U.S. patent number 3,690,227 [Application Number 05/054,780] was granted by the patent office on 1972-09-12 for frictional self-draining structure.
Invention is credited to 90212, Lloyd G. Welty, 410 S. Beverly Dr..
United States Patent |
3,690,227 |
|
September 12, 1972 |
FRICTIONAL SELF-DRAINING STRUCTURE
Abstract
A frictional, in situ self-draining composite structure for
runway and roadway structural docking and pathway surface. The
composite structure has a solid base to which is bound a porous
superstratum of aggregate and resinous binder. The composite
structure is fabricated by applying a first mixture containing
about two to about four parts by volume of aggregate particles of
crushed rock, river gravel, crushed coral, coarse sand, slag, or
crushed refractory material and one part by volume of a settable
resinous binder to the base section and allowing it to set, and
then by applying a second mixture containing about two to about
four parts by volume of scoria and/or slag particles and one part
by volume of a settable resinuous binder to the first porous
layer.
Inventors: |
Lloyd G. Welty, 410 S. Beverly
Dr. (Beverly Hills, CA), 90212 (N/A) |
Family
ID: |
21993495 |
Appl.
No.: |
05/054,780 |
Filed: |
July 14, 1970 |
Current U.S.
Class: |
404/2;
404/20 |
Current CPC
Class: |
E01C
11/226 (20130101); E01C 3/06 (20130101); E04D
11/02 (20130101); E01C 7/30 (20130101); E01C
7/32 (20130101); E01D 19/083 (20130101) |
Current International
Class: |
E01C
7/30 (20060101); E01C 7/32 (20060101); E01C
11/22 (20060101); E01C 3/00 (20060101); E01C
11/00 (20060101); E01C 3/06 (20060101); E01D
19/08 (20060101); E01D 19/00 (20060101); E01C
7/00 (20060101); E04D 11/02 (20060101); E04D
11/00 (20060101); E01c 011/24 () |
Field of
Search: |
;94/7,9,10,22,23 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Jacob L. Nackenoff
Attorney, Agent or Firm: Harris, Kiech, Russell &
Kern
Claims
I claim:
1. A high strength, frictional, in situ self-draining structure,
comprising: a solid imperforate and substantially impervious
substrate base having a top surface adapted for the collection and
channeling of liquid to a drain; and a superstratum layer porous
throughout its depth and bonded to said base for the drainage of
fluid from the top surface of said base, consisting of aggregate
particles of greater size than 1/16-inch mesh bonded together with
a resinous binder which is present in an amount insufficient to
fill the voids between aggregate particles and, having about 2 to
about 4 parts by volume of said aggregate particles and 1 part by
volume of said binder to give said layer a porosity of at least 10
percent and to give said layer an impact strength of at least 1,000
pounds per square inch.
2. The high strength, frictional, in situ self-draining composite
structure defined in claim 1 wherein the aggregate particles of the
superstratum layer are selected from the group particles of crushed
scoria, rock, river gravel, crushed coral, coarse sand, slag, and
crushed refractory material.
3. The high strength, frictional, in situ self-draining composite
structure defined in claim 1 wherein the drain is at the base of
the sloped upper surface of said base.
4. The high strength, frictional, in situ self-draining composite
structure defined in claim 3 wherein the drain is a drainage
conduit which is partially embedded in the top surface of said
base, the top portion of said drain conduit being perforated with a
plurality of holes.
5. The high strength, frictional, in situ self-draining composite
structure defined in claim 1 including heating means below the top
surface of the porous superstratum layer.
6. A high strength, frictional, in situ self-draining composite
structure comprising: a solid imperforate and substantially
impervious substrate base having a top surface for the collection
and channeling of liquid to a drain and a superstratum porous
throughout its depth and bonded to said base, said superstratum
having a first porous layer bonded to said base and a second porous
layer contiguous with and bonded to said first porous layer, said
first porous layer consisting of aggregate particles of greater
size than 1/16-inch mesh bonded together with a settable resinous
binder which is present in an amount insufficient to fill the voids
between aggregate particles, said first porous layer having about 2
to about 4 parts by volume of said aggregate particles and 1 part
by volume of said settable resinous binder to give said layer a
porosity of at least 10 percent and to give said layer an impact
strength of at least 1,000 pounds per square inch, said second
porous layer consisting of scoria and/or slag particles of greater
size than 1/16-inch mesh bonded together with a settable resinous
binder which binder serves to bond said first layer to said second
layer and which is present in an amount insufficient to fill the
voids between aggregate particles, said second porous layer having
about 2 to about 4 parts by volume of said scoria and/or slag
particles and 1 part by volume of said settable resinous binder to
give said layer a porosity of at least 10 percent and to give said
layer an impact strength of at least 1,000 pounds per square
inch.
