Pavement joint and joint making process

Abstract

A pavement joint and joint making process are provided. A pavement edger used to make the joint is capable of creating a stepped tapered ramp having a highly compacted step and a highly compacted upper portion of the tapered portion. The resulting ramp allows for safety during pavement laying work stoppage and creation of solid pavement joints.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates generally to paving and, more particularly, to a pavement joint and joint making process.

2. Related Art

Typically, screed pavers include a self-propelled paving machine having a hopper for receiving paving material, e.g., asphalt, from a truck so that the truck progressively dumps its load of paving material into the hopper. A conveyor system on the paving machine transfers paving material from the hopper rearwardly for discharge onto the roadbed in front of transversely arranged screw augers which spread the material laterally in front of a main screed. This main screed functions to compress and level the paving material distributed by the augers to give a smooth finished road surface. The height and attack angle of the main screed may be varied to control the depth and surface of the pavement mat. The main screed may also include screed extenders to allow for a wider pavement mat to be laid.

One of the problems in paving of multiple lanes, especially on high speed interstate highways, is the drop off at an edge of a new pavement mat. During paving operations, it is oftentimes impossible to pave two lanes in a short time span due to a variety of reasons, e.g., traffic, equipment shortages, etc. One reason, in particular, is time constraints caused by the paving crew having to back up and start the second or closure pass on a two lane paving operation at mid-day. Where more than two lanes are being paved, the paving crew must back up at least twice during the day to minimize drop off length on both lanes being paved. Despite the drop off problem, it has become common practice for paving crews to pave only a single lane during one paving day to avoid having to back up. The entire length of this pass therefore becomes a drop off. Where an edge must be left overnight, a drop off of up to 1½ inches has not been considered objectionable for a short distance.

While a drop-off is usually only an overnight or weekend problem, it creates safety problems such as: vehicle wheels becoming caught on the drop off during lane changes onto or from the new mat, and loose stones/aggregate being kicked up by vehicles. In response to these safety problems, federal and some state highway contracting regulations are now mandating that any drop off between a new pavement mat and any adjacent material, e.g., un-repaved asphalt, shall not have a height over one inch unless a paved ramp is provided from/to the new pavement mat. Because it is often highly undesirable to lay a new layer of pavement of an inch or less, in most cases when one lane is laid, it must be provided with a ramp.

Ramps, unfortunately, create a number of other problems. One problem is at the beginning or ending of a mat, the wedge section must be adjusted manually during the transition, thus increasing the potential for an unacceptable section of pavement. Another problem with ramps is that they make it more difficult to create solid joints.

To address the joint creation and drop off problems, the concept of the “tapered joint” ramp was developed. At least two versions of tapered joints are in use: First, as shown in FIG. 1A , the “Jersey Unit,” as developed in the state of New Jersey during the 1980's, includes a first pavement mat 6 including a ramp 1 having a tapered portion 2 extending from a surface 3 of an adjacent and/or underlying material 4 directly up to a horizontal surface 5 of a new pavement mat 6 . Second, as shown in FIG. 1B , the “Stepped Tapered Joint,” as currently used in the state of Michigan, includes a first pavement mat 16 including a ramp 11 having a tapered portion 12 extending from a step 12 B to a second step 12 A on a surface 13 of an adjacent and/or underlying material 14 . The stepped tapered joint is basically a stepped jersey unit.

While tapered joint ramps cure the drop off problem, it unfortunately remains extremely difficult to form a solid long-lasting joint for the reasons that follow.

