Method of applying surfacing materials

Abstract

A method of applying surfacing material to highway deck and bridge deck surfaces includes transporting a portable surfacing material applicator to the deck surface, and supplying the portable surfacing material applicator with liquid adhesive. The portable surfacing material applicator is moved along the deck surface, and the adhesive is distributed through an adhesive distribution outlet onto the deck surface. The amount of adhesive distributed by the adhesive distribution outlet is controlled.

Description

RELATED APPLICATIONS

[0001] This application is a Continuation-In-Part of U.S. patent application Ser. No. 09/795,774 filed Feb. 28, 2001.

TECHNICAL FIELD

[0002] This invention relates to a method and apparatus for applying surfacing materials, especially to highway deck and bridge deck surfaces. More particularly, this invention pertains to a method and apparatus suitable for applying membranes to deck surfaces where maneuverability of typical highway repair and construction machinery is limited.

BACKGROUND OF THE INVENTION

[0003] Highway pavements experience deterioration over time due to the effects of the loading of vehicular traffic and the effects of weathering of the pavement by the elements, including in particular moisture and temperature variations. This traffic and weathering causes cracks to develop in the paved surface, and the cracks can spread and cause further deterioration. Water can penetrate the paved surface by flowing into the cracks, causing further damage.

[0004] Damaged paved surfaces are usually repaired by applying a new surface layer of paving material over the damaged portions or over the entire paved surface. To prevent reflective cracking, various reinforcement materials and methods are used to treat existing cracks in the original pavement surface. One commercial crack repairing product is a reinforcement mat constructed from polypropylene fibers. A tack coat of asphalt is applied to the area surrounding the crack in the existing pavement, and then a polypropylene mat is applied over the crack. Finally, a surface layer of paving material is applied over the mat.

[0005] Typical equipment for applying pavement repair reinforcements includes a distributor truck that drives slowly along the damaged highway and distributes molten asphalt with an array of spray nozzles. Generally continuous sheets of reinforcement material, such as continuous sheets of non-woven fiber glass mats, are unrolled from the distributor truck, or some other type of distribution equipment.

[0006] It would be advantageous if improvements could be made in the methods and equipment for applying pavement surfacing materials to highways and other similar surfaces.

SUMMARY OF THE INVENTION

[0007] The above objects as well as other objects not specifically enumerated are achieved by a portable applicator configured to apply surfacing material to highway deck and bridge deck surfaces. The applicator includes a frame and wheels for supporting the frame and allowing the applicator to move along a deck surface. The applicator also includes an adhesive vessel supported by the frame, the adhesive vessel being configured to store a liquid adhesive. An adhesive distribution outlet is mounted on the frame and connected to the adhesive vessel. The adhesive distribution outlet is configured to distribute liquid adhesive from the adhesive vessel onto the deck surface. A controller for controlling the amount of adhesive distributed by the adhesive distribution outlet is provided. A reinforcement distributor is included for paying out reinforcement material onto the deck surface.

[0008] According to this invention there is also provided a method of applying surfacing material to highway deck and bridge deck surfaces. The method includes transporting a portable surfacing material applicator to the deck surface, and supplying the portable surfacing material applicator with liquid adhesive. The portable surfacing material applicator is moved along the deck surface, and the adhesive is distributed through an adhesive distribution outlet onto the deck surface. The amount of adhesive distributed by the adhesive distribution outlet is controlled.

[0009] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is a schematic view in elevation of conventional, prior art pavement repair equipment.

[0011] FIG. 2 is a schematic perspective view of a paved surface over a bridge.

[0012] FIG. 3 is a schematic side elevational view of a portable surfacing material applicator according to the invention.

[0013] FIG. 4 is a schematic end view in elevation of the applicator of FIG. 3.

[0014] FIG. 5 is schematic elevational view of the applicator of the invention being loaded into a pickup truck.

[0015] FIG. 6 is schematic elevational view of the applicator of the invention being towed by a pickup truck.

