operation creates a pervious
concrete slab where the top approximately 11/2'' has smaller voids
to trap pollutants captured from substances like oil and grease.
Edges near the forms may be compacted using a small, hand-held
press to prevent raveling of the edges.
[0071] After placement of the pervious concrete layer, at operation
157, a mist of water can be applied to the pervious concrete, and
the pervious concrete may be protected by covering it with plastic
sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and
kept damp for 5 to 7 days until full hydration has occurred in the
pervious concrete. In one example, the curing process begins within
approximately ten minutes of the initial placement of the pervious
concrete layer, and continues for at least 7 days. In one example
of the invention, the pervious concrete layer is believed to reach
its maximum strength after 28 days of curing.
Pothole Repair
[0072] If a pothole 160 (FIG. 25) develops in the pervious concrete
pavement due to loss of compaction of the sub-soil 112 or course
aggregate 116 below a portion of the pervious concrete, the pothole
160 may be repairable using the process of FIG. 27, in accordance
with an embodiment of the present invention. FIG. 25 shows an
example of a sectional view of pothole 160 formed in a pavement
made in accordance with an embodiment of the present invention;
FIG. 26 shows an example of a sectional view of a repaired pothole
in a pavement made in accordance with an embodiment of the present
invention. As recognized by the present inventor, pervious concrete
with basalt rebar reinforcements has a restorative memory such that
some potholes 160 may be repairable without the use of additional
pervious concrete material 52 on the surface.
[0073] Referring to FIG. 27, a process is illustrated for repairing
a pothole 160 that exists in a pavement of pervious concrete and
basalt reinforcement members. At operation 161, a pothole is
identified that has formed underneath a section of cracked pervious
concrete. The basalt rebar or other basalt reinforcement will
bend/flex down into the collapsed section until the pressure has
been removed and the rebar returns to its original position.
[0074] At operation 162, one or more holes 163 are drilled into or
about the collapsed section of the pervious concrete, wherein the
hole(s) are drilled deep enough to allow a sand slurry injection
164 of operation 165 to reach underneath the pervious and fill the
void created by the loss of compaction in the subgrade.
[0075] At operation 165, sand or a slurry of sand 164 is injected
into the drilled hole(s) 163, which fills the void(s) in the
subgrade or sub-soil below the pothole. The injected sand slurry
164 provides for both long term stable subsurface conditions by
restoring the level of the compacted soil or course aggregate
underneath the pervious concrete 52, and also retains an effective
permeability through the repaired subsurface beneath the repaired
pothole. Once completed, the rebar 54 and the pervious concrete 52
returns to their original position, and hence the pervious concrete
has been repaired.
[0076] In one example, the methods disclosed herein for forming a
pavement or surface 50, 60, 70, 80, 90 or 110 (such as a road,
alley, parking area, sidewalk or other surface) may include forming
the surface through the use of one or more basalt reinforcement
members combined with pervious concrete, without the need for
installing stormwater pipes or other stormwater drainage.
[0077] Embodiments of the invention can be used to make or repair
various pavements surfaces or roadways, such as but not limited to
streets, sidewalks, driveways, parking lots, highway shoulders,
non-vehicular bridges, lightweight vehicular bridges, heavy
highways, and lightweight structural components such as parking
garage floors, curbs, or other floors, for example.
[0078] Through the use of embodiments of the present invention,
streets or other structures can be created with significantly
reduced or zero runoff, meaning that streets or other structures
such as parking lots, sidewalks, etc. can be formed without the
need for underground pipes or catch basins, which can result in a
significant cost savings when building or maintaining such streets
or other infrastructure. Embodiments of the present invention may
also eliminate the need for rainfall stormwater management or
portions thereof, as well as pumps which are used in cities such as
New Orleans.
[0079] In another embodiment, where existing streets or
infrastructure already have storm systems in place, the streets,
roads, sidewalks and other infrastructure can be replaced with
streets, sidewalks or other structures utilizing embodiments of the
present invention. In repairing an existing road, the processes
described above could also include an operation of removing the
existing pavement and/or other materials present, until the soil
layer is exposed.
[0080] In one example, a concrete structure using pervious concrete
may be formed using construction techniques that are used with
impervious concrete; and in other embodiments, different
construction techniques are used for forming concrete structures
using pervious concrete. For instance, in accordance with an
embodiment of the present invention, the basalt rebar members
combined with the pervious concrete material can be configured by
placing the basalt rebar members in a pattern that is specially
adapted or designed to increase the structural integrity of the
pervious concrete structure.
[0081] In another embodiment of the present invention, a method is
disclosed for planting of trees, shrubs or other vegetation along
sidewalks or roadways. In one example, the method includes
identifying a location for having the tree, shrub or vegetation
planted, providing pervious concrete material with basalt
reinforcement members around the desired location for the tree,
shrub or vegetation, and allowing the pervious concrete to form.
The tree, shrub or vegetation can then be planted after the
pervious concrete cures. Because of the pervious nature of the
concrete, water will drain through the concrete structure
(sidewalk, road) and provide water and nutrients to the tree, shrub
or vegetation. Therefore, the tree, shrub or vegetation will not
have a tendency to uproot the sidewalk, road, or other concrete
structure, as typically happens with sidewalks or roads that
utilize impervious concrete. Moreover, the roots of tree, shrub and
other vegetation will receive more water and air through the use of
pervious concrete than with conventional impervious concrete.
[0082] While the methods disclosed herein have been described and
shown with reference to particular operations performed in a
particular order, it will be understood that these operations may
be combined, sub-divided, or re-ordered to form equivalent methods
without departing from the teachings of the present invention.
Accordingly, unless specifically indicated herein, the order and
grouping of the operations is not a limitation of the present
invention.
[0083] It should be appreciated that reference throughout this
specification to "one embodiment" or "an embodiment" or "one
example" or "an example" means that a particular feature, structure
or characteristic described in connection with the embodiment may
be included, if desired, in at least one embodiment of the present
invention. Therefore, it should be appreciated that two or more
references to "an embodiment" or "one embodiment" or "an
alternative embodiment" or "one example" or "an example" in various
portions of this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures or characteristics may be combined as desired in one or
more embodiments of the invention.
[0084] Similarly, it should be appreciated that in the foregoing
description of exemplary embodiments of the invention, various
features of the invention are sometimes grouped together in a
single embodiment, figure, or description thereof for the purpose
of streamlining the disclosure and aiding in the understanding of
one or more of the various inventive aspects.
[0085] While the invention has been particularly shown and
described with reference to various embodiments thereof, it will be
understood by those skilled in the art that various other changes
in the form and details may be made without departing from the
spirit and scope of the invention.
* * * * *
References