# US 8,784,557 B2 · Pavement overlay material and method

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- Number: US 8,784,557 B2
- Document ID: US8784557B2
- Status: Granted
- Kind: B2
- Application number: 13/019,535
- Filed: 2011-02-02
- Published: 2011-08-04
- Granted: 2014-07-22
- Earliest claimed: 2010-02-02
- Assignees: Pavement Surface Coatings, LLC
- Applicants: Nicholas Reck
- Inventors: Nicholas Reck
- Web page: https://patentgrep.com/patent/US8784557B2

## CPC

- C04B 28/02: containing hydraulic cements other than calcium sulfates
- E01C 7/147: {Repairing concrete pavings, e.g. joining cracked road sections by dowels, applying a new concrete covering (applying thin surface layers with other binder E01C7/35; repairing pavings in general E01C11/005; roughening by means of tools E01C11/24)}
- E01C 11/005: {Methods or materials for repairing pavings (E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00)}
- C04B 2111/0075: {for road construction}
- C04B 2111/60: Flooring materials
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H)
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

A mix design for a polymer modified cement pavement overlay is disclosed along with a method of making and using the mix on a variety of pavement substrates. The mix includes a specific dry combination of: finely divided Elotex 2311 and 2322 or 2320 polymers; Type 2 or C144 aggregate or equivalent; Type I/II cement; Type F or Type C fly ash; intermediate length polymer microfibers; plasticizer; (optionally) calcium chloride or equivalent; (optionally) quikrete retarder or equivalent; and water. The mixture is combined and applied to the substrate in depths of about ⅛ to about 1 inch in lifts. The mixture is allowed to cure for 3-4 hours before being returned to traffic. The placed mixture exhibits preferred qualities of substrate adhesion, flexibility, tire friction, and wearability.

## Claims

### Claim 1

A polymer modified cement pavement overlay mixture, comprising by weight:
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve workability and void distribution, about 0.5 wt % to about 1.0 wt %;
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve cured state flexibility and adhesion with a substrate, about 3.0 wt % to about 3.5 wt %;
masonry mortar aggregate (ASTM C144) about 49 wt % to about 59 wt %;
type II hydraulic Portland cement about 15 wt % to about 25 wt %;
class C or class F fly ash about 1 wt % to about 20 wt %;
polycarbonate superplasticizer about 0 wt % to 2 wt %;
polypropylene microfibers, about 0.25 to about 1.5 inches long, about 0.8 wt % to about 1.16 wt %; and
water about 11 wt % to about 21 wt %.

### Claim 2 (depends on 1)

A mixture as in claim 1, further comprising:
calcium chloride about 0.01 wt % to about 10 wt % blended with a retarding admixture (ASTM C494 Type B) about 0 wt % to about 5 wt %.

### Claim 3

A method of making a pavement overlay mixture, comprising the steps of:
combining
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve workability and void distribution, about 0.5 wt % to about 1.0 wt %;
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve cured state flexibility and adhesion with a substrate, about 3.0 wt % to about 3.5 wt %;
masonry mortar aggregate (ASTM C144) about 49 wt % to about 59 wt %;
type II hydraulic Portland cement about 15 wt % to about 25 wt %;
class C or class F fly ash about 1 wt % to about 20 wt %;
polycarbonate superplasticizer about 0 wt % to 2 wt %; and
polypropylene microfibers, about 0.25 to about 1.5 inches long, about 0.8 wt % to about 1.16 wt % in a dry form blend;
adding said dry blend to a mixing machine containing water apportioned as about 11 wt % to about 21 wt %, all said percentages being by weight of said overlay mixture; and
mixing for more than 5 minutes.

### Claim 4 (depends on 3)

A method as in claim 3, further comprising the step of:
testing said mixture following mixing for flowability in a standard ASTM flow meter cone test such that time required for passthrough is consistently between 5 and 60 seconds.

### Claim 5

A hardened pavement overlay, comprising:
a ⅛ to 1 inch thick, screed placed, and 4 hour cured mixture, including by weight prior to placement:
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve workability and void distribution, about 0.5 wt % to about 1.0 wt %;
a redispersible binder based on a copolymer of vinyl acetate and ethylene formulated to improve cured state flexibility and adhesion with a substrate, about 3.0 wt % to about 3.5 wt %;
masonry mortar aggregate (ASTM C144) about 49 wt % to about 59 wt %;
type II hydraulic Portland cement about 15 wt % to about 25 wt %;
class C or class F fly ash about 1 wt % to about 20 wt %;
polycarbonate superplasticizer about 0 wt % to 2 wt %;
polypropylene microfibers, about 0.25 to about 1.5 inches long, about 0.8 wt % to about 1.16 wt %; and
water about 11 wt % to about 21 wt %.

### Claim 6 (depends on 5)

A hardened pavement overlay as in claim 5, further comprising by weight prior to placement:
calcium chloride about 0.01 wt % to about 10 wt % blended with a retarding admixture (ASTM C494 Type B) about 0 wt % to about 5 wt %.