IE20200124A2 - Binding means for surface treatments - Google Patents

Abstract

A surface treatment 1 for surfaces arranged to carry vehicular or pedestrian traffic comprises a binding means 2 and a particulate material 3 wherein the binding means 2 comprises at least an epoxy and a curing agent. The binding means 2 is curable in the presence of water and/or at temperatures below 5°C. <Figure 1c>

Description

The present invention relates to binding means for use in surface treatments, particularly surface treatments that can be applied to e.g. road surfaces during inclement weather conditions.

Surface treatments such as high friction surfaces (HFS) or jointing materials are often used on surfaces designed to carry vehicular or pedestrian traffic. HFS are typically composed of polish-resistant, abrasion-resistant aggregate particles which are bonded to the surface of a substrate using a binder. The microtexture provided by the surface of the aggregate particles 10 increases the skid resistance of the road or surface to which the particles are bonded. HFS can be applied at places where skidding would prove particularly dangerous such as at road junctions and bends, the approaches to traffic lights and zebra crossings, or at places with elevated crash or slip risks. Jointing materials are typically used to fill gaps or recesses in a surface, such as gaps between slabs or cracks in the surface.

When applying surface treatments to roads or other surfaces the choice of binder is crucial. While two-part adhesives comprising an epoxy and a hardener are often employed, such adhesives typically require elevated temperatures to cure and must be applied to dry surfaces. In places where rainfall and generally low temperatures are common throughout the year, suitable conditions for applying outdoor surface treatments can be relatively rare. Although amine and 20 polyamine hardeners have addressed some of the problems of the prior art, binders which employ such hardeners are not suitable for use below 5 °C. Prior art hardeners can also produce sulphuric acid when used in the presence of salt e.g. on salted roads during winter. The presence of such sulphuric acid is detrimental to the mechanical and adhesive properties of the binder. There exists a need for a binder that can be applied to surfaces and cured in a variety of weather conditions, including temperatures of less than 5 °C, and on wet surfaces as well as salted roads.

It is common to use surface treatments at high demand sites, such as where there is a heavy flow of traffic or where heavy braking is needed. Failures such as cracks and/or potholes can easily develop in the surface and/or underlying road at these points. HFS failures include delamination whereby binder and aggregate become detached from the substrate, chip loss 30 whereby aggregate is lost or removed from the HFS, and excessive polishing where the friction of the surface is reduced due to gradual polishing of the aggregate. Failures can result from shear stresses applied to the surface and typically occur in localised regions, such as at the part of a road where tyres usually tread. Since it would be expensive and inefficient to replace large areas of damaged surfaces, there exists a need for an ability to repair small localised areas, ideally in a 35 wide range of weather conditions and in a short time frame. 05/06/2020 It is an object of the present invention to obviate or mitigate the problems outlined above. In particular, it is an object of the invention to provide surface treatments that can be used in a wide range of outdoor weather conditions.

It is a further object of the invention to provide surface treatments that are curable at low 5 temperatures, in particular at temperatures below 5 °C.

It is a further object of the invention to provide surface treatments that can be applied and cured on damp or wet surfaces such as roads.

It is a further object of the invention to provide surface treatments that can be applied and cured in the presence of salt e.g. on salted surfaces or roads.

It is a further object of the invention to provide a surface repair system that can be easily transported and applied to selected areas of wet or damp road surfaces under low temperature conditions.

It is a further object of the invention to provide a means by which surfaces such as road or pavement surfaces can be repaired more quickly.

According to a first aspect of the invention there is provided a binding means for a surface treatment, the binding means comprising at least an epoxy and a curing agent, wherein the binding means is curable in the presence of water and/or at temperatures below 5 °C. By ‘in the presence of water’ it is meant moist, damp and/or wet conditions where water is present, for 20 example on a surface. Advantageously, the binding means can be adhesively attached to a surface, allowing features or defects in the surface to be filled and/or allowing particles such as aggregates to be attached to the surface. Further advantageously, the binding means can be used on wet or damp surfaces such as roads, for example during or shortly after spells of rain, and in low temperature conditions that are typical in many geographical areas at times throughout 25 the year.

