Crack resistant coating and method of applying crack resistant coating
View Patent ↗The present invention relates to a method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface. The method comprises the steps of applying a binding material to the surface, applying an aggregate mixture within 15 seconds of applying the binding material to the surface, and allowing the binding material to fill some of the air voids in the aggregate mixture to form a substantially voidless layer with a height of at least 0.38 cm.
1. A method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface, the method comprising the steps of:
applying a binding material to the surface in a volume determined by
selecting the binding material and an aggregate mixture;
determining a binding material application rate in L/m 2 ;
determining a percent binding material residuum for the binding material;
determining an amount of binding material adsorbed, where the amount of binding material adsorbed is 0.00 L/m 2 if the surface has been pretreated within three, months and 0.142 L/m 2 if the surface has not been pretreated within three months;
determining a percent aggregate mixture air voids based on laboratory tests on the aggregate mixture;
selecting a substantially voidless layer height of at least 0.38 cm; and
calculating the volume of binding material needed by solving the following system of equations:
volume of binding material needed=(((binding material application rate)(percent binding material residuum))−amount of binding material adsorbed)(1000cm 3 /L);
volume of total air voids=(percent aggregate mixture air voids)(crack resistant layer thickness)(1 m 2 )(100 2 cm 2 /m 2 );
AVFA =(volume of binding material needed)(volume of total air voids); and
substantially voidless layer height=(crack resistant layer thickness)( AVFA );
applying the aggregate mixture within 15 seconds of applying the binding material to the surface, where the aggregate mixture comprises aggregate particles and an asphalt solution and where the aggregate mixture has a plurality of air voids; and
allowing the binding material to fill some of the air voids in the aggregate mixture to form a substantially voidless layer with a height of at least 0.38 cm.
2. The method of claim 1 where the substantially voidless layer has a height of at least 0.46 cm.
3. The method of claim 2 where the binding material fills at least 18% of the air voids in the aggregate mixture (AVFA).
4. The method of claim 2 where the binding material fills at least 24% of the air voids in the aggregate mixture (AVFA).
5. The method of claim 2 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating contains a total binding material in an amount greater than about 1.00 L/(m 2 -cm), where the total binding material is a sum of the net binding material and the asphalt solution.
6. The method of claim 5 where the total binding material is greater than about 1.30 L/(m 2 -cm).
7. The method of claim 5 where the total binding material is greater than about 1.51 L/(m 2 -cm).
8. The method of claim 2 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating has a thickness of at least 0.635 cm.
9. The method of claim 8 where the thickness is at least 1.27 cm.
10. The method of claim 8 where the thickness is at least 1.90 cm.
11. The method of claim 8 where the thickness is at least 2.54 cm.
12. The method of claim 1 where the substantially voidless layer has a height of at least 0.55 cm.
13. The method of claim 1 where the substantially voidless layer has a height of at least 0.75 cm.
14. The method of claim 13 where the binding material fills at least 18% of the air voids in the aggregate mixture (AVFA).
15. The method of claim 13 where the binding material fills at least 24% of the air voids in the aggregate mixture (AVFA).
16. The method of claim 13 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating contains a total binding material in an amount greater than about 1.00 L/(m 2 -cm), where the total binding material is a sum of the net binding material and the asphalt solution.
17. The method of claim 16 where the total binding material is greater than about 1.30 L/(m 2 -cm).
18. The method of claim 16 where the total binding material is greater than about 1.51 L/(m 2 -cm).
19. The method of claim 13 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating has a thickness of at least 0.635 cm.
20. The method of claim 19 where the thickness is at least 1.27 cm.
21. The method of claim 19 where the thickness is at least 1.90 cm.
22. The method of claim 19 where the thickness is at least 2.54 cm.
23. The method of claim 1 where the binding material fills at least 15% of the air voids in the aggregate mixture (AVFA).
24. The method of claim 1 where the binding material fills at least 18% of the air voids in the aggregate mixture (AVFA).
25. The method of claim 1 where the binding material fills at least 22% of the air voids in the aggregate mixture (AVFA).
26. The method of claim 1 where the binding material fills at least 24% of the air voids in the aggregate mixture (AVFA).
27. The method of claim 1 Where the aggregate mixture is applied within 10 seconds of applying the binding material to the surface.
28. The method of claim 1 where the aggregate mixture is applied within 5 seconds of applying the binding material to the surface.
29. The method of claim 1 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating contains a total binding material in an amount greater than about 1.00 L/(m 2 -cm), where the total binding material is a sum of the net binding material and the asphalt solution.
30. The method of claim 29 where the total binding material is greater than about 1.30 L/(m 2 -cm).
31. The method of claim 29 where the total binding material is greater than about 1.51 L/(m 2 -cm).
32. The method of claim 1 where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating has a thickness of at least 0.635 cm.
33. The method of claim 32 where the thickness is at least 1.27 cm.
34. The method of claim 32 where the thickness is at least 1.90 cm.
35. The method of claim 32 where the thickness is at least 2.54 cm.