EP1176257B1 - Process for making an asphalt and mixing device - Google Patents

Description

The invention relates to a process for producing an asphalt product using additives, a reactive additive, an activator and a reactive curing binder, comprising a base binder in the form of bitumen or bitumen substitutes and a flux component. And the invention relates to a mixing device for producing an asphalt product mixture from aggregates, one or more reactive additives and an activator and a reactive curing binder, comprising a base binder and a flux component.

For example, in the course of manhole repairs, pothole repairs, for closing trimmings, in leveling or in the asphalting of small-scale driveways or courtyards, in the production of hall floors, and in many other cases relatively small amounts of building materials needed, so the transport by truck's neither economic nor technical possible or structurally sensible. Nevertheless, the consumption of mixed material is often so high that the use of building material filled in buckets or sacks (for example cold mixed material) is uneconomical because of the accumulation of packaging material and for the costs involved.

Asphalt is a mixture according to the German term made of bitumen and granular aggregates. Frequently, however, asphalt products today instead of bitumen contain bitumen substitutes, such as synthetic or natural polymers or resins. For the present invention, such bitumen-free mixtures under asphalt should also be understood. Asphalt is used in many ways, preferably for road surfaces, but also for hall floors, sealing purposes, drip pans, dams, etc. Asphalt is therefore manufactured and installed in various embodiments.

1. 1. Heißasphalt in Form von Walzasphalt:
   • In einer ortsfesten Asphaltmischanlage wird Gestein mit einer bestimmten Kornzusammensetzung auf ca. 180 bis 200°C erhitzt und dabei getrocknet. Danach wird heißes Bitumen mit ca. 180°C in entsprechender Menge (4-8%) zugemischt. Das Mischgut muss danach in beheizten Silos gelagert oder sofort mittels LKW zur Baustelle transportiert werden. Dort wird das Mischgut mit Asphaltfertigern heiß eingebaut und muss bei Temperaturen von mindestens 130°C mit Walzen verdichtet werden.
   • Bei Verwendung entsprechend weicher Bindemittelqualitäten, die in weiterer Folge auch geringe Standfestigkeit des daraus hergestellten Asphaltbelages bewirken, kann der Walzasphalt auch bei Temperaturen von 90 bis 120°C eingebaut werden, man spricht dann von "Warmasphalt".
2. 2. Heißasphalt in Form von Gussasphalt
   In einer ortsfesten Mischanlage oder häufig auch in einer mobilen Kleinmischanlage wird feinkörniges Gestein auf ca. 200 bis 300°C erhitzt und dabei getrocknet. Danach wird heißes Bitumen mit ca. 200 bis 250°C in entsprechender Menge (6-15%) zugemischt. Das Mischgut muss binnen kurzer Zeit (oxidativer Abbau des Bindemittels bei diesen hohen Temperaturen) zur Baustelle transportiert werden und wird in der Regel händisch oder bei Großbaustellen mit speziellen Gussasphaltfertigern bei Temperaturen um 200°C eingebaut. Ein Verdichten ist nicht erforderlich.
3. 3. Kalte Asphaltbauweisen
   In einer stationären Mischanlage wird mäßig feuchtes Gestein mit kalt flüssigen Bitumenemulsionen vermischt, zur Baustelle gefahren, mit Fertigern oder Gradern eingebaut und dann mit schweren Walzen verdichtet. Ein derartiges Mischgut eignet sich für den Bau von Tragschichten im untergeordneten Straßennetz. Das enthaltene Wasser muss allmählich verdunsten, im selben Ausmaß erfolgt die Festigkeitszunahme. Derartige Bauweisen sind auf warme Witterung angewiesen, die Festigkeitszunahme erfolgt sehr langsam und es dauert Wochen bis Monate mitunter Jahre bis zum Erreichen der Endfestigkeit.

Asphalt is mainly produced in the following listed ways:

1. 1. Hot asphalt in the form of rolled asphalt:
   • In a stationary asphalt mixing plant, rock with a certain grain composition is heated to about 180 to 200 ° C and dried. Thereafter, hot bitumen at about 180 ° C in an appropriate amount (4-8%) is added. The mix must then be stored in heated silos or immediately transported by truck to the construction site. There the mix with asphalt pavers is installed hot and must be compacted at temperatures of at least 130 ° C with rollers.
   • When using correspondingly soft binder qualities, which subsequently cause low stability of the resulting asphalt pavement, the rolled asphalt can also be installed at temperatures of 90 to 120 ° C, it is then called "warm asphalt".
2. 2. Hot asphalt in the form of mastic asphalt
   In a stationary mixing plant or often in a mobile small-scale mixing plant fine-grained rock is heated to about 200 to 300 ° C and dried. Thereafter, hot bitumen at about 200 to 250 ° C in an appropriate amount (6-15%) mixed. The mix must be inside A short time (oxidative degradation of the binder at these high temperatures) are transported to the site and is usually installed by hand or in large construction sites with special mastic asphalt pavers at temperatures around 200 ° C. A compaction is not required.
3. 3. Cold asphalt constructions
   In a stationary mixing plant moderately moist rock is mixed with cold liquid bitumen emulsions, driven to the site, installed with pavers or graders and then compacted with heavy rollers. Such a mix is suitable for the construction of base layers in the subordinate road network. The water contained must evaporate gradually, to the same extent increases the strength. Such constructions are dependent on warm weather, the increase in strength is very slow and it takes weeks to months sometimes years to reach final strength.

Another form of cold construction is suitable for the production of thin cover layers for the maintenance of existing asphalt roads. Again, working with bitumen emulsions as a binder, the mixing process of rock and bitumen emulsion is carried out on self-propelled machines. Also, this construction requires largely warm weather and pad temperatures of about + 10 ° C.