7. The high strength, frictional, in situ self-draining composite
structure defined in claim 6 wherein said second porous layer is at
least one-half inch thick.
Description
The field of the present invention includes pavement surfaces,
drainage surfaces, and insulating surfaces.
Pavement surfaces consisting of scoria or slag and a settable
resinous binder are disclosed in U.S. Pat. No. 2,925,831 to Lloyd
G. Welty and John N. Hinkson and No. 3,396,641 to Lloyd G. Welty
and Simon J. Sluter. The pavement surfaces disclosed in these
patents are solid nonporous structures which have relatively high
frictional surfaces. The frictional properties of such pavement
surfaces greatly exceed the frictional properties of the surfaces
of conventional pavements, such as concrete pavements; however,
since these patented pavement surfaces are solid, nonporous and not
self-draining, they must be constructed with a sloped top surface
to allow water to run off therefrom to prevent pooling of the water
on the surface. During rain falls, the surface of the pavement is
covered with a layer of water, even when the surface is sloped. A
water layer or water pooling creates a dangerous situation on roads
and runways because the wheels of most vehicles, including
airplanes, hydroplane on wet surfaces when the vehicle is traveling
at high speeds, such as a car traveling fifty or sixty miles per
hour. (See the technical paper entitled "Phenomena of Pneumatic
Tire Hydroplaning" by Walter B. Horne and Robert C. Dreher in NASA
Technical Note TN D-2056, November 1963.)
Due to their solid construction, these pavement surfaces are
relatively heavy and cannot be used as replacement surfaces on most
existing bridges and elevated structures because such bridges and
structures were not designed or constructed to support the weight
of such pavement surfaces. Furthermore, due to their weight, it is
not practical or feasible to employ them in roofing.
Although the aforementioned patented pavement structures are a
great improvement over conventional pavements, their use in many
areas of the country has been thwarted by economic considerations.
In most areas of the country, cement, gravel, and sand are locally
available and are the predominant materials used in conventional
pavement construction. In contrast, scoria is found only in certain
areas of the western states and slag is produced only in
steel-making areas. Since scoria and slag are not locally available
in most areas of the country, the transportation costs of these
materials sharply raises the construction cost of scoria and slag
pavement structures.
The present invention is directed to a frictional, in situ
self-draining composite structure comprising a solid substrate base
to which is bonded a porous superstratum. The porous superstratum
has a first porous layer adjacent to the base which consists of
aggregate particles of greater size than 1/16-inch mesh and a
settable resinous binder which binds the aggregate particles into a
cohesive porous mass. The porous superstratum also has a second
porous layer which is contiguous with the first porous layer; the
second porous layer consists of scoria or slag particles having a
size greater than 1/16-inch mesh and a settable resinous binder
which binds the particles into a cohesive porous frictional mass.
The composite structure of the present invention is suitable for
road surfaces, pathway surfaces, runway surfaces, rooftop surfaces,
and the like.
An object of this invention is to provide a lightweight, strong,
frictional, in situ self-draining surface structure which is
suitable for roadways, runways, and the like.
Another object of the present invention is to provide a frictional,
in situ self-draining composite structure having a planar,
horizontal top surface. More particularly, it is an object of the
present invention to provide a frictional, self-draining composite
structure surface which will eliminate hydroplaning conditions on
high speed roads and on aircraft runways.
A related object is to provide an in situ self-draining composite
structure which provides for the rapid drainage therethrough of
fuel oil, inflammable liquids, poisonous liquids, caustic liquids
and/or obnoxious liquids spilled, either by accident or from
spillage during fueling of vehicles or aircraft, on the surface of
such structure. More particularly, it is an object to provide a
vehicle pavement surface which will permit the rapid in situ
self-drainage therethrough of dangerous or inflammable liquids and
which will inhibit the burning of drained inflammable liquids.
A further object of the present invention is to provide a partially
porous composite structure with insulative qualities. More
particularly, it is an object to provide an insulative roadway or
runway structure that will inhibit the freezing of water in the
porous layer of the structure and of ground water below the base of
the pavement.
Another and further object of the present invention is to provide
an in situ self-draining composite structure having a highly
frictional top surface which is both durable and self-sharpening
and has light-reflecting characteristics. More particularly, it is
an object to provide a composite structure which has a slag or
scoria top surface and which is constructed principally of locally
available materials.
