Road maintenance machine and methods

Abstract

A road maintenance machine is provided with a heater assembly mounted on a general purpose chassis which is adapted for selectively attaching various road working devices. The heater assembly includes multiple rows of high temperature burner units each having means for burning fuel and projecting the generated heat downward against the road surface. The rows are spaced apart to allow the top of the surface to partially cool between burner rows as the heat penetrates the pavement in order to maintain the surface temperature below its flash point but high enough to achieve sufficient heat penetration to soften the pavement material to a significant depth. Heat shields and exhaust hoods are provided between the rows of burners to confine and direct the heat and combustion products. The chassis is provided with an adjustable hydraulic mechanism to which an asphalt planer, a scarifier assembly or a grooving cylinder may be attached to work the softened pavement material. An elevator is mounted at the rear of the machine to clear the roadway of planed material. An oscillating screed may be connected to the machine behind the scarifier assembly to smooth the worked surface. Methods are described for asphalt heating, asphalt planing, asphalt scarifying and asphalt grooving using the road maintenance machine.

Description

BACKGROUND OF THE INVENTION

Many modern roadway surfaces are composed of asphalt, macadam or other bituminous covering to form a smooth pavement. Over a period of time, weathering and extensive use of the roadways will render the pavement surface hard and brittle, resulting in irregularities and cracking in the pavement. Shrinkage cracks may develop allowing water penetration to cause further deterioration of the roadway surface. Once started, pavement deterioration increases at an accelerated rate and, unless prompt action is taken, complete reconstruction may be required. The breakdown of pavement structure may be further accelerated by the lack of proper drainage or the presence of corrosive foreign matter, such as chemicals or road salts. Improper construction, such as the use of too little or too much asphaltic binder, an unsatisfactory grade of aggregate or inadequate compaction may cause further pavement deterioration.

In response to these road pavement problems, reconditioning apparatus and equipment have been developed to rework, and, if necessary remove, the weathered pavement. A typical system utilizes heating apparatus to soften the pavement, followed by apparatus to rake or plane the surface. In some cases an additional coating is spread over the reworked surface and the mixture is compressed by compacting equipment.

A basic problem in restoring road surfaces has been heating the pavement surface to a temperature and depth sufficient to permit the surface material to be adequately worked. Intense heat must be applied in order to obtain sufficient heat penetration through the pavement surface because of the low heat conductivity of asphalt. However, intense heat cannot be applied for a long period since asphalt burns at a relatively low temperature. Such asphalt burning may result in sufficient damage to prevent reuse of the asphalt for resurfacing purposes. Furthermore, smoke from the burning asphalt pollutes the atmosphere.

To overcome this heating problem maintenance machines must frequently make multiple passes over the same section of roadway in order to heat and work the pavement to a sufficient depth. This procedure is inefficient and time-consuming and substantially increases maintenance costs. Other machines use multiple heater units each operating at a temperature below the asphalt burning point. A large number of such units are required to achieve the desired heat penetration, thus adding to the bulkiness and cost of the equipment.

Another basic problem in road maintenance is that the type of reconditioning needed varies greatly with different pavement sections depending upon the original composition, the extent of deterioration and other factors. For example, surfaces having bumps and irregularities as well as minor cracking may be sufficiently restored by heating and planing the surface. Asphalt planing may be the only practical method for treating roadway surfaces in tunnels and on bridges where a specified headroom clearance is required. Other roadways having deep ruts and grooves require more extensive working. It may be necessary to rake or scarify the heated pavement surface and then smooth and resurface the pavement. Moreover, some highway portions require special treatment, such as grooving to prevent automobile skidding.

The great variation in the type of machinery and process required to recondition different roadway sections necessitates the use of a variety of equipment, thus substantially increasing the cost of maintenance. Furthermore, multiple passes of such equipment are frequently needed in order to produce a finished surface of satisfactory smoothness and durability.

SUMMARY OF THE INVENTION

The present invention is directed to road conditioning apparatus and methods for reworking and restoring road surfaces. More particularly, a general purpose roadway maintenance machine is disclosed having the necessary attachments and modifications to provide a variety of resurfacing operations. A burner system is attached to the general purpose maintenance machine for heating and softening the pavement to the necessary temperature and depth without burning or damaging the pavement surface.

In accordance with one aspect of the present invention, the maintenance machine is equipped with a burner assembly having multiple rows of high temperature burner units suspended above the paved surface. Each burner unit directs heat to the pavement surface at a temperature substantially higher than the burning temperature of asphalt. The burner rows are spaced apart from each other along the line of travel of the maintenance machine to allow the pavement surface to partially cool between heat applications as heat penetrates into the pavement. The alternating periods of heating and cooling prevent the pavement surface temperature from exceeding the flash point of the asphalt yet allow penetration of heat to a substantial depth below the surface. The depth of heat penetration desired, the permissible surface temperature and the heat conduction characteristics of the surface material determine the arrangement of the burner assembly. Extra burners may be added to increase the depth of heat penetration. The temperature at the pavement surface may be varied by changing the horizontal spacing between rows of burner units, the vertical distance between burner units and the surface and the velocity of the maintenance machine.