[0016] FIG. 7 is schematic elevational view of the applicator of the invention being trailered behind a pickup truck.

[0017] FIG. 8 is a schematic view of the applicator of the invention showing an additional roller to integrate the asphalt with the reinforcement mat.

[0018] FIG. 9 is a schematic view of an embodiment of the invention in which the creel is mounted above the portable applicator.

[0019] FIG. 10 is a schematic view of an embodiment of the invention in which the creel is mounted behind the portable applicator.

[0020] FIG. 11 is a schematic view of an embodiment of the invention in which the reinforcement mat and the adhesive material are applied in front of the portable applicator.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The conventional pavement repairing operation shown in FIG. 1 includes an asphalt distribution vehicle such as asphalt distribution truck 10 which includes a tank containing heated asphalt, and which deposits or sprays molten asphalt 12 to form a layer 14 of molten asphalt on a highway 16. The repair of the pavement includes the application of a reinforcement membrane, such as a web of nonwoven fiber glass mat 18. The reinforcement mat 18 can be distributed in any suitable manner, such as by mounting a roll 20 of the reinforcement mat on a tractor 22, and paying out the reinforcement mat 18 as the tractor moves along the highway in the application direction, as indicated by arrow 24. The tractor 22 drives across the top surface of the reinforcement mat 18, providing contact between the layer 14 of molten asphalt and the reinforcement mat 18. It is to be understood that a separate roller vehicle, such as a paving roller, not shown, could also be used. Preferably, the asphalt is spread over the road in a generally even coating so as to provide a good waterproofing layer against the penetration of moisture from the upper portion of the highway. The integration of the reinforcement mat 18 with the asphalt helps strengthen the asphalt layer 14 and holds the asphalt in place. A preferred reinforcement mat is a Trupave® reinforcement mat as disclosed in copending U.S. patent application Ser. No. 09/795,774 filed Feb. 28, 2000, which is herein incorporated by reference in entirety. However, the instant invention is useful for any reinforcement mat. Subsequent to the application of the reinforcement mat 18, an applicator or distributor 28 applies hot mix asphaltic surfacing material 30 onto the reinforcement mat 18 to form the new highway wear surface 32. A pressure roller, such a paving roller 34 densifies the hot mix surfacing asphalt material to form the finished pavement 36.

[0022] While the equipment described above for applying a repair membrane in a conventional manner is quite suitable for highways in general, there is a need for alternative equipment and installation methods of waterproofing and reinforcement surfacing materials, especially for bridge decks and highway decks. The tight quarters for these deck structures dictate that the highway reinforcement application equipment must be more nimble and flexible in order to properly lay down the asphalt layer 14 and the reinforcement mat 18. The type of decks needing the equipment and installation method of the invention can be any type of highway deck or bridge deck, including overpasses and above grade or below grade crossing where access to repair is restricted or limited. In contrast to the highway proper, highway decks and bridge decks are typically supported by framing members, and most are not supported directly by the ground. Such decks typically have narrow or nonexistent shoulders. As shown in FIG. 2, a bridge 40 connects a road 42 across a divide, such as a creek 44. The road 42 narrows as it crosses the bridge deck 46. The deck 46 is flanked by guard rails 48 for protection of the vehicles crossing the bridge 40. In order to repair defects in the surface of the road 42, such as potholes 50 or transverse cracks 52, the repair equipment must be capable of operating in the confined space within the guardrails or restraining walls. The width of the bridge deck 46 may be as narrow as 20 feet or even narrower, particularly in rural areas. Further, where the road 42 curves on the bridge deck 46, the use of conventional highway repair equipment such as that shown in FIG. 1 is even more of a problem. Another aspect of repairing the road surface on highway decks and bridge decks is that it may be necessary to close off one or more lanes of traffic while allowing other lanes to remain open for continued use by vehicular traffic. In such a situation, with no room for a highway shoulder, it becomes even more imperative for the highway repair equipment to be able to maneuver in tight spaces.

