CA2113407A1 - Composition and method for sealing potholes - Google Patents

Composition and method for sealing potholes

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Publication number
CA2113407A1
CA2113407A1 CA 2113407 CA2113407A CA2113407A1 CA 2113407 A1 CA2113407 A1 CA 2113407A1 CA 2113407 CA2113407 CA 2113407 CA 2113407 A CA2113407 A CA 2113407A CA 2113407 A1 CA2113407 A1 CA 2113407A1
Authority
CA
Canada
Prior art keywords
pothole
acid copolymer
ethylene
thermoplastic material
melt index
Prior art date
Legal status (The legal status 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 status listed.)
Abandoned
Application number
CA 2113407
Other languages
French (fr)
Inventor
James H. Reimer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plastic Flamecoat Systems Inc
Original Assignee
Plastic Flamecoat Systems Inc
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 Plastic Flamecoat Systems Inc filed Critical Plastic Flamecoat Systems Inc
Publication of CA2113407A1 publication Critical patent/CA2113407A1/en
Abandoned legal-status Critical Current

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  • Road Repair (AREA)

Abstract

ABSTRACT
A composition and method for repairing a pothole in a paved roadway comprising the steps of cleaning and drying the pothole, sealing the pothole with a flame sprayed layer of thermoplastic material having a melt index from about 10 to 500, preferably an ethylene methacrylic acid copolymer optionally mixed with particles of recycled tires, and thereafter filling the pothole with a suitable patching material.

Description

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PFSI-2 1 ,855 IN THE UNITED STATES PATENT AND TRADEMARK OF~ICE

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COMPOSITION AND METHOD FOR SEALING POTHOLES ~ - -, ;.' ~' ''' BACKGROUND OF THE INVENTION

1. Field of the Invention This invention relates to the repair of potholes in asphaltic pavement or concrete roadways, and more particularly, to a compositi~n and method for effectively sealing the bottom and sides of potholes when they are patched.
5 2. Description of Related Art Potholes are often created when water that has seeped or otherwise penetrated beneath the surface of a roadway softens the underlying base. When the roadway is subjected to vehicular traf~lc, the pressure exerted on the roadway due to the weight of the vehicles is transferred to the softened suppor~ layer.
10 Because the subsurface water permeating the base is incompressible, it is forced upward through cracks in the roadway as the support layer compresses, and the hydraulic pressure thus created ~urther erodes the pavement or concrete, leadingto localized structural failure and collapse.
With conventional pothole patching compositions and methods, patching 15 material is packed into the pothole. Depending upon the type and quality of the patching material used, however, further water seepage and ~he hydraulic pressure associated with repeated compression cycles due to vehicular traffic are ~ -likely to either erode the patching material or erode the edges of the former pothole around the patching material. In either case, the pothole typically 20 reappears at the same location some time afterward, and is often larger than befiore. Tn many instances potholes are patched repeatedly over a period of years 2 ~3~7 until the roadway is so degraded that resurfacing, repaving or reconstruction isrequired.
Prior art compositions~ methods and devices said to be useful for repairing pavement and potholes are disclosed, for example, in United St~tes Patent Nos.
3,891,585; 3,919,148; 3,930,100; 4,069,182; 4,113,401; 4,744,693; ~,781,490;
and 5,092,706.
Patent Nos. 3,891,585; 3,930,100; 4,069,182 and 4,113,401 generally relate to elastomeric pavement repair compositions that are formulated using paving grade asphalt, commercially processed reclaimed rubber (including tire orinnertube rubber) and aggre~ate. The use of asphalt-con~aining rubber in such high percentages and temperatures as to cause jelling in the formation of a completely elastic mixture when heated, is said to be unique in its ~ormulation and its application for pavement repairs.
IJ.S. 3,919,148 discloses an elastomeric pavement patch material prepared from a hot asphalt-rubberjelly composition that is mixed with a predetermined amount of a compatible solvent to form an elastomeric material having a predetermined viscosity. The addition of the solvent lowers the viscosity of thecomposition and permits its application with existing equipment. The material can be applied, worked on and covered with chips for up to an hour after its application. When the material begins to set up, it sets up at a very rapid rate, which is independent of the evaporation of the solvent. The reclaimed rubber used in the invention can be prepared from reclaimed tires, tire scrap, innertube scrap, retread scrap, tire peel, tire carcass and other rubber scrap.
U.S. 4,781,490 discloses a pothole repair method in which an aqueous 2S solution of a water soluble acid s~lt of an amine compound is applied to the pothole area prior to filling it with an asphaltic concrete patch.
IJ.S. 5,092,706 discloses heating and drying a pothole (liquid spray followed by hot air blower or gas flame burner); spraying a composite tack (which can include polymeric mixtures but must include a lossy microwave material) into the pothole at a thickness of approximately 1/16 inch; filling the 2 1~ i 3 1~ 0 7 : 3 pothole with asphalt patch material and thereafter microwaving the patch to ~ -produce a strong interface bond.
Flame spray technology, used in the method of the inven~ion, is previously known within the industrial coating art but ~o applicant's knowledge has not S previously been used for the application disclosed herein.