In accordance with another aspect of the present invention, heat shields are provided between the rows of burners to confine the heat from the burners substantially below the burner apparatus. Hoods may be mounted on the heat shields over apertures in the shields to confine and direct the heat and products of combustion upward and away from the maintenance equipment and trees or other objects susceptible to heat and smoke.

In accordance with another aspect of the present invention, the maintenance machine is equipped with an asphalt planer behind the heater elements of the burner system for removing the heated surface material to form a smooth new surface for the roadway. Distortions and irregularities are leveled and high spots are evened out. Excessive bitumen which has risen to the top of the pavement surface due to prolong wear and heat is removed. Oxidized and brittle portions of the pavement are also planed off before resurfacing. The cuttings from the asphalt planer are picked up and loaded by a conveyor elevator attached to the maintenance machine.

In accordance with another aspect of the invention the maintenance apparatus is equipped with a rake or scarifier behind the heating elements of the burner system for reworking the pavement surface preparatory to resurfacing. After the application of an emulsion or rejuvenating agent, a new resurfacing material is applied, followed by compaction. As an alternative, the maintenance machine may be equipped with an oscillating mechanism for smoothing the surface after scarifying.

A further aspect of the present invention utilizes a grooving mechanism attached to the maintenance machine behind the heating elements of the burner system to apply parallel grooves transversely across a portion of roadway in order to give the roadway surface non-skid characteristics.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and for further objects and advantages thereof, reference may now be had to the following description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a side elevation of the road maintenance machine of the present invention.

FIG. 1A is a close-up view of a portion of the road maintenance machine shown in FIG. 1.

FIG. 2 is a close-up view of a portion of the road maintenance machine of FIG. 1 showing the burner assembly of the present invention.

FIG. 3 is a front partial view of the burner assembly of FIG. 2.

FIG. 4 is a cross section of the burner assembly of FIG. 3 taken on line 3--3.

FIG. 5 is a cross section of the burner assembly of FIG. 3 taken along line 4--4.

FIG. 6 is a partial side elevation showing an extension to the burner assembly of the present invention.

FIG. 7 is a close-up view of a portion of FIG. 6 showing the interconnection of the burner assembly with its extension.

FIG. 8 is a perspective view of the asphalt planer assembly of the present invention.

FIG. 9 is a side view of the asphalt planer shown in FIG. 8.

FIG. 10 shows a side view of the elevator assembly of the present invention.

FIG. 11 is a partial top view of the elevator shown in FIG. 10.

FIG. 12 is a partial side elevation of the maintenance machine of FIG. 1 showing the scarifier attachments of the present invention.

FIG. 13 is a partial rear view showing the rear portion of the scarifier assembly of FIG. 12.

FIG. 14 is a simplified rear view of the oscillating screed of the present invention.

FIG. 15 is a simplified side view of the screed of FIG. 14.

FIG. 16 is a side elevation view of the grooving attachment for the present invention.

FIG. 17 is a top view of the grooving attachment of FIG. 16.

FIG. 18 is a schematic flow diagram of part of the fuel supply of the invention.

FIG. 19 is a front view of one of the regulation mechanisms of the fuel system depicted in FIG. 18.

FIG. 20 is a graphic depiction of the asphalt heating method of the present invention.

FIG. 21 graphically shows the asphalt scarifying method of the present invention.

FIG. 22 is a graphic depiction of the asphalt scarifying method utilizing an oscillating screed.

FIG. 23 is a graphic depiction of the asphalt planing method of the present invention.

FIG. 24 depicts graphically the asphalt grooving method of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1 and 2, a road maintenance machine 10 includes a chassis 12 having a burner assembly 14 attached to the front portion of the chassis. The middle section of the chassis 12 is provided with convertible gear means 16 for the attachment of various devices depending upon the type of maintenance work needed. As shown in FIG. 1, an asphalt planer 18 is attached to gear means 16 in raised position. An elevator 20 is provided at the rear of chassis 12 for removing the planed paving material from the roadway.

Chassis 12 is preferably a modified form of a standard road grading machine, such as caterpillar motor grader model 12. The drive assembly gear ratio has been modified to provide the necessary operating speeds. The conventional front wheels have been replaced with metal front wheels 22 to provide additional weight and durability due to their location in close proximity to the burner assembly. Gear means 16 is the standard gear driven mechanism found on conventional graders. Alternately, an appropriate hydraulically driven system may be provided.

Burner assembly 14 is supported by two chassis booms 26 which project in front of machine 10 parallel to the roadway and connected to chassis 12 by conventional means. Booms 26 are supported by a plurality of tension cables 28 connected at various points along the boom. Cables 28 extend rearwardly over a mast 30 fixed to chassis 12 just behind front wheels 22 and projecting vertically above the chassis. Cables 28 each terminate in an eyelet 34 anchored to chassis 12 in front of chassis cab 32.