[0023] As shown in FIGS. 3 and 4, the portable applicator 60 of the invention includes a frame 62, and is supported by main support wheels 64. The wheels allow the portable applicator to be moved along the surface of the bridge deck 46. Preferably the portable applicator 60 includes two main support wheels 64 and at least one caster wheel 66. Since the portable applicator 60 is primarily supported by two drive wheels 64, it is easily maneuvered by a single operator for the desired alignment with the portion of the road that is to be reinforced during the surfacing process.

[0024] The portable applicator 60 includes a tank or vessel 68 supported by the frame 62. Optionally, a heater 70 is provided to maintain the proper temperature of the molten adhesive contained in the tank. The preferred adhesive is a modified asphalt, although any other asphalt or any other adhesive material, such as a hot melt polymer material, suitable for adhering the reinforcement mat 18 to the road could be used. Asphalt from the vessel 68 is distributed onto the road via the adhesive distribution outlet 72, which is mounted on the frame 62 and connected to the adhesive vessel 68. The adhesive distribution outlet 72 can be any member suitable for distributing the liquid asphalt 12 onto the deck surface 46. Preferably, as shown, the adhesive distribution outlet 72 is an elongated slot connected to an adhesive distribution box 74, which is a substantially rectangular chamber, although it could have many other shapes. For example, the distribution outlet can be one or more nozzles for spraying liquid asphalt. The adhesive distribution box is optional, but is useful in providing a uniform layer of asphalt 12 onto the road surface 46.

[0025] The portable applicator 60 is provided with a controller for controlling the amount of adhesive distributed by the adhesive distribution outlet 72. One example of the controller is a damper 78 in the distribution box 74 to regulate the size or the width of the slot, i.e., the distribution outlet 72. The damper can be controlled by a hand lever, not shown, or by any other suitable device. Another example of the controller is the valve 80 placed in the conduit 82 supplying asphalt from the vessel 68 to the adhesive distribution outlet 72. It can be seen that using either the valve 80 or the damper 78, the amount of liquid asphalt distributed from the portable applicator 60 can be controlled. Other devices for controlling the flow of liquid asphalt or adhesive can be used, including, for example, pressure regulators and thermal devices.

[0026] A preferred feature of the portable applicator 60 is a reinforcement distributor indicated generally at 86 for paying out the reinforcement mat 18. The reinforcement mat 18 is typically supplied in a roll 88, and preferably a cradle or creel 90 is attached to the frame 62 for holding the roll 88 during the unwinding or paying out of the reinforcement mat. The portable applicator 60 is also optionally provided with guide rollers 92, 94 and 96 for guiding the reinforcement mat 18 into contact with the road surface 46. Collectively, the creel 90, and the guide rollers 92, 94 and 96 form the reinforcement distributor 86 for paying out the reinforcement mat 18. It is to be understood that the reinforcement distributor 86 can have different structures from that shown, as long as it is directly or indirectly connected to the frame 62, and as long as it serves the function of paying out the reinforcement mat 18. For example, the guide rollers 92, 94 and 96 are optional. Also, the reinforcement distributor 86 could include a chute, not shown, for guiding the reinforcement mat 18. The reinforcement distributor could include trackers, not shown, for maintaining straight the path of the reinforcement mat 18. The rollers 92, 94, and 96 could be free rolling, stationary with low friction surfaces, or motorized. A brake or other metering device, not shown, could be applied to the reinforcement mat 18 to assure control of the tension of the mat 18 during layout. The distributor 86 could also carry a roll of mat 18 wider than the applicator 60, for example by extending one or more ends of the cradle 90. Likewise, the asphalt distribution system could be provided with a girth wider than the applicator 60.