All previously known asphalt constructions, which were listed for the sake of clarity above, have the common feature that they can be installed either only in the warmer season, or that freshly mixed hot asphalt mix needs to be processed before its appreciable cooling. Especially the last requirement requires a quick Mischgutverbrauch and a correspondingly high speed of installation. at Small and very small construction lots or repair work, this requirement can not be met in many cases. In addition, without exception, all hot mixing plants in the frost period, which are usually the months of December to March, are closed for operational and construction-ergonomic reasons. The building material hot asphalt is therefore not available.

The practice of the construction industry shows, however, that especially in this time, many damage to asphalt roads occur (example: potholes due to frost heave) or before the onset of winter still important repairs are carried out.

According to the prior art such work can be carried out only with cold mix on flux oil or solvent-based. However, cold mixed material is on the one hand harmful to the environment (elutable mineral oils or solvent emissions) and on the other hand has only limited structural strength properties, so that such construction versions have only a very limited life or, in principle, have to be redone in the warmer months with hot mix, ie represent a pure temporary.

The aim of the present invention is to find a process for the production and further processing of an asphalt product mixture, and an apparatus for its production which is suitable for small construction lot with rather low consumption of mixed material in the unit time and in the cool season, when hot mix is not available available can be held.

The invention is based on a reactive curing binder system, that in the AT 406 375 B is described on. Through this patent, the binder chemical composition is protected and there are applications in the direction of producing a cold mix (claims 12 and 13) shown.

So far, all components except for the activator were premixed in asphalt manufacturing plants for the use of such a cold mix, packaged delivered to the place of use and there if necessary with the activator. When applied in accordance with thin layers in practice, the premix is applied to the desired location and wetted with activator. So there is no mixing with the activator instead, so that it can lead to an inhomogeneous distribution of the activator and thus to an inhomogeneous curing of the asphalt product. Furthermore, the activator is applied in excess and there is no control over how much activator is incorporated. Since water is an activator, since it is often present on site and is harmless from an environmental point of view, there is also a risk of frost during winter processing. Furthermore, the premixing of all components except the activator has the disadvantage that this premix has only a limited shelf life, namely in the best case about half a year. The containers must be tightly closed in order to prevent a premix reaction with the air, in particular with the moisture contained in the air. Furthermore, the premix gives a fixed mixing ratio which is optimal only for a particular application and can not be adapted to local conditions.

It is also an object of the present invention to avoid the disadvantages just mentioned.

The object is achieved in that in the method described above, the pre-mixed with the activator aggregates, the reactive curing binder and the reactive additive is metered into a mixing device and mixed in the mixing device and that then taken the asphalt product mixture of the mixing device and to the desired location is applied. This ensures that the activator that the Reaction triggers or accelerates, is homogeneously distributed, before a reaction can take place. The activator is also included in the mixture in a predetermined limited amount.

Further preferred embodiments of the invention will become apparent from the dependent claims.

The asphalt product mixture is largely mixed cold or hot (20 to 70 ° C), can be installed cold and cold compacted and obtains its strength by a chemical reaction and not by a cooling process.

No substance, such as solvent or water, must escape from the covering material and therefore no shrinkage or crack formation must be expected.

The increase in strength takes place in a very short time (a few hours) and extremely environmentally friendly (no solvent release).

The final quality of the asphalt product corresponds fully to the properties of known asphalt products. Asphalt layers do not have to be removed before overbuilding with another layer of asphalt, as is the case with conventional cold mixed material.

It can be realized a sustainable raw material concept in that the binder contains renewable raw materials in a significant proportion.

During the treatment of the aggregates no total drying must be carried out as before, but a residual moisture content of 3% is permissible and even advantageous.

The supply of the covering material to the construction site is eliminated, since the asphalt product is produced on site.

There are considerable advantages in the energy balance in production, processing and disposition.

The asphalt product can also be economically produced in small quantities (from 200 kg) (hot mixes from 100 tons, cast asphalt from 5 tons) and can be produced and installed at a time of year when no other mix of equivalent quality is available.

It will enable building solutions that were previously not possible (for example, hard-to-reach places such as urban blocks of houses).

It comes to waste prevention by eliminating small packaging (plastic or sheet metal containers, bags, etc.).

The asphalt product mixture can be produced in a wide range of variations, so that the properties of sealing asphalt, mastic asphalt, rolled asphalt to drain asphalt can be adjusted.

The method of the invention can also be used to repair over-greasy topcoats (e.g., "sweating" surface treatment).

The asphalt product mixture can also be based on Recycled asphalt granulate instead of rock material to be produced (raw material savings, particularly cost by low binder dosing). Furthermore, as additives also porous materials, such as Leca, foam glass, etc., or rubber granules alone or as a mixture with rock material can be used.

The asphalt product mixture can also be produced and used in a dyed color, which extends its field of application accordingly and makes it possible to economically protect hazardous areas.

The mixing device according to the invention is characterized in that the device contains a batch mixer with an agitator, which is mounted on a vehicle or on a trailer of a vehicle and that a container for the pre-mixed with the activator additives is provided on the vehicle, and that the device further Containers (7, 8) for the individual components or any premixtures of individual components, ie from the base binder, the flux component and optionally the reactive additive or reactive additives and these containers (7, 8) via lines (9) and metering devices (10 ) are connected to the mixing chamber of the batch mixer (1) in order to meter in the premixed with the activator aggregates, the reactive curing binder and the reactive additive simultaneously in the mixing chamber. The asphalt product mixture can thus be produced on site in the required amount and in the mixture of the application and the conditions on site. Furthermore, eliminates the process of filling in containers.

Preferably, the batch mixer is a compulsory mixer. Preferably, a conveyor belt for metering the aggregates is provided in the batch mixer between the outlet opening of the container for the aggregates and the feed opening of the batch mixer, with the desired amount of aggregates can be dosed easily and without much work in the batch mixer.

Preferably, the bottom and the outer wall of the batch mixer are double-walled and the space in the bottom receives a heating element, in particular a gas burner, and communicates with the space in the outer wall. This allows the batch mixer to be heated to a working temperature of 40 - 70 ° C. Hot air or the hot gas of the gas burner flows from the space in the floor into the space in the outer wall and thus heats the contents of the batch mixer evenly.

