WO2010110906A1 - Reinforced pervious concrete - Google Patents

Reinforced pervious concrete Download PDF

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Publication number
WO2010110906A1
WO2010110906A1 PCT/US2010/000903 US2010000903W WO2010110906A1 WO 2010110906 A1 WO2010110906 A1 WO 2010110906A1 US 2010000903 W US2010000903 W US 2010000903W WO 2010110906 A1 WO2010110906 A1 WO 2010110906A1
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WO
WIPO (PCT)
Prior art keywords
basalt
pervious concrete
pavement
layer
concrete
Prior art date
Application number
PCT/US2010/000903
Other languages
French (fr)
Inventor
Jon Dennis Sader
Original Assignee
Make It Right Foundation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Make It Right Foundation filed Critical Make It Right Foundation
Publication of WO2010110906A1 publication Critical patent/WO2010110906A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C11/00—Details of pavings
    • E01C11/22—Gutters; Kerbs ; Surface drainage of streets, roads or like traffic areas
    • E01C11/224—Surface drainage of streets
    • E01C11/225—Paving specially adapted for through-the-surfacing drainage, e.g. perforated, porous; Preformed paving elements comprising, or adapted to form, passageways for carrying off drainage
    • E01C11/226—Coherent pavings
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C7/00—Coherent pavings made in situ
    • E01C7/08—Coherent pavings made in situ made of road-metal and binders
    • E01C7/10—Coherent pavings made in situ made of road-metal and binders of road-metal and cement or like binders
    • E01C7/14—Concrete paving
    • E01C7/142—Mixtures or their components, e.g. aggregate
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C7/00—Coherent pavings made in situ
    • E01C7/08—Coherent pavings made in situ made of road-metal and binders
    • E01C7/10—Coherent pavings made in situ made of road-metal and binders of road-metal and cement or like binders
    • E01C7/14—Concrete paving
    • E01C7/145—Sliding coverings, underlayers or intermediate layers ; Isolating or separating intermediate layers; Transmission of shearing force in horizontal intermediate planes, e.g. by protrusions, by inlays
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A10/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE at coastal zones; at river basins
    • Y02A10/30—Flood prevention; Flood or storm water management, e.g. using flood barriers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/30—Adapting or protecting infrastructure or their operation in transportation, e.g. on roads, waterways or railways

Definitions

  • This invention relates to, in general, concrete for use in surfaces or pavements such as roads, sidewalks, driveways, bridges, and the like.
  • embodiments of the invention utilize pervious concrete material with basalt reinforcement members (basalt rebar members, basalt mesh, or both) to form concrete structures or pavements that can be used for construction of roads, sidewalks and other concrete structures or infrastructure.
  • basalt reinforcement members basalt rebar members, basalt mesh, or both
  • the concrete structures or pavements formed permit water and air to pass through the concrete structures, which provides various benefits, such as reducing the need for complex and expensive storm water runoff systems in flood prone areas.
  • a pavement comprising pervious concrete material and one or more basalt reinforcing members embedded in or positioned below the pervious concrete material.
  • the one or more basalt reinforcing members may be basalt rebar rods, or basalt rebar rods having a Figure-Eight shape, or a mesh made of basalt strands.
  • the one or more basalt reinforcing members add structural rigidity to the pervious concrete, making the pervious concrete capable or supporting loads as normally experienced on pavements.
  • the pavement may also include a layer of filtration fabric positioned below the basalt reinforcing members.
  • the pavement may include a compacted soil layer; a layer of filtration fabric positioned above the compacted soil layer; and a layer of course aggregate material positioned above the layer of filtration fabric.
  • the one or more basalt reinforcing members may be positioned above the layer of course aggregate material.
  • the pervious concrete material forms the upper surface of the pavement.
  • the one or more basalt reinforcing members are positioned approximately two inches or more above the bottom of the pervious concrete material.
  • the pavement may be used to form a road, parking lot, driveway, sidewalk or other structure as disclosed herein, which allows water or moisture to pass through the surface of the pavement and be filtered. Such a pavement reduces flooding and the need for complex storm drainage systems adjacent to the pavement.
  • the method includes the operations of compacting a sub-base layer; installing a filtration fabric above the sub-base layer; installing a layer of aggregate material above the filtration fabric; positioning one or more basalt rebar reinforcement members above the layer of aggregate material; and pouring a layer of wet pervious concrete material above the one or more basalt rebar reinforcement members.
  • the method may also include leveling said layer of wet pervious concrete, and compacting said layer of wet pervious concrete.
  • the method may also include curing said layer of pervious concrete.
  • the method may also include placing the one or more basalt rebar reinforcement members approximately two or more inches above the layer of aggregate material, and in another example, the method may include pouring a portion of said wet pervious concrete material below the one or more basalt rebar reinforcement members, so that the wet pervious concrete material embeds the one or more basalt rebar reinforcement members.
  • a road can be formed which allows water or moisture to pass through the road and be filtered, thereby reducing flash flooding and reducing or eliminating the need for complex storm drainage systems adjacent to the road.
  • Fig. 1 illustrates an example of a reinforced concrete structure including pervious concrete material and basalt rebar members, in accordance with one embodiment of the present invention.
  • Fig. 2 illustrates an example of a reinforced concrete structure including pervious concrete material and a basalt mesh, in accordance with one embodiment of the present invention.
  • Fig. 3 illustrates a conventional road using impervious concrete and storm water drains.
  • Fig. 4 illustrates an example of a road made using an embodiment of the present invention having pervious concrete and without storm water drains.
  • Fig. 5 illustrates a conventional parking lot using impervious concrete and storm water pipes.
  • Fig. 6 illustrates an example of a parking lot made using an embodiment of the present invention having pervious concrete and without storm water pipes.
  • Fig. 7 illustrates an example of a sidewalk made using an embodiment of the present invention having pervious concrete.
  • Fig. 8 illustrates a conventional sidewalk tree grate using impervious concrete.
  • Fig. 9 illustrates an example of a sidewalk tree grate made using an embodiment of the present invention having pervious concrete, where the size of the tree grate can be smaller when compared with the tree grate of Fig. 8.
  • Fig. 10 illustrates an example of a basalt rebar rod or member, in accordance with one embodiment of the present invention.
  • Fig. 11 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar members, in accordance with one embodiment of the present invention.
  • Fig. 12 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 11, in accordance with one embodiment of the present invention.
  • Fig. 13 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 11, in accordance with one embodiment of the present invention.
  • Fig. 14 illustrates an example of a process for forming a pavement with pervious concrete and basalt rebar, in accordance with an example of the present invention.
  • Fig. 15 illustrates an example of a basalt rebar rod or member having a " Figure Eight" shape, in accordance with one embodiment of the present invention.
  • Fig. 16 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar members having "Figure Eight" shapes, in accordance with one embodiment of the present invention.
  • Fig. 17 illustrates a sectional view of the example of a reinforced concrete surface of Fig.
  • Fig. 18 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 16, in accordance with one embodiment of the present invention.
  • Fig. 19 illustrates an example of a process for forming a pavement with pervious concrete and basalt rebar members having "Figure Eight" shapes, in accordance with an example of the present invention.
  • Fig. 20 illustrates an example of a basalt mesh, in accordance with one embodiment of the present invention.
