Patent Application
20230257941
Paved surfaces (roadways, parking lots, driveways, sidewalk, trails, and patios) of concrete or asphalt that include joints between portions of the paved surface, are susceptible to erosion (e.g. concrete spalling and subbase failures) in, at, and around the joints. Erosion occurs when water, fuel, or salt, and combinations thereof, contacts the joint, where the water, fuel, or salt and combinations thereof infiltrates the joint and the seam between the joint and paved structure to erode the paved surface and the subbase (e.g. gravel or dirt) underneath the paved surface. This erosion weakens the structural integrity of the paved surface leading to crumbling or fracturing of the paved surface. Erosion is hastened by temperature changes (freezing and thawing) of the ground that cause movement and breakage of the paved surfaces, in particular, at the joints of paved surfaces.
This damage produces an uneven surface affecting the ability to easily travel over and around the paved surface on foot or in a vehicle. The damage produced from this erosion effects the usability and safety of the paved surface decreasing the amount of time before repair or replacement.
Conventional methods for installing and repairing joints of paved surfaces include using tar-based materials that are installed in the paved surface joints. The installation of these tar-based materials includes installing backer rod and then placing tar-based material below the paved surface, such that the height of the tar-based material is less than the height of the paved surface (i.e. not flush with the paved surface). Installation in this manner is done because the tar-based material does not adhere to the paved surface, so any tar-based material flush with or above the paved surface is more easily caught and peeled out of the paved surface by traffic (e.g. vehicles, snow plows) traversing the paved surface. Additionally, installation of the tar at the top of the paved surface speeds the peeling of the tar-based material when the paved surface is treated with salt. The salt treatment draws moisture (water) out of the tar-based material, drying the tar-based material, and in combination with being level at the paved surface hastening peeling. Installation of the tar-based material in the conventional manner has the drawback of allowing erosion at the joint because water can pool and infiltrate at the low point of the tar-based material at the joint. Longevity for tar based applications is approximately one (1) to two (2) years in length, where after this time erosion requires replacement of material.
Similar to tar-based materials, another conventional method for installing and repairing joints of paved surfaces includes using polyurethane, silicone, and caulk materials (referred to as caulk) that are installed in the paved surface joints. The installation of caulk includes installing the caulk material below the paved surface, such that the height of the caulk material is less than the height of the paved surface. Installation in this manner is done because the caulk material does not adhere to the paved surface, so any amount of material level with or above the surface is more easily caught and peeled out of the paved surface by traffic (e.g. vehicles, snow plows) traversing the paved surface. Longevity for polyurethane, silicone, and caulk materials is approximately one (1) to two (2) years in length, where after this time erosion requires replacement of material.
Additionally, installation of the caulk at the top of the paved surface speeds the peeling of the polyurethane material when the paved surface is treated with salt. The salt treatment draws moisture (water) out of the caulk, drying the polyurethane material, and in combination with being level at the paved surface hastening peeling. Installation of caulk in this manner has the drawback of allowing erosion at the joint because water can pool and infiltrate at the low point of the caulk at the joint.
While caulk is designed to provide a watertight seal against the joint, the caulk is not temperature resistant, nor salt resistant, and as the paved surface fluctuates the caulk is pulled away from the structure and/or concrete producing holes to open the paved surface to water, salt, and fuel, hastening erosion.
Another conventional method of repairing a paved surface joint includes applying cold patch to the eroded joint. Cold patching damaged joints does provide a level surface. However, the cold patch is not waterproof, so immediately after patching water begins the erosion process both at the joint and where the cold patch meets the concrete or asphalt. Additionally, the cold patch does not adhere to the paved surface such that fluctuations in temperature cause the cold patch to be pushed out of the joint, further leading to erosion from water, fuel, and salt exposure. Moreover, cold patches are not conventionally used along the entire length of a joint because of the inability of the cold patch to withstand temperature fluctuations. Longevity of the cold patch is approximately six months to one year in length, where after this time erosion requires replacement of the cold patch.
Another conventional method for repairing the joint and paved surface is complete replacement of the portion of the paved surface that contains erosion to ultimately create new joints. However, the new paved surface will immediately after installation begin the erosion process at the joints of the structure. Additionally, complete replacement of the paved surface is time consuming (paved surface replacement requires approximate cure times as follows: 1 day to receive foot traffic, 3 days to receive light traffic, 7 days to receive heavy traffic (i.e. semis), and 28 days to reach full strength) and requires more material than repairing or patching the joint.
It is therefore desirable to have a method for repairing the joints of paved surfaces that provides longevity of use (i.e. more than one year before another repair must be made, and preferably more than two years and up to 10 years before another repair must be made). It is further desirable to have a method of repairing or installing joints of paved surfaces that is resistant to damage (i.e. cracking, creation of a gap) during temperature changes. It is further desirable to have method of repairing or installing joints of paved surfaces that takes less than three hours to complete repair. Finally, it is desirable to have a method of repairing or installing joints of paved surfaces that are level with the paved surface to reduce erosion contributing to longevity of use.