Another and further object of the present invention is to provide
an in situ self-draining composite structure which is resistant to
the action of water, fuel, and oil. More particularly, it is an
object of the present invention to provide a self-draining
structure which can be back-flushed at periodic intervals with
water to remove sand, dirt, rubber particles and the like from the
channels of the structure.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view of the self-draining composite
structure of the present invention;
FIG. 2 is an enlarged cross-sectional view of the self-draining
composite structure taken over the encircled area of FIG. 1;
and
FIG. 3 is an enlarged cross-sectional view of the self-draining
composite structure taken over the encircled area of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the frictional, in situ self-draining
composite structure 10 includes a solid substrate base 11 and
porous superstratum 12 which is bonded to the base 11. The porous
superstratum 12 has a first porous layer 13 which is bonded to the
base 11 and a second porous layer 14 which is contiguous with and
bonded to the first layer 13. Partially embedded in the base 11 is
a drainage conduit 11a having its longitudinal axis at right angles
to the plane of the drawing. The upper portion of the conduit 11a
is apertured (not shown) with a plurality of slots or holes to
permit the flow of water into the conduit 11a from the upper
surface of the base 11 and from the porous superstratum 12. The top
surface of the base 11 is sloped to assist or promote the run-off
of water from the surface into the conduit 11a. The conduit 11a
runs the length of the structure 10 and empties into a master
drainage system, storm sewer, stream or the like (not shown).
In most instances, the base is impervious to water and is
constructed from conventional construction materials such as
concrete and asphalt. In the case of bridge roadway construction,
the base 11 will generally be made of metal, such as steel or
aluminum, structural members, plates or webbed or foraminous
members. Foraminous members are particularly advantageous where
weight is a critical engineering factor. When the base 11 is a
metal web structure, the upper surface of the base 11 usually is
not sloped and conduit 11a is omitted because liquids can drain
from the porous super-structure through the holes of the foraminous
structure. In the case of roofing construction, the base 11 will
generally be made of wood board, plywood board, or lightweight
metal sheet.
The top surface of the second porous layer 14 is flat and
substantially horizontal; however, the top surface can be sloped in
the appropriate situation, such as in the construction of banked
turns, or roofs.
In FIG. 2 the first porous layer 13 is shown constructed of a
plurality of aggregate particles 16 which are bonded together with
a settable resinous binder 15 at points of contact 17 (FIG. 3).
Between the aggregate particles 16, which are coated with a layer
of the settable resinous binder, are lateral and vertical
interconnecting drainage canals or channels 18 for the drainage of
fluids from the top surface of the first layer 13 down to the base
11. The first layer 13 can be bonded to the top surface of the base
11 with a resinous settable binder; however, other means of
securing the first layer 13 to the base 11 can also be employed as
described below. The aggregate particles 16 are crushed rock, river
gravel, crushed coral, coarse sand, slag, or crushed refractory
material, and are at least 1/16-inch mesh, preferably at least
1/8-inch mesh. The first layer 13 contains from about 2 parts to
about 4 parts by volume of aggregate particles to give the first
layer a porosity of at least 10 percent, that is, at least 10
percent of the total volume of layer 13 are channels or air spaces;
preferably the porosity will be at least 20 percent. The porosity
is the percentage of free volume in a porous layer that is
accessible from the surface of the porous layer by channels and
conduits. The porosity is conveniently measured by preparing a cube
of known size or volume of the aggregate and binder mixture in a
mold. After the binder has set, the cube of material and the mold
are weighted. The cube of material in the mold is then filled and
saturated with water and the combination is weighted. The
difference between the first and second weightings is the weight of
water in the free volume of the cube of material, and, assuming
water weighs one gram per cubic centimeter, the free volume of the
cube is directly found. The porosity is the percentage of the
cube's volume that is free volume. With small-sized aggregate
particles, i.e., 1/16 -inch mesh, the porosity of the first layer
approaches the 10 percent limit; with larger-sized aggregate
particles, i.e., 1/4-inch mesh or larger, the porosity approaches
25 percent or more. The first porous layer also contains one part
by volume of a resinous settable binder to give the first layer an
impact strength of at least 1,000 pounds per square inch,
preferably at least 2,000 pounds per square inch. The impact
strength increases with increasing proportions of binder.
The preferred settable resinous binders 15 employed in the first
porous layer 13 include catalyzed epoxy, phenolic, polystyrene,
acrylic esters with resorcinol-formaldehyde, polyurethanes,
polyester and silicon resins which set at ordinary room temperature
and at accelerated rates with increased temperatures. Epon, or
resins (such as 828) supplied by Shell Chemical Company, Araldite
resins (such as 502, 6010, 6020, and the like) supplied by Ciba
Plastics, Plastics Division, C-8 Devron and other epoxy resins are
generally prepared by the condensation of an epichlorohydrin and a
bisphenol such as Bisphenol-A (4,4'-isopropylidenediphenol) to
various molecular weight polymers. Catalysis by agents and mixtures
thereof including organic bases, acid anhydrides, compounds
containing active hydrogen, certain resins, and the like, is
employed in the multitudinous commercially available formulations.