  • Fig. 21 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar mesh, in accordance with one embodiment of the present invention.
  • Fig. 22 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 21, in accordance with one embodiment of the present invention.
  • Fig. 23 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 21, in accordance with one embodiment of the present invention.
  • Fig. 24 illustrates an example of a process for forming a pavement with pervious concrete and basalt mesh, in accordance with an example of the present invention.
  • Fig. 25 illustrates a representation of a sectional view of an example of a road made using pervious concrete and basalt rebar, wherein a pothole has developed.
  • Fig. 26 illustrates a representation of a sectional view of an example of a road made using pervious concrete and basalt rebar, wherein a pothole has been repaired.
  • Fig. 27 illustrates an example of a process for repairing a pothole in a road formed with pervious concrete and basalt rebar, in accordance with an example of the present invention.
  • embodiments of the invention utilize pervious concrete material with basalt reinforcement members (basalt rebar members, basalt mesh, or both) to form concrete structures or pavements that can be used for construction of roads, sidewalks and other concrete structures or infrastructure.
  • basalt reinforcement members basalt rebar members, basalt mesh, or both
  • the concrete structures formed permit water and air to pass through the concrete structures, which provides various benefits, such as reducing the need for complex and expensive storm water runoff systems in flood prone areas.
  • the PSI rating level of the pervious concrete structure formed is believed to be sufficient to withstand traffic loads and other weight bearing loads because basalt reinforcement members both reinforce the pervious concrete material and the basalt reinforcement members can be exposed to water without rusting or being weakened by rust over time.
  • roads and streets can be formed so that the amount of rainwater runoff in flash flood prone areas is reduced. Instead, rainwater or other moisture passes through the pervious concrete surface and down below the grade of the concrete surface.
  • the groundwater aquifers can be more readily replenished because the water/moisture passes through the pervious concrete to the aquifers located below such pervious concrete.
  • several environmental constraints typically experienced by impervious or traditional concrete can be avoided or minimized while serving many of the same purposes as standard concrete. For instance, pervious concrete allows water to pass through it and seep into the soil therefore becoming instrumental in recharging groundwater and reducing large amounts of stormwater runoff. Because pervious concrete allows water and air to pass through the concrete structure, there is a large reduction in the need for complex and expensive storm water runoff systems in flood prone areas.
  • Basalt is a naturally occurring volcanic rock that employs a variety of benefits when compared to steel reinforcement typically used for reinforced concrete. It is believed that basalt materials have a higher tensile strength than fiberglass or possibly steel. Basalt is a naturally occurring rock which means it can resist rust or any type of corrosion and does not absorb any amount of water. Basalt rebar is also about !4 of the weight of steel rebar, which makes basalt rebar much easier to transport and assemble on the job site. Also, basalt rebar can be easily cut and shaped using common tools in the field.
  • Fig. 1 illustrates an embodiment of the invention, where a concrete structure 50 is formed using pervious concrete 52 and one or more basalt rebar members 54, the basalt rebar members 54 configured in a manner to impart structural rigidity and strength to the concrete structure.
  • the basalt rebar members 54 are configured in a generally square matrix pattern, but it is understood that the basalt rebar members 54 may be configured in other different patterns and densities depending upon the particular structure being built and the desired load bearing characteristics.
  • the basalt rebar members 54 can be molded in order to form or reinforce a desired structure.
  • the basalt rebar members 54 may be temporarily held together in a desired patters using coated wire twist ties, also known as bar ties (not shown), which temporarily can affix rebar members to one another.
  • the bar ties can be, in one example, 16 gauge, 6 inch steel ties if desired.
  • Fig. 2 illustrates another embodiment of the invention, where a concrete structure 60 is formed using pervious concrete 52 and a basalt mesh 62, the basalt mesh 62 provided to impart structural rigidity and strength to the concrete structure.
  • the basalt mesh 62 may be obtained in rolls and has a generally square matrix pattern, but it is understood that the basalt mesh 62 may be configured in other different patterns, densities and thicknesses depending upon the particular structure being built and the desired load bearing characteristics.
  • Pervious concrete 52 is commercially available from many concrete companies, such as Lafarge North America, Inc.
  • Basalt rebar and basalt mesh may be available from Raw Energy Materials, Inc. of Pompano Beach, Florida.
  • the basalt rebar members 54 can be rods made of a unidirectional composite of basalt fibers.
  • one or more basalt reinforcement members e.g., 54, 62
  • Pervious concrete material 52 is poured on top of such basalt reinforcement members, and the top of the pervious concrete material is compacted (in one example, the top half inch of pervious concrete material may be compacted).
  • the surface of the pervious concrete material can be covered with plastic, ply, or a tarp to keep the pervious concrete moist during curing which may take a number of days for the pervious concrete to fully cure.
  • joints between pervious concrete members can be placed for instance, every twenty feet, and it is believed that expansion joints would not be needed since pervious concrete material does not expand or contract in the same manner as impervious concrete.
  • the plastic/ply/tarp also functions to keep rainwater out of the pervious concrete material while the pervious concrete material is curing.
  • Embodiments of the invention may be used to form roadways 70 (Fig. 4)(compare to Fig. 3 showing a conventional road 72 using impervious concrete 74 with storm drain pipes); parking lots 80 (Fig. 6)(compare to Fig. 5 showing a conventional parking lot 82 with impervious concrete 72 and storm water pipes); sidewalks (Fig. 7); and sidewalks 90 with tree grates 91 (Fig. 9)(compare with Fig. 8 showing larger tree grates 94 used with conventional impervious concrete 74).
  • Other concrete structures may be built using embodiments of the present invention, such as bridges or portions of bridges, curbs, portions of sewer systems, retaining walls, or any other concrete structures where it may be desirable to allow water and air to pass through.
  • pervious concrete 52 may be formed in a manner that is thicker in consistency compared to regular concrete 74, as pervious concrete 52 can be formed as a mixture of cement, coarse aggregates (i.e., 3/8" gravel or limestone), water, and little or no sand.
  • Pervious concrete 52 may be formed so that it has a large volume (e.g., approximately 15-30%) of interconnected voids 100 (Figs. 1-2) allowing rainwater to percolate through the pervious concrete 52 into the underlying soil, with the tradeoff being that the larger the voids 100, the lower the strength of the pervious concrete 52.
  • pervious concrete 52 may be delivered to a job site in a conventional ready-mix concrete truck, and can be poured within one hour of being initially mixed.
  • Pervious concrete 52 may be poured into standard concrete forms using 2" x 4" wood forms or other conventional forms or related techniques, in one example.
  • a surface or pavement 110 such as a road, sidewalk, driveway, parking lot, or the like, can be formed using pervious concrete 52 reinforced with basalt rebar 54.
  • Figs. 10-13 show an example of basalt rebar 54 and show sectional views of one example of a pavement 110 formed in accordance with an embodiment of the present invention, wherein the pavement 110 includes a compacted soil layer 112, a geotextile filtration fabric layer 114, a layer of course aggregate 116, one or more basalt rebar rods 54 with one or more support blocks 118, and a layer of pervious concrete 52.
  • a curb 119 may be made of pervious or impervious concrete.
  • Fig. 14 One example of a method of forming a pavement using pervious concrete 52 and basalt rebar members 54 is illustrated in Fig. 14.
  • the sub-soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller.