In terms of the jersey unit, a number of problems arise:

First, traffic which crosses over tapered portion 2 of ramp 1 partially compacts a line 7 between horizontal portion 5 of pavement mat 6 and tapered portion 2 of ramp 1 . This compaction makes it very difficult or impossible to discern the actual edge of mat 6 during laying of a second pavement mat 8 , shown in phantom in FIG. 1 A. As a result, either ramp 1 must be removed or very precise paving machine operation is required to follow an almost non-existent edge 7 of first pavement mat 6 . When second pavement mat 8 is laid over ramp 1 , frequently the result is a feathered joint 9 where second pavement mat 8 lays over ramp 1 but does not have its edge meet cleanly with edge 7 of first pavement mat 6 , i.e., either second pavement mat 8 is short of edge 7 or passes over edge 7 . Feathered joint 9 is problematic because it may include a visible rut between pavement mats that can lead to deterioration and ravel under traffic. Additionally, water may gain easy access through feathered joint 9 and under second pavement mat 8 which may cause roadway heaving or separation problems.

Second, full compaction is oftentimes only applied to the horizontal part of first pavement mat 6 . Tapered portion 2 of ramp 1 is normally only exposed to that compaction provided by the screed that forms it and whatever traffic crosses it. See e.g., U.S. Pat. No. 4,181,449 to Lenker, and U.S. Pat. No. 4,818,140 to Carlson. As a result, tapered portion 2 includes a low density area 10 which by the time second pavement mat 8 is laid has cooled and is extremely resistant to further compaction. Second pavement mat 8 does not contain a sufficient amount of hot material over low density area 10 to allow further compaction. The resulting joint therefore is immediately suspect.

Third, because the outermost extent of tapered portion 2 must be created by pavement material at its core particle size, e.g., small stones, it is oftentimes impossible to construct the outermost extent of tapered portion 2 such that it irremovably compacts into the rest of tapered portion 2 and/or adjacent/underlayer material 4 . As a result, a loose aggregate safety problem persists.

Referring to FIG. 1B , the stepped tapered joint ramp was developed to alleviate the problems of raveling and edge following. By providing a step 12 B at an edge 17 of new pavement mat 16 , a feathered edge is prevented. Further, step 12 B provides a defined line or edge 17 which alleviates the problem of having to follow an undecipherable compacted edge of first pavement mat 16 . Unfortunately, the compaction problem for the tapered or wedge section 12 remains, i.e., a low density area 20 that is resistant to compaction exists. Further, if the proper height for step 12 B is not incorporated, e.g., because different asphalt formulations have different compaction ratios, step 12 B can be rolled out of existence when the rest of first pavement mat 16 is compacted.

One remedy for the joint creation problems of ramps has been to remove the ramps prior to laying the second pavement mat. Unfortunately, this process is very time consuming and difficult because the material has cooled and hardened. It may also necessitate additional lane closure to accommodate equipment.

In view of the foregoing, there is a need for a pavement edger, machine, ramp and joint, and processes for making the ramp and joint which allow for accommodation of drop off from a new pavement mat and the creation of solid pavement joints.

SUMMARY OF THE INVENTION

In a first general aspect of the invention is provided a process of forming a stepped tapered pavement joint comprising the steps of: laying a first pavement mat having an edge, and forming a highly compacted step on the edge of the first pavement mat and a highly compacted tapered portion extending away from a substantially vertical face of the step; laying a second pavement mat adjacent the first pavement mat such that an edge of the second pavement mat abuts the vertical face; and compacting the second pavement mat to form a joint.

In a second general aspect of the invention is provided an asphalt joint comprising: a first asphalt section mating with a second asphalt section to form a substantially seamless joint with the second asphalt section, the second asphalt section including a first step and a ramp portion extending away from a lower portion of the first step, and wherein the first step and at least a section of the ramp portion are highly compacted prior to the first asphalt section mating with the second asphalt section.

In a third general aspect of the invention is provided an asphalt joint made by the process comprising the steps of: laying a first pavement mat having an edge, and forming a highly compacted step on the edge of the first pavement mat and a highly compacted tapered portion extending away from a substantially vertical face of the step; laying a second pavement mat adjacent the first pavement mat such that an edge of the second pavement mat abuts the vertical face; and compacting the second pavement mat to form a joint.