Booms 26 and burner assembly 14 may be detached from chassis 12 and disassembled for transporting to another work site. As shown in FIG. 1A, each of booms 26 are preferably attached to chassis 12 by a connecting plate 35 having a pin 36 at one end projecting downward into an aperture at the end of the boom nearest the chassis 12. A pin 37 integral with the other end of plate 35 extends vertically down into an aperture in the end of a chassis member 38 at the front of chassis 12. A lower ledge 39 of chassis member 38 juts horizontally out beneath boom 26 to provide vertical support for the booms.

A rectangular framework 40 is horizontally suspended below booms 26 by cables 42 each connected to a bracket 44 integral with framework 40. Cables 42 extend rearwardly to two take-up reels 46 which are attached on either side of chassis 12 behind vertical mast 30. Reels 46 may be rotated by hydraulic controls in cab 32 to raise and lower framework 40 as required.

Burner assembly 14 is provided with multiple rows of burner units 50, preferably having two units per row. Each burner row 50 is suspended parallel to the ground and spaced horizontally apart from the adjacent rows along the direction of travel. A rectangular insulator panel 52 is suspended horizontally between each row of burners by a bracket 54 or other suitable attachment device connected to framework 40. Each burner unit in turn is suspended by attachment to an angle iron subframe 56 interconnecting the insulator panels 52. Framework 40 is supported against horizontal movement by two bars 58 rotatably mounted between a front axle member 60 of chassis 12 and brackets 61 on the rear portion of framework 40.

Fuel for the burner assembly 14 is supplied under pressure from two large tanks 62 mounted above chassis 12 behind cab 32. Each tank is connected to a common high pressure distribution manifold 64 via a high pressure hose through a main snap valve (not shown) that can shut off all gas flow. The fuel is distributed to each burner unit 50 by a hose 66 running from distribution manifold 64 along the center of chassis 12 and burner assembly 14 to connect to feeder pipes 68. A preferred embodiment employs two 500 gallon liquid petroleum gas tanks connected to a common high pressure manifold with high pressure LPG hose rated at a 150 pounds per square inch. The burner assembly has eight rows of burners, and the manifold has 16 outlets, one for each row, making it possible to add eight additional rows of burning units when needed. The basic manifold is normally equipped with schedule 80 piping and eight regulators, pressure gauges and snap valves for independent control of each row of burners.

With reference to FIG. 3, a cross section is shown of one row of burners 50 disclosing two burner units 50a and 50b. Each unit includes an outer tubing 70, forming a cylindrical mixing chamber 74 for vaporizing the liquid fuel. As best shown in FIG. 4, feeder pipe 68 passes through an opening in tubing 70 at about the center of the chamber 24 connecting to a distributor tube 72 extending perpendicular to pipe 68 substantially the full length of outer tubing 70. Distributor tube 72 is open at either end to provide inlets for the fuel to enter the mixing chamber 74. Outer tubing 70 is provided with orifices 76 spaced at even intervals along the lower length of tubing 70.

As seen in FIG. 5, each orifice 76 is fitted with a conventional needle valve 78 for feeding an even flow of fuel out of the orifice. High temperature combustion of the fuel occurs in multiple burner cylinders 80. Each cylinder 80 is vertically attached to outer tubing 70 directly below each orifice 76 and projects downwad with a slight outward flare at the lower end, having a diameter approximately the same as the diameter of tubing 70. The open upper end of cylinders 80 provide passageways 82 on either side of tubing 70 to draw air into the burner cylinders 80 for mixing with the fuel vapors to enhance fuel burning. The lower end of cylinders 80 are also open to direct the heat and products of combustion downward onto the pavement surface. Burner cylinders 80 and orifices 76 are spaced along the tubing 70 such that the heat projected downward by cylinders 80 completely covers a strip of pavement along the entire length of each burner unit. In a preferred embodiment of the burner units, the outer tubing of the mixing chamber is two inches in diameter and four feet long, having eight orifices spaced at six inch intervals. The burner cylinders are each two inches in diameter and four inches long. Each burner unit burns a maximum of eight gallons per hour, producing an operating temperature of 1600.degree. to 2000.degree. Fahrenheit.

An important feature of the burner assembly is the use of spaced multiple rows of burner units 50 as best seen in FIG. 2. Each burner row 50 is spaced sufficiently apart from the next burner row 50 so that the accumulative effect of the high temperature heat emitted by the burner cylinders 80 will not raise the asphalt temperature above its burning point, normally about 250.degree. Fahrenheit. The pavement surface is alternately heated and allowed to partially cool as each row of burner units 50 pass by. This process allows a low temperature heat to penetrate deeply into the asphalt pavement without damaging the surface material. The number of burner rows used is flexible depending on the depth of heating required and the heat gradient of the road material.

Another important feature of the burner assembly is shown in FIG. 2. The rectangular insulator panels 52 are mounted to frame 40 by brackets 54 and interconnected by subframe 56 and are disposed horizontally between two rows of burner units 50. The width of insulator panels 52 may vary but is preferably wide enough to abut the burner cylinders 80 on either side of panel 52 thereby conserving fuel and shielding the burner units 50 and the external environment from extreme heat.