According to a second aspect of the invention there is provided a surface treatment comprising a binding means and a particulate material wherein the binding means comprises at least an epoxy and a curing agent and the binding means is curable in the presence of water 30 and/or at temperatures below 5 °C. Advantageously, the combination of particulate material and a binding means utilizing a curing agent allows the surface treatment to be applied in a wide range of weather conditions.

Preferably the surface treatment is a high friction surface treatment. 35 Optionally the surface treatment is a jointing material.

Optionally the surface treatment is a jointing material for a road, pavement or similar surface.

Optionally the binding means is a jointing material. 05/06/2020 Optionally the surface treatment is used to create a high friction surface coating for a road, pavement or similar surface.

Preferably the surface treatment is applied to a surface for vehicular or pedestrian traffic. 5 Ideally the surface treatment is applied to the surface of a substrate.

Preferably the substrate is a road and the surface is a road surface.

Optionally the road surface is already at least partially covered by a surface treatment of a same, similar or distinct type.

Preferably the substrate is a driveway, roadway, highway, street, paving or pavement 10 surface.

Preferably the substrate is a deck, platform, stairwell or mezzanine surface for pedestrian or vehicular traffic.

Preferably the substrate is an asphalt road, roadway or pavement.

Preferably the substrate is a Stone Mastic Asphalt (SMA) road, roadway or pavement. 15 Preferably the substrate is a concrete substrate.

Preferably the substrate is a steel or wooden substrate.

Preferably the substrate is a high friction surface.

Preferably the substrate is a partially damaged high friction surface.

Preferably the substrate comprises at least one defect or gap.

Preferably the substrate comprises at least one crack or pothole.

Ideally the surface treatment is for filling a defect or gap in a surface or substrate.

Optionally the surface treatment is a jointing material for filling defects, gaps, cracks or potholes.

Ideally the epoxy has at least 1.5 epoxy groups per molecule.

Preferably the epoxy has an epoxy group content of 5260-5420 mmol/kg.

Preferably the epoxy is a Bisphenol A epoxy resin.

Preferably the epoxy is a Bisphenol F epoxy resin.

Preferably the epoxy is an epichlorohydrian-based epoxy.

Preferably the epoxy is a novalac epoxy.

Preferably the epoxy is a cycloaliphatic epoxy.

Preferably the epoxy is an epoxy diluent.

Preferably the epoxy is a glycidylamine epoxy.

Ideally the curing agent comprises a hardener.

Preferably the curing agent comprises a mannich base hardener. The mannich base is 35 a beta-amino-ketone this is formed by the reaction of an amine, formaldehyde or aldehyde and carbon acid. Advantageously, mannich base hardeners provide rapid curing at ambient and low temperatures, including below 5 °C, and have favourable mechanical strength, hardness and chemical resistance properties. Mannich base hardeners also do not react with salt to form 05/06/2020 sulphuric acid, meaning that such hardeners are suitable for use in surface treatments applied to salted roads/surfaces.

Preferably the curing agent comprises an aliphatic hardener.

Optionally the curing agent comprises a phenolic hardener.

Preferably the curing agent comprises a polymercaptan hardener Optionally the curing agent comprises synthetic resin. Advantageously, the synthetic resin forms an adduct with the mannich base.

Optionally the synthetic resin comprises styrenated phenol and/or gum rosin.

Preferably the curing agent comprises a diluent such as benzyl alcohol. Advantageously, 10 a diluent can be used to alter the viscosity of the curing agent to increase the ease with which the curing agent can be manipulated, mixed, spread and/or poured.

Preferably the particulate material comprises aggregate.

Optionally the particulate material comprises sand.

Preferably the sand is coarse dried sand.

Preferably the particulate material comprises aggregate and sand.

Ideally the aggregate comprises particles of an aggregate material.

Preferably the aggregate has a polished stone value of greater than 60.

Preferably the aggregate comprises particles of calcined bauxite.

Preferably the aggregate comprises particles of steel slag.

Preferably the aggregate comprises particles of sandstone, tuff, flint, basalt or granite.

Preferably the aggregate is a mixture of two or more aggregate materials.

Preferably the average aggregate particle size is greater than 0.1 mm.

Preferably the average aggregate particle size is greater than 0.5 mm.

Preferably the average aggregate particle size is less than 20 mm.

Preferably the average aggregate particle size is less than 10 mm.

Preferably the average aggregate particle size is less than 5 mm.