Plasticizers such as Thiokol fluid and others can be employed
therein. Phenolformaldehyde liquids can be cured with organic
bases, resorcinol-formaldehydes cure at room temperature with
additional formaldehyde and urea-melamine- formaldehyde cures at
room temperature or copolymerizes with others of the phenolics and
epoxies. True polymerizing adhesive bonding agents derived of
styrene, allylic compounds, acrylic and methacrylic esters are
cured with benzoyl peroxide or other organic peroxide and
especially in the presence of a redox catalyst system.
Polyurethanes and hybrids with polyurea cure in the presence of
water and acid.
Referring to FIG. 2 again, the second porous layer 14 is shown
having scoria or slag particles 19 which are bound together with a
settable resinous binder, such as one of those binders described
above, at points of contact 20 between the particles 19. Between
the particles 19, which are coated with a layer of a settable
resinous binder, are lateral and vertical interconnecting drainage
channels 21 for the drainage of liquids from the top surface of
layer 14 down to the top surface of the first layer 13. The second
layer 14 is bound to the top surface of the first layer 13 with the
resinous settable binder. In general, the channels 21 of the second
layer 14 are contiguous with the channels 18 of the first layer 13.
The slag or scoria particles 19 are at least 1/16-inch mesh in
size, preferably at least 1/8-inch mesh. The second porous layer 14
contains from about 2 to about 4 parts by volume of aggregate
particles to give the second layer a porosity of at least 10
percent, that is, at least 10 percent of the total volume of the
second layer 14 are canals, channels or air space; preferably the
porosity of the second layer will be at least 20 percent. Moreover,
the porosity of the second layer is preferably equal to, or greater
than, the porosity of the first layer. With smaller-size particles
of scoria or slag, such as 1/16-inch mesh, the porosity of the
second layer approaches the 10 percent limit; with larger-size
particles, such as 1/4-inch mesh or larger, the porosity approaches
25 percent or more. The second porous layer also contains one part
by volume of a settable resinous binder, such as one of the binders
described above, to give the second porous layer an impact strength
of at least 1,000 pounds per square inch, preferably at least 2,000
pounds per square inch.
As employed herein, the slag is defined as the dross which is
obtained as a product of smelting a metal from an ore containing
silicates and generally a lower specific gravity than the metallic
substances extracted. For example, slag may be produced in a
smelting operation in which fluxing agents such as limestone and
fluorite are intermixed with a siliceous ore, for example, of iron,
which mixture is then fused as in a blast furnace. The slag as
dross forms a fluid layer overlying matter smelted metal wherefrom
it is poured off and cooled. The cool material is then fragmented
by conventional grinding, rolling, and screening methods.
The scoria employed in the composite structure is of volcanic
origin and is generally cinder-like in character. The scoria may
occur in the form of vesicular lapilli, porous volcanic bombs, as
scoria or as massive effusive formations of volcanic origin. The
material is usually red or black in color and has a cellular
structure in which there is a multitude of elongated or spheroidal
cavities arranged in contiguity. A large proportion of the cavities
is closed, i.e., the structure is largely unicellular, in the
natural state. After the scoria is mined, it is reduced to the
appropriate size by a fracturing, fragmentation or crushing
operation to provide scoria particles having highly irregular forms
with large exposed surface areas presenting a myriad of outwardly
projecting spicules as well as multitudinous depressions and
cavities and the openings thereto exposed but frequently having
less area than the area within the cavities.
The use of slag and/or scoria particles in a second porous layer
provides that the top surface of the composite structure will be
highly frictional and will possess excellent light reflected
qualities. The slag or scoria particles have many concave
reflective surfaces facing in all directions. This gives a uniform
reflective surface for light proportional to the particle size and
the number of particles per square foot. In addition, the particle
surface creates a backward reflection toward the light source.
The scoria or slag particles maintain their high and uniform
coefficient of frictional resistance with wear. When an exposed
particle eventually breaks down and disintegrates because of wear,
impact, and abrasion, an underlying particle thereby becomes
exposed, thus maintaining the high frictional qualities of the top
surface. Thus, the composite structure employs a uniformly
frictional surface with numerous frictional particles per square
foot of surface. For example, one square foot of the second porous
layer employing scoria and/or slag particles of 1/8-inch mesh
provides a surface with about 12,000 to about 18,000 particles.