  • the soil is moist, but free of standing water, to aid in the compaction.
  • a non- woven, geotextile filtration fabric 114 is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below.
  • the geotextile fabric 1 14 also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer 52.
  • coarse aggregate material 1 16 such as limestone, crushed glass, superheated clay, is placed on the filtration fabric 1 14.
  • coarse aggregate 116 is placed on top of the geotextile fabric 1 14 which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil 112 below.
  • basalt rebar members 54 are placed on the coarse aggregate 116.
  • the basalt rebar members 54 are placed in 1 ' x 1 ' grids covering the entire area where the pervious concrete will be installed.
  • the grid may be formed using basalt rebar members 54 that are held together in the grid through the use of wire ties.
  • each basalt rebar rod 54 may have a diameter of approximately 5/8", although the dimensions of the basalt rebar members will vary depending upon the needs of a particular application.
  • Concrete chairs or support blocks 118 may be used to support the basalt rebar, for instance 2" above the layer of coarse aggregate 116.
  • rebar 54 This will allow the rebar 54 to become embedded in the pervious concrete 52 about 2-2 1 A" from the bottom of the pervious concrete layer.
  • three chairs or support blocks can be evenly installed underneath the rebar grid for support.
  • the pervious concrete 52 is poured over the basalt rebar 54.
  • the pervious concrete 52 is poured such that there is a sufficient amount ready for compaction, for example 6" for sidewalks and driveways, 10-12" for streets/roadways.
  • the pervious concrete layer 52 is leveled and compacted while still wet.
  • a vibrating mechanical screed is used to level off the pervious concrete 52, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface.
  • At least 1 A" of the pervious concrete layer 52 may be striked-off above the form to allow for compaction.
  • Operation 130 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 1 1 A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges.
  • a mist of water can be applied to the pervious concrete 52, and the pervious concrete 52 may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete.
  • plastic sheeting e.g., a 6 mil polyethylene cover such as Visqueen
  • the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer 52, and continues for at least 7 days.
  • the pervious concrete layer is believed to reach its maximum strength after 28 days of curing.
  • a pavement surface 1 10 such as a road, sidewalk, driveway, parking lot, or other surface can be formed using pervious concrete 52 with one or more basalt rebar reinforcement members 140 that have a "Figure Eight" shape.
  • Fig. 15 shows and example of a basalt rebar member 140 having a " Figure Eight" shape
  • Figs. 16-18 show a sectional view of one example of a pavement 1 10 formed in accordance with an embodiment of the present invention, wherein the pavement includes a compacted soil layer 112, a geotextile filtration fabric layer 1 14, a layer of course aggregate 116, one or more basalt rebar "Figure Eight" members 140 with one or more support blocks 118, and a layer of pervious concrete 52.
  • a method for forming a pavement surface 110 using pervious concrete 52 with a reinforcement of basalt rebar members 140 having a "Figure Eight" shape is illustrated in Fig. 19.
  • Operations 141-143 can be similar to operations 110-124 of Fig. 14, in one example.
  • the sub-soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller.
  • the soil is moist, but free of standing water, to aid in the compaction.
  • a non- woven, geotextile filtration fabric is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below.
  • the geotextile fabric also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer.
  • coarse aggregate material such as limestone, crushed glass, superheated clay, is placed on the filtration fabric.
  • coarse aggregate is placed on top of the geotextile fabric which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil below.
  • basalt rebar members 140 having "Figure Eight" shapes are placed on the coarse aggregate.
  • these basalt rebar members 140 are placed in 1 ' x 1 ' grids covering the entire area where the pervious concrete will be installed.
  • the grid may be formed using basalt rebar members that are held together in the grid through the use of wire tires.
  • each basalt rebar member may have multiple oval portions forming the "Figure Eight" shape, wherein each oval portion is approximately 13" in length and has two legs (e.g., each 3/16" diameter) separated by a distance of approximately 1", although the dimensions of the basalt rebar member will vary depending upon the needs of a particular application.
  • Concrete chairs or support blocks may be used to support the basalt rebar, for instance 2" above the layer of coarse aggregate. This will allow the rebar to become embedded in the pervious concrete about 2-2 1 A" from the bottom of the pervious concrete layer. In one example, for each 8' span of rebar, three chairs or support blocks can be evenly installed underneath for support.
  • the pervious concrete is poured over the shaped rebar.
  • the pervious concrete is poured such that there is a sufficient amount ready for compaction, for example 6" for sidewalks and driveways, 10-12" for streets/roadways.
  • the pervious concrete layer is leveled and compacted while still wet.
  • a vibrating, mechanical screed is used to level off the pervious concrete, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface.
  • at least 1 A" of the pervious concrete layer may be striked-off above the form to allow for compaction.
  • Operation 126 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 1 1 A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges.
  • a mist of water can be applied to the pervious concrete, and the pervious concrete may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete.
  • plastic sheeting e.g., a 6 mil polyethylene cover such as Visqueen
  • the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer, and continues for at least 7 days.
  • the pervious concrete layer is believed to reach its maximum strength after 28 days of curing. Formation of Roads, Sidewalks, Driveways, etc. using Pervious Concrete and Basalt GeoMesh
  • a pavement surface 1 10 such as a road, sidewalk, driveway, parking lot, or other surface can be formed using pervious concrete 52 with a reinforcement of basalt geomesh or mesh 150.
  • Figs. 20-23 show an example of a basalt mesh 150, and show sectional views of one example of a pavement formed in accordance with an embodiment of the present invention, wherein the pavement 110 includes a compacted soil layer 1 12, a geotextile filtration fabric layer 1 14, a layer of course aggregate 116, a layer of basalt geomesh 150, and a layer of pervious concrete 52.
  • a method for forming a pavement surface using pervious concrete 52 with a reinforcement of basalt geomesh 150 is illustrated in Fig. 24.
  • Operations 151-153 can be similar to operations 120-124 of Fig. 14, in one example.
  • the sub- soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller.
  • the soil is moist, but free of standing water, to aid in the compaction.
  • a non- woven, geotextile filtration fabric is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below.
  • the geotextile fabric also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer.
  • coarse aggregate material such as such as limestone, crushed glass, superheated clay, is placed on the filtration fabric.
  • coarse aggregate material such as limestone, crushed glass, superheated clay
  • more than 6" of coarse aggregate is placed on top of the geotextile fabric which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil below.
  • a basalt geomesh 150 is placed directly on top of the coarse aggregate without the use of concrete chairs or steel substitutes.
  • a basalt geomesh 150 is a mesh or basalt strands having a plurality of approximately 1" by 1" squares of basalt strands.
  • Operations 156-157 may be similar to operations 130-132 of Fig. 14, in one example.
  • the pervious concrete layer is leveled and compacted while still wet.
  • a vibrating, mechanical screed is used to level off the pervious concrete, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface.
  • At least 1 A" of the pervious concrete layer may be striked-off above the form to allow for compaction.
  • Operation 156 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 1 1 A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges.
  • a mist of water can be applied to the pervious concrete, and the pervious concrete may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete.
  • plastic sheeting e.g., a 6 mil polyethylene cover such as Visqueen
  • the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer, and continues for at least 7 days.
  • the pervious concrete layer is believed to reach its maximum strength after 28 days of curing.