The above asphalt joint and joint making process solves many of the above described joint problems such as: rounded edges from traffic creating feathered joints, and lack of full compaction because of hardened and compaction resistant tapered portions.

The foregoing and other features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:

FIGS. 1A-1B are side views of prior art pavement mat edges;

FIG. 2 is a perspective view of a paving machine equipped with an edger in accordance with the present invention;

FIG. 3 is a front perspective view of the edger;

FIG. 4 is a front elevational view of a first embodiment of the edger mounted to the paving machine;

FIG. 5 is a front elevational view of a second embodiment of the edger mounted to the paving machine;

FIG. 6 is a front elevational view of the edger in a retracted position;

FIG. 7 is a rear perspective view of the edger in operation;

FIG. 8 is a side elevational view of the edger in operation as viewed from within the screed;

FIG. 9 is a front elevational view of a flexible seal strike off for the edger in accordance with an embodiment of the invention; and

FIG. 10 is a top view of the strike off on the edger;

FIG. 11 is a cross-sectional view of a pavement ramp created with the edger in accordance with the invention; and

FIG. 12 is a cross-sectional view of a joint in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Although certain preferred embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of the preferred embodiment.

For definition herein, a “mat” or “pavement mat” is considered a layer of paving material. A “step” is considered an offset area where a substantially vertical surface meets another surface. “Paving material” is any material used for paving roadways, such as bituminous material like asphalt.

For initial reference, attention is directed to FIG. 11 which illustrates a ramp 100 created in accordance with the present invention. Ramp 100 includes a step 111 on an edge 110 of pavement mat 102 and a tapered portion 108 extending away from a vertical face 112 of step 111 . Step 111 and at least a section, e.g., upper end 114 , of tapered portion 108 are compacted between 85% and 93% of complete compaction of the paving material to create highly compacted areas 118 , 120 . By “highly compacted” is meant that paving material is compacted between 85% to 93% of its complete compaction, a percentage higher than if paving material was simply leveled by a screed 40 . Screeding normally only provides a compaction rate of 80% or less. A second step 116 is also provided at a lower end 115 of tapered portion 108 . Tapered portion 108 may also include a flattened portion 117 at lower end 115 . Ramp 100 will be discussed in more detail below.

Referring to FIG. 2 , a paving machine 30 equipped with an edger or pavement edge maker 50 of the present invention is illustrated operating to spread and grade paving material 32 , e.g., a paving road mix such as asphalt, etc., on an adjacent surface 34 to form pavement mat 102 with a ramp 100 on its edge or shoulder. The paving machine 30 has a rear main screed 40 extending from an upright moldboard 42 . Elevation of screed 40 is determined by adjustment of a pair of tow arms 44 pivotally connected to a supporting frame 46 for moldboard 42 and screed 40 . Asphalt mix carried by paving machine 30 is spread laterally in front of moldboard 42 by augers (not shown) which are spaced forwardly of moldboard 42 . Paving machine 30 may also include an optional screed extender 48 ( FIGS. 4-7 ) to extend screed 40 and/or a vertically adjustable end gate 49 (FIGS. 3 - 7 ), as are commonly known in the art. End gate 49 may include a vertically adjustable sled 47 , as is conventional.

Referring to FIGS. 3-8 , edger 50 is illustrated in more detail. Edger 50 includes a first compaction surface 52 , a second compaction surface 53 and a third substantially vertical compaction surface 54 . Compaction surfaces 52 , 53 , 54 are preferably constructed of metal plating, e.g., steel plating. Compaction surfaces 52 , 53 , 54 have a special alignment to create ramp 100 in accordance with the present invention. In particular, compaction surfaces 52 , 53 are angled upwardly at an angle α relative to a forward direction of travel A of paving machine 30 to receive and compact paving material 32 thereunder. Similarly, third compaction surface 54 is also angled upwardly at angle α along a lower edge 59 thereof. The angle α is less than 45° so as to allow receipt and compaction of paving material 32 without plowing thereof. First compaction surface 52 is fixed relative to edger mounting plate 88 and may include support structure 55 between a back surface thereof and an edger mounting plate 88 . Compaction surfaces 53 , 54 are vertically adjustable relative to first compaction surface 52 as will be further described below.