This type of surface provides a consistent braking action
simultaneously to all wheels of a vehicle or aircraft whether the
surface is wet or dry.
The 10 percent porosity limit of the first and second porous layers
is critical. When the porosity of a layer is below 10 percent, the
self-drainage characteristics are adversely affected, that is,
drainage of water is effectively inhibited. The reason for this is
not understood at this time; however, it is believed that when the
porosity is less than 10 percent the channels within a porous layer
are quite narrow and have constricted areas with cross-sectional
areas approaching the cross-sectional areas of capillary tubes. In
such constricted areas, water droplets are effectively trapped by
capillary action and block or dam the small channels of the porous
layer which inhibits or prevents drainage and allows water to back
up and form pools on the surface of the pavement structure. One of
the draining characteristics of the present pavement surface that
has been observed is that in situ water drains through the pavement
surface at an increased rate once the channels of the first and
second porous layers have been wetted with water. At the present
time there is no explanation for this phenomenon.
As described above, the binder and particles in both porous layers
are combined within a certain ratio range to provide that each
layer has a porosity of at least 10 percent, preferably at least 20
percent, and an impact strength of at least 1,000 pounds per square
inch, preferably at least 2,000 pounds per square inch. The impact
strength of a layer can be increased by increasing the proportion
of binder within the range; however, the volume of binder used must
be controlled to insure that the porous layer has a porosity of at
least 10 percent. In normal practice, small pavement samples will
be prepared, prior to large-scale fabrications of a pavement
structure, to determine the proper volumetric proportions of
particles and resin to furnish a pavement structure having the
desired porosity and impact strength.
The composite structure 10 of FIG. 1 is fabricated by first
preparing a mixture of the aggregate particles of at least
1/16-inch mesh preferably free of fines, and a settable resinous
binder in the liquid state; the two ingredients are mixed in a
ratio, by volume, of about 2 to about 4 parts aggregate particles
to 1 part binder. The aggregate particles and binder are mixed
until the particles are uniformly coated or wetted with the binder.
The top surface of the base element 11 is precleaned and roughened
by sandblasting, wire brushing, acid washing, and the like to
remove dirt, loose material, oil, grease and the like. The surface
is then coated with a layer of a settable resinous binder in the
fluid state. The selection of appropriate settable resin binder
will depend upon the nature of the substrate surface and the
ambient temperatures under which the surface is to be employed. The
mixture of the aggregate particles and binder, is then applied to
the base 11 and compacted to insure maximum bonding to the top
surface of the base and between the aggregate particles. The
mixture can then be allowed to set to form the first porous layer
13 of the superstrata portion 12.
The second porous layer 14 is fabricated by preparing a mixture of
scoria and/or slag particles of at least 1/16-inch mesh, preferably
free of fines, and the settable resinous binder in the liquid state
employing, by volume, about 2 to about 4 parts scoria and/or slag
to 1 part binder. The particles of scoria and/or slag and the
binder are mixed or tumbled to insure that each particle is
uniformly coated or wetted with the binder. The mixture is then
applied to the top of the first porous layer 13 and compacted to
insure maximum bonding to the top surface of the first layer 13 and
between the scoria and/or slag particles 19. This mixture is rolled
or tamped before it sets to make the top surface planar and
substantially horizontal. The mixture is then allowed to set to
form the second porous layer 14. The mixture of scoria and/or slag
particles and binder can be applied to the first porous layer
before or after it has set; normally after the first layer has
set.
The resulting first porous layer 13 and the resulting second porous
layer 14 will each have a porosity of at least 10 percent,
preferably at least 20 percent, and an impact strength of at least
1,000 pounds per square inch, preferably at least 2,000 pounds per
square inch.
Another method of fabricating the composite structure of the
present invention includes the step of applying a layer of a fluid
adhesive bonding agent to the top surface of the base 11. The
selection of an appropriate bonding agent will depend upon the
nature of the substrate surface and the ambient conditions under
which the surface is to be employed. In some instances the solution
of adhesive material will solidify by evaporation of a solvent
carrier. Likewise, it is possible to employ bonding agents which
can be applied in molten condition and which solidify on cooling;
however, it is generally preferred to employ a settable resinous
binder with a catalyzed setting tie as described above. Solvent
solutions such as asphaltic, coal tar, or other resinous materials
exemplify the first-mentioned type of adhesive bonding agents.