  • a pothole 160 (Fig. 25) develops in the pervious concrete pavement due to loss of compaction of the sub-soil 112 or course aggregate 116 below a portion of the pervious concrete, the pothole 160 may be repairable using the process of Fig. 27, in accordance with an embodiment of the present invention.
  • Fig. 25 shows an example of a sectional view of pothole 160 formed in a pavement made in accordance with an embodiment of the present invention
  • Fig. 26 shows an example of a sectional view of a repaired pothole in a pavement made in accordance with an embodiment of the present invention.
  • pervious concrete with basalt rebar reinforcements has a restorative memory such that some potholes 160 may be repairable without the use of additional pervious concrete material 52 on the surface.
  • a process is illustrated for repairing a pothole 160 that exists in a pavement of pervious concrete and basalt reinforcement members.
  • a pothole is identified that has formed underneath a section of cracked pervious concrete.
  • the basalt rebar or other basalt reinforcement will bend/flex down into the collapsed section until the pressure has been removed and the rebar returns to its original position.
  • one or more holes 163 are drilled into or about the collapsed section of the pervious concrete, wherein the hole(s) are drilled deep enough to allow a sand slurry injection 164 of operation 165 to reach underneath the pervious and fill the void created by the loss of compaction in the subgrade.
  • sand or a slurry of sand 164 is injected into the drilled hole(s) 163, which fills the void(s) in the subgrade or sub-soil below the pothole.
  • the injected sand slurry 164 provides for both long term stable subsurface conditions by restoring the level of the compacted soil or course aggregate underneath the pervious concrete 52, and also retains an effective permeability through the repaired subsurface beneath the repaired pothole. Once completed, the rebar 54 and the pervious concrete 52 returns to their original position, and hence the pervious concrete has been repaired.
  • the methods disclosed herein for forming a pavement or surface 50, 60, 70, 80, 90 or 110 may include forming the surface through the use of one or more basalt reinforcement members combined with pervious concrete, without the need for installing stormwater pipes or other stormwater drainage.
  • Embodiments of the invention can be used to make or repair various pavements surfaces or roadways, such as but not limited to streets, sidewalks, driveways, parking lots, highway shoulders, non-vehicular bridges, lightweight vehicular bridges, heavy highways, and lightweight structural components such as parking garage floors, curbs, or other floors, for example.
  • streets or other structures can be created with significantly reduced or zero runoff, meaning that streets or other structures such as parking lots, sidewalks, etc. can be formed without the need for underground pipes or catch basins, which can result in a significant cost savings when building or maintaining such streets or other infrastructure.
  • Embodiments of the present invention may also eliminate the need for rainfall stormwater management or portions thereof, as well as pumps which are used in cities such as New La.
  • the streets, roads, sidewalks and other infrastructure can be replaced with streets, sidewalks or other structures utilizing embodiments of the present invention.
  • the processes described above could also include an operation of removing the existing pavement and/or other materials present, until the soil layer is exposed.
  • a concrete structure using pervious concrete may be formed using construction techniques that are used with impervious concrete; and in other embodiments, different construction techniques are used for forming concrete structures using pervious concrete.
  • the basalt rebar members combined with the pervious concrete material can be configured by placing the basalt rebar members in a pattern that is specially adapted or designed to increase the structural integrity of the pervious concrete structure.
  • a method for planting of trees, shrubs or other vegetation along sidewalks or roadways.
  • the method includes identifying a location for having the tree, shrub or vegetation planted, providing pervious concrete material with basalt reinforcement members around the desired location for the tree, shrub or vegetation, and allowing the pervious concrete to form.
  • the tree, shrub or vegetation can then be planted after the pervious concrete cures. Because of the pervious nature of the concrete, water will drain through the concrete structure (sidewalk, road) and provide water and nutrients to the tree, shrub or vegetation. Therefore, the tree, shrub or vegetation will not have a tendency to uproot the sidewalk, road, or other concrete structure, as typically happens with sidewalks or roads that utilize impervious concrete. Moreover, the roots of tree, shrub and other vegetation will receive more water and air through the use of pervious concrete than with conventional impervious concrete.

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Abstract

A pavement such as a road, driveway, sidewalk, parking lot or the like, formed with pervious concrete material and one or more basalt reinforcing members embedded in or positioned below the pervious concrete material. The one or more basalt reinforcing members add structural rigidity to the pervious concrete, making the pervious concrete capable or supporting loads as normally experienced on pavements. The one or more basalt reinforcing members may be basalt rebar rods, or basalt rebar rods having a Figure-Eight shape, or a mesh made of basalt strands. In one example, the pavement may also include a layer of filtration fabric positioned below the basalt reinforcing members. Various methods are described for forming pavements, roads, driveways, sidewalks, parking lots or the like. Such a pavement allows water or moisture to pass through the surface of the pavement and be filtered. Such a pavement reduces flooding and the need for complex storm drainage systems adjacent to the pavement.

Description

REINFORCED PERVIOUS CONCRETE
Cross Reference to Related Application
This application claims priority to and the benefit under 35 U.S. C. 119(e) to U.S. Provisional Patent Application No. 61/211,396 entitled "Reinforced Pervious Concrete" filed March 25, 2009, the disclosure of which is hereby incorporated by reference in its entirety. Field of the Invention
This invention relates to, in general, concrete for use in surfaces or pavements such as roads, sidewalks, driveways, bridges, and the like.
Background For decades, during significant rainstorms or snowmelt, cities and towns have experienced flooding of roads, streets, parking lots, etc. As recognized by the present inventor, what is needed is a new concrete structure that can be used to build roads, streets and other concrete structures while reducing flooding risks.
Summary In light of the above and according to one broad aspect of one embodiment of the invention, disclosed herein are new methods and structures for forming concrete structures that can be used to make roads, sidewalks and other pavements or infrastructures. Specifically, embodiments of the invention utilize pervious concrete material with basalt reinforcement members (basalt rebar members, basalt mesh, or both) to form concrete structures or pavements that can be used for construction of roads, sidewalks and other concrete structures or infrastructure. Through the use of embodiments of the present invention, the concrete structures or pavements formed permit water and air to pass through the concrete structures, which provides various benefits, such as reducing the need for complex and expensive storm water runoff systems in flood prone areas.
In accordance with another broad aspect of an embodiment of the invention, disclosed herein is a pavement, comprising pervious concrete material and one or more basalt reinforcing members embedded in or positioned below the pervious concrete material. The one or more basalt reinforcing members may be basalt rebar rods, or basalt rebar rods having a Figure-Eight shape, or a mesh made of basalt strands. The one or more basalt reinforcing members add structural rigidity to the pervious concrete, making the pervious concrete capable or supporting loads as normally experienced on pavements. In one example, the pavement may also include a layer of filtration fabric positioned below the basalt reinforcing members.
In another embodiment of the present invention, the pavement may include a compacted soil layer; a layer of filtration fabric positioned above the compacted soil layer; and a layer of course aggregate material positioned above the layer of filtration fabric. The one or more basalt reinforcing members may be positioned above the layer of course aggregate material. In one example, the pervious concrete material forms the upper surface of the pavement.
In another example of the invention, the one or more basalt reinforcing members are positioned approximately two inches or more above the bottom of the pervious concrete material. The pavement may be used to form a road, parking lot, driveway, sidewalk or other structure as disclosed herein, which allows water or moisture to pass through the surface of the pavement and be filtered. Such a pavement reduces flooding and the need for complex storm drainage systems adjacent to the pavement.