Exhaust hoods 96 are each mounted on one of the insulator panels 52, over an opening in the corresponding panel 52. Each hood 96 has an inverted cone-shaped portion 97 extending upward from insulator panel 52 and connecting at its upper narrow end to a vertical pipe portion 98 which terminates in an angled pipe portion 99. Each exhaust hood 96 is preferably made of a fireproof material such as asbestos. The angled portion 99 is constructed to direct heat and products of combustion generated beneath insulator panels 52 away from the maintenance apparatus and any external areas which should be protected. If necessary, the hood may be cooled with a water spray.

With reference to FIGS. 6 and 7, a burner extension assembly 84 is shown, having additional rows of burner units 51 and insulator panels 53 mounted on an extension framework 85 in a manner substantially the same as that of burner assembly 14. Boom extensions 86 are provided each having a reduced diameter portion 88 which will extend into a chassis boom 26. A similar extension portion 90 projects from framework 85 to connect into framework 40. Extension cables 92 are connected at suitable points on boom extensions 86 and project rearwardly over vertical mast 40 and anchor to chassis 12. Burner units 51 may be raised and lowered in a manner similar to that of burner units 50 through bracket-cable-pulley combinations 94 substantially identical to that shown for burner assembly 14.

FIGS. 8 and 9 show in more detail the asphalt planer 18 and the gear means 16 for operating the planer. Two lever arms 102 are attached on each side of the chassis 12. The lever arms 102 are mounted on a horizontal shaft 104 supported between chassis bracket 106 and gear drive 108. A lift arm 110 is connected to the outer end of each lever arm 102. Lift arms 110 on each side of the chassis extend downward to attach to a common moldboard plate 112. Plates 112 are disposed vertically below chassis 12 and are connected by a rod 114 attached between the upper portions of plates 112. Moldboards 116 are integral with plates 112 and extend vertically below the plates in a V-shaped angle with respect to each other. Moldboards 116 have adjacent overlapping ends which are spaced apart to provide an opening 121 at the rearward apex of the V-shaped angle in order to form a windrow of the planed material along the approximate center of the machine 10. A cutting blade 120 is adjustably provided on each moldboard 116 and is secured in position by a cover plate 122. An adjustment plate 124 is secured between the cover plate 122 and moldboard 116 directly above cutting blade 120. Adjustment brackets 126, each having an adjusting screw 128, are attached to the upper edge of adjustment plate 124 to provide for a vertical adjustment of the cutting blade 120 when cover plate 122 is loosened.

An outboard extension 130 is provided at the outer end of each moldboard 116. A supplemental cutting blade 132 attached to the lower part of extension 130 adds extra cutting width to each cutting blade 120. An adjustment plate 125, adjustment brackets 127 and screws 129 provide for vertical positioning of supplemental cutting blade 132 in the same manner as for blade 120. A similar extension 130 may be added to the other moldboard 116 in order to provide for uniform cutting width for both moldboards and extensions.

In a preferred embodiment, moldboards 116 are positioned at an angle approximately 90.degree. relative to each other. The blades have self-sharpening cutting edges made from Jones Laughlin Jalloy steel or the equivalent. Each blade is 68 inches long by 9 inches wide by 1/4 inch thick, and together the two blades provide an eight foot cutting swath. The 17 inch long moldboard extensions are of similar material and increase the cutting width on each moldboard by 12 inches.

With reference to FIGS. 10 and 11, elevator 20 is attached to the rear end of chassis 12 at an angle of about 45.degree. relative to the pavement. A main frame 132 includes two spaced-apart support beams 133 with a conveyor 134 running between. An upper sprocket 135a is mounted on a shaft 136a secured between support beams 133 at the approximate center of shaft 136a. A similar lower sprocket 135b is centered on a shaft 136b fixed at the lower ends of beams 133. A single conveyer chain 137 runs between the upper and lower sprockets 135a and 135b. Paddles 138 are affixed to the conveyer chain 137 at spaced intervals to form projecting lifts. A hydraulic motor 140 and a gear box 141 driven by motor 140 are mounted above the conveyer 134 on a horizontal platform 142 by braces 144 extending from each of the beams 133. A drive chain 146 connects a drive sprocket 147 on gear box 141 to an outboard sprocket 139 mounted on shaft 136a. A tension sprocket 148 rides on chain 146 and is carried on brace 150 which is biased downward by spring 152 to maintain proper tension in the drive chain 146. An elevator extension panel 154 projects downward at about 90.degree. from the upper portion of beams 133 to direct the elevated materials into a proper receptacle. A pair of chains 156 are attached to the outer end of elevator extension panel 154, providing support and vertical adjustment of extension 154 as needed.

A conveyer shoe 157 attached to the lower end of beams 133 normally rides on the planed surface of the asphalt pavement to pick up all windrowed material from the asphalt planer 18. When the conveyer is not in operation, shoe 157 is raised from the road surface by a cable (not shown) which is controlled from chassis cab 32. A diesel fuel spray pump and tank (not shown) may be utilized to spray a fine mist of diesel fuel over paddles 138 to prevent accumulation of asphalt. A protective shield may be used to cover the lower portion of the conveyer 134 to confine the diesel spray and to shield the engine radiator from the heated asphalt.

In a preferred embodiment conveyer 134 is 16 feet long and mounted at about a 45.degree. angle relative to the pavement. Thirty steel conveyer paddles 19-3/4 inches long by four inches wide by 1/4 inch thick are spaced at 12inch intervals along a number 160 roller chain having 2 inch pitch. The conveyer shoe is made of one inch thick high carbon steel wearing plate and is replaceable. A Rivinius power take-off attached to a model 12 engine drives a Dennison hydraulic pump through a two-way valve to a Dennison hydraulic motor connected to a Hewitt Robbins gear box. Driving sprocket 147 is geared down to ninety revolutions per minute driving the 30 foot conveyer chain 137 at a speed of three revolutions per minute.

FIGS. 12 and 13 disclose a scarifier assembly 160 which may be attached to gear means 16 in place of asphalt planer 18. A sacrifier framework 162, connected to the lift arms 110, is disposed horizontal to the ground and extends underneath chassis 12 above the pavement area previously covered by burner assembly 14. Two rows of scarifier teeth 144 are mounted on a subframe 166 attached to scarifier framework 162. A heavy duty spring 168 is provided to connect each tooth 164 to subframe 166 and to bias tooth 164 downward against the pavement. Spring 168 and tooth 164 are connected together by a plate 170 and nuts and bolts 172 so that they can be adjusted for wear. Two separate rear scarifier untis 174 are provided with mounting arms 176 which are attached to chassis 12 behind rear wheels 23. A support bar 177 is attached by a pair of brackets 179 to chassis 12. Support bar 177 extends across the entire width of chassis 12 behind wheels 23 to connect to mounting arms 176. A cable 178 is provided at the front of mounting arms 176 to allow each rear scarifier unit to be raised and lowered as needed. Each row of front scarifiers 164 is ideally operated independent of the other rows to insure uniform scarification regardless of the pavement cross section. Scarifier extensions may be added on the outboard side of each front of the scarifier row as desired. Likewise additional rows of teeth may be added or alternatively the density of teeth in each row may be increased.

A preferred embodiment of the scarifier assembly is provided with two rows of teeth, each being eight feet wide. The scarifier teeth are 18 inches long, having a 5/8 inch by 7/8 inch diamond cross section and are disposed on two inch centers. Successive rows of teeth are offset to provide one inch groove spacing over the full width of the scarifier unit. The rear scarifier units utilize similar 18 inch teeth and are approximately twelve inches wide. Scarifier extensions are normally added in twelve inch sections with a maximum suggested width of the total scarifier unit being 16 feet.

Referring now to FIGS. 14 and 15 a simplified sketch of an oscillating screed 190 is shown. The screed is attached to the rear of chassis 12 to be used in conjunction with scarifier assembly 60. A screed support 192 is mounted directly to the chassis 12 and extends transversely behind elevator 20 substantially over the pavement portion which has been worked by the scarifier assembly. Bar frame 194 is attached horizontally below support 192 and includes bar extensions 195 projecting rearward normal to bar frame 194 and parallel to the pavement surface. Screed boxes 196 are attached by connectors 198 to the rear ends of bars 195 and extend transversely across the worked portion of the pavement. A hydraulic motor 200 is mounted on the screed boxes 196 being driven by a hydraulic pump (not shown). Motor 200 may be the same as conveyer motor 140 since elevator 20 is not normally in use when oscillating screed 190 is in operation. Motor 200 drives a reciprocating bar 202 connected along the front of screed boxes 196 to smooth out the scarified pavement. Typically, bar 202 is a saw-toothed blade type which reciprocates horizontally in 4 inch oscillations transverse to the direction of travel. A conventional heater mechanism (not shown) may be utilized to warm screed boxes 196 in order to improve performance. The heaters are supplied by the fuel system which furnishes fuel to burner assembly 14.

FIGs. 16 and 17 disclose a grooving attachment 210 which may be connected to gear means 16 in place of asphalt planer 18 or scarifier assembler 160. Groover frame 212 is connected to lift arms 110 by a pair of horizontally disposed support members 214 on either side of chassis 12. An axle 216 runs between members 214 and carries a grooving cylinder 218. Radial fins 220 extend substantially across the length of cylinder 218 and project perpendicular to the surface of the cylinder. The fins are spaced at even intervals around the circumference of cylinder 218, preferably three to four inches apart to provide for a regular non-skid grooving pattern in the pavement.

FIGS. 18 and 19 disclose the fuel supply system in greater detail. The fuel from tanks 62 is direted through high pressure hose 230 and strainers 232 to manifold 64 which divides into three feeder branches 234, 235, and 236. Two check valves 238 are provided to cut off all fuel flow to the feeder branches.