Aqueous emulsions and dispersions of adhesive bonding agents of a
similar character could be employed likewise. Molten asphalts, coal
tar, resins and synthetic resins exemplify the second type of
bonding adhesive. While the fluid adhesive bonding agent is still
in the fluid state, a layer of aggregate particles, free of fines
and of uniform size, are preferably applied to the treated surface
of the base. Generally the aggregate is applied with rolling action
of troweling to assure that lower surfaces of the aggregate
particles are thoroughly wetted by the liquid adhesive bonding
agent and are embedded partially therein. Surfaces such as pathways
and roofs to which only a thin covering is to be applied, mesh
sizes of one-sixteenth and one-eighth inch or larger may be
employed. In the event that the composite structure is to be used
for vehicular or aircraft traffic, such as trucks and airplanes,
aggregate of one-eighth, one-fourth, three-eighths, and one-half
inch or larger mesh sizes are employed. Ordinarily, the bonding
agent is then allowed to set. The mixture of aggregate particles
and resin is then applied to the pretreated upper surface of the
solid substrate base in the manner described above.
When the composite structures of this invention are being
constructed on a new or fresh concrete base 11, aggregate
particles, free of fines, and of uniform size, may be partially
embedded in the top surface of the concrete base while the concrete
is soft and fresh to provide an alternative bonding layer. After
the concrete is set, the top surface of the base 11, which is
covered with embedded aggregate particles, is covered with a layer
of settable resinous binder to which is applied prior to setting
the aggregate particles and binder mixture employed in the
fabrication of the first porous layer 13.
In a preferred embodiment of the present invention where the top
surface of the base 11 is sloped, the first porous layer is laid in
such a manner that its top surface is substantially horizontal and
the second porous layer is laid in a relatively thin layer such
that its top surface is planar and substantially horizontal. In
this preferred embodiment the second porous layer has a thickness
of at least one-fourth inch and preferably at least one-half inch,
whereas the first porous layer has a thickness of at least 2
inches.
In order to insure rapid draining and prevent back-up, the
composite structure is constructed with one or more drainage
conduits between the phase of the solid substrate base and the
first porous layer; the drainage conduits preferably run the length
of the base section and perpendicular to the gradient of the base
section. The conduits are slotted by a plurality of holes in their
upper surfaces, and can be made of metal, brick clay, stone, or
plastic material. In an alternative embodiment of the present
invention (not shown) the drainage conduit can be a slit trench
constructed in the base section, the drainage conduit can be a
conduit foraminous about its entire circumference which is merely
laid on top of the base 11, and surrounded by the first porous
layer.
Although not shown in the drawing, the present composite structure
can be constructed with heating elements near the upper surface of
the superstratum portion. The use of such heating elements will
prevent ice formation in the channels 18 and 21 of the composite
structure and will insure adequate drainage during freezing
weather. The heating elements can be conduits through which steam
or hot water is circulated, or they can be waterproofed electrical
heating elements.
The drainage conduit 11a (FIG. 1) not only can be utilized for
drainage, but it can also be utilized for back-flushing; i.e.,
water can be pumped through the drainage conduit under pressure to
force water up through the channels 18 and 21 of the porous
superstratum and out through the top surface of the composite
structure to remove dirt, rubber, and other particles from the
channels.
EXAMPLE 1
A concrete runway substrate runway base having a lateral gradient
of 2.degree. is coated with a settable resinous binder of the
following formula: Component Parts
_________________________________________________________________________
_ Epon 828 (Shell Chem. Co.) 100 Triethenediamine or equivalent
base 8 Phenyl glycidyl ether 5 Fluid thiokol (plasticizer) 10
_________________________________________________________________________
_
Immediately after application of the binder, a mixture of crushed
white rock (50 percent 1/4-inch mesh, 30 percent 1/8-inch mesh, and
20 percent 1/16-inch mesh) and the settable resinous binder of the
above formula (221 parts by weight rock to 31 parts by weight
binder; i.e., about 3.5 parts by volume rock to 1 part by volume
binder) are applied to the base at a thickness no less than 6
inches. The mixture of rock and binder are rolled to form a
substantially horizontal upper surface; the mixture is then allowed
to set to form the first porous layer having a porosity of 19
percent. After the above mixture has set, a mixture of slag (50
percent 1/4-inch mesh, 30 percent 1/8-inch mesh, and 20 percent
1/16-inch mesh) and the settable resinous binder of the above
formula (255 parts by weight slag to 34 parts by weight binder;
i.e., about 3.75 parts by volume slag to 1 part by volume binder)
is applied to the first porous layer to a depth of 1 inch. The
mixture of slag and binder is rolled to form a substantially
horizontal surface; the mixture is then allowed to set to form the
upper porous layer having an approximate porosity of 23.7
percent.