Preferably the aggregate particle size is 0.5-20 mm.

Preferably the aggregate particle size is 1-3 mm.

Preferably the particulate material comprises a coloured aggregate or filler material for 30 road markings.

Preferably the epoxy and curing agent are mixable.

Preferably the epoxy and curing agent are mixed before curing.

Preferably the particulate material is at least partially embedded in the mixed epoxy and curing agent.

Preferably the particulate material is resin bound or resin bonded in the binding means.

Preferably the aggregate is resin bound in the surface treatment.

Preferably the aggregate is resin bonded in the surface treatment.

Preferably the curing agent is formed by mixing a hardener with synthetic resin. 05/06/2020 Ideally the binding means chemically bonds to the surface and/or particulate material. Ideally the binding means adhesively bonds to the surface and/or particulate material. Ideally the binding means mechanically bonds to the surface and/or particulate material. Preferably the binding means forms a layer having a thickness of 0.1-50 mm.

Preferably the binding means forms a layer having a thickness of 0.5-10 mm.

Preferably the binding means forms a layer having a thickness of 1-2 mm. Preferably the resin bonded binding means forms a layer having a thickness of 1-20 mm. Preferably the resin bonded binding means forms a layer having a thickness of 1-5 mm. Preferably the resin bonded binding means forms a layer having a thickness of 1-2 mm.

Preferably the particulate material and binding means form a layer having a thickness of 1-50 mm.

Preferably the particulate material and binding means form a layer having a thickness of 5-20 mm.

According to a third aspect of the invention there is provided a method of applying a surface treatment to a surface, the method comprising: mixing at least an epoxy and a curing agent to form a binding means; applying the binding means to a surface; and curing the binding means such that the binding means bonds to the surface, wherein the binding means is curable in the presence of water and/or at temperatures below 5 °C. Advantageously, the method allows 20 surface treatments to be applied to a surface in a wide range of weather conditions.

Optionally the method comprises forming a jointing material by mixing at least the epoxy with the curing agent.

Ideally the method comprises pouring the binding means onto the surface.

Preferably the method comprises screeding the binding means over the surface.

Advantageously, screeding of the binding means provides an even surface of uniform height above e.g. an uneven substrate.

Optionally the method comprises filling and overbanding of a road surface.

Optionally the method comprises filling and overbanding of a crack or other defect in a 30 road surface.

Preferably the method comprises applying the binding means to the surface using an application means.

Preferably the application means comprises a cartridge gun.

Optionally the application means comprises a shoe.

Ideally the method comprises mixing particulate material with the epoxy and curing agent.

Optionally the method comprises mixing the particulate material with the surface treatment before the surface treatment is applied to the surface. 05/06/2020 Preferably the method comprises mixing particulate material with the epoxy and curing agent.

Ideally the method comprises at least partially embedding particulate material in the binding means.

Preferably the method comprises at least partially embedding particulate material in the binding means prior to the step of curing the binding means.

Ideally the method comprises at least partially embedding aggregate and/or sand in the binding means prior to the step of curing the binding means.

Preferably the method comprises broadcasting the aggregate over the binding means 10 after the binding means has been applied to the surface.

Preferably the method comprises broadcasting the aggregate using a dispersion means.

Preferably the method comprises broadcasting the aggregate over the binding means by hand.

Preferably the method comprises broadcasting the aggregate using a shovel or a chip 15 spreader.

Ideally the method includes applying the binding means to the surface while the binding means is in a liquid state.

Ideally the method includes applying the surface treatment to the surface while at least the epoxy and curing agent are in a liquid state.

Preferably the method comprises curing the binding means to be in a solid state.

Preferably the pot life of the surface treatment is 5-15 minutes.

Preferably the curing takes less than one hour.

Preferably the curing takes less than half an hour.

Preferably the curing takes 10-15 minutes. Advantageously, a short curing time allows 25 the surface treatment to be used a short time after the treatment has been applied.

Preferably the method comprises levelling the surface treatment using a levelling means. Preferably the levelling means is a screed board.