Preferably, the agitator is struck at the bottom of the opposite lid of the batch mixer, so that the bearings and seals of the agitator are not exposed to excessive heat.

According to a particular embodiment, an outlet opening is provided at the upper edge of the outer wall, which is connected via a hose or via a pipe to the tank for rock material. Thus, the hot air or hot gas flows through the hose or pipe into the aggregate tank and heats it.

Further, the aggregate container contains a heater which is operated with gas, oil, the waste heat of the exhaust gases or the cooling circuit of the engine of the vehicle or with microwave energy.

A particular embodiment of the mixing device is characterized in that on the vehicle devices for tearing, scraping and crushing of surface covering layers and a conveyor for introducing the crushed surface covering layer material in the Batch mixer, a device for the continuous delivery of the asphalt product mixture and a compaction roller are provided.

1. 1. Asphaltbelagsmischung zum Verschließen von Künetten
   In einer erfindungsgemäßen mobilen Mischvorrichtung, ausgerüstet mit einem Chargen-Zwangsmischer oder einem kontinuierlich arbeitenden Durchlaufmischer werden 80 kg Sand 0/2 mit entsprechender Kornabstufung und 120 kg Splitt 2/6 vorgelegt (die Gesamtfeuchte des Gesteinsmaterials soll unter 3 Gew.% Wassergehalt liegen). Der Zuschlagstoff kann je nach Jahreszeit mit aktueller Lagertemperatur verarbeitet oder im Mischer leicht vorgewärmt (40 bis 70°C) werden. Als Energielieferant für die Vorwärmung kann eine Gas- oder Ölflamme oder auch die Abwärme eines LKW-Motors (Auspuffgase, Kühlkreislauf) dienen. In einer besonders modernen Ausführungsvariante kann auch Mikrowellenenergie, z.B. in Form eines Mikrowellen-Durchlauferhitzers, für die Vorwärmung der Zuschlagstoffe eingesetzt werden.
   Über die Dosierstationen werden je nach erforderlichem Bindemittelgehalt 10 bis 30 kg im kalten Zustand fließfähiges, reaktiv aushärtendes Bindemittel direkt kalt oder ebenfalls entsprechend auf 20 bis 70°C vorgewärmtes, reaktiv aushärtendes Bindemittel sowie 1 bis 10 kg des die Aushärtungsreaktion auslösenden Reaktivzusatzes in den Mischer eingebracht.
   Nach einer Mischzeit von einigen Minuten wird das frisch hergestellte Belagsmischgut über die Boden-Auslaßvorrichtung direkt in die zu verschließende Künette oder eine Schiebetruhe entleert. Das zu diesem Zeitpunkt noch immer gut rieselfähige Mischgut wird daraufhin zum Einbauort verbracht, niveaugerecht mittels geeigneter Nivellierhilfen händisch oder maschinell verteilt und anschließend mittels Rüttelplatte, Walze oder Stampfer verdichtet.
   Zur Verbesserung der Boden- und Flankenhaftung kann vor dem Belagseinbau ein Voranstrich aus reaktiv aushärtendem Bindemittel auf den Bestand aufgebracht werden.
   Die Aktivierungszeit des reaktiv aushärtenden Bindemittel-Systems kann so eingestellt werden, dass der Aushärteprozess unmittelbar nach dem Verdichten beginnt und damit die rasche Festigkeitszunahme ein Befahren der aufgefüllten Künette sofort oder binnen weniger Stunden möglich macht. Nach etwa einem Tag weist die Künette eine Beschaffenheit auf, als wäre sie mit herkömmlichem Heißasphalt verschlossen worden.
2. 2. Farbige Asphaltbelagsmischung, beispielsweise zum Herstellen eines Zebrastreifens
   In einer zu Ausführungsbeispiel 1 analogen Vorgangsweise werden Zuschlagstoffe, Reaktivzusatz und entsprechend farbig pigmentiertes, reaktiv aushärtendes Bindemittel zu einer farbigen Asphaltbelagsmischung verarbeitet. Alternativ kann auch ein unpigmentiertes, reaktiv aushärtendes Bindemittel eingesetzt werden und das Farbpigment, vorzugsweise in einer Menge von 1 bis 10% bezogen auf Gesamtmischgut, beim Mischvorgang zugegeben werden.
   Für farbige Asphaltprodukte können keine bitumenhaltigen Basisbindemittel eingesetzt werden, sondern es finden hellfarbige transparente synthetische oder natürliche Polymere oder Harze Verwendung.
3. 3. Asphaltbelagsmischung zum Ausbessern einer überfetteten Oberflächenbehandlung
   Die Bauweise der Oberflächenbehandlung ist eine weltweit bewährte Bauweise zur Abdichtung oder zur Griffigkeitssteigerung bestehender Asphaltschichten. Üblicherweise wird eine dünne Lage Bindemittel (als Emulsion oder Fluxbitumen) aufgesprüht und danach mit Splitt abgestreut. Durch die überhöhte Verkehrsbelastung kommt es nun manchmal vor, daß der Splitt in der Radspur derart stark in die Unterlage eingedrückt oder der unzureichend feste Splitt zertrümmert wird, so daß das Bindemittel hochgedrückt wird und ein klebriger, bindemittelüberfetteter "schwitzender" Fahrbelag entsteht. Dasselbe Problem kann auch auftreten, wenn bei der Bauausführung das Bindemittel für die Oberflächenbehandlung überdosiert wurde.