The finished composite structure has excellent frictional and
drainage qualities which are ideal for runway surfaces.
The present frictional self-draining pavement structure is
particularly valuable for the prevention of hydroplaning of wheeled
vehicles, including airplanes. Hydroplaning can take place when a
pavement surface is covered with a thin layer, such as
one-sixteenth inch or less, of water and the wheeled vehicle is
traveling at speeds greater than 30 miles per hour, depending on
vehicle weight. When hydroplaning, the wheels of the vehicle lose
contact with the pavement surface which inhibits or prevents
effective steering, guidance and stopping of the vehicle.
Hydroplaning is a very serious problem on rainy days with respect
to high-speed highway driving and airplane landings. The crowning
of roads or runways does not circumvent this problem because water
runs off across the road or runway presenting a layer of water on
the pavement surface. The only practical solution to hydroplaning
is to fabricate roads and runways in accordance with the present
invention which provides for in situ water drainage through the
surface of the pavement structure which in turn prevents liquids
from laking on the pavement surface.
A pavement surface substantially equal to the pavement surface
described above is prepared by employing the settable resinous
binder of the following formula in place of the above-described
binder: Component Parts
_________________________________________________________________________
_ Liquid resin 1010 (Shell Chem. Co.) 100 Hardener Type U (Shell
Chem. Co.) 10 Plasticizer (dimethylcyclohexyl phthalate) 2
_________________________________________________________________________
_
EXAMPLE 2
A used crowned concrete freeway surface having a lateral gradient
of 3 percent is sandblasted to remove loose material and acid
treated to remove oil, gums and rubber. The surface is then sprayed
with an asphalt emulsion. A single layer of 3/8-inch mesh river
gravel is rolled on the asphalt treated surface; the surface is
sprayed again with the asphalt emulsion. After the asphalt emulsion
has solidified, a mixture of river-gravel (1/16-inch to 1/4-inch
mesh) and a liquid settable resin of the following formula:
Component Amounts
_________________________________________________________________________
_ Fluid resin (Applied Plastics Co., #210) 6 parts by weight
Hardener (Applied Plastics Co., 1 part by weight #180) Plasticizer
(General Mills Corp., #125) 10% by volume of fluid resin and
hardener
_________________________________________________________________________
_ Binder (175 parts by weight gravel to 36 parts by weight binder;
i.e., 24 parts by volume gravel to 1 part by volume binder) is
applied to the asphalt treated freeway surface at depth no less
than 4 inches to form the first porous layer; the first layer is
rolled to form a substantially horizontal surface and allowed to
set to form a layer with a porosity of about 20 percent. After the
first porous layer has set, a mixture of scoria (50 percent
1/4-inch mesh, 30 percent 1/8-inch mesh, and 20 percent
one-sixteenth inch mesh) and liquid binder of the above formula
(about 2 parts by weight scoria to 1 part by weight binder, i.e.,
about 2.6 parts by volume scoria to 1 part binder) is applied over
the layer to a depth of about 1 inch to form the second porous
layer. The second layer is rolled to form a substantially
horizontal layer and allowed to set to form a layer with a porosity
of about 24 percent.
The resulting roadway is durable and has excellent frictional and
drainage characteristics.
A pavement surface having properties and characteristics similar to
the above-described pavement surface is prepared by employing the
liquid settable resin of the following formula in place of the
above-described resin: Component Parts
_________________________________________________________________________
_ Liquid resin: Epotuf 37.130 (Reichold Chem. Co.) 100 Hardener:
Epotuf 37-623 (Reichold Chem. Co.) 7.5 Plasticizer: Kesscoflex BCP
(Kessler Chem. Co.) 2.5
_________________________________________________________________________
_
EXAMPLE 3
A substrate surface of hot asphalt "plant mix" applied over a
standard crushed rock base is covered with 1/2-inch screened
crushed quartz aggregate of the character described above. While
the substrate is still in a heated condition, the aggregate layer
is rolled with sufficient pressure to imbed the aggregate particles
about halfway into the soft asphalt layer.
A fluid setting adhesive agent of the following formula is then
applied as by spraying over the aggregate studded substrate
surface: Component Amount
_________________________________________________________________________
_ Fluid resin (Applied Plastics Co., #210) 4 parts by weight
Hardener (Applied Plastics Co., #180) 1 part by weight Plasticizer
(General Mills Corp., #125) 3% by volume of fluid resin and
hardener
_________________________________________________________________________
_
EXAMPLE 4
A substrate of freshly poured and rough-finish concrete having a 4
percent sloped surface is covered with a thin layer of slag
aggregate of 1/2-inch to 1-inch screen size; the surface is then
rolled to imbed the particles about halfway into the concrete.