'''~ 23.'l31~37 SUMMARY OF THE INVl~NTION
According to the present invention, a composition and method are disclosed for repairing potholes through the use of flame spray technology, and more particularly, through the use of flame sprayed thermoplastic coatings to seal 5 the interior and surrounding edges of potholes prior to patching the potholes with conventional materials. Applicant has discovered that by sealing the interior and adjacent surfaces of a pothole with a layer of flame sprayed thermoplastic material prior to refilling the pothole with a patching material, a seal is produced that prevents or significantly impedes the inward migration of moisture through the affected area and also the erosion that occurs when subsurface moisture is forced toward the surface under pressure due to vehicular traffic on a roadway.
According to one embodiment of the invention, potholes are first cleaned to remove chunks of debris, dried to remove excess moisture, and then sealed with a flame sprayed coating of a thermoplastic resin such as, for example, an ethylene ac;d copolymer like ethylene methacrylic acid ~EMAA) copolymer, preferably having a melt index in the range of ~rom about 10 to about 500.
According to another embodiment of the invention, particles of ground rubber from recycled tires are mixed with the sealing material prîor to flame spraying.The thermoplastic resin is preferably flame sprayed into the pothole to form a continuous sealing layer having a thickness ranging from about 30 to about 40 mils, which desirably serves as a pliable but moisture impervious membrane within and immediately surrounding the pothole.

2 ~ .~ 3 ~

The apparatus of the invention is ~urther described and explained in relation to the following figures of the drawings wherein:
FIG. 1 is a simplified cross-sectional elevation view of a pothole in a 5 paved roadway;
FIG. 2 is an enlarged cross-sectional detail view of the pothole of FIG. 1 after it has been cleaned and sealed with a flame sprayed layer in accordance with the method of the invention and before the patching material is added; and . :~
FIG. 3 is a simplified cross-sectional elevation view of the pothole of FIG.
1 after the pothole is sealed and patched in accordance with the method of the invention.
Like reference numerals are used to indicate like parts in all figures of the drawings.

^-` 2 ~ :i 3 ~

~ESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, paved roadway 10 is depicted as having concrete layer 12 disposed over subsurface soil layer 14. Potho]e 16 defined by interior walls 18 has formed in paved roadway 10, and extends downward]y through S concrete layer 12 into subsurface soil layer 14. Broken chunks 20 of pavement are shown in the bottom portion of pothole 16. It shou]d be understood that whi]e paved roadway 10 is depicted as a simple two layer construction ~or eaise of illustration, the invention is likewise applicable to potholes in other pavementconstruction that may include a plurality of subsurface layers, different pavingmaterials, steel reinforcing bars, or the like. Thus, for example, the composition and method of the invention are likewise suitable for repairing potholes in asphalt pavement. Similarly, whi]e roadways are the most common location in which potholes occur, it will be apparent upon reading this disclosure that the composition and method of the invention are likewise applicable to potholes in other paved surfaces such as airport runways or the like.
According to the method of the invention, loose debris such as broken chunks 20 shown in PIG. 1 are desirably removed from pothole 16, and any standing water is also removed by any suitable conventional means. Once any standing water has been removed from pothole 16, interior walls 18 are desirablyfurther dried by use of the flame from a flame spray gun prior to starting the flow of thermoplastic powder as disclosed, ~or example, in U.S. Patents Nos.
4,632,309 or 4,934,595, which are incorporated by reference herein. ~ ;
Referring to FIGS. 2 and 3, once pothole 16 is free of loose debris and excess moisture, it is preferably sealed by flame spraying a thermoplastic resincoating over interior walls 18 and the edges of the pavement surface surroundingthe pothole. The thermoplastic resin is preferably supplied to the flame spray gun in a finely divided particulate form, most preferably entrained in a flow of air. Preferred thermoplastic resins for use in the method of the invention comprise a major portion of an olefinic copolymer containin~g a carboxyl group and having a very low viscosity ae the melting point. ParticlJlarly pre~erred 7 2 1 1 3 ~ ~ 1 thermoplastic resins for use in the invention are ethylene acid copolymers having a melt index ranging from about 10 to about 500, most preferably ethylene methacrylic acid (EMAA) copolymer. The thermoplastic resin is preferably flame sprayed into pothole 16 and over the surrounding edges 28 to a thickness 5 ranging from about 30 to 40 mils, although it will be appreciated that the thickness of sealing layer 22 can vary according to factors such as the polymer used, the texture and type(s) of material present in interior walls 18, the type of patching material to be utilized, and the like. Applicant has discovered that a flame sprayed coating of a polymer such as EMAA provides a seal within pothole 16 that is substantially impervious to the further migration of water through the pothole.
In addition to the preferred thermoplastic polymer, it will be appreciated by those of ordinary skill in the art that minor effective amounts of other materials utilized in mixing or compounding flame sprayable thermoplastic resinscan also be included within the scope of the present invention. A particularl~
preferred EMAA copolymer suitable for use in the method of the invention is commercially available from Plastic Flamecoat Systems, Inc. under the tradename PFS-113. EMAA copolymer is preferred for use in the method of the invention because of its excellent adhesion in addition to its function as a moisture barrier.
According to one preferred embodiment of the invention, visible in FIG.
3, particles 26 of recycled tire rubber can optionally be mixed into the thermoplastic powder that is flarne sprayed into pothole 16. The use of recycledtire rubber is not required, but in the preferTed composition of the invention, serves the two-fold purpose of reducing the needed quantity of the more expensive thermoplastic resin while simultaneously providing a beneficial end use for recycled tires.
Sealing layer 22 cools quickly when applied to the interior of pothole 16, and according to the method of the invention, a conventional pothole patching material 24 such as an asphalt-aggregate mixture is then placed and compacted into pothole 16 over seaiing layer 22. (In FIG. 3 only a portion of pothole patching material 24 is shown for ease of illustration.) ~,:; ,.,,, ,.,.~

