WO2017199013A1

WO2017199013A1 - A method of producing a road making material and to a road made therefrom

Info

Publication number: WO2017199013A1
Application number: PCT/GB2017/051360
Authority: WO
Inventors: Toby Jon MCCARTNEY
Original assignee: Mccartney Toby Jon
Priority date: 2016-05-18
Filing date: 2017-05-16
Publication date: 2017-11-23
Also published as: GB201608715D0

Abstract

A method of producing a road making material includes the sequential steps of, separately heating aggregate and bitumen, mixing the heated aggregate and bitumen, and adding plastics to the heated mix to produce a bitumous compound.

Description

A METHOD OF PRODUCING A ROAD MAKING MATERIAL AND TO A

ROAD MADE THEREFROM

This invention relates to a method of producing a road making material and to a road made therefrom. Materials for making roads, sometimes called pavements in some jurisdictions, include stone, aggregate, wood block, vitrified brick and bitumen (sometimes called asphalt). The term "road" used herein includes within its scope pedestrian paths (known as pavements, or sidewalks in some countries) or cycle paths.

Bitumen is a sticky black and highly viscous liquid or semi-solid form of petroleum and may be found in natural deposits or may be refined. The first general use of bitumen in road construction, where it is used as a binder mixed with aggregate particles, was devised by Scotsman John McAdam and the surface became known as "Tarmacadam", abbreviated to "Tarmac" in common parlance.

Mixed-in-place surfacing involves mixing aggregates in a roadway with bitumen in order to obtain a stronger and generally water-repelling surface, with the resultant mixture being compacted. Plant mix surface dressings provide improved strength and waterproofing for higher volumes of automotive traffic and provide an improved riding quality surface. Such a plant mix process generally involves aggregates up to about 3cm mesh size which is heated to a temperature of 150°C - 250°C and mixed in a plant with bitumen. The resulting compound is taken to a roadway where it is poured into a laying machine and applied to a road surface, whereupon it is rolled before the mixture cools. Such road surfaces are susceptible to being permeated by rain water and for the surface to break up leaving potholes which are damaging to vehicle tyres, wheels and suspensions, and which can cause severe accidents.

Currently, different grades of bitumen such as 30/40, 60/70 and 80/100 are available in dependence upon the required penetration value, but, for the reason previously stated, there is a demand for an improved road surface.

A different, but worldwide problem, is the disposal of plastics waste. It will be realised that plastics like low density polyethylene is used for bags, sacks, bin liners and squeezable detergent bottles, high density polyethylene is used for bottles for pharmaceuticals, disinfectants, milk and fruit juices, polypropylene is used for bottle caps, film wrapping for food and microwave trays for ready-made meals, polystyrene is used for yoghurt pots and egg packs, foamed polystyrene is used for food trays, egg boxes, and disposable cups, and polyvinylchloride (PVC) is used for mineral bottles, credit cards, toys, electrical fittings, etc. Currently, such plastics materials are used in virtually every sector of the economy from agriculture to packaging, automobile and building construction, and communications equipment. Such plastics material is non-biodegradable and, according to recent studies, can remain unchanged for as long as 4,500 years. At present, the majority of plastics waste is put into landfill, leading to ecological problems.

Currently, a bitumen compound road will last for approximately four to five years, after which it needs to be repaired or replaced on a regular basis, thereby incurring additional cost and inconvenience to road users. Current bitumen compound suffers from temperature effects, oxidation leading to cracking and crazing, the forementioned water problems forming potholes and reducing the life of roads, and relatively high cost in needing to repair or resurface a road on a regular basis.

With regard to plastic waste, attempts at recycling have proved unsuccessful or too expensive and burning the plastics materials has been shown to release gases which are dangerous to the environment.

This invention seeks to utilise waste plastics material, although it is to be understood that the benefit of the method of this invention is not dependent upon such use, since other sources of plastics may be utilised.

Primarily, this invention seeks to produce an improved road making material and an improved road produced therefrom.

According to this invention there is provided a method of producing a road making material including the sequential steps of

(1) separately heating aggregate and bitumen,

(2) mixing the heated aggregate and bitumen, and

(3) adding plastics to the heated mix to produce a bitumen compound.

Currently, it is preferred no other materials are added to the mix.

Preferably, the aggregate and bitumen are heated separately to 120°C - 180°C, advantageously to a temperature in the range 120°C - 160°C. Conveniently, the grade of bitumen is one of 40/60, 60/70, 80/100 or 100/150, but is, preferably, 40/60 for a heavily trafficked road.

Advantageously, the aggregate has a mesh size in the range 1mm - 55mm and, preferably, has a mesh size of 10mm or 14mm.

Advantageously, the ratio of plastics to bitumen is in the range 5% - 25% of plastics to bitumen.

Preferably, the ratio of plastics to bitumen is in the range 5% - 10% of plastics to bitumen.