Third compaction surface 54 is substantially vertical, as best seen in FIGS. 4-5 , and is also angled in a horizontal lateral direction B at an angle β, as best seen in FIG. 3 . Horizontal lateral angle β allows compaction surface 54 to receive and compact paving material 32 horizontally to form substantially vertical face 112 . To accommodate angle β and to prevent material from passing between first and third compaction surfaces 52 , 54 , first compaction surface 52 includes mating angled edge 61 created by having a rearward lower edge 58 shorter than a forward upper edge 60 . Similarly, second compaction surface 53 may also include a rearward lower edge 62 that is longer than a forward upper edge 64 to accommodate angle β and to assure that outermost edge 70 of second compaction surface closes against end gate 49 when retracted, as will be discussed below. First compaction surface 52 may also include a curved edge 56 to accommodate paving material 32 adjacent thereto.

As best shown in FIGS. 4-5 , rearward lower edge 62 of second compaction surface 53 is angled at an angle Δ relative to horizontal lateral direction B to create tapered portion 108 , as will be described below. Second compaction surface 53 is preferably pivotally mounted to third compaction surface 54 by a hinge 66 to allow for adjustment of angle Δ. Adjustment of angle Δ has two effects: first, it alters angle Δ of tapered portion 108 , and second, either alone or in combination with vertical adjustment, it varies the height of second step 116 on lower end 115 of tapered portion 108 . Second step 116 is created between second compaction surface 53 and end gate 49 , which acts as a fourth compaction surface.

Angular adjustment of second compaction surface 53 relative to either moldboard 42 or optional end gate 49 , along with vertical movement of optional end gate 49 , may create a gap between second compaction surface 53 and the above structures. To prevent passage of paving material 32 therethrough, a flexible seal strike off 68 is provided on outer edge 70 of second compaction surface 53 . As shown in FIGS. 9 and 10 , flexible seal strike off 68 is preferably a flexible sheet of spring steel 72 having a beveled corner 74 and a connection flap 76 . Strike off 68 is attached, e.g., by welding, bolting, etc., by connection flap 76 to second compaction surface 53 and extends generally upwardly therefrom. As angle Δ of third compaction surface 53 and/or vertical movement of end gate 49 varies, strike off 68 flexes to accommodate the gap and maintain a strike off surface, as best shown in FIGS. 4-5 and 10 . If end gate 49 is ever raised above second compaction surface 53 , beveled corner 74 allows for re-mating and gradual flexing of strike off 68 against end gate 49 .

Referring to FIGS. 4-5 , edger 50 also preferably includes an adjustment system 80 . Adjustment system 80 can adjust the depth of third compaction surface 54 and second compaction surface 53 , relative to first compaction surface 52 ; adjusts angle Δ of second compaction surface 53 ; and can also operate as a retraction mechanism for second and third compaction surfaces, 53 , 54 as will be described below. Adjustment is preferable to accommodate varying system characteristics, e.g., different paving material 32 having different compaction ratios, change in atmospheric temperature, different screeds, screed extenders or end gates, etc. Preferably, adjustment system 80 is adjustable to allow for pavement mats with a thickness ranging from approximately 1 inch to 5 inches uncompacted, i.e., ¾ inches to 4 or more inches compacted. It should be recognized, however, that if characteristics are known to be constant or fairly constant, that a fixed device is considered within the scope of the invention. In this circumstance, compaction surfaces 52 , 53 , 54 would be fixed in position. Strike off 68 , if necessary, would also be fixed, e.g., a welded plate.