According to a fourth aspect of the invention there is provided a surface repair kit 30 comprising an epoxy and a curing agent wherein at least the epoxy and curing agent are mixable to form a binding means and the binding means is curable in the presence of water and/or at temperatures below 5 °C. Advantageously, the surface repair kit can be used to fix sections/areas of a surface that have become damaged or worn, removing the need for more invasive wholescale replacement of the surface. Further advantageously, the surface repair kit can be transported 35 directly to site and immediately applied to the surface of a substrate after mixing, irrespective of the weather conditions.

Preferably the surface repair kit contains sufficient material to cover 0.25-10 m2 in area with surface treatment.

Preferably the surface repair kit contains sufficient material to cover at least 1 m2 in area with surface treatment.

Preferably the surface repair kit comprises 0.5-10 kg or 0.5-10 litres of epoxy.

Preferably the surface repair kit comprises 1-3 kg or 1-3 litres of epoxy.

Preferably the surface repair kit comprises 2 kg or 2 litres of epoxy.

Preferably the surface repair kit comprises 0.2-4 kg or 0.2-4 litres of hardener.

Preferably the surface repair kit comprises 0.4-1.2 kg or 0.4-1.2 litres of hardener.

Preferably the surface repair kit comprises 0.8 kg or 0.8 litres of hardener.

Preferably the surface repair kit comprises 0.3-6 kg or 0.3-6 litres of synthetic resin.

Preferably the surface repair kit comprises 0.6-1.8 kg or 0.6-1.8 litres of synthetic resin.

Preferably the surface repair kit comprises 1.2 kg of synthetic resin. 05/06/2020 Preferably the surface repair kit comprises produce 0.5-10 kg or 0.5-10 litres of curing agent.

Preferably the surface repair kit comprises produce 1-3 kg or 1-3 litres of curing agent.

Preferably the surface repair kit comprises produce 2 kg or 2 litres of curing agent. sufficient sufficient sufficient hardener hardener hardener and and and synthetic synthetic synthetic resin resin resin to to to Preferably the surface repair kit comprises particulate material.

Preferably the surface repair kit comprises aggregate and/or sand.

Preferably the surface repair kit comprises 1-50 kg of particulate material.

Preferably the surface repair kit comprises 1-25 kg of particulate material.

Preferably the surface repair kit comprises 10 kg of particulate material.

Preferably the surface repair kit comprises 1-50 kg of aggregate.

Preferably the surface repair kit comprises 1-25 kg of aggregate.

Preferably the surface repair kit comprises 10 kg of aggregate.

Preferably the surface repair kit comprises 1-20 kg of sand.

Preferably the surface repair kit comprises 1-6 kg of sand.

Preferably the surface repair kit comprises 4 kg of sand.

Ideally the surface repair kit further includes one or more buckets for mixing the curing agent, epoxy resin and particulate material.

Preferably the surface repair kit comprises one mixing bucket.

Preferably the mixing bucket has a volume of 1-10 litres.

Preferably the mixing bucket has a volume of 5 litres.

Preferably at least the epoxy and curing agent are mixable in the mixing bucket to form the binding means. 05/06/2020 Preferably the epoxy, curing agent and particulate material are mixable in the mixing bucket.

Preferably the surface repair kit comprises one curing agent bucket.

Preferably the curing agent bucket has a volume of 1-5 litres.

Preferably the curing agent bucket has a volume of 2.5 litres.

Preferably the curing agent bucket is smaller than the mixing bucket.

Ideally the surface repair kit comprises an application means.

Preferably the application means is a cartridge gun.

Preferably the cartridge gun comprises a storage means for storing surface treatment 10 and a dispensing means for allowing the binding means to exit the cartridge gun and be applied to a surface.

It will be appreciated that optional features applicable to one aspect of the invention can be used in any combination, and in any number. Moreover, they can also be used with any of the 15 other aspects of the invention in any combination and in any number. This includes, but is not limited to, the dependent claims from any claim being used as dependent claims for any other claim in the claims of this application.

The invention will now be described with reference to the accompanying drawings which show by way of example only a number of embodiments of surface treatments/binders in 20 accordance with the invention.

Figure 1a is a cross sectional view of a high friction surface coating applied to a surface.

Figure 1b is a cross sectional view of a jointing material applied to a surface between neighbouring slabs.

Figure 1c is a cross sectional view of a high friction surface coating and a jointing material applied to a surface having a defect.

Figure 2 is a method of applying a surface treatment to a surface.

Figure 3 is an alternative method of applying a surface treatment to a surface.