Advantageously, the ratio of plastics and bitumen to aggregate is 4% - 10% by weight of plastics and bitumen to aggregate.

Conveniently, the proportions of aggregate and bitumen are 95% aggregate and 5% bitumen.

Preferably, waste plastics is collected, cleaned and shredded to 1mm - 50mm to be heated and added to the mix.

Advantageously, plastics micro-beads of 5μιη to 1mm or pelletised plastics in the range 1mm to 10mm are used.

Preferably, the bitumous compound is used to form a road surface.

Advantageously, the road surface is made by laying the bitumous compound at a temperature in the range of 70°C - 160°C and subsequently rolling the compound so that it is compacted.

Advantageously, the road surface is made by laying the material of step 3 at a temperature in the range of 70°C - 160°C and subsequently rolling the material so that it is compacted, the rolling weight being up to approximately 10,160kg (10 ton).

In a feature of this invention there is provided a method of producing a road making material including the sequential steps of

(a) heating aggregate and bitumen, and

(b) mixing the heated aggregate and bitumen with micro-bead plastics material, whereby the micro-beads are melted into the aggregate and bitumen mix. It will, therefore, be understood that plastics melted with hot bitumen forms an oily coat which is provided over aggregate and the resulting mixture of a compound is laid onto a road surface. The plastics material increases the melting point of the bitumen. Such a technology provides improved strength of road surface having improved impermeability. When waste plastics are utilised, benefits to the environment are also forthcoming. In underdeveloped countries, employment is provided for people to pick the plastics from rubbish dumps, although in more developed countries it is envisaged that plastics-collecting machinery will be utilised.

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 shows a flow chart of one method of producing a road making material and to a road made therefrom which is disclosed in our co-pending application PCT/GB2017/050172, and

Figure 2 shows a flow chart of a method of producing a road making material and to a road made therefrom in accordance with this invention.

This invention preferably uses waste plastics that is collected from landfill sites, dumps, garbage trucks, school collection programmes, or by purchase from waste buyers/collectors, although it is to be understood that the improved road making material of this invention is not dependent upon the use of waste plastics since it is possible that plastics material from a chemical plant may be utilised.

Referring to Figure 1, in step 1 waste plastics material is collected from the forementioned landfill sites, etc. The collected waste plastics is sorted, if required, and cleaned by, for example, washing and cut to a size of 1mm - 55mm using a shredding machine in step 2.

Alternatively, micro-beads of 5μιη to 1mm or pelletised plastics in the range lmm to 10mm are used.

The shredded plastics is then heated in step 3 to a temperature of 120°C - 180°C, preferably 165°C. It has been found that the plastics softens at 120°C and there is no gas evolution in the range 120°C - 180°C. The bitumen is similarly heated, usually in a separate furnace up to 160°C in step 3.

In step 4, the plastics are mixed with the bitumen at a rate of 5% - 25% by weight of plastics to the weight of bitumen. A mixing plant is used to control the temperature of the plastics and bitumen which are mixed together so as to provide a substantially uniform coating of plastics on the bitumen.

The bitumen used may have grades 60/70, 80/100 or 100/150, but for heavily trafficked roads is, preferably, 40/60 grade.

In step 5, the heated plastics/bitumen mixture is mixed with aggregate where the plastics/bitumen mix is 4% - 10% by weight to aggregate. The aggregate is typically 1mm - 55mm, preferably 10mm or 14mm and has stone dust and lime as a filler. The aggregate may, preferably, be granite stone or may be ceramics or other suitable material. The plastics/bitumen, when mixed with the aggregate, produces a bitumous compound which is aggregate coated with plastics/bitumen and the compound may be transported to a laying machine where it is laid on a pre -prepared surface, the road laying temperature being between 70°C - 160°C in step 6. The surface is then rolled by a roller having up to an 10,160kg (10-ton) capacity, for example.

Alternatively, steps 4 and 5 are combined in step 7 where the heated plastics and bitumen are mixed with aggregate whereby the plastics and bitumen mixture coats the aggregate.

In an aspect of this invention, it will be understood that micro-beads of plastics material pose an environmental hazard when disposed in waste water and such micro- beads readily pass through sewage treatment plants without being removed by filtering, leading to plastic particle pollution in water supplies. In a preferred aspect of this invention, such micro-beads are collected and used in a road making material.

Referring to Figure 2, aggregate, having a mesh size in the range 1mm - 55 mm, preferably 10mm or 14mm, is heated to a temperature in the range 120°C - 180°C in step 21, preferably 120°C - 160°C. Bitumen, which may be one of a grade of 40/60, 60/70, 80/100 or 100/150, but is, preferably, 40/60 for a heavily trafficked road, is heated to a temperature in the range 120°C - 180°C , preferably 120°C - 160°C, in step 22 and, in step 23, the heated aggregate and bitumen are mixed together in a temperature range 120°C - 180°C. In step 24, micro-beads of plastic material in the range 5μηι to 1mm, or, alternatively, shredded plastics of 1mm -

50mm, or pelletised plastic in the range 1mm to 10mm, is added to the mix to produce a plastics coated bituminous compound. By virtue of being small particle size, so the plastics will melt, thereby coating the aggregate and bitumen mix to produce a bituminous compound. The plastics coated bituminous compound is laid to form a road surface using a laying temperature between 70°C - 160°C, with the surface subsequently being rolled by a roller having up to a 10,160Kg (10-ton) capacity.

In this invention, typically the ratio of plastics to bitumen is in the range 5% - 25% of plastics to bitumen but is preferably in the range 5% - 10% of plastics to bitumen, and in step 24 the ratio of plastics and bitumen to aggregate is 4% - 10% by weight of plastics and bitumen to aggregate. Advantageously, the proportions of aggregate and bitumen are 95% aggregate and 5% bitumen.

The use of micro-beads plastic material has the advantage of having a high surface area to volume ratio, whereby the particles melt more readily, thus reducing the required mixing time.

The order of the steps is important for asphalt plants whereby in this invention bitumen and plastics are provided to the plant in solid form and can be safely and easily stored.

It is believed that using plastics with bitumen to coat aggregate for a road making material has the following advantages over currently produced bitumised road surfaces:

1. A stronger road with increased Marshall stability value - road strength increased by approximately 100%, leading to maintenance intervals being doubled. It is estimated that using this invention will produce a road that will last up to ten years before maintenance is required, and may even last four or five times longer.

2. Improved resistance towards rain water penetration and water

stagnation.

3. Reduced stripping and production of potholes.

4. Increased binding and improved bonding of the mix.

5. Reduced pores in aggregate with consequential reduction in rutting and ravelling.

6. No leaching of plastics.

7. Improved UV protection. Increased load withstanding, thereby satisfying present day needs with heavier road vehicles and increased vehicle density.

Decrease in cost of road construction.

Useful utilisation of waste plastics.

When using pellets or microbeads, the particle size is completely uniform meaning that the mixing time after the pellets are added is consistent and can be minimised to increase the efficiency of the asphalt plant. Producing microbeads and pelletising

requires consistency of the ingredients in order to work and as such quality control is entrained into the production of the microbeads or pellets, further increasing the efficiency of asphalt plants and minimising any contamination of the down stream product. This is because the formation of a microbead or pellet is only possible if there is no contamination as any contaminants tend to block the filters in the pelletising machines.

Claims

CLAIMS 1. A method of producing a road making material including the sequential steps of:

1. separately heating aggregate and bitumen,

2. mixing the heated aggregate and bitumen,

3. adding plastics to the heated mix to produce a bitumous compound.

2. A method as claimed in claim 1, wherein in step 1, the aggregate and bitumen are each heated up to a temperature in the range 120° - 180°C.

3. A method as claimed in claim 1, wherein the aggregate and bitumen are heated separately to a temperature in the range 120°C - 160°C.

4. A method as claimed in any preceding claim, wherein the grade of bitumen is one of 40/60, 60/70, 80/100 or 100/150.

5. A method as claimed in any of claims 1 to 3, wherein the grade of bitumen is one of 40/60 for a heavily trafficked road.

6. A method as claimed in any preceding claim, wherein the aggregate has a mesh size in the range 1mm - 55mm.

7. A method as claimed in any preceding claim, wherein the aggregate has a mesh size of 10mm or 14mm.

8. A method as claimed in any preceding claim, wherein the ratio of plastics to bitumen is in the range 5% - 25% of plastics to bitumen.

9. A method as claimed in claim 8, wherein the ratio of plastics to bitumen is in the range 5% - 10% of plastics to bitumen.

10. A method as claimed in any preceding claim, wherein in step 3, the ratio of plastics and bitumen to aggregate is 4% - 10% by weight of plastics and bitumen to aggregate.

11. A method as claimed in ay preceding claim, wherein the proportions of aggregate and bitumen are 95% aggregate and 5% bitumen.

12. A method as claimed in any preceding claim, wherein, waste plastics is collected, cleaned and shredded to 1mm - 50mm to be heated and added to the mix.

13. A method as claimed in any of claims 1 to 11, wherein plastics micro-beads of 5μιη to 1mm or pelletised plastics in the range 1mm to 10mm are used.

14. A method as claimed in any preceding claim, wherein the bitumous compound is used to form a road surface.

15. A method as claimed in claim 14, wherein the road surface is made by laying the bitumous compound at a temperature in the range of 70°C - 160°C and subsequently rolling the compound so that it is compacted.

16. A method of producing a road making material including the sequential steps of

(a) heating aggregate and bitumen, and

(b) mixing the heated aggregate and bitumen with micro-bead plastics material, whereby the micro-beads are melted into the aggregate and bitumen mix.