In accordance with another broad aspect of an embodiment of the invention, disclosed herein is a method for forming a road. In one example of the invention, the method includes the operations of compacting a sub-base layer; installing a filtration fabric above the sub-base layer; installing a layer of aggregate material above the filtration fabric; positioning one or more basalt rebar reinforcement members above the layer of aggregate material; and pouring a layer of wet pervious concrete material above the one or more basalt rebar reinforcement members. In another example, the method may also include leveling said layer of wet pervious concrete, and compacting said layer of wet pervious concrete. In another embodiment, the method may also include curing said layer of pervious concrete. The method may also include placing the one or more basalt rebar reinforcement members approximately two or more inches above the layer of aggregate material, and in another example, the method may include pouring a portion of said wet pervious concrete material below the one or more basalt rebar reinforcement members, so that the wet pervious concrete material embeds the one or more basalt rebar reinforcement members. In this manner, a road can be formed which allows water or moisture to pass through the road and be filtered, thereby reducing flash flooding and reducing or eliminating the need for complex storm drainage systems adjacent to the road. The foregoing and other useful features and advantages of the invention will be apparent from the following more particular description of a various embodiments of the invention as illustrated in the accompanying drawings.
Brief Description of the Drawings Fig. 1 illustrates an example of a reinforced concrete structure including pervious concrete material and basalt rebar members, in accordance with one embodiment of the present invention. Fig. 2 illustrates an example of a reinforced concrete structure including pervious concrete material and a basalt mesh, in accordance with one embodiment of the present invention.
Fig. 3 illustrates a conventional road using impervious concrete and storm water drains. Fig. 4 illustrates an example of a road made using an embodiment of the present invention having pervious concrete and without storm water drains.
Fig. 5 illustrates a conventional parking lot using impervious concrete and storm water pipes.
Fig. 6 illustrates an example of a parking lot made using an embodiment of the present invention having pervious concrete and without storm water pipes.
Fig. 7 illustrates an example of a sidewalk made using an embodiment of the present invention having pervious concrete.
Fig. 8 illustrates a conventional sidewalk tree grate using impervious concrete.
Fig. 9 illustrates an example of a sidewalk tree grate made using an embodiment of the present invention having pervious concrete, where the size of the tree grate can be smaller when compared with the tree grate of Fig. 8.
Fig. 10 illustrates an example of a basalt rebar rod or member, in accordance with one embodiment of the present invention.
Fig. 11 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar members, in accordance with one embodiment of the present invention.
Fig. 12 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 11, in accordance with one embodiment of the present invention. Fig. 13 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 11, in accordance with one embodiment of the present invention.
Fig. 14 illustrates an example of a process for forming a pavement with pervious concrete and basalt rebar, in accordance with an example of the present invention. Fig. 15 illustrates an example of a basalt rebar rod or member having a "Figure Eight" shape, in accordance with one embodiment of the present invention.
Fig. 16 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar members having "Figure Eight" shapes, in accordance with one embodiment of the present invention. Fig. 17 illustrates a sectional view of the example of a reinforced concrete surface of Fig.
16, in accordance with one embodiment of the present invention.
Fig. 18 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 16, in accordance with one embodiment of the present invention.
Fig. 19 illustrates an example of a process for forming a pavement with pervious concrete and basalt rebar members having "Figure Eight" shapes, in accordance with an example of the present invention.
Fig. 20 illustrates an example of a basalt mesh, in accordance with one embodiment of the present invention.
Fig. 21 illustrates a cutaway view of an example of a reinforced concrete surface including pervious concrete material and basalt rebar mesh, in accordance with one embodiment of the present invention.
Fig. 22 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 21, in accordance with one embodiment of the present invention. Fig. 23 illustrates a sectional view of the example of a reinforced concrete surface of Fig. 21, in accordance with one embodiment of the present invention.
Fig. 24 illustrates an example of a process for forming a pavement with pervious concrete and basalt mesh, in accordance with an example of the present invention. Fig. 25 illustrates a representation of a sectional view of an example of a road made using pervious concrete and basalt rebar, wherein a pothole has developed.
Fig. 26 illustrates a representation of a sectional view of an example of a road made using pervious concrete and basalt rebar, wherein a pothole has been repaired.
Fig. 27 illustrates an example of a process for repairing a pothole in a road formed with pervious concrete and basalt rebar, in accordance with an example of the present invention.
Detailed Description
Disclosed herein are new methods and structures for forming concrete structures or reinforced pavements that can be used to make roads, sidewalks and other infrastructures. Specifically, embodiments of the invention utilize pervious concrete material with basalt reinforcement members (basalt rebar members, basalt mesh, or both) to form concrete structures or pavements that can be used for construction of roads, sidewalks and other concrete structures or infrastructure. Through the use of embodiments of the present invention, the concrete structures formed permit water and air to pass through the concrete structures, which provides various benefits, such as reducing the need for complex and expensive storm water runoff systems in flood prone areas.
By embedding basalt reinforcement members within pervious concrete, the PSI rating level of the pervious concrete structure formed is believed to be sufficient to withstand traffic loads and other weight bearing loads because basalt reinforcement members both reinforce the pervious concrete material and the basalt reinforcement members can be exposed to water without rusting or being weakened by rust over time. Through the use of pervious concrete combined with one or more basalt reinforcement members, roads and streets can be formed so that the amount of rainwater runoff in flash flood prone areas is reduced. Instead, rainwater or other moisture passes through the pervious concrete surface and down below the grade of the concrete surface.
Through the use of embodiments of the present invention, during rain or snow or other moisture conditions, the groundwater aquifers can be more readily replenished because the water/moisture passes through the pervious concrete to the aquifers located below such pervious concrete. Moreover, through the use of embodiments of the present invention, several environmental constraints typically experienced by impervious or traditional concrete can be avoided or minimized while serving many of the same purposes as standard concrete. For instance, pervious concrete allows water to pass through it and seep into the soil therefore becoming instrumental in recharging groundwater and reducing large amounts of stormwater runoff. Because pervious concrete allows water and air to pass through the concrete structure, there is a large reduction in the need for complex and expensive storm water runoff systems in flood prone areas.
Many characteristics of basalt materials have been recognized by the present inventor as useful when combined with pervious concrete. Basalt is a naturally occurring volcanic rock that employs a variety of benefits when compared to steel reinforcement typically used for reinforced concrete. It is believed that basalt materials have a higher tensile strength than fiberglass or possibly steel. Basalt is a naturally occurring rock which means it can resist rust or any type of corrosion and does not absorb any amount of water. Basalt rebar is also about !4 of the weight of steel rebar, which makes basalt rebar much easier to transport and assemble on the job site. Also, basalt rebar can be easily cut and shaped using common tools in the field.
Fig. 1 illustrates an embodiment of the invention, where a concrete structure 50 is formed using pervious concrete 52 and one or more basalt rebar members 54, the basalt rebar members 54 configured in a manner to impart structural rigidity and strength to the concrete structure. In this example, the basalt rebar members 54 are configured in a generally square matrix pattern, but it is understood that the basalt rebar members 54 may be configured in other different patterns and densities depending upon the particular structure being built and the desired load bearing characteristics. For complex structures, the basalt rebar members 54 can be molded in order to form or reinforce a desired structure.