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8 21~ ~. 3 ~ ~ t Pothole repairs made in accordance with the method of the invention demonstrate significantly improved service life and resistance to washout, enlargement or further structural collapse.
Other alterations and modifications of the invention will likewise become 5 apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventor is legally entitled.

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Claims (18)

1. A method for repairing a pothole in a paved surface, the pothole having interior surfaces and surrounding edges, the method comprising the steps of:
removing loose debris from the pothole;
removing excess moisture from the pothole;
coating the interior surfaces and surrounding edges of the pothole with a continuous polymeric layer by flame spraying a powdered thermoplastic material into and around the pothole; and thereafter filling the pothole with a conventional pothole patching material.
2. The method of claim 1 wherein the polymeric layer has a thickness ranging from about 30 to about 40 mils.
3. The method of claim 1 wherein the thermoplastic material comprises a major portion of an ethylene acid copolymer.
4. The method of claim 3 wherein the ethylene acid copolymer is ethylene methacrylic acid copolymer.
5. The method of claim 1 wherein the thermoplastic material has a melt index in the range of from about 10 to about 500.
6. The method of claim 3 wherein the ethylene acid copolymer has a melt index in the range of from about 10 to about 500.
7. The method of claim 4 wherein the ethylene methacrylic acid copolymer has a melt index in the range of from about 10 to about 500.
8. The method of claim 1 wherein rubber particles from recycled tires are mixed with the powdered thermoplastic material prior to flame spraying.
9. A method for sealing a pothole in a paved surface comprising the steps of:
removing loose debris from the pothole;
removing excess moisture from the pothole; and coating the pothole with a continuous polymeric layer by flame spraying a powdered thermoplastic material into and around the pothole.
10. The method of claim 9 wherein the polymeric layer has a thickness ranging from about 30 to about 40 mils.
11. The method of claim 9 wherein the thermoplastic material comprises a major portion of an ethylene acid copolymer.
12. The method of claim 11 wherein the ethylene acid copolymer is ethylene methacrylic acid copolymer.
13. The method of claim 9 wherein the thermoplastic material has a melt index in the range of from about 10 to about 500.
14. The method of claim 11 wherein the ethylene acid copolymer has a melt index in the range of from about 10 to about 500.
15. The method of claim 12 wherein the ethylene methacrylic acid copolymer has a melt index in the range of from about 10 to about 500.
16. The method of claim 9 wherein rubber particles from recycled tires are mixed with the powdered thermoplastic material prior to flame spraying.
17. A flame sprayable composition for sealing a pothole in a paved surface, the composition consisting essentially of an ethylene acid copolymer having a melt index in the range of from about 10 to about 500 in combination with recycled tire particles.
18. The composition of claim 17 wherein the ethylene acid copolymer is an ethylene methacrylic acid copolymer.
CA 2113407 1993-09-27 1994-01-13 Composition and method for sealing potholes Abandoned CA2113407A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12701193A 1993-09-27 1993-09-27
US08/127,011 1993-09-27

Publications (1)

Publication Number Publication Date
CA2113407A1 true CA2113407A1 (en) 1995-03-28

Family

ID=22427872

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2113407 Abandoned CA2113407A1 (en) 1993-09-27 1994-01-13 Composition and method for sealing potholes

Country Status (1)

Country Link
CA (1) CA2113407A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6475316B1 (en) 2000-07-07 2002-11-05 3M Innovative Properties Company Methods of enhancing adhesion
GB2449908A (en) * 2007-06-07 2008-12-10 Purton Sustainable Technologies Ltd Plug for repairing road surfaces

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6475316B1 (en) 2000-07-07 2002-11-05 3M Innovative Properties Company Methods of enhancing adhesion
GB2449908A (en) * 2007-06-07 2008-12-10 Purton Sustainable Technologies Ltd Plug for repairing road surfaces
GB2449908B (en) * 2007-06-07 2009-08-19 Purton Sustainable Technologie Method and plug used to repair roads

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