As previously mentioned separate fuel hoses 66 direct fuel to each of the burner units from feeder branches 234-236. For simplicity only one feeder hose branch is shown. Each hose has a separate snap valve 242 to control the supply of fuel to its respective row of burner units 50. A pressure regulator 244 is provided in each fuel hose line downstream from valve 242 to maintain proper pressure, which is displayed by a gauge 246. A needle valve 248 is provided in a secondary fuel line 250 which bypasses valve 242 and regulator 244 to supply enough fuel at all times for pilot burners (not shown) in each row of burner units 50.

In operation, the burner assembly 14 is suspended from boom members 26 which are connected to chassis 12. The proper working attachments are connected to hydraulic means 16 and chassis 12, and the conveyer shoe 157 is raised or lowered as needed. Check valves 238 are opened admitting fuel to distributor manifold 64 and through needle valves 248 and secondary lines 250 to pilot burners (not shown) via high pressure hose 66. After the pilot burners are lit, snap valves 244 are opened to admit fuel to burner units 50. The fuel pressure for each pressure hose 66 is monitored and regulated using gauge 246 and pressure regulator 244.

The maintenance machine 10 is then moved along the paved surface to be worked at a predetermined constant speed to heat the pavement surface to the desired depth and temperature. The road surface is heated in successive strips of pavement surface transverse to the line of travel of machine 10. Each strip is rapidly heated as a row of burner units 50 passes over. Between burner rows the insulator panels 52 conserve heat and protect burner units 50 and the surrounding environment by substantially confining the generated heat below the panels 52 near the pavement surface. Exhaust hoods 96 direct excess heat and products of combustion upward and away from the machine 10 and vulnerable objects along the side of the roadway.

By the time the next row of burner units 50 has reached a previously heated strip of pavement, it has partially cooled while maintaining a sufficiently high temperature to promote heat penetration through the pavement surface. The next burner row again briefly applies high temperature heat to the strip of road surface to raise the temperature of the surface and enhance heat penetration.

This heating process is repeated as each row of burner units 50 passes over each successive pavement strip until the entire paved surface has been softened to the depth needed. Sufficient rows of burner units 50 are preferably attached to achieve the desired pavement heating in one pass of machine 10.

A preferred embodiment employs fuel tanks totaling 1,000 gallons maintaining pressure to the burners at 30 pounds per square inch. The burner assembly burns from 125 to 600 gallons per hour at a temperature from 1650.degree. to 2000.degree. Fahrenheit, depending upon the number of burners necessary for the type of method being performed. The rows of burner units are spaced 30 inches apart and between seven to nine inches from the pavement surface. The maintenance machine moves at a speed of 35 feet per minute maintaining the surface below the burner units at a temperature of about 225.degree. Fahrenheit while heating the pavement to a depth of 1/2 to 3/4 inch.

Referring to FIGS. 20-24, the various methods for utilizing the general purpose road maintenance machine 10 are shown. A method for converting a bleeding, slick asphalt surface to a non-skid surface is illustrated in FIG. 20. A dump truck 260 dumps a load of dry chip material 262, preferably crushed aggregate, into a chip spreader 264 which spreads the chip material uniformly over the surface of the roadway. Burner assembly 14 of the present invention, and if necessary burner extension assembly 84, heat the chips and the surface together to the desired depth, usually about 3/4 inch. Neither the front scarifier assembly 160 nor the rear scarifier units 174 are used. Finally, a compaction machine 266 follows the maintenance machine 10, pressing the crushed rock into the heated surface to provide a refinished non-skid road surface. This method is useful in situations where the pavement surface has become slick, particularly when wet, because of excessive bitumen bleeding to the surface due to heavy use and heat. The addition of the crushed stone both counteracts the excess bitumen and also provides a roughened surface.

As an alternative to the above method, FIG. 23 discloses a method of asphalt planing. This process may be used when the surface of the existing pavement has deteriorated to the point of not being reusable, for example because of excessive oxidization or bitumen content. Asphalt planing may be the only practical possibility in situations requiring a specified overhead clearance, such as on bridges or in tunnels. The pavement surface is first softened using burner assembly 14 to heat the existing asphalt surface to a depth of about 1/4 inch. The asphalt planer 18 which has been mounted in place of scarifier assembly 160 is used to shear off the heated material leaving a smooth, even surface. Elevator 20 then picks up and transfers the planed off asphalt 270 to dump truck 260 being towed backwards by machine 10. The asphalt planer 18 is designed to enable cutting the roadway flush to all curbs, inlets and manholes and other similar obstructions within the paved area. Although it is normally necessary to make only one pass using the planer attachment, sufficient cuts should be made so that all irregularities of high spots are eliminated. If the pavement is to be resurfaced, a shoulder is normally cut along the gutter line to obviate the necessity of feathering the edge of the new surface. Refinishing of the surface is optional depending upon the degree of planing and the type of surface needed.

In situations where the existing surface is reusable but substantial resurfacing is required, the asphalt scarifying method shown in FIG. 21 is used. The existing surface is softened with heat by burner assembly 14. Burner extension assembly 84 is normally attached since the heating depth in the pavement should reach 1/2 to 3/4 inch. After the pavement is thoroughly heated, scarifier unit 160 and rear scarifier units 174 thoroughly rake and mix the pavement surface to the heated depth to prepare the surface for paving. The reworked paving material 268 is then tacked with an emulsion or rejuvenating agent 269 which is normally spread by tanker truck 272 in the amount of 0.10 to 0.15 gallons per square yard. Next, the dump truck 260 transfers a mixture of surfacing material 273 into a paving machine 265 to spread a new surface on the roadway, The final step is compaction with a roller machine 266.

This process of compacting new material together with heated and worked existing paving material results in a new homogeneous pavement surface having excellent cohesion characteristics. The newly laid aggregate material becomes integral with the preexisting surface and minimizes a disjuncture at the point of resurfacing. The absence of a fissure between the two layers of surfacing eliminates the possibility of moisture spreading through undersurface cracks and causing rapid deterioration in the pavement. This process also makes it possible to utilize all existing surface materials to best advantage.

In a preferred method, the surface is heated and scarified to a depth of 3/4 inch. A rejuvenating agent complying with the Asphalt Institute designations SS-2 is applied at a rate of 0.1 gallon per square yard and a layer from 3/4 inch to one inch of asphalt mix is spread by a mechanical spreader providing a layer from 75 to 100 pounds per square yard. Compaction is achieved using a Tandom steel roller resulting in a new surface which is homogeneously bonded or welded to the existing scarified surface of the pavement.

A variation of the previously discussed asphalt scarifying method using an oscillating screed is shown in FIG. 22. This process may be used where the pavement is somewhat distorted, cracked or oxidized but where usage does not warrant resurfacing. The surface is first heated and raked and the reworked material 268 is passed through an oscillating screed 190 attached to the rear of machine 10. As with the asphalt scarifying method, the pavement is heated by burner assembly 14, preferably also utilizing burner extension assembly 84. Scarifiers 160 and 174 rake and mix the heated surface which then passes through oscillating screed 190. Screed 190 smoothes out the pavement surface and provides initial compaction. A rejuvenating agent 269 is then spread by tanker truck 272, or as an alternative a fine silicious mixture 274, such as sand, is spread by dump truck 260, depending on the bitumen content of the pavement. As a final step, compaction by roller 266 finishes the pavement surface.

FIG. 24 shows the asphalt grooving process of the present invention. The pavement surface is first heated to a depth of about 1/2 inch using burner assembly 14 and if necessary, burner extension assembly 84. Grooving attachment 210 is then rolled over the softened surface leaving parallel transverse grooves along the pavement. In one application the grooves were 3/8 inch wide and 3/8 inch deep and were 3 inches apart, 96 inches across the pavement. The grooving process is normally used when a surface highly resistant to skidding is desired. In some cases where the pavement has become slick, the asphalt grooving method may be used as an alternative to the asphalt heating and asphalt planing processes already mentioned.

Having described the invention in connection with certain specific embodiments thereof, it is to be understood that further modifications in both the apparatus and the methods disclosed may suggest themselves to those skilled in the art, and it is intended to cover such modifications as followed in the scope of the appended claims.

Claims

1. A method of heating and working a paved surface using a road maintenance machine comprising:

alternately applying heat to the paved surface at temperatures substantially above the burning temperature of said paved surface, and allowing said surface to partially cool to maintain the temperature of said surface below said burning temperature until said surface has been heated and softened to a predetermined depth;

said heat being generated by spaced apart rows of burner units carried by said road maintenance machine in a single pass over said paved surface, each adjacent pair of rows of burner units having a space between said rows sufficient for said cooling step;

confining the heat between said rows of burner units with a confining surface covering the space between each pair of adjacent rows of burner units, said heat being confined substantially between said confining surface and said paved surface; and

working said heated surface while in a softened state to a depth no more than said predetermined depth.

2. The method of claim 1 and further comprising the step of substantially directing the heat confined below said burner units through a confining conduit away from the burner units and the sides of the paved surface.

3. The method of claim 1 wherein said working step comprises planing surface material from the softened surface to said predetermined depth to form a smooth new road surface and removing said planed surface material from the new road surface.

4. The method of claim 1 and further comprising the steps of spreading new surface material evenly over the paved surface, and compacting the worked surface and the new surface material to press the new surface material into the worked surface while said surface and said new surface material are heated and softened.

5. The method of claim 1 wherein said working step comprises raking the heated surface to said predetermined depth to loosen and mix the surface material using multiple rows of scarifiers attached to said road maintenance machine.

6. The method of claim 5 and further comprising the steps of spreading a resurfacing material evenly behind said maintenance machine, and compacting the raked surface and the resurfacing material to form a new substantially homogeneous road surface.

7. The method of claim 6 wherein the step of spreading the resurfacing material includes tacking the raked surface with an emulsion or rejuvenating agent.

8. The method of claim 5 and further comprising the steps of smoothing and partially compacting the raked surface by an oscillating screed attached to said road maintenance machine, spreading a resurfacing material evenly on the smoothed surface behind said maintenance machine, and compacting the smoothed surface and the resurfacing material to form a new substantially homogeneous road surface.