Figure 4 is a kit of parts comprising means for applying a surface treatment to a surface. 30 Figure 5 is an alternative kit of parts comprising means for applying a surface treatment to a surface.

In figure 1a there is shown a surface treatment in the form of a high friction surface coating, generally indicated at numeral 1. The high friction surface treatment 1 comprises a binder 35 2 and particulate material in the form of aggregate 3. The surface treatment 1 is shown in the cured state after having been applied to the surface 4 of road 5. Application of the surface treatment 1 to the road provides a surface with a skid resistance value of greater than 70 i.e. a high friction surface. The binder 2 of the high friction surface treatment 1 is a cured mixture of an 05/06/2020 epoxy and a curing agent which includes a hardener and synthetic resin and which is generally insensitive to the presence of moisture and low temperatures. The binder 2 is curable in the presence of water and/or at temperatures below 5 °C.

In figure 1b there is shown a surface treatment in the form of a jointing material, generally 5 indicated at numeral 11. The jointing material 11 comprises a binder 12 and particulate material in the form of sand 13. The jointing material 11 is shown in the cured state after having been used to fill a gap in the road surface 15 between slabs or pavers 16. Application of the jointing material 11 to the road provides a flat surface free of gaps or defects. The binder 12 of the jointing material 11 is a cured mixture of an epoxy and a curing agent which includes a hardener and synthetic 10 resin and which is generally insensitive to the presence of moisture and low temperatures. The binder 12 is curable in the presence of water and/or at temperatures below 5 °C.

In figure 1c there is shown a road 5 having a surface 4 to which a high friction surface treatment in the form of a high friction surface coating 1 has been applied. The high friction surface coating 1 is similar to that shown in figure 1a. The road 5 includes a defect 6 in the form of a 15 crack. The defect 6 is shown as having developed in both the high friction surface coating 1 and the underlying road 5. The defect 6 has a defect surface 14 and is filled with jointing material 11. The jointing material 11 is similar to that shown in figure 1 b. The jointing material 11 comprises a binder 12 and particulate material and is shown in the cured state after having been used to ‘fill and overband’ defect 6 and thereby repair the road 5/high friction surface coating 1. Particles of 20 sand 15 e.g. are dispersed in a generally uniform manner throughout the cured binder 12 and aggregate particles 13 are embedded in the jointing material 11 towards the exposed surface. The sand 15 is coarse dried sand. The aggregate 13 used in the jointing material 11 is similar to the aggregate 3 used in the surface coating 1.

In the example embodiments of figures 1a-c, the epoxy used in binders 2,12 has at least 25 1.5 epoxy groups per molecule and/or an epoxy group content of 5260-5420 mmol/kg. Suitable epoxies for use in the present invention include: Bisphenol A epoxy resins such as Epikote 828 manufactured by Hexion; Bisphenol F epoxy resins such as Epikote 862 (RTM) manufactured by Hexion, or other resins such as Bisphenol A/F Epikote 169 manufactured by Hexion.

The curing agent used in binders 2,12 includes a mannich base hardener such as KH500 30 manufactured by Kukdo. The mannich base is a beta-amino-ketone which is formed by the reaction of an amine, formaldehyde or aldehyde and carbon acid. Use of a mannich base hardener allows rapid curing at ambient and low temperatures (i.e. below 5 °C) as well as ensuring favourable mechanical strength, hardness and chemical resistance properties. Mannich base hardeners also allow curing of the binders 2,12 in the presence of water, i.e. moist, damp and/or 35 wet conditions where water is present on e.g. a road surface or salted road surface. Prior to being mixed with the epoxy, the mannich base hardener is mixed with synthetic resin to form the curing agent. The synthetic resin forms an adduct with the KH500 Mannich base. The synthetic resin 05/06/2020 can be styrenated phenol, gum rosin, or any mixture of the two. The curing agent is mixed with the epoxy in order to form binder 2,12 which has a pot life of 5-15 minutes.

The aggregates 3,13 shown in figures 1a and 1c consist of particles of calcined bauxite which have a particle size of 1-3 mm. Examples of alternative aggregates which are also suitable 5 include sandstone, tuff, flint, basalt and granite. Steel slag may also be used as aggregate 3,13. In some embodiments, aggregate 3,13 is a mixture of particles of two or more different aggregate materials, or aggregate 3,13 and sand, and the surface treatments 1,11 can include coloured aggregate or filler material for road markings. The sand 15 shown in figures 1b and 1c is a particulate material dispersed throughout the binder 2,12 when the binder is in a cured state. The 10 sand 15 is coarse dried sand.