   In einer besonderen Ausführungsvariante der Erfindung kann nun bei sommerlichen Unterlagstemperaturen, bei denen das "Schwitzen" vorzugsweise auftritt, die überfettete Oberfläche maschinell aufgerissen und abgeschabt werden und dieses Belagsmaterial in einen Zwangsmischer gefördert werden. Im Zwangsmischer werden zusätzliches hochfestes Splittmaterial, der reaktionsfähige Fluxölanteil des reaktiv aushärtenden Bindemittels (jedoch nicht das Bindmittel selbst!) sowie der Reaktivzusatz und erforderlichenfalls ein Aktivator zugemischt. Damit wird einerseits eine Reduktion des Gesamtbindemittelgehaltes und andererseits eine härtere Bindemittelqualität des Belagsmaterials erreicht. Nach dem homogenen Vermischen wird das Mischgut sofort wieder eingebaut und angewalzt. Vorzugsweise ist der Zwangsmischer als fahrbare Arbeitsmaschine ausgelegt, die alle Arbeitsvorgänge vereinigt, sodass alle Arbeitsschritte beim langsamen Überfahren der Schadensbereiche in einem einzigen Arbeitsgang ausgeführt werden.
   Diese Technologie ermöglicht die Reparatur ohne größere Behinderung des fließenden Verkehrs, die Verkehrsfreigabe kann innerhalb weniger Minuten bis Stunden erfolgen. Nach bisherigem Stand der Technik können "schwitzende Oberflächenbehandlungen" nur
   • durch Überbauen mit einem weiteren Asphaltbelag
   • durch Wegfräsen
   • oder durch Nachsplitten (mit zweifelhaftem Erfolg und zusätzlicher Verkehrsgefährdung)
   mit mehr oder minder großem Kostenaufwand repariert werden.
4. 4. Asphaltproduktmischung zum Versiegeln einer offenporigen Tragschichte oder die entsprechende Anwendung für Abdichtungszwecke im Hochbau
   Bedingt durch das ständig zunehmende Verkehrsaufkommen, besonders in der Sommerreisezeit sowie die gleichzeitig knapper bemessenen Straßenbaubudgets passiert es, daß Straßenbaumaßnahmen zu einem sehr späten Zeitpunkt des Jahres ausgeführt werden. So kommt es immer wieder vor, dass Asphalt-Tragschichten kurz vor Wintereinbruch hergestellt werden, so daß die zur Abdichtung des wasserdurchlässigen Tagschichtbestandes erforderliche Asphalt-Deckschicht nicht mehr aufgebracht werden kann. Die Folge sind schwere Frostschäden im gebundenen und ungebundenen Oberbau während des Winters.
   Mit der Technologie der vorliegenden Erfindung ist es möglich, eine extrem dünne und daher besonders preisgünstige Versiegelungsschichte herzustellen, die eine Abdichtung des Tragschicht-Bestandes gegen eindringendes Wasser sicherstellt.
   Da beim Einbau mit einer relativ kalten Unterlagstemperatur gerechnet werden muss, wird für diese Ausführungsform ein niedrigviskoses reaktiv aushärtende Bindemittel mit entsprechend hohem Reaktivfluxölanteil eingesetzt. Im fahrbaren Zwangsmischer werden in das reaktiv aushärtende Bindemittel der Reaktivzusatz sowie des weiteren ein Naturasphaltpulver oder ein entsprechendes pulverisiertes Hartbitumen eingemischt. Diese Mischung wird auf die zu versiegelnde Unterlage über eine Lochschablone in Form zahlreicher dünner Materialstränge ausfließen gelassen und mittels einer steifen Gummi-Rakel auf der Unterlage derart verstrichen, dass kein Materialüberschuss vorliegt, sondern "scharf abgezogen" wird. Auf diese Weise sammelt sich die Hauptmenge an reaktiv aushärtendem Bindemittel in den Rautiefen bzw. den Stellen mit Grobkornanreicherungen in der Unterlage, also genau dort, wo die Abdichtung zu erfolgen hat. Unmittelbar danach wird im selben Arbeitsgang das reaktiv aushärtende Bindemittel mit einer dünnen Lage Feinsplitt (Korngröße 0,5 bis 4 mm) abgestreut, um den Bindemittelfilm gegen den Verkehr abzustumpfen und eine Mindestgriffigkeit sicherzustellen. Binnen weniger Stunden ist diese Asphaltschichte verkehrsgerecht belastbar.
   Eine sehr ähnliche Ausführungsvariante ist für die Abdichtung von Gebäuden, zum Beispiel von Betondecken anwendbar. Vorzugsweise werden dafür zusätzlich Nadelfilz-Vliese in die mehr oder minder mineralstoffgefüllte Schichten aus reaktiv aushärtendem Bindemittel eingelegt. Mit einem derartigen System können auch Dichtungswannen ausgebildet werden.
5. 5. Asphaltproduktmischung zur Herstellung einer wasserundurchlässigen Sperrschicht im Wasserbau (Dichtungsmastix)
   In einer zu Ausführungsbeispiel 1 analogen Vorgangsweise werden entsprechend feinkörnige und von der Mineralstoffsieblinie dicht aufgebaute Gesteinskörnungen mit der entsprechend höheren Menge an reaktiv aushärtendem Bindemittel gemischt, so daß ein dichtes bindemittelreiches Mischgut entsteht, das dem herkömmlichen Heißasphaltmastix, wie er für Dichtungsasphalt eingesetzt wird, in seinen gegen Wasser abdichtenden Eigenschaften entspricht.
   Ein derartiger Mastix wird beispielsweise im Wasserdammbau eingesetzt, wenn es darum geht, eine Asphalt-Kerndichtung wasserdicht an die Betonsohle anzuschließen. Mit der erfindungsgemäßen Technologie kann die akute Verbrennungsgefahr für das Baustellenpersonal beim Umgang mit Asphalt-Heißmastix vermieden werden.
6. 6. Asphaltbelagsmischung zur farbigen Gestaltung von Asphalt- oder Betonflächen
   In einer zu Ausführungsbeispiel 2 und 4 ähnlichen Vorgangsweise wird ein farbig pigmentiertes, reaktiv aushärtendes Bindemittel im Zwangsmischer mit einem kornabgestuften feinkörnigen (0,1 bis 2 mm) Sandgemisch vermischt. Nach dem Vermischen aller Komponenten wird das Bindemittel mittels Rakel-System oder breiter Zahnspachtel auf der zu beschichtenden Unterlage gleichmäßig und in dünner Schicht verteilt und erforderlichen Falls mit Gummispachteln geglättet. Unmittelbar danach wird die Bindemittelschicht mit einem marktüblichen Dekor-Sand (in der Regel ein einbrennlackierter Quarzsand) entsprechender Korngröße (1 bis 4 mm) gleichmäßig abgestreut und in das Bindemittel mittels leichter Walzen oder anderer geeigneter Preßvorrichtungen eingedrückt. Danach erfolgt das Aushärten des Bindemittels und damit des dekorativen farbigen Belages von selbst. Es kann aber auch durch eine zugeführte Aktivierungswärme gestartet oder beschleunigt werden. Als Aktivierungswärmequelle eignet sich im einfachsten Fall eine Gasbrennerflamme oder ein Flächenstrahler mit Gasflammen (ein sogenannter Replaster) oder aber auch ein Mikrowellen-Heizgerät entsprechender Bauart. Im geringen Ausmaß auftretendes unzureichend gebundenes Rollkorn kann nach erfolgter weitgehender Aushärtung der Schichte, also nach wenigen Minuten bis Stunden abgekehrt werden.
   In einer weiteren Ausführungsvariante dieses Verfahrens kann anstelle des pigmentierten Reaktivbindemittels ein unpigmentiertes oder neutral pigmentiertes Bindemittel eingesetzt werden. Als Abstreukörnung wird anstelle des lackierten Abstreusandes ein dekorativer Naturgesteinssand, z.B. ein grauer oder brauner Granit, ein grüner Diabas, ein roter Porphyr oder ein weißer Marmor usw. verwendet. Nun hat man die Möglichkeit, über die Verwendung von Schablonen beim Abstreuvorgang in bestimmten Mustern, z.B. in einer Art Pflastermuster mit Abmessungen von 50 x 50 cm die Art der Abstreukörnung abzuwechseln. Auf diese Weise kann eine Art Natursteinpflaster-Effekt erzielt werden. Zusätzlich können vor dem Aushärtevorgang Prägestempel in die Asphaltschichte eingedrückt werden, sodass ein Pflasterfugen-Effekt entsteht.
   Mit dieser neuartigen Belagstechnik lassen sich langweilig aussehende schwarze Asphaltflächen auf erstaunlich kostengünstige Weise in natursteinartig aussehende optisch sehr ansprechend Flächen verwandeln.
7. 7. Asphaltbelagsmischung auf der Basis von Recycling-Asphaltgranulat
   In einer zu Ausführungsbeispiel 1 analogen Vorgangsweise werden als Zuschlagstoff keine natürlichen Gesteinsmaterialien eingesetzt, sondern entsprechend für die Wiederverwendung aufbereitetes Altasphaltgranulat. Die erforderliche niedrige Reaktivbindemittelmenge im Ausmaß von nur 2-3 Gew.% bezogen auf Gesamtmischgut ermöglichen eine sehr wirtschaftliche Bauweise, vor allem, weil keine Trocknung des zumeist feuchten Recyclinggranulates zwingend erforderlich ist und das Granulat im Bedarfsfall unmittelbar dort verarbeitet werden kann, wo es bei Fräsoder Aufbereitungsvorgängen anfällt, ohne den Transportumweg über eine stationäre Mischanlage gehen zu müssen.
8. 8. Asphaltproduktmischung zum Verschließen einer Fuge zwischen Gebäudewand und Asphaltfläche oder im Pflasterbereich
   Ein fabriksmäßig vorgefertigtes Granulat aus Monokorn-Sand (wahlweise 1-8 mm Korngröße), Reaktivbindemittel (8-12 Gew.%) und Reaktivzusatz wird in der aufzufüllenden Fuge vorgelegt und im Zuge der Verarbeitung dann mit Aktivator übergossen. Die in den Hohlraum des Monokorn-Granulates eindringende Aktivatorsubstanz startet die Aushärtungsreaktion, sodass baustellenseitig kein direkter Mischvorgang oder Aufheizvorgang, wie es bei Fugenvergussarbeiten typischerweise sonst üblich ist, erforderlich wird. Der Aktivator beinhaltet gegebenenfalls auch eine polymermodifizierte Bindemittelkomponente, sodass bei der Aushärtung gleichzeitig auch eine Vergütung (Polymermodifizierung) erfolgt.
   Dieses Verfahren ist auch in färbiger Ausführungsvariante durchführbar, so daß diese Art von Fugenfüllung bevorzugt auch im Betonbereich oder Natursteinpflaster-Bereich einsetzbar ist. Der besondere Vorteil ist, dass die Fugen längere Zeit wasserdurchlässig bleiben, weil der hohlraumreicher Kornaufbau einem Drainasphalt ähnlich ist.
9. 9. Asphaltproduktmischung für Brücken zur Ausbildung hochwertiger Dilatationsfugen

EXAMPLES

1. 1. Asphaltbelagsmischung for closing Künetten
   In a mobile mixing device according to the invention, equipped with a batch compulsory mixer or a continuously operating continuous mixer, 80 kg of sand 0/2 with corresponding grain grading and 120 kg of grit 2/6 are submitted (the total moisture content of the rock material should be less than 3% by weight of water content). Depending on the season, the aggregate can be processed at the current storage temperature or slightly preheated in the mixer (40 to 70 ° C). As an energy supplier for the preheating can serve a gas or oil flame or the waste heat of a truck engine (exhaust gases, cooling circuit). In a particularly modern embodiment, microwave energy, for example in the form of a microwave continuous flow heater, can also be used for preheating the aggregates.
   Depending on the required binder content 10 to 30 kg in the cold state flowable, reactive curing binder directly cold or also corresponding to 20 to 70 ° C preheated, reactive curing binder and 1 to 10 kg of the curing reaction triggering reactive additive introduced into the mixer ,
   After a mixing time of a few minutes, the freshly prepared coating mix is emptied via the bottom outlet device directly into the trimming or a sliding trolley. That at this time still good flowable mix is then transported to the installation site, level managed by means of suitable leveling manually or mechanically distributed and then compacted by means of vibrating plate, roller or rammer.
   To improve the soil and flank adhesion, a primer coat of reactive curing binder can be applied to the structure before the lining installation.
   The activation time of the reactively curing binder system can be adjusted so that the curing process begins immediately after compaction and thus the rapid increase in strength makes it possible to drive on the refilled rake immediately or within a few hours. After about one day, the chill shows a texture as if it had been sealed with conventional hot asphalt.
2. 2. Colored Asphaltbelagsmischung, for example, for making a crosswalk
   In a procedure analogous to Example 1, aggregates, reactive additive and correspondingly pigmented, reactive curing binder are processed to form a colored asphalt surfacing mixture. Alternatively, it is also possible to use an unpigmented, reactively curing binder and to add the color pigment, preferably in an amount of from 1 to 10%, based on total mixture, during the mixing process.
   For colored asphalt products, bituminous base binders can not be used, but light-colored transparent synthetic or natural polymers or resins are used.
3. 3. Asphalt coating mixture for repairing an overfat surface treatment
   The design of the surface treatment is a worldwide proven construction method for sealing or increasing the grip of existing asphalt layers. Usually, a thin layer of binder (as an emulsion or flux bitumen) is sprayed on and then sprinkled with chippings. Due to the excessive traffic load, it sometimes happens now that the chippings in the wheel track so strongly pressed into the pad or the insufficiently solid chippings is smashed, so that the binder is pushed up and a sticky, binder over-greasy "sweating" driving surface arises. The same problem can also occur if the binder for the surface treatment was overdosed during construction.
   In a particular embodiment of the invention, the superfatted surface can now be mechanically torn open and scraped off at summery underlying temperatures, in which the "sweating" preferably occurs, and this covering material is conveyed into a forced mixer. In the compulsory mixer additional high-strength grit material, the reactive flux oil content of the reactive curing binder (but not the binder itself!) And the reactive additive and, if necessary, an activator are added. Thus, on the one hand, a reduction of the total binder content and, on the other hand, a harder binder quality of the covering material is achieved. After homogeneous mixing, the mix is immediately reinstalled and rolled. Preferably, the compulsory mixer is designed as a mobile work machine, which combines all operations, so that all steps are carried out in slow overrun of the damage areas in a single operation.
   This technology allows repair without major obstruction of the flowing traffic, the traffic can be released within a few minutes to hours. According to the prior art, "sweating surface treatments" can only
   • by overbuilding with another asphalt surface
   • by milling away
   • or by splitting (with dubious success and additional traffic hazard)
   be repaired with more or less cost.
4. 4. Asphalt product mixture for sealing an open porous bearing layer or the corresponding application for sealing purposes in building construction
   Due to the ever increasing volume of traffic, especially in the summer travel time and at the same time scarce road construction budgets it happens that road construction measures are carried out at a very late time of the year. So it happens again and again that asphalt base courses are made shortly before the onset of winter, so that the time required to seal the water-permeable daily shift inventory asphalt pavement can no longer be applied. The result is severe frost damage in the bound and unbound superstructure during the winter.
   With the technology of the present invention, it is possible to produce an extremely thin and therefore particularly inexpensive sealant layer which is impervious to penetration of the backing layer stock Ensures water.
   Since it must be expected during installation with a relatively cold pad temperature, a low-viscosity reactive curing binder with a correspondingly high reactive flux oil content is used for this embodiment. In the mobile compulsory mixer, the reactive additive and, moreover, a natural asphalt powder or a corresponding pulverized hard bitumen are mixed into the reactive curing binder. This mixture is allowed to flow out to the base to be sealed via a hole template in the form of numerous thin strands of material and passed by means of a stiff rubber doctor blade on the surface so that no material surplus is present, but "sharply withdrawn" is. In this way, the majority of reactive hardening binder collects in the roughness depths or the places with coarse grain enrichments in the base, ie exactly where the seal has to be made. Immediately thereafter, in the same operation, the reactive curing binder is sprinkled with a thin layer of fine grit (grain size 0.5 to 4 mm) to blunt the binder film against traffic and to ensure minimum grip. Within a few hours, this asphalt layer can be loaded to suit the traffic.
   A very similar embodiment variant is applicable for the sealing of buildings, for example concrete ceilings. Preferably, for this purpose additionally needle felt nonwovens are inserted into the more or less mineral-filled layers of reactive curing binder. With such a system also seal pans can be formed.
5. 5. asphalt product mixture for producing a water-impermeable barrier layer in hydraulic engineering (sealing mastic)
   In an analogous to Embodiment 1 procedure accordingly fine-grained and densely built by the mineral sieve aggregates are mixed with the correspondingly higher amount of reactive curing binder, so that a dense binder-rich mix arises, the conventional Heißasphaltmastix as it is used for sealing asphalt in his complies with water-sealing properties.
   Such a mastic is used, for example, in dam construction when it comes to connect an asphalt core gasket watertight to the concrete floor. With the technology according to the invention, the acute risk of burns for construction site personnel when handling asphalt hot mastic can be avoided.
6. 6. Asphalt coating mixture for the colored design of asphalt or concrete surfaces
   In a similar procedure to Embodiment 2 and 4, a color pigmented, reactive curing binder is mixed in the compulsory mixer with a grain-graded fine-grained (0.1 to 2 mm) sand mixture. After mixing all the components, the binder is distributed evenly and in a thin layer by means of a doctor blade system or a wide toothed spatula on the substrate to be coated and, if necessary, smoothed with rubber spatulas. Immediately thereafter, the binder layer with a commercially available decorative sand (usually a baked-quartz sand) corresponding grain size (1 to 4 mm) uniformly sprinkled and pressed into the binder by means of light rollers or other suitable pressing devices. Thereafter, the curing of the binder and thus the decorative takes place However, it can also be started or accelerated by an applied activation heat. As activation heat source is in the simplest case, a gas burner flame or a surface radiator with gas flames (a so-called replaster) or even a microwave heater of appropriate design. To a lesser extent occurring insufficiently bound grain can be turned off after a substantial hardening of the layer, so after a few minutes to hours.
   In a further embodiment of this process, an unpigmented or neutral pigmented binder can be used instead of the pigmented reactive binder. As Abstreukörnung a decorative natural rock sand, eg a gray or brown granite, a green diabase, a red porphyry or a white marble, etc. is used instead of the painted Abstreusandes. Now you have the option of alternating the type of Abstreukörnung about the use of stencils during the Abstreuvorgang in certain patterns, eg in a kind of plaster pattern with dimensions of 50 x 50 cm. In this way, a kind of natural stone plaster effect can be achieved. In addition, embossing stamps can be pressed into the asphalt layer before the curing process, so that a plaster joint effect is created.
   With this new type of padding technology, boring looking black asphalt surfaces can be transformed into natural-looking, visually appealing surfaces in an astonishingly cost-effective manner.
7. 7. Asphalt-surfacing mixture based on recycled asphalt granulate
   In an analogous to Embodiment 1 approach are used as aggregate no natural rock materials, but in accordance with the recycled Altasphaltgranulat processed. The required low amount of reactive binder in the amount of only 2-3 wt.% Based on total mix allow a very economical design, especially because no drying of the usually wet recycled granules is absolutely necessary and the granules can be processed directly where needed in case of need Milling or conditioning operations incurred without having to go through the transport detour via a stationary mixing plant.
8. 8. asphalt product mixture for closing a gap between the building wall and asphalt surface or in the pavement area
   A prefabricated granulate of monocrystal sand (optionally 1-8 mm grain size), reactive binder (8-12 wt.%) And reactive additive is placed in the gap to be filled and then doused in the course of processing with activator. The activator substance penetrating into the cavity of the monocrystalline granules starts the curing reaction, so that on site no direct mixing process or heating process, as is typically customary in the case of joint casting work, is required. If appropriate, the activator also contains a polymer-modified binder component, so that at the same time a hardening (polymer modification) takes place.
   This method can also be carried out in a colored embodiment, so that this type of joint filling can preferably also be used in the concrete area or natural stone pavement area. The particular advantage is that the joints remain permeable to water for a long time, because the cavity-rich grain structure is similar to a drainage asphalt.
9. 9. Asphalt product mixture for bridges for the formation of high quality dilatation joints

The transition of a road into a bridge is exposed to particularly high loads, on the one hand continuously oscillations occur and on the other hand, both structures have different thermal expansion behavior. To form such bridge dilatation joints, the so-called Thorma-joint method has proven particularly well. This is a Heißvergußverfahren, for the execution of the Dilatationsbereich first about the entire width of the road about 50 cm wide in the thickness of the road asphalt layer is removed and then alternately layer by layer with hot binder and grit in the grain size of about 10 mm is replenished. This results in a large number of small expansion areas, because the elastic binder surrounds the grit like a dense skin. At the same time, the split grain framework ensures stability and resilience.

This hot process can be carried out cold with an asphalt product mixture. The particular advantage of this is that even smaller bridge joints can be carried out with it because the mechanical engineering effort is minimal. It is first introduced a layer of an elastomer-modified, reactive curing binder in the dilatation, then an asphalt layer mixture is introduced a few centimeters thick and compacted, so that the stones of the mixture are penetrated by the binder saturated. Then the next layer of reactive curing binder and again asphalt layer mixture is introduced and so on until the total pad thickness is filled up. Within a few hours, the entire system cures and a dilatation joint with excellent elasticity remains back.

Now still the mixing device according to the invention will be described with reference to an embodiment shown in the drawing.

On a vehicle 2 is a large container 3 of rock material, e.g. Gravel that can be discharged via an outlet opening 4. When chippings are delivered, this falls onto a conveyor belt 6 guided underneath, and from there into the inlet connection 5 of the forced mixer 1, which is arranged on a platform 16 mounted on the rear of the vehicle 2.

Also mounted on the vehicle are two containers 7 and 8 which contain the remaining components of the asphalt product mixture. For example, For example, the container 8 could contain a mixture of base binder and the flux component and the container 7 a reactive additive. The metering devices 10 deliver predetermined amounts from the containers 7 and 8 into the mixing chamber of the forced mixer 1. The metering devices 10, like the closure of the outlet opening 4 of the container 3, can be regulated by a control unit 17, at which the metered quantities can be set and in which also already proven recipes for different cold mix mixtures can be stored according to different applications.

• 70°C erhitzt. Das heiße Gas steigt aus dem Raum 13 im Boden 11 in den Raum in der Außenwand 12 und tritt durch die Austrittsöffnung in der Außenwand 12 und den Schlauch 15 in den Behälter 3, wo er den Splitt vorwärmt.

The compulsory mixer 1 is shown cut in its bottom portion and it can be seen that both the bottom 11 and the outer wall 12 is double-walled. The space 13 in the bottom 11 receives a gas burner 14, which the compulsory mixer 1 to a working temperature of 40

• Heated to 70 ° C. The hot gas rises from the space 13 in the bottom 11 in the space in the outer wall 12 and passes through the outlet opening in the outer wall 12 and the hose 15 in the container 3, where he preheats the chippings.

In order not to expose the bearings and seals of the agitator 18 to excessive heat, the agitator on the bottom 11 opposite lid of the compulsory mixer 1 is arranged. The stirring arm 19 projects down into the compulsory mixer 1, as can be seen through the closable lid opening 20.