In aspects, a method of installing a mastic joint that is water, fuel, salt, and temperature resistant at a paved surface, the method including cutting the paved surface based on predetermined parameters forming a joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; preparing the joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the mastic joint.
In aspects, the method of paragraph [0010], wherein the paved surface is a surface material of concrete.
In aspects, the method of paragraph [0010], wherein the paved surface is a surface material of asphalt.
In aspects, the method of paragraph [0010], wherein preparing the joint comprises applying denatured alcohol to the adjacent paved surface.
In aspects, the method of paragraph [0011], wherein the minimum depth is equal to the depth of the paved surface.
In aspects, the method of paragraph [0010], wherein the width is from 0.9525 to 4.0 centimeters.
In aspects, the method of paragraph [0010], wherein the width is from 0.9525 to 3.175 centimeters.
In aspects, the method of paragraph [0010], further comprising cutting the paved surface based on predetermined parameters forming a second joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the second joint; preparing the second joint; applying hot mastic to the second joint to install a second mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the second mastic joint, wherein the application forms a mastic joint intersection between the mastic joint and the second mastic joint.
In aspects, a method of installing a mastic joint that is water, fuel, salt, and temperature resistant at a paved surface where the mastic join has a structure at its terminus, the method comprising forming the paved surface based on predetermined parameters forming a joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; preparing a joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 25% to 40% of the mastic joint.
In aspects, the method of paragraph [0016], wherein the paved surface is a surface material of concrete.
In aspects, the method of paragraph [0016], wherein the paved surface is a surface material of asphalt.
In aspects, the method of paragraph [0016], wherein preparing the joint comprises applying denatured alcohol to the adjacent paved surface and structure.
In aspects, the method of paragraph [0017], wherein the minimum depth is equal to the depth of the paved surface.
In aspects, the method paragraph [0016], further comprising forming the paved surface based on predetermined parameters forming a second joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the second joint; preparing the second joint; applying hot mastic to the second joint to install a second mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the second mastic joint, wherein the application forms a mastic joint intersection between the mastic joint and the second mastic joint.
In aspects, a mastic joint of a paved surface, the mastic joint comprising, parameters that provide water, fuel, salt and thermal resistance, where the parameters comprise a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; wherein the mastic joint is produced by making a joint of the paved surface to the parameters; preparing a joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base with a bulking stone, where the bulking stone is from 20% to 35% of the mastic joint.
In aspects, the method of paragraph [0013] wherein preparing the joint further comprises applying a primer to the adjacent paved surface.
As used herein, the following terms have the accompanying defined meaning:
“Mastic” means a material for hot application that is a polymer binder with factory blended fillers, fine aggregate, and fibers, including reinforcing (bulking) stone (e.g. granite aggregate) having the capability of (1) withstanding motor vehicle (including semis) weight without deformation of the mastic, (2) adhering to surface material and any structure at the terminus of a joint, (3) preventing melting or deteriorating of the surface material or the plastic of any structure at the terminus of a joint, (4) resisting water, fuel, and salt (i.e. the mastic resists infiltration by water, fuel, salt, and mixtures thereof), (5) resisting thermal fluctuations (i.e. the mastic remain flexible under temperature changes to maintain adhesion to the surface material).
“Bulking stone” means a fine aggregate that provides volume when added to the mastic, where the fine aggregate is from 0.3175 to 0.635 centimeters (0.125 to 0.25 inches). The bulking stone may be of any material that is non-reactive with the mastic, such as, granite, quartz, limestone, pea gravel, and the like.
“Joint” means the area between portions of a paved surface.
“Surface material” means the material of a paved surface and includes concrete or asphalt.
“Structure” means a fabricated installation that includes steel and may include concrete, where the steel and/or concrete is in contact with the surface material concrete or asphalt. For example, structures include manholes, spill buckets, and fuel islands, where the fuel island includes canopy column(s), fuel pump island, and bumper posts.
A method of installing mastic joints on a paved surface is described. The method of installing mastic joints may be used as a repair (i.e. erosion of the paved surface at the joint) or in connection with a new installation of the paved surface. The method of installing mastic joints made include installation with joints that have a structure at the joint terminus. The method produces a joint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic joint that is thermally resistant (i.e. the mastic remains flexible at varying temperatures such that adherence of the mastic to the adjacent surface material is maintained). In repairs, the mastic joint of the method provides longevity of use of at least one year and up to 5 years prior to any repair or replacement. In new installations, the mastic joint provides longevity of use of at least 1 year and up to 10 years prior to any repair or replacement when in regions having a freeze and thaw cycle similar to that of the Midwest region. Finally, the method of installing a mastic joint does not affect the structural integrity of the adjacent or surrounding paved surface, where the adjacent or surrounding surface material does not require repair or replacement sooner than if the method had not been deployed.