After the concrete has set, a mixture of the fluid epoxy resin of
the following formula: Component Parts by Weight
_________________________________________________________________________
_ Epon 828 (Shell Chem. Co.) 95 Triethenediamine or an equivalent
base 7 Phenyl glycidyl ether 4.5 Fluid thiokol (plasticizer) 5
_________________________________________________________________________
_ is sprayed over the aggregate layer. Before the resin has set, a
mixture of slag aggregate (1/2-inch to 1-inch mesh) and the fluid
epoxy resin of the above formula (3.5 parts by volume slag to 1
part by volume resin) is applied to the cement base to a depth of
12 inches. The mixture is rolled to form a substantially horizontal
surface and then allowed to set to form the first porous layer. A
mixture of scoria (1/4-inch to 1/16-inch mesh) and the fluid epoxy
resin of the above formula (3.75 parts by volume scoria to 1 part
by volume resin) is spread over the first porous layer to a depth
of about 1 inch. The material was tamped and rolled to form a
substantially horizontal surface which has excellent frictional
qualities and drainage qualities.
In the same manner old concrete roadways or runways can be
resurfaced; however, the old surface should be pretreated first by
sandblasting or abrading mechanically an acid washing the surface
to remove dirt, gums, rubbers and other oxidized materials
therefrom.
EXAMPLE 5
An upper surface of an aluminum foraminous structural panel is
cleaned with detergent and water and allowed to dry. The surface is
then cleaned with a petroleum spirit to remove grease, oil and
gums. The surface is then sandblasted and wire-brushed to remove
all loose material and prepare a clean metal uncovered surface. A
catalyzed setting adhesive resin of a phenolic epoxy or
silicon-type having a viscosity of about 400 to 5,000 centipoises
is applied as a coating to the cleaned surface. Dry scoria
aggregate (1/4-inch to 3/8-inch mesh) is applied to the treated
surface before the resin has been allowed to set. A dough-like
mixture of crushed light quartz (1/4-inch mesh) and a catalyzed
setting adhesive resin of the phenolic epoxy or silicon-type (about
3.5 parts by volume rock to 1 part resin) is applied to a depth of
2 inches over the metal substrate. The material is rolled to form a
substantially horizontal surface and allowed to set to form the
first porous layer. A dough-like mixture of scoria (1/8-inch mesh
and a catalyzed setting adhesive resin of the phenolic epoxy or
silicion-type (3 parts by volume scoria to 1 part by volume resin)
is applied to a depth of one-half inch over the first porous layer.
The material is tamped, rolled and troweled to form a substantially
horizontal layer and then allowed to set to approximately 24 hours
to form a highly frictional lightweight surfacing material. This
surfacing is ideally suited for marine decking, traffic decking for
bridges, and for a lightweight highly insulative roofing
material.
EXAMPLE 6
A substrate of freshly poured and rough-finish concrete having a 5
percent sloped surface is covered with a thin layer of an 80:20
mixture of slag:score aggregate of 1/2-inch to 1-inch screen size;
the surface is then rolled to imbed the particles about halfway
into the concrete. After the concrete has set, a mixture of the
fluid epoxy resin of the following formula: Component Parts
_________________________________________________________________________
_ Liquid resin: Epi-rex 510 (Celanese) 100 Hardener: Epicure 872
(Celanese) 5 Plasticizer: dioctylphthalate 5
_________________________________________________________________________
_ is brushed over the aggregate layer. Before the resin has set, a
mixture of 50:50 granite:slag aggregate (1/2-inch to 1-inch mesh)
and the fluid epoxy resin of the above formula (3.0 parts by volume
of the aggregate mixture to 1 part by volume resin) is applied to
the cement base to a depth of 12 inches. The mixture is rolled to
form a substantially horizontal surface and then allowed to set to
form the first porous layer. A 60:40 mixture of slag:scoria
(1/4-inch to 1/16-inch mesh) and the fluid epoxy resin of the above
formula (3.75 parts by volume of the slag:scoria mixture to 1 part
by volume resin) is spread over the first porous layer to a depth
of about 2 inches. The material was tamped and rolled to form a
substantially horizontal surface which has excellent frictional
qualities and drainage qualities.
In the same manner old concrete roadways or runways can be
resurfaced; however, the old surface should be pretreated first by
sandblasting or abrading mechanically an acid washing to remove
dirt, gums, rubbers and other oxidized materials therefrom.
Although the above examples have illustrated the composite
structure of the present invention in runway, highway bridge
decking, and roofing applications, it is not contemplated that the
present invention be limited to such uses.
* * * * *