A method 100 for applying a surface treatment 1,11 to a surface 4,14 will now be outlined with respect to figure 2. In step 101 hardener is mixed with synthetic resin in the ratio of 2:3 by weight to form a curing agent. In step 102, the curing agent is mixed with epoxy in a ratio of 1:1 by weight to form a binder 2,12 having a pot life of approximately 5-15 minutes. In step 102 sand 15 15 may be added to the binder 2,12 in a ratio of 1:1. Alternatively, an appropriate amount of sand 15 may be pre-mixed with the epoxy and/or curing agent such that the ratio of epoxy:curing agent:sand in the formed binder 2,12 is 1:1:1.

In step 103 the liquid binder is applied to a surface (e.g. surface 4 in figure 1a). Where the surface is generally flat the binder 2,12 can be applied via pouring and/or screeding to form a 20 generally flat layer having a thickness of 1-2 mm. Where the surface contains defects, recesses, gaps, potholes or cracks 6 and the surface treatment is to be used as a jointing compound 11 for repair or filling of a defect, recess, gap or pothole, the liquid binder 2,12 can be applied via pouring until the defect, recess or gap is substantially filled with the binder 2,12. The liquid binder 2,12 may be used to fill a crack in a road in a ‘fill and overband’ operation in which the liquid binder 25 2,12 is poured into the crack via a shoe prior to dressing the surface with skid resistant aggregate. Sealing cracks in this way prevents water ingress and protects the road from break up and eventual pothole formation.

Binder 2,12 can be applied to the surface 4,14 using an application device such as a cartridge gun having a storage compartment for storing the binder 2,12 and a dispensing conduit 30 which allows the binder 2,12 to exit the cartridge gun and be applied to the surface 4,14. Use of a cartridge gun to apply the binder 2,12 is particularly useful in the case of filling defects 6 or recesses, since the dispensing conduit can be directed into the opening of the defect 6 or recess for direct filling thereof. Alternatively a shoe having a handle, a storage compartment and a dispensing aperture can be used as the application device. Binder 2,12 is poured into the shoe 35 while the shoe is pulled over the defect or crack by the handle, the binder 2,12 passing into the defect or crack under the force of gravity. Since the binder 2,12 is curable in the presence of water and/or at temperatures below 5 °C, step 103 can be carried out on outside/outdoor surfaces during low temperature conditions and during or shortly after spells of rain. 05/06/2020 In optional step 104 an aggregate 3,13 can be broadcast over the binder layer 2,12 to form a resin bound layer of high friction surface treatment 1,11. The aggregate 3,13 can be broadcast over the binder either by hand or using a dispersion device such as shovel or a chip spreader. In step 105 the surface treatment 1,11 is levelled using a levelling device such as a 5 screed board. In step 106 the surface treatment 1,11 is left to cure for approximately 10-15 minutes, after which time the binder 2,12 is in a solid state. After the binder 2,12 has fully cured, assuming that calcined bauxite is used as the aggregate 3,13, the surface treatment 1,11 will exhibit a skid resistance value of greater than 70.

An alternative method 200 for applying a surface treatment 1,11 to a surface 4 will now 10 be outlined with respect to figure 3. In step 201 the hardener is mixed with synthetic resin in the ratio of 1:1 to form a curing agent. In step 202, the curing agent is mixed with epoxy in a ratio of 1:1 to form a binder 2,12. At this point sand may be added to the binder 2,12 in a ratio of 1:1. Alternatively, an appropriate amount of sand may be pre-mixed with the epoxy and/or curing agent such that the ratio of epoxy:curing agent:sand in the formed binder 2,12 is 1:1:1.

In step 203 an appropriate amount of aggregate is mixed with the binder in a ratio of 11:1 by weight to form a mixture having a pot life of approximately 10-15 minutes.