In order to produce cold mixed material for the immediately following processing, chips are removed from the container 3 by opening the closure of the outlet opening 4 and metered via the conveyor belt 6 and the inlet connection 5 into the forced mixer 1. Then by the control unit 17 and the metering units 10 corresponding amounts of the remaining components from the containers 7 and 8 and metered through the lines 9 in the compulsory mixer 1. After a mixing time of 2 to 4 minutes, the coating of the chippings is completely given and the compulsory mixer can be emptied with constant stirring via a hydraulically driven bottom rotary valve.

By means of the mobile mixer device according to the invention, cold mixed material can be produced at any desired location, in any desired quantity and in any desired mixing ratio. The heating element in the bottom of the compulsory mixer makes it possible to use it all year round, even at low winter temperatures.

Claims (22)

1. Method for producing an asphalt product using aggregates, a reactive additive, an activator, and a reactively curing binding agent, comprising a base binding agent in the form of bitumen or bitumen replacement materials and a flux component, characterised in that the aggregates pre-mixed with the activator, the reactively curing binding agent, and the reactive additive are simultaneously dosed into a mixing device and mixed in the mixing device, and in that the asphalt product mixture is removed from the mixing device and applied in the desired location.
2. Method according to Claim 1, characterised in that the activator is provided in the form of residual moisture in the aggregates as a water content quantity of less than 3 wt. %.
3. Method according to Claim 1 or 2, characterised in that the aggregates are pre-warmed to 40-70°C prior to dosing the same.
4. Method according to Claim 1, 2, or 3, characterised in that the reactively curing binding agent is pre-warmed to 20-70°C prior to dosing the same.
5. Method according to one of the Claims 1 to 4, characterised in that the location to which the asphalt product mixture is to be applied is pre-treated with a reactively curing binding agent prior to applying the same.
6. Method according to one of the Claims 1 to 5, characterised in that a colour pigmented, reactively curing binding agent or a non-pigmented reactively curing binding agent and a colour pigment, preferably in a quantity of 1 to 10 wt. %, are dosed.
7. Method according to Claim 6, characterised in that the binding agent contains lightly coloured transparent synthetic or natural polymers or resins as base binding agents.
8. Method according to one of the claims 1 to 5, characterised in that the aggregates are dosed in the form of grain graded, fine grained sand mixtures and a colour pigmented, reactively curing binding agent or a non-pigmented reactively curing binding agent and a colour pigment are dosed, and in that the asphalt product mixture is applied in a thin layer, covered with decorative sand, and lightly compressed.
9. Method according to one of the Claims 1 to 5, characterised in that the aggregates are dosed in the form of grain graded, fine grained sand mixtures and a non-pigmented or neutral pigmented reactively curing binding agent is dosed, and in that the asphalt product mixture is applied as a thin layer, covered with coloured decorative sand, and lightly compressed.
10. Method according to Claim 8 or 9, characterised in that the curing of the asphalt product is activated or accelerated by means of heat from a heat source.
11. Method according to one of the Claims 1 to 5, characterised in that the aggregates and the reactively curing binding agent in the form of a broken up binding agent fat coating asphalt covering which has previously been torn and scraped, and comprises additional highly compressed grit material, a reactable flux component, and the reactive additive as well as a further activator if required are dosed onto the mixing device.
12. Method according to one of the Claims 1 to 5, characterised in that the aggregates and part quantities of the reactively curing binding agent are dosed into the mixing device in the form of a moist asphalt granulate together with a correspondingly reduced quantity of a reactively curing binding agent.
13. Method according to one of the Claims 1 to 5, characterised in that fine grained rock grains with a tightly compressed mineral line are dosed as aggregates.
14. Method according to one of the Claims 1 to 5, characterised in that natural asphalt powder or pulverised hard bitumen is dosed as an aggregate.
15. Mixing device for producing an asphalt product mixture consisting of aggregates, one or more reactive additives and an activator, and a reactively curing binding agent comprising a base binding agent and a flux component, characterised in that the device comprises a batch mixer (1) with a stirrer (18) fitted to a vehicle (2) or a trailer of a vehicle, and in that a container (3) for the aggregates pre-mixed with the activator is envisaged on the vehicle (2), and in that the device comprises further containers (7, 8) for the individual components or any pre-mixtures consisting of individual components, e.g. of the base binding agent, the flux component, and possibly the reactive additive, or the reactive additives, and in that these containers (7, 8) are connected with the mixing chamber of the batch mixer (1) via lines (9) and dosing means (10) for simultaneously dosing the aggregates pre-mixed with the activator, the reactively curing binding agent, and the reactive additive into the mixing chamber.
16. Mixing device according to Claim 15, characterised in that the batch mixer consists of a forced mixer (1).
17. Mixing device according to Claim 15 or 16, characterised in that a conveyor (6) for dosing the aggregates into the batch mixer (1) is envisaged between the outlet opening (4) of the container (3) for the aggregates and the supply opening (5) of the batch mixer (1).
18. Mixing device according to one of the Claims 15 to 17, characterised in that the floor (11) and the outer wall (12) of the batch mixer (1) are double-walled, and in that the space (13) within the floor (11) contains a heater element, in particular a gas burner (14), and communicates with the space in the outer wall (12).
19. Mixing device according to one of the Claims 15 to 18, characterised in that the stirrer (18) is affixed to the lid of the batch mixer (1) opposite the floor (11).
20. Mixing device according to Claims 18 or 19, characterised in that an outlet opening is envisaged in the upper rim of the outer wall (12), which is connected with the container (3) for aggregates via a hose (15) or a pipe.
21. Mixing device according to one of the Claims 15 to 20, characterised in that the container (3) for the aggregates comprises a heating means that can be operated with gas, oil, the exhaust heat from exhaust gas, or the cooling circuit of the vehicle engine, or with microwave energy.
22. Mixing device according to one of the Claims 15 to 21, characterised in that means for tearing, scraping and breaking up surface covering layers as well as a conveyor for adding the broken up surface covering layer material to the batch mixer (1), a means for continuously dispensing the asphalt product mixture, and a compression cylinder are envisaged on the vehicle.

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