9. The method of claim 8 wherein said spreading step comprises tacking said smoothed surface with a rejuvenating agent.

10. The method of claim 8 wherein said spreading step comprises distributing sand or other silicious material evenly over said smoothed surface.

11. The method of claim 1 wherein said working step comprises impressing the heated surface with a grooving cylinder mounted on said road maintenance machine to form a new paved surface having evenly spaced grooves running transverse across the road surface.

12. A method of restoring a paved road surface using a road maintenance machine moving along a roadway comprising:

intermittently applying heat at a temperature substantially above the burning temperature of said road surface to strips of said road surface transverse to the direction of travel of the road maintenance machine as the machine moves continuously forward along the roadway to heat and soften the road surface material to a predetermined depth while maintaining the temperature of said surface below said burning temperature,

confining with a confining surface spanning between consecutive intermittent heating steps the heat generated during said intermittent heating to a zone substantially between said confining surface and said road surface to further heat and soften the road surface material,

shearing the heated and softened material from the roadway into a windrow to form a new road surface, and

conveying the windrow of sheared material from the new road surface to a hauling vehicle for disposal of the sheared material.

13. A method of restoring a paved road surface using a road maintenance machine moving along a roadway comprising:

intermittently applying heat at a temperature substantially above the burning temperature of said road surface to strips of said road surface transverse to the direction of travel of the road maintenance machine as the machine moves continuously forward along the roadway to heat and soften the road surface material to a predetermined depth while maintaining the temperature of said surface below said burning temperature,

confining with a confining surface spanning between consecutive intermittent heating steps the heat generated during said intermittent heating to a zone substantially between said confining surface and said road surface to further heat and soften the road surface material,

scarifying the heated and softened surface material to break up and thoroughly mix said material,

tacking said mixed material with an emulsion or rejuvenating agent,

spreading a layer of resurfacing material evenly over the mixed road surface material, and

compacting the layer of resurfacing material and the mixed road surface material to form a new homogeneous road surface.

14. A method of restoring a paved road surface using a road maintenance machine moving along a roadway comprising:

intermittently applying heat at a temperature substantially above the burning temperature of said road surface to strips of said road surface transverse to the direction of travel of the road maintenance machine as the machine moves continuously forward along the roadway to heat and soften the road surface material to a predetermined depth while maintaining the temperature of said surface below said burning temperature,

confining with a confining surface spanning between consecutive heating steps the heat generated during said intermittent heating to a zone substantially between said confining surface and said road surface to further heat and soften the road surface material,

scarifying the heated and softened surface material to break up and thoroughly mix said material,

leveling and partially compacting the mixed material,

spreading a restoring material over the leveled surface to restore the bitumen content of the mixed surface material to a desired proportion, and

compacting the restored material and the mixed surface material to form a new homogeneous road surface.

15. A method of restoring a paved road surface using a road maintenance machine moving along a roadway comprising:

intermittently applying heat at a temperature substantially above the burning temperature of said road surface to strips of said road surface transverse to the direction of travel of the road maintenance machine as the machine moves continuously forward along the roadway to heat and soften the road surface material to a predetermined depth while maintaining the temperature of said surface below said burning temperature,

confining with a confining surface spanning between consecutive heating steps the heat generated during said intermittent heating to a zone substantially between said confining surface and said road surface to further heat and soften the road surface material, and

impressing the heated and softened surface material with evenly spaced grooves transverse to the direction of travel of the road maintenance machine to form a road surface adapted to prevent skidding of vehicles traveling thereon.

16. A method of restoring a paved road surface using a road maintenance machine moving along a roadway comprising:

spreading a layer of aggregate material evenly over the paved surface in front of the road maintenance machine,

intermittently applying heat at a temperature substantially above the burning temperature of said road surface to strips of said road surface and said layer of aggregate material transverse to the direction of travel of the road maintenance machine as the machine moves continuously forward along the roadway to heat and soften the road surface material to a predetermined depth while maintaining the temperature of said surface below said burning temperature,

confining with a confining surface spanning the heat between said intermittent heating to a zone substantially between said confining surface and said road surface to further heat and soften the road surface material, and

compressing the layer of aggregate material into the heated and softened surface material to form a new homogeneous road surface.

17. A method of heating and working an asphalt road surface in a single pass of a mobile road maintenance machine having a plurality of spaced-apart rows of burners disposed transverse to the direction of travel of said machine, comprising:

directing heat generated by said rows of burners to said asphalt road surface at temperatures substantially higher than the burning temperature of said asphalt surface to bring said surface to a temperature sufficient to soften said asphalt surface;

moving said machine along said asphalt road surface to allow said surface to partially cool between said rows of burners to maintain the temperature of said surface below said burning temperature;

confining the portions of said heat between said rows of burners with a plurality of insulator panels each extending substantially parallel to said asphalt surface between two adjacent rows of burners, said heat being confined to a zone bounded vertically substantially between said panels and said asphalt surface to promote conduction of said heat into said asphalt surface to soften said surface to a predetermined depth; and

working said softened asphalt surface to a depth not more than said predetermined depth.