Retraction is preferable because it allows edger 50 to operate as an edger and as a screed joint maker for creation of joint 101 of FIG. 12 . Hence, edger 50 can crate ramp 100 and also joint 101 without having to remove any parts from paving machine 30 or edger 50 .

In order to vertically adjust second and third compaction surfaces 53 , 54 , in a first preferred embodiment shown in FIG. 4 , adjustment system 80 includes a threaded vertical adjustment crank 82 which is fixedly attached at a lower end 84 thereof to third compaction surface 54 . Vertical adjustment crank 82 threads into a threaded mount 86 fixedly coupled to edger mounting plate 88 . Third compaction surface 54 is pivotally coupled to a pivot plate 81 which is fixed to first compaction surface 52 . A pivot pin 83 extends through pivot plate 81 into third compaction surface 54 . By turning vertical adjustment crank 82 , second and third compaction surfaces 53 , 54 are vertically adjusted as crank 82 is held by threaded mount 86 . Third compaction surface 54 may include a rounded rear edge to accommodate pivoting motion, if necessary.

As shown in FIG. 6 , second and third compaction surfaces 53 , 54 can also be retracted such that their lowermost edges are even or flush with rearward edge 58 of first compaction surface 52 and/or screed 40 an/or screed extender 48 . The edges that second and third compaction surface 53 , 54 will be flush with will depend on the vertical positioning of edger 50 by a vertical positioning system 150 , discussed below, and the degree of retractability of surfaces 52 , 54 . In its fully retracted position, outermost edge 70 of second compaction surface 53 is substantially flush with an inner surface of end gate 49 such that flexible seal strike off 68 is not in use. In this retracted position, edger 50 need not be removed during the laying of a second pavement mat 130 , as shown in FIG. 12 , and can operate as a joint maker.

Referring to FIG. 5 , an alternative embodiment for vertical adjustment is shown. In this embodiment, rear edges of second and third compaction surfaces 53 , 54 may be held to edger mounting plate 88 by channels (not shown) or other structure to allow for translational vertical movement. Otherwise, vertical adjustment works in the same way as with the first embodiment.

Adjustment system 80 also includes angular adjustment crank 90 to vary angle Δ of second compaction surface 53 . As noted above, second compaction surface 53 is pivotally attached to lower edge 59 of third compaction surface 54 by a hinge 66 . At a lower end 92 , angular adjustment crank 90 is fixedly and pivotally attached to second compaction surface 53 on an upper side thereof. Angular adjustment crank 90 also is coupled to vertical adjustment crank 82 by element 94 . Element 94 is fixedly attached at one end 95 to vertical adjustment crank 82 and holds threaded mount 96 for angular adjustment crank 90 at a second end 97 . As vertical crank 82 is moved, angular adjustment crank 90 and, hence, second compaction surface 53 , moves with vertical crank 82 because of element 94 . To adjust angle Δ, crank 90 is turned to either increase or decrease the distance between second compaction surface 53 and threaded mount 96 . As noted above, adjustment of angle Δ has two effects: it alters the angle of tapered portion 108 , and it varies the height of second step 116 on lower end 115 of tapered portion 108 . Hence, either vertical or angular adjustment can vary the height of step 116 .

It should be recognized that while a particular adjustment system 80 has been illustrated, that a variety of different mechanisms are possible. Accordingly, the scope of this invention should not be limited to any particular adjustment mechanism. It should also be recognized that any other structural elements that may be necessary to retain compaction surfaces 52 , 53 , 54 in proper positioning may also be provided. For instance, channel members (not shown) may be provided on edger mounting plate 88 to mate with parts of compaction surfaces 52 , 53 , 54 , e.g., channel slide members, to direct movement and retain the surfaces relative to edger mounting plate 88 .

Edger 50 can be mounted to a front side of screed 40 or screed extender 48 by edger mounting plate 88 and an adjustable system of bolts 76 and slots 78 , as shown in FIGS. 3-5 . It should be recognized, however, that any system which allows for quick connection of edger 50 to screed 40 or screed extender 48 may be utilized. A quick connection is preferable because edger 50 may have to be removed for transport, especially when mounted in screed extender 48 .

In a preferred embodiment, edger 50 is mounted to screed 40 or screed extender 48 by an edger positioning system 150 , as shown in FIGS. 3 and 8 . Edger positioning system 150 can be any device 152 that allows vertical adjustment of edger 50 relative to screed/extender 40 , 48 . Vertical adjustment is required for start up and ending a pavement mat, or paving on or off bridges. In a preferred embodiment, edger positioning system 150 is constituted by a hydraulic ram system 156 , as shown in FIG. 8 . Other possibilities, for edger positioning system 150 are spring biased systems, or motorized systems, etc. Edger positioning system 150 can be mounted to screed 40 or screed extender 48 by a bolt and slot systems 154 , or the above mentioned quick connect systems (not shown).

In pavement mat starting operation, end gate 49 , screed 40 and screed extender 48 , if provided, would be in contact with adjacent surface 34 . If edger positioning system 150 is an automatic type device, e.g., a hydraulic ram system 156 , it is preferable to have edger 50 positioned out of contact with adjacent surface 34 , i.e., with second compaction surface 53 out of contact. Alternatively, if edger positioning system 150 is a spring-biased system, edger 50 may be in ground contact and biased upwardly. As paving machine 30 proceeds to begin paving operations, screed 40 and screed extender 48 , if provided, are raised. Simultaneously, end gate 49 lowers, either controllably or by its own accord as is common in the art, to maintain ground contact. At this time, edger positioning system 150 operates to correctly position edger 50 relative to screed 40 . For instance, if edger positioning system 150 is a spring-biased system, edger 50 being raised with screed 40 out of ground contact would allow the springs (not shown) to bias edger 50 downwardly to a correct position, possibly set by an adjustable stop. If edger positioning system 150 is a hydraulic ram system 156 , then hydraulic ram system 156 can be activated to position edger 50 correctly. In pavement mat ending operation, edger positioning system 150 would operate in reverse order as discussed above, i.e., raising edger 50 out of ground contact as screed 40 and screed extender 48 , if provided, are lowered.

Edger 50 may also include a side 98 and cover 99 to enclose the side, top and front of edger 50 . Cover 99 may include a handle 140 , as shown in FIG. 8 , for ease of transport of edger 50 .

Referring to FIGS. 7 , 11 and 12 , operation of edger 50 to create ramp 100 , illustrated in FIG. 11 , will be described. Edger 50 is mounted either inside screed 40 or screed extension 48 . Vertically movable end gate 49 may be added, if desired. As paving machine 30 proceeds, paving material 32 is heated and laid out in front of screed 40 which levels most of paving material 32 into a pavement mat 102 . At an edge 110 of pavement mat 102 , edger 50 works to create ramp 100 in accordance with the present invention. In particular, first compaction surface 52 vertically compacts a top surface of edge 110 of pavement mat 102 . Simultaneously, substantially vertical third compaction surface 54 horizontally compacts substantially vertical face 112 of edge 110 . In combination, first and third compaction surfaces 52 , 54 provide a highly compacted step 111 having a highly compacted portion 118 . Again, “highly compacted” means that paving material 32 is compacted between 85% to 93% of its complete compaction, a percentage higher than if material 32 was simply leveled by screed 40 .

As will be observed in FIGS. 4-5 and 8 , it is preferable to mount edger 50 such that rearward lower edge 58 of first compaction surface 52 is a distance D above the bottom of screed 40 or screed extender 48 . In this way, a pre-compaction zone 160 is created beneath edger 50 and a primary compaction zone 162 is created beneath screed 40 or screed extender 48 . It should be recognized, however, that rearward lower edge 58 of first compaction surface 52 need not be above the bottom of screed 40 or screed extender 48 to attain the advantages of the present invention.

At the same time that step 111 is being formed, second compaction surface 53 is also forming and compacting tapered portion 108 having an upper end 114 and a lower end 115 . Second compaction surface 53 is positioned vertically and angled so as to highly compact tapered portion 108 and form a highly compacted area 120 therein. Preferably, tapered portion 108 also includes a second step 116 at lower end 115 thereof. Second step 116 is formed against moldboard 42 or end gate 49 which acts as a fourth compaction surface. Second step 116 prevents loose aggregate from being left behind as in prior art devices. It will also be noticed that if a gap is present between second compaction surface 53 and end gate 49 , strike off 68 will create a flattened portion 117 at lower end 115 of tapered portion 108 .

In view of the foregoing, the process of producing ramp 100 includes: forming highly compacted step 111 on edge 110 of first pavement mat 102 by horizontally compacting substantially vertical face 112 and by vertically compacting a top surface of first pavement mat 102 ; and forming a tapered portion 108 extending away from substantially vertical face 112 of step 111 with tapered portion 108 including a at least a section or area 120 that is highly compacted. Highly compacted areas 118 , 120 are compacted between 85% and 93% of complete compaction. As an option, another step 116 may be formed at a distal end 115 of tapered portion 108 from substantially vertical face 112 . Further, pavement mat 102 may be rolled to a more complete compaction, e.g., up to approximately 98% of complete compaction as a finishing step.

Referring to FIG. 12 , a joint 101 , created with paving machine 30 and edger 50 , in accordance with the present invention is illustrated.

Joint 101 can be created using the above processes for creating ramp 100 of FIG. 11 , followed by: laying a second pavement mat 130 adjacent first pavement mat 102 such that an edge 132 of second pavement mat 130 abuts substantially vertical face 112 of edge 110 , and then compacting second pavement mat 130 . The final compaction would be up to approximately 98% of complete compaction. Preferably, laying of second pavement mat 130 would include using edger 50 with second and third compaction surfaces 53 , 54 retracted so as to form a contiguous joint maker surface. In this instance, edger 50 may be vertically adjusted to have its rearward lower edges 58 , 62 even or flush with screed 40 or screed extender 48 so as to provide even compaction across the entire second pavement mat 130 , and whatever part of first pavement mat 102 is covered. As an alternative, edger 50 could be removed and pavement mat 130 laid in a conventional manner.

As an alternative, processes are provided in accordance with the invention to create joint 101 from nothing as follows: First, lay first pavement mat 102 having edge 110 . Pavement mat 102 can be leveled by a conventional screed 40 . Next, form highly compacted step 111 on edge 110 of first pavement mat 102 and a highly compacted tapered portion 108 extending away from vertical face 112 of step 111 . Highly compacted areas 118 and 120 are compacted between 85% to 93% of complete compaction. Pavement mat 102 may be rolled to a more complete compaction, e.g., up to approximately 98% of complete compaction. Last, a second pavement mat 130 is laid adjacent first pavement mat 102 such that an edge 132 of second pavement mat 120 abuts vertical face 112 . Laying second pavement mat 130 includes leveling with a conventional screed.

It is to be recognized, that the presence of highly compacted areas 118 , 120 provide an advantage to creation of joint 101 . For instance, one will recognize that when second pavement mat 130 is laid, less material 134 is necessary over tapered portion 108 . In normal non-highly compacted ramps/joints, as shown in FIGS. 1A and 1B , an upper section of tapered portion 2 , 12 would include a low density area 10 , 20 . Low density area 10 , 20 , because of its thickness and the thinner amount of paving material in the second pavement mat atop of it, would not be sufficiently heated to accommodate further compaction. In contrast, in accordance with the present invention, upper end 114 of tapered portion 108 is already highly compacted and therefore does not need as much further compaction. Further, the thinner layer of material overlying upper end 114 provides sufficient heat to allow for finishing compaction of upper end 114 and the seam between vertical face 112 and edge 132 of second pavement mat 130 .