If desired, the basalt rebar members 54 may be temporarily held together in a desired patters using coated wire twist ties, also known as bar ties (not shown), which temporarily can affix rebar members to one another. The bar ties can be, in one example, 16 gauge, 6 inch steel ties if desired. Fig. 2 illustrates another embodiment of the invention, where a concrete structure 60 is formed using pervious concrete 52 and a basalt mesh 62, the basalt mesh 62 provided to impart structural rigidity and strength to the concrete structure. In one example, the basalt mesh 62 may be obtained in rolls and has a generally square matrix pattern, but it is understood that the basalt mesh 62 may be configured in other different patterns, densities and thicknesses depending upon the particular structure being built and the desired load bearing characteristics.
Pervious concrete 52 is commercially available from many concrete companies, such as Lafarge North America, Inc. Basalt rebar and basalt mesh may be available from Raw Energy Materials, Inc. of Pompano Beach, Florida. In one example, the basalt rebar members 54 can be rods made of a unidirectional composite of basalt fibers.
In one example, to construct a surface such as a road or sidewalk or other concrete structure using an embodiment of the present invention, after the sub-grades and sub-bases have been prepared, one or more basalt reinforcement members (e.g., 54, 62) are positioned along the surface as desired to achieve the required structural integrity or PSI ratings. Pervious concrete material 52 is poured on top of such basalt reinforcement members, and the top of the pervious concrete material is compacted (in one example, the top half inch of pervious concrete material may be compacted). The surface of the pervious concrete material can be covered with plastic, ply, or a tarp to keep the pervious concrete moist during curing which may take a number of days for the pervious concrete to fully cure. In one example, joints between pervious concrete members can be placed for instance, every twenty feet, and it is believed that expansion joints would not be needed since pervious concrete material does not expand or contract in the same manner as impervious concrete. The plastic/ply/tarp also functions to keep rainwater out of the pervious concrete material while the pervious concrete material is curing.
Embodiments of the invention may be used to form roadways 70 (Fig. 4)(compare to Fig. 3 showing a conventional road 72 using impervious concrete 74 with storm drain pipes); parking lots 80 (Fig. 6)(compare to Fig. 5 showing a conventional parking lot 82 with impervious concrete 72 and storm water pipes); sidewalks (Fig. 7); and sidewalks 90 with tree grates 91 (Fig. 9)(compare with Fig. 8 showing larger tree grates 94 used with conventional impervious concrete 74). Other concrete structures may be built using embodiments of the present invention, such as bridges or portions of bridges, curbs, portions of sewer systems, retaining walls, or any other concrete structures where it may be desirable to allow water and air to pass through.
In one example of the present invention, pervious concrete 52 may be formed in a manner that is thicker in consistency compared to regular concrete 74, as pervious concrete 52 can be formed as a mixture of cement, coarse aggregates (i.e., 3/8" gravel or limestone), water, and little or no sand. Pervious concrete 52 may be formed so that it has a large volume (e.g., approximately 15-30%) of interconnected voids 100 (Figs. 1-2) allowing rainwater to percolate through the pervious concrete 52 into the underlying soil, with the tradeoff being that the larger the voids 100, the lower the strength of the pervious concrete 52. This filtration effect also helps to purify the water by capturing pollutants as the water drains through the small voids 100 in the pervious concrete 52 before it reaches a storm drain. Various mixes of pervious concrete 52 materials are described in "Practical Application of Pervious Concrete: Mix Designs That Are Workable" by Rick Blackburn, Axim Italcementi Group (2006) (presentation from National Ready Mixed Concrete Association Conference, available at http://www.rmc-foundation.org); "Development of Mix Proportion for Functional and Durable Pervious Concrete" by K. Wang, V. R. Schaefer, J.T. Kevern, M.T. Suleiman, Iowa State University, (2006) (presentation from National Ready Mixed Concrete Association Conference, available at http://www.rmc- foundation.org); "Making Pervious Concrete Placement Easy Using a Novel Admixture System" by Mark Bury, Christine Mawby, and Dale Fisher, Degussa Admixtures, Inc., (2006) (available at http://www.nnc-foundation.org); and "Mix, Forms, and Admixtures" by Charles
Wolfersberger, Charger Enterprises Inc. (available at http://www.perviousconcrete.com), the disclosures of which are hereby incorporated by reference. The particulars of the mix used to create wet pervious concrete 52 will depend on the loading requirements and other details of the particular application. In one example, a pervious concrete mix available from Lafarge North America Inc. may be used for street paving and other applications.
In one example, pervious concrete 52 may be delivered to a job site in a conventional ready-mix concrete truck, and can be poured within one hour of being initially mixed. Pervious concrete 52 may be poured into standard concrete forms using 2" x 4" wood forms or other conventional forms or related techniques, in one example.
Formation of Roads, Sidewalks, Driveways, etc. using Pervious Concrete and Basalt Rebar
Reinforcement Rods
In one example, a surface or pavement 110 such as a road, sidewalk, driveway, parking lot, or the like, can be formed using pervious concrete 52 reinforced with basalt rebar 54. Figs. 10-13 show an example of basalt rebar 54 and show sectional views of one example of a pavement 110 formed in accordance with an embodiment of the present invention, wherein the pavement 110 includes a compacted soil layer 112, a geotextile filtration fabric layer 114, a layer of course aggregate 116, one or more basalt rebar rods 54 with one or more support blocks 118, and a layer of pervious concrete 52. A curb 119 may be made of pervious or impervious concrete.
One example of a method of forming a pavement using pervious concrete 52 and basalt rebar members 54 is illustrated in Fig. 14. Referring to Fig. 14, at operation 120, the sub-soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller. In one example, the soil is moist, but free of standing water, to aid in the compaction.
At operation 122, a non- woven, geotextile filtration fabric 114 is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below. The geotextile fabric 1 14 also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer 52.
At operation 124, coarse aggregate material 1 16, such as limestone, crushed glass, superheated clay, is placed on the filtration fabric 1 14. In one example, more than 6" of coarse aggregate 116 is placed on top of the geotextile fabric 1 14 which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil 112 below.
At operation 126, basalt rebar members 54 are placed on the coarse aggregate 116. In one example, the basalt rebar members 54 are placed in 1 ' x 1 ' grids covering the entire area where the pervious concrete will be installed. The grid may be formed using basalt rebar members 54 that are held together in the grid through the use of wire ties. In one example, each basalt rebar rod 54 may have a diameter of approximately 5/8", although the dimensions of the basalt rebar members will vary depending upon the needs of a particular application. Concrete chairs or support blocks 118 may be used to support the basalt rebar, for instance 2" above the layer of coarse aggregate 116. This will allow the rebar 54 to become embedded in the pervious concrete 52 about 2-2 1A" from the bottom of the pervious concrete layer. In one example, for each 8' span of rebar, three chairs or support blocks can be evenly installed underneath the rebar grid for support.
At operation 128, the pervious concrete 52 is poured over the basalt rebar 54. In one example, the pervious concrete 52 is poured such that there is a sufficient amount ready for compaction, for example 6" for sidewalks and driveways, 10-12" for streets/roadways.