In step 204 the liquid binder and aggregate mixture is applied to a surface (e.g. surface 4 in figure 1a). Where the surface 4 is generally flat and free of defects the high friction surface treatment can be applied as a high friction surface coating 1 via pouring and/or screeding to form 20 a generally flat layer of resin bonded aggregate having a thickness of 1-20 mm. Where the surface 4 contains defect(s) 6 and the high friction surface treatment is to be used to repair the defect(s) 6, the mixture can be applied via pouring into the defect 6 until the defect 6 is substantially filled with the mixture. The liquid binder and aggregate mixture may be used to fill a crack in a road in a ‘fill and overband’ operation in which the liquid binder and aggregate mixture is poured into the 25 crack via a shoe prior to dressing the surface with skid resistant aggregate. Sealing cracks in this way prevents water ingress and protects the road from break up and eventual pothole formation. Since the binder 2,12 is curable in the presence of water and/or at temperatures below 5 °C, step 204 can be carried out on outside/outdoor surfaces during low temperature conditions and during or shortly after spells of rain.

In step 205 the surface treatment 1,11 is levelled using a levelling device such as a screed board. In step 206 the surface treatment 1,11 is left to cure for approximately 10-15 minutes, after which time the binder 2,12 is in a solid state. After the binder 2,12 has fully cured, assuming that calcined bauxite is used as the aggregate 3,13, the surface treatment 1,11 will exhibit a polished stone value of greater than 60.

In figure 4 there is shown a surface treatment repair kit indicated generally by the numeral comprising an epoxy 22, a hardener 23, synthetic resin 24, sand 15 and aggregate 3,13. The epoxy 22, hardener 23 and synthetic resin 24 are mixable to form a binder 2,12 which is curable in the presence of water and/or at temperatures below 5 °C. The formed binder 2,12 can be 05/06/2020 adhesively attached to a surface 4,14, allowing features or defects in the surface 4,14 to be filled and/or allowing particles such as aggregates and/or sand to be attached to the surface 4,14.

The surface repair kit 21 can be used as a jointing material and/or to fix sections or areas of a surface that have become damaged or worn, removing the need for more invasive wholescale 5 replacement of surface. The surface repair kit 21 can be transported directly to site either by being carried by hand or using only a small vehicle. The surface treatment 1,11 can be mixed and immediately applied to a surface such as a road surface 4.

The surface repair kit 21 contains sufficient material to cover a surface area of at least 1 m2 with the surface treatment 1,11. In the example outlined here, the surface repair kit 21 contains 10 2 kg of epoxy 22, 1 kg of hardener 23, 1 kg of synthetic resin 24, 4 kg of sand 15 and 10 kg of aggregate 3,13. The synthetic resin 24 can be styrenated phenol, gum rosin, or any mixture of the two.

Providing only limited amounts of each material in the repair kit 21 makes the kit 21 suitable for covering small areas of a surface 4,14 where e.g. a high friction surface treatment 15 has become damaged or worn or where only a limited amount of jointing material is required. In total, the surface repair kit 21 has a mass of less than 20 kg meaning that it can easily be transported to a site or carried by a single person to e.g. places that are generally inaccessible to vehicles, such as railway station stairs. The surface repair kit can be used to make a number of surface treatments 1,11 including jointing material 11 (which may or may not include sand 15 20 and/or aggregate 3,13) and high friction coating 1 (which may or may not include sand 15).

The surface repair kit 21 also contains a 5 litre mixing bucket 28 and a 2.5 litre curing agent bucket 29. In preferred embodiments, the curing agent bucket 29 is used to mix the hardener 23 and resin 24 and the mixing bucket 28 is used to mix the epoxy 22 and curing agent, and optionally the sand 15 and/or aggregate 3,13, depending on whether sand 15 is to be included 25 in the binder 2,12, and whether the aggregate 3,13 is to be resin bound or resin bonded (c.f. steps 103, 203). The buckets 28,29 are made from PVC but can be made from any suitable material such as another plastic or a metal. The surface repair kit 21 may contain a plurality, e.g. five, single-use buckets of each type.

Figure 5 shows a further embodiment of a surface repair kit 31 comprising a part A 36, 30 a part B 37, aggregate 3,13 and a mixing bucket 28. Parts A and B 36,37 are supplied in separate containers and can be decanted into the mixing bucket 38 and mixed in equal parts to form a surface treatment comprising binder 2,12 and sand 15 mixed therein. Part A 36 comprises epoