SOUND BARRIER PANEL
A sound barrier panel is providing having a concrete substrate and a noise attenuation layer forming a composite panel, in which the noise attenuation layer is formed of recycled shredded rubber and a binder.
1 . A sound barrier panel comprising:
a concrete substrate; and
a noise attenuation layer formed of recycled shredded rubber and a binder, said noise attenuation layer and said concrete substrate combined to form a composite panel.
2 . The sound barrier panel of claim 1 , wherein said concrete substrate and said noise attenuation layer are physically bonded.
3 . The sound barrier panel of claim 2 , wherein a backing sheet is interposed between said concrete substrate and said noise attenuation layer, said backing sheet formed of a material that can readily bond to both the concrete substrate and the noise attenuation layer.
4 . The sound barrier panel of claim 1 , wherein said concrete substrate and said noise attenuation layer are formed in a common mold.
5 . The sound barrier panel of claim 1 , wherein said noise attenuation layer is formed from 10 lbs. of recycled shredded rubber per square foot of surface area of noise attenuation layer.
6 . The sound barrier panel of claim 5 , wherein said noise attenuation layer is further formed from about 25% by volume of binder.
7 . The sound barrier panel of claim 1 , wherein said noise attenuation layer further includes recycled shredded plastic.
8 . The sound barrier panel of claim 1 , wherein said noise attenuation layer further includes recycled shredded fiberglass.
9 . The sound barrier panel of claim 1 , wherein said recycled shredded rubber is shredded to a thickness of no greater than about one inch and an area of about 5 to about 16 sq.in.
10 . The sound barrier panel of claim 1 , wherein said concrete substrate includes reinforcing elements selected from rebar or wire mesh.
11 . The sound barrier panel of claim 10 , wherein:
said noise attenuation layer includes a base panel and a plurality of post projecting therefrom; and
said reinforcing elements are supported on said plurality of posts.
12 . The sound barrier panel of claim 1 , wherein said concrete substrate includes recycled shredded material selected from recycled rubber, recycled plastic and recycled fiberglass.
13 . The sound barrier panel of claim 1 , wherein said noise attenuation layer includes side walls forming a mold for receiving said concrete substrate.
14 . The sound barrier panel of claim 1 , wherein said noise attenuation layer includes a plurality of fingers projecting outward from a surface opposite the surface facing said concrete substrate.
15 . The sound barrier panel of claim 14 , wherein each of said plurality of fingers is generally hook-shaped.
16 . The sound barrier panel of claim 15 , wherein said hook-shape of each of said fingers curls inward toward said surface.
17 . The sound barrier panel of claim 15 , wherein said fingers are resiliently deflectable.
18 . A method for forming a pre-cast sound barrier panel comprising:
pouring a first mixture of recycled shredded rubber and a binder into a mold;
allowing the mixture to cure; and then
pouring a concrete-forming mixture onto the first mixture within the same mold.
19 . The method for forming a pre-cast sound barrier panel of claim 18 , further comprising the step of applying an intermediate sheet on said first mixture before it cures, the intermediate sheet formed of a material capable of bonding to concrete.
20 . The method for forming a pre-cast sound barrier panel of claim 18 wherein the first mixture is poured to form a second mold into which the second concrete-forming mixture is poured.