At operation 130, the pervious concrete layer 52 is leveled and compacted while still wet. In one example, a vibrating mechanical screed is used to level off the pervious concrete 52, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface.
In one example, at least 1A" of the pervious concrete layer 52 may be striked-off above the form to allow for compaction. Operation 130 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 11A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges.
After placement of the pervious concrete layer, at operation 132, a mist of water can be applied to the pervious concrete 52, and the pervious concrete 52 may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete. In one example, the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer 52, and continues for at least 7 days. In one example of the invention, the pervious concrete layer is believed to reach its maximum strength after 28 days of curing.
Formation of Roads, Sidewalks, Driveways, etc. using Pervious Concrete and "Figure Eight"
Shaped Basalt Rebar Reinforcement Members
In another embodiment of the invention, a pavement surface 1 10 such as a road, sidewalk, driveway, parking lot, or other surface can be formed using pervious concrete 52 with one or more basalt rebar reinforcement members 140 that have a "Figure Eight" shape. Fig. 15 shows and example of a basalt rebar member 140 having a "Figure Eight" shape, and Figs. 16-18 show a sectional view of one example of a pavement 1 10 formed in accordance with an embodiment of the present invention, wherein the pavement includes a compacted soil layer 112, a geotextile filtration fabric layer 1 14, a layer of course aggregate 116, one or more basalt rebar "Figure Eight" members 140 with one or more support blocks 118, and a layer of pervious concrete 52.
One example of a method for forming a pavement surface 110 using pervious concrete 52 with a reinforcement of basalt rebar members 140 having a "Figure Eight" shape is illustrated in Fig. 19. Operations 141-143 can be similar to operations 110-124 of Fig. 14, in one example. At operation 141 of Fig. 19, the sub-soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller. In one example, the soil is moist, but free of standing water, to aid in the compaction. At operation 142, a non- woven, geotextile filtration fabric is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below. The geotextile fabric also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer. At operation 143, coarse aggregate material, such as limestone, crushed glass, superheated clay, is placed on the filtration fabric. In one example, more than 6" of coarse aggregate is placed on top of the geotextile fabric which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil below.
At operation 144, basalt rebar members 140 having "Figure Eight" shapes are placed on the coarse aggregate. In one example, these basalt rebar members 140 are placed in 1 ' x 1 ' grids covering the entire area where the pervious concrete will be installed. The grid may be formed using basalt rebar members that are held together in the grid through the use of wire tires. In one example and as shown in Fig. 15, each basalt rebar member may have multiple oval portions forming the "Figure Eight" shape, wherein each oval portion is approximately 13" in length and has two legs (e.g., each 3/16" diameter) separated by a distance of approximately 1", although the dimensions of the basalt rebar member will vary depending upon the needs of a particular application. Concrete chairs or support blocks may be used to support the basalt rebar, for instance 2" above the layer of coarse aggregate. This will allow the rebar to become embedded in the pervious concrete about 2-2 1A" from the bottom of the pervious concrete layer. In one example, for each 8' span of rebar, three chairs or support blocks can be evenly installed underneath for support.
At operation 125, the pervious concrete is poured over the shaped rebar. In one example, the pervious concrete is poured such that there is a sufficient amount ready for compaction, for example 6" for sidewalks and driveways, 10-12" for streets/roadways. At operation 126, the pervious concrete layer is leveled and compacted while still wet. In one example, a vibrating, mechanical screed is used to level off the pervious concrete, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface. In one example, at least 1A" of the pervious concrete layer may be striked-off above the form to allow for compaction. Operation 126 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 11A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges.
After placement of the pervious concrete layer, at operation 127, a mist of water can be applied to the pervious concrete, and the pervious concrete may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete. In one example, the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer, and continues for at least 7 days. In one example of the invention, the pervious concrete layer is believed to reach its maximum strength after 28 days of curing. Formation of Roads, Sidewalks, Driveways, etc. using Pervious Concrete and Basalt GeoMesh
Reinforcement In another embodiment of the invention, a pavement surface 1 10 such as a road, sidewalk, driveway, parking lot, or other surface can be formed using pervious concrete 52 with a reinforcement of basalt geomesh or mesh 150. Figs. 20-23 show an example of a basalt mesh 150, and show sectional views of one example of a pavement formed in accordance with an embodiment of the present invention, wherein the pavement 110 includes a compacted soil layer 1 12, a geotextile filtration fabric layer 1 14, a layer of course aggregate 116, a layer of basalt geomesh 150, and a layer of pervious concrete 52.
One example of a method for forming a pavement surface using pervious concrete 52 with a reinforcement of basalt geomesh 150 is illustrated in Fig. 24. Operations 151-153 can be similar to operations 120-124 of Fig. 14, in one example. At operation 151 of Fig. 24, the sub- soil that will be underneath the pervious concrete is compacted, for instance using a vibrating roller. In one example, the soil is moist, but free of standing water, to aid in the compaction. At operation 152, a non- woven, geotextile filtration fabric is placed to cover the compacted soil and acts as a silt catcher in use, when the water percolates into the soil below. The geotextile fabric also functions as a weed blocker to prevent any unwanted growth that could disrupt the pervious concrete layer. At operation 153, coarse aggregate material, such as such as limestone, crushed glass, superheated clay, is placed on the filtration fabric. In one example, more than 6" of coarse aggregate is placed on top of the geotextile fabric which in use increase the storage capacity, as well as provide a secondary filtration layer to capture pollutants before they enter storm drains or compacted soil below.
At operation 154, a basalt geomesh 150 is placed directly on top of the coarse aggregate without the use of concrete chairs or steel substitutes. In one example, a basalt geomesh 150 is a mesh or basalt strands having a plurality of approximately 1" by 1" squares of basalt strands.
At operation 155, once the basalt geomesh 150 has been installed over the coarse aggregate, pervious concrete is poured over the geomesh 150 until the desired thickness of concrete has been reached.
Operations 156-157 may be similar to operations 130-132 of Fig. 14, in one example. In particular, at operation 156 of Fig. 24, the pervious concrete layer is leveled and compacted while still wet. In one example, a vibrating, mechanical screed is used to level off the pervious concrete, wherein the screed is a flat board or tool used to smooth concrete after it has been placed on a surface.
In one example, at least 1A" of the pervious concrete layer may be striked-off above the form to allow for compaction. Operation 156 may also include compacting the pervious concrete, for instance, through the use of a heavy steel roller to compact the pervious concrete layer. This operation creates a pervious concrete slab where the top approximately 11A" has smaller voids to trap pollutants captured from substances like oil and grease. Edges near the forms may be compacted using a small, hand-held press to prevent raveling of the edges. After placement of the pervious concrete layer, at operation 157, a mist of water can be applied to the pervious concrete, and the pervious concrete may be protected by covering it with plastic sheeting (e.g., a 6 mil polyethylene cover such as Visqueen), and kept damp for 5 to 7 days until full hydration has occurred in the pervious concrete. In one example, the curing process begins within approximately ten minutes of the initial placement of the pervious concrete layer, and continues for at least 7 days. In one example of the invention, the pervious concrete layer is believed to reach its maximum strength after 28 days of curing.