Second pavement mat 130 is compacted in a conventional way from a level shown in phantom in FIG. 12 to form joint 101 . Compaction at this point is up to approximately 98% of complete compaction. Adjacent to second step 116 , second pavement mat 130 has the same thickness as first pavement mat 102 .

The invention also includes joint 101 created by the above processes and including: a first asphalt section 102 mating with a second asphalt section 130 to form a substantially seamless joint with second asphalt section 130 . Second asphalt section 130 including a first step 111 and a ramp portion 108 extending away from a lower portion of first step 111 . First step 111 and a section 120 of ramp portion 108 are highly compacted prior to first asphalt section 102 mating with second asphalt section 130 .

While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.

For instance, it should be recognized that edger 50 may either provide pre-compaction or post-compaction of pavement depending on its position relative to the screed. In other words, although edger 50 has been illustrated as being mounted in front of screed 40 or screed extender 48 , it is also within the scope of the invention that edger 50 follow screed 40 or screed extender 48 to provide post-compaction. In this instance, the forming steps for ramp 100 are preceded by the leveling of first pavement mat 102 by screed 40 .

Claims

1. A process of forming a stepped tapered pavement joint comprising the steps of:laying a first pavement mat having an edge, and forming a highly compacted step on the edge of the first pavement mat and a highly compacted tapered portion extending away from a substantially vertical face of the step; laying a second pavement mat adjacent the first pavement mat such that an edge of the second pavement mat abuts the vertical face; and compacting the second pavement mat to form a joint.

2. The process of claim 1, wherein the step of forming further includes forming a step on a distal end of the tapered portion from the vertical face.

3. The process of claim 1, wherein the step of compacting the joint includes compacting the pavement mats to approximately 98% of complete compaction.

4. The process of claim 1, wherein the step of forming includes compacting the highly compacted step and the highly compacted tapered portion between 85% and 93% of complete compaction.

5. The process of claim 1, wherein the step of forming includes compacting the edge of the first pavement mat with an edger having:a first compaction surface to compact a top surface of the step, a second compaction surface to compact the tapered portion, and a substantially vertical third compaction surface to compact the vertical face.

6. An asphalt joint comprising:a first asphalt section mating with a second asphalt section to form a substantially seamless joint with the second asphalt section, the second asphalt section including a first step and a ramp portion extending away from a lower portion of the first step, and wherein the first step and at least a section of the ramp portion are highly compacted prior to the first asphalt section mating with the second asphalt section.

7. The asphalt joint of claim 6, wherein the first step and section of the ramp portion are compacted between 85% to 93% of complete compaction prior to the first asphalt section mating with the second asphalt section.

8. The asphalt joint of claim 7, wherein the second asphalt section includes a second step at a distal end of the ramp portion from the first step.

9. An asphalt joint made by a process comprising the steps of:laying a first pavement mat having an edge, and forming a highly compacted step on the edge of the first pavement mat and a highly compacted tapered portion extending away from a substantially vertical face of the step; laying a second pavement mat adjacent the first pavement mat such that an edge of the second pavement mat abuts the vertical face; and compacting the second pavement mat to form a joint.

10. The asphalt joint of claim 9, wherein the step of forming further includes forming a step on a distal end of the tapered portion from the vertical face.

11. The asphalt joint of claim 9, wherein the step of compacting the joint includes compacting the pavement mats to approximately 98% of complete compaction.

12. The asphalt joint of claim 9, wherein the step of forming includes compacting the highly compacted areas between 85% and 93% of complete compaction.

13. The asphalt joint of claim 9, wherein the step of forming includes compacting the edge of the first pavement edge with an edger having:a first compaction surface to compact a top surface of the step, a second compaction surface to compact the tapered portion, and a substantially vertical third compaction surface to compact the vertical face.