[0027] The portable applicator 60 is preferably provided with a handle 100 for guiding and moving the applicator. Optionally, the portable applicator 60 can also be provided with brakes or wheel locks, not shown, and with instrumentation for gauging the temperature of the asphalt adhesive or the thickness of the layer 14 of the asphalt adhesive. Also, the portable applicator 60 can be motorized for ease of handling, preferably by providing a small gas or electric motor to drive one or more of the wheels 64. Preferably, however, the applicator 60 is small enough and light enough that a motor is unnecessary. Most preferably, the applicator 60 weighs less than about 200 pounds when empty. The light weight nature of the applicator as well as the use of one or more front caster wheels 16 will give the applicator 60 a configuration that will allow the applicator to be operated by one person. Alternatively, the applicator may be pulled by another motive device, for example by a tractor, through a chain, up a steep incline.

[0028] Additionally, the applicator will have a small turning radius. Preferably, the wheelbase of the support wheels 64 is sufficiently small that the applicator 60 can be turned on a turning radius less than about 8 feet, and more preferably on a turning radius less than about 4 feet, as measured by the inside wheel. In certain applications, the rear wheels 64 are also steerable or may locking casters, to reduce the turning radius, up to a zero-turning radius. Also, preferably the adhesive distribution outlet 72 has an elongated dimension or length within the range of from about 1 foot to about 4 feet. Most preferably the entire portable applicator 60 is configured to handle reinforcement mats 18 that are less than about four feet in width, and are incapable of handling mats of greater width. However, it is to be understood that in some embodiments of the invention the portable applicator 60 is designed to handle mat widths that are greater than 4 feet. One of the great benefits of the increased handleability of the portable applicator of the invention is that the applicator can be readily oriented for optimum alignment with various traffic lanes or with particular highway defects, such as the potholes 50 and transverse cracks 52 in the bridge deck 46. Attempting to properly align conventional adhesive and membrane application equipment in the typical tight configuration of a highway deck or bridge deck or other obstructed or confined area often results in folded, wrinkled or unevenly laid reinforcement mats 18. In some instances requiring a sharp turning radius, the mat may be slitted, for example on the inside radius and the mat allowed to overlap, so as to conform to a sharp radius. Additionally, it may be necessary to cut the mat into discrete portions and overlap such portions on a sharp radius application.

[0029] Additionally, an optional roller 97 can be provided to press the mat 18 into the asphalt layer 14, as shown in FIG. 8. In one embodiment, the roller 97 is water-filled to accommodate portability and may be made from plastic so as to be light weight when unfilled, and should be easily removed when not required. Preferably the roller 97 is mounted on a suitable mounting device, such as roller mounting assembly 98. The roller mounting assembly 98 is hinged to the applicator 90 at pivot point 99, and may be swung out of the way when not in use. Additionally, the handle 100 can be an extended handle so that an operator can walk behind the portable applicator without stepping on the roller 97.

[0030] The portability of the portable applicator 60 of the invention is illustrated further by reference to FIGS. 5-7. As shown in FIG. 5, in a preferred embodiment of the invention, the portable applicator 60 of the invention can be readily pushed up a simple ramp 104 and transported in a pickup truck 106 or other vehicle. This ability to readily and simply transport the portable applicator 60 in a truck provides a tremendous advantage over the conventional equipment for applying highway repair membranes and coatings. Small highway and bridge deck surfacing projects are much more economically feasible with the portable applicator of the invention.

[0031] As shown in FIG. 6, in another preferred embodiment of the invention, the portable surfacing material applicator 60 is transported to the deck surface 46 by towing, using a towing hitch 108, or any other suitable towing device, to connect the portable applicator 60 with the truck 106. In yet another embodiment of the invention, as shown in FIG. 7, the portable applicator 60 is transported to the deck surface on a trailer 110. All of these embodiments of the invention illustrate different ways in which the portable applicator 60 of the invention can be readily and conveniently transported to the location of the highway deck or bridge deck that requires surfacing.

[0032] In another embodiment of the invention the cradle or creel 90 is mounted above and/or behind the tank 68, as shown in FIGS. 9 and 10, respectively. Where the roll 88 is mounted behind the portable applicator 60, it may be necessary to extend the handle 100 farther in the rearward direction. Alternatively, a handle 101 can be provided on the front of the portable applicator.