Pothole Repair If a pothole 160 (Fig. 25) develops in the pervious concrete pavement due to loss of compaction of the sub-soil 112 or course aggregate 116 below a portion of the pervious concrete, the pothole 160 may be repairable using the process of Fig. 27, in accordance with an embodiment of the present invention. Fig. 25 shows an example of a sectional view of pothole 160 formed in a pavement made in accordance with an embodiment of the present invention; Fig. 26 shows an example of a sectional view of a repaired pothole in a pavement made in accordance with an embodiment of the present invention. As recognized by the present inventor, pervious concrete with basalt rebar reinforcements has a restorative memory such that some potholes 160 may be repairable without the use of additional pervious concrete material 52 on the surface. Referring to Fig. 27, a process is illustrated for repairing a pothole 160 that exists in a pavement of pervious concrete and basalt reinforcement members. At operation 161 , a pothole is identified that has formed underneath a section of cracked pervious concrete. The basalt rebar or other basalt reinforcement will bend/flex down into the collapsed section until the pressure has been removed and the rebar returns to its original position.
At operation 162, one or more holes 163 are drilled into or about the collapsed section of the pervious concrete, wherein the hole(s) are drilled deep enough to allow a sand slurry injection 164 of operation 165 to reach underneath the pervious and fill the void created by the loss of compaction in the subgrade. At operation 165, sand or a slurry of sand 164 is injected into the drilled hole(s) 163, which fills the void(s) in the subgrade or sub-soil below the pothole. The injected sand slurry 164 provides for both long term stable subsurface conditions by restoring the level of the compacted soil or course aggregate underneath the pervious concrete 52, and also retains an effective permeability through the repaired subsurface beneath the repaired pothole. Once completed, the rebar 54 and the pervious concrete 52 returns to their original position, and hence the pervious concrete has been repaired.
In one example, the methods disclosed herein for forming a pavement or surface 50, 60, 70, 80, 90 or 110 (such as a road, alley, parking area, sidewalk or other surface) may include forming the surface through the use of one or more basalt reinforcement members combined with pervious concrete, without the need for installing stormwater pipes or other stormwater drainage. Embodiments of the invention can be used to make or repair various pavements surfaces or roadways, such as but not limited to streets, sidewalks, driveways, parking lots, highway shoulders, non-vehicular bridges, lightweight vehicular bridges, heavy highways, and lightweight structural components such as parking garage floors, curbs, or other floors, for example.
Through the use of embodiments of the present invention, streets or other structures can be created with significantly reduced or zero runoff, meaning that streets or other structures such as parking lots, sidewalks, etc. can be formed without the need for underground pipes or catch basins, which can result in a significant cost savings when building or maintaining such streets or other infrastructure. Embodiments of the present invention may also eliminate the need for rainfall stormwater management or portions thereof, as well as pumps which are used in cities such as New Orleans. In another embodiment, where existing streets or infrastructure already have storm systems in place, the streets, roads, sidewalks and other infrastructure can be replaced with streets, sidewalks or other structures utilizing embodiments of the present invention. In repairing an existing road, the processes described above could also include an operation of removing the existing pavement and/or other materials present, until the soil layer is exposed.
In one example, a concrete structure using pervious concrete may be formed using construction techniques that are used with impervious concrete; and in other embodiments, different construction techniques are used for forming concrete structures using pervious concrete. For instance, in accordance with an embodiment of the present invention, the basalt rebar members combined with the pervious concrete material can be configured by placing the basalt rebar members in a pattern that is specially adapted or designed to increase the structural integrity of the pervious concrete structure.
In another embodiment of the present invention, a method is disclosed for planting of trees, shrubs or other vegetation along sidewalks or roadways. In one example, the method includes identifying a location for having the tree, shrub or vegetation planted, providing pervious concrete material with basalt reinforcement members around the desired location for the tree, shrub or vegetation, and allowing the pervious concrete to form. The tree, shrub or vegetation can then be planted after the pervious concrete cures. Because of the pervious nature of the concrete, water will drain through the concrete structure (sidewalk, road) and provide water and nutrients to the tree, shrub or vegetation. Therefore, the tree, shrub or vegetation will not have a tendency to uproot the sidewalk, road, or other concrete structure, as typically happens with sidewalks or roads that utilize impervious concrete. Moreover, the roots of tree, shrub and other vegetation will receive more water and air through the use of pervious concrete than with conventional impervious concrete.
While the methods disclosed herein have been described and shown with reference to particular operations performed in a particular order, it will be understood that these operations may be combined, sub-divided, or re-ordered to form equivalent methods without departing from the teachings of the present invention. Accordingly, unless specifically indicated herein, the order and grouping of the operations is not a limitation of the present invention.
It should be appreciated that reference throughout this specification to "one embodiment" or "an embodiment" or "one example" or "an example" means that a particular feature, structure or characteristic described in connection with the embodiment may be included, if desired, in at least one embodiment of the present invention. Therefore, it should be appreciated that two or more references to "an embodiment" or "one embodiment" or "an alternative embodiment" or "one example" or "an example" in various portions of this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined as desired in one or more embodiments of the invention. Similarly, it should be appreciated that in the foregoing description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. While the invention has been particularly shown and described with reference to various embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.

Claims

Claims:
1. A pavement, comprising: pervious concrete material; and one or more basalt reinforcing members embedded in the pervious concrete material.
2. The pavement of claim 1, wherein the one or more basalt reinforcing members are basalt rebar rods.
3. The pavement of claim 1, wherein the one or more basalt reinforcing members are basalt rebar rods having a Figure-Eight shape.
4. The pavement of claim 1, wherein the one or more basalt reinforcing members are a mesh made of basalt strands.
5. The pavement of claim 1 , further comprising a layer of filtration fabric positioned below the basalt reinforcing members.
6. The pavement of claim 1 , further comprising: a compacted soil layer; a layer of filtration fabric positioned above the compacted soil layer; and a layer of course aggregate material positioned above the layer of filtration fabric.
7. The pavement of claim 6, wherein the one or more basalt reinforcing members are positioned above the layer of course aggregate material.
8. The pavement of claim 7, wherein the pervious concrete material forms the upper surface of the pavement.
9. The pavement of claim 1, wherein the one or more basalt reinforcing members are positioned approximately two inches or more above the bottom of the pervious concrete material.
10. The pavement of claim 1 , wherein the pavement is a road.
11. The pavement of claim 1 , wherein the pavement is a parking lot.
12. The pavement of claim 1, wherein the pavement is a driveway.
13. The pavement of claim 1 , wherein the pavement is a sidewalk.
14. A method for forming a road, comprising: compacting a sub-base layer; installing a filtration fabric above the sub-base layer; installing a layer of aggregate material above the filtration fabric; positioning one or more basalt rebar reinforcement members above the layer of aggregate material; and pouring a layer of wet pervious concrete material above the one or more basalt rebar reinforcement members.
15. The method of claim 14, further comprising: leveling said layer of wet pervious concrete; and compacting said layer of wet pervious concrete.
16. The method of claim 14, further comprising curing said layer of pervious concrete.
17. The method of claim 14, wherein the operation of positioning one or more basalt rebar reinforcement members further comprises: placing the one or more basalt rebar reinforcement members approximately two or more inches above the layer of aggregate material.
18. The method of claim 14, wherein the pouring operation includes pouring a portion of said wet pervious concrete material below the one or more basalt rebar reinforcement members, so that the wet pervious concrete material embeds the one or more basalt rebar reinforcement members.
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