The parameters of the mastic joint that provide water, salt, fuel (and mixtures thereof) and thermal resistance are a width and depth of the mastic joint. The width of the mastic joint is from 0.9525 to 5.080 centimeters (0.375 to 2.00 inches (in.)). Preferably, the width of the mastic joint is from 0.9525 to 4.0 centimeters (0.375 to 1.5748 in.), and most preferably, the width of the mastic joint is from 0.9525 to 3.175 centimeters (0.375 to 1.25 in.). The width (in connection with the depth) ensures that there is sufficient area between the adjacent surface material to install the mastic joint according to the method 100 for adherence of the mastic joint to the adjacent surface material, including the surface material or subbase below the joint. For example, the width 204 of the mastic joint of
The width is also determined by correcting any existing erosion while not exceeding the maximum width of 5.080 centimeters (2.00 inches), while selecting a width as close to the preferred widths as possible to still correct the erosion. For example, in a repair if erosion of the joint is of a width greater than 2.54 cm (1 in.) a width greater than 2.54 cm and less than 5.080 centimeters (2.00 inches) is selected, most preferably of 3.175 cm (1.25 in.) if this preferred width will remove erosion of the paved surface. If the most preferred width will not remove erosion of the paved surface the preferred width is evaluated to determine if this preferred width will remove erosion.
The parameter of depth of the mastic joint provides water, fuel, salt, and thermal resistance is determined based on the surface material depth. The mastic joint may be full depth of the paved surface (i.e. the depth down to the subbase). The mastic joint may be partial depth of the paved surface. In instances where the mastic joint is partial depth, the minimum depth of the mastic is at least and including 2.54 centimeters (1 inch) to provide the water, fuel, salt and thermal resistances. When the mastic joint is used as a repair, partial depth repair is not done when the surface material that would be directly below the mastic joint shows signs of erosion or damage, such that the surface material directly below the joint must be intact without erosion for a partial depth replacement. Preferably, when the mastic joint is installed as part of a new installation, the mastic joint depth is at least from 2.54 centimeters (1 inch) or greater. For example,
The parameter of width and depth must also provide a minimum surface area of contact with the adjacent paved surface to ensure proper adhesion of the mastic to the paved surface to prevent water, salt, fuel, and combinations thereof from infiltrating the seam between the mastic joint and the paved surface. Preferably, the minimum surface area of all sides of the mastic joint (both sides and bottom) in contact with the adjacent paved surface or subbase, as measured on a 2.54 centimeters (1 inch) cross section is 7.62 square centimeters (3 square inches). Thus, the width and depth of the mastic joint must be determined to meet this minimum surface area. For example the sides making up the surface area are represented by 308 in
The parameter of levelness of the mastic joint with the paved surface provides protection from cracking and peeling of the mastic joint from the joint. Levelness of the mastic joint means that the mastic joint is substantially flush with the paved surface, where substantially means that the mastic joint extends from 0 to 5 millimeters above the paved surface. For example,
In 104, a joint is prepared for receiving the mastic. The joint preparation may include ensuring the subbase is level at the predetermined depth, which may include removing debris, adding subbase material and/or smoothing the subbase. Preparation of the joint may further include removal of any rust, dirt, or debris from the adjacent paved surface, such as through sandblasting.
Preparation of the joint further includes ensuring the joint and adjacent paved surface is dry and the pores of the surface material and structure are clean to create binding elasticity between the mastic and the surface material and structure. Preparation of the joint includes application of denatured alcohol, which may be followed by application of a primer (e.g. mastic primer, water-based elastomeric coating and sealant that is acrylic resin) to the adjacent paved surface and structure to promote adherence of the mastic to the adjacent paved surface. Preparation of the joint provides for maximum adherence of the mastic to the adjacent paved surface and subbase, while using the least amount of mastic, thus increasing the efficiency of the installation process.
In 106, the mastic is applied to the prepared joint forming the mastic joint. The mastic is applied in accordance with mastic manufacturer specifications. The application of the mastic includes applying the mastic to the joint hot, while mixing the mastic base (i.e. mastic without bulking stone added) with bulking stone, where from 20%-40% of the mastic is bulking stone (i.e. bulking stone percentage). More preferably the bulking stone is from 20-35% of the mastic. The percentage of bulking stone in the mastic is dependent on the width and volume of the joint, where a joint having a greater width or volume requires a higher percentage of bulking stone of the mastic. Preferably, the mastic is not placed in lifts exceeding 7.62 centimeters (3 inches) in height to speed with cooling. Applying the mastic may include phased application. Cooling of the mastic in partial depth applications to cure for receiving traffic takes approximately 1 hour for foot traffic and all vehicle traffic. Cooling of the mastic in full depth application to cure for receiving foot traffic takes approximately 30 minutes to 2 hours for foot traffic and all vehicle traffic.
Preferably, the mastic is applied to the entire length of the joint, including where joints intersect. For example, as represented in
This application claims the benefit of U.S. Provisional Application No. 63/310,664 entitled “METHOD OF INSTALLING A MASTIC JOINT” filed Feb. 16, 2022, which is incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63310664 | Feb 2022 | US |