[0033] As shown in FIG. 11, the distribution outlet 72 may be mounted in front of the portable applicator 60. In such a case, it would be possible for the mat 18 to be applied ahead of the applicator 60, as shown. The portable applicator 60 could also include a roller, not shown, similar to the roller 97, to press the mat 18 into the asphalt layer 14. Instead of a separate roller, i.e., roller 97, a roller can be used in place of one of the sets of wheels, either the front wheels 66 or the main support wheels 64, to press the mat 18 into the asphalt layer 14. Whichever roller is used, it is preferable for such a roller to be mounted for lifting or retraction to enable maneuverability of the applicator 60. In yet another variation of the invention, not shown, the adhesive distribution outlet 72 is positioned beneath portable applicator 60.

[0034] The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope.

Claims

1. A portable applicator configured to apply surfacing material to highway deck and bridge deck surfaces, the applicator comprising a frame, wheels for supporting the frame and allowing the applicator to move along a deck surface, an adhesive vessel supported by the frame, the adhesive vessel being configured to store a liquid adhesive, an adhesive distribution outlet mounted on the frame and connected to the adhesive vessel, the adhesive distribution outlet being configured to distribute liquid adhesive from the adhesive vessel onto the deck surface, a controller for controlling the amount of adhesive distributed by the adhesive distribution outlet, and a reinforcement distributor for paying out reinforcement material onto the deck surface.

2. The portable applicator of claim 1 in which the wheelbase is sufficiently small that the applicator can be turned on a turning radius less than about 8 feet.

3. The portable applicator of claim 1 in which the applicator is configured to be operated by one person.

4. The portable applicator of claim 1 including a heater for heating liquid adhesive in the vessel.

5. The portable applicator of claim 1 in which the adhesive distribution outlet has a length within the range of from about 1 foot to about 4 feet.

6. The portable applicator of claim 1 in which the applicator is adapted to be transported in a pickup truck.

7. The portable applicator of claim 1 in which the wheels comprise two primary support wheels and at least one caster wheel.

8. The portable applicator of claim 1 in which the applicator weighs less than about 200 pounds empty.

9. The portable applicator of claim 1 in which the controller is a valve regulating the flow of liquid adhesive from the adhesive vessel.

10. The portable applicator of claim 1 in which the adhesive distribution outlet is an elongated slot, and the controller is configured to regulate the width of the slot.

11. The portable applicator of claim 1 in which the reinforcement distributor is a creel mounted on the frame.

12. A method of applying surfacing material to highway deck and bridge deck surfaces comprising transporting a portable surfacing material applicator to the deck surface, supplying the portable surfacing material applicator with liquid adhesive, moving the portable surfacing material applicator along the deck surface, distributing the adhesive through an adhesive distribution outlet onto the deck surface, and controlling the amount of adhesive distributed by the adhesive distribution outlet.

13. The method of claim 12 in which the wheelbase is sufficiently small that the applicator can be turned on a turning radius less than about 8 feet.

14. The method of claim 12 including operating the applicator with one person.

15. The method of claim 12 including heating liquid adhesive in the vessel with a heater.

16. The method of claim 12 in which the adhesive distribution outlet has a width within the range of from about 1 foot to about 4 feet.

17. The method of claim 12 including transporting the portable surfacing material applicator to the deck surface in a pickup truck.

18. The method of claim 12 including transporting the portable surfacing material applicator to the deck surface on a trailer.

19. The method of claim 12 including transporting the portable surfacing material applicator to the deck surface by towing the portable surfacing material applicator.

20. The method of claim 12 in which the wheels comprise two primary support wheels and at least one caster wheel.

21. The method of claim 12 in which the applicator weighs less than about 200 pounds empty.

22. The method of claim 12 including paying out reinforcement material onto the distributed deck surface using a distributor mounted on the portable surfacing material applicator.

23. The method of claim 12 in which the adhesive distribution outlet is an elongated slot, and further including regulating the width of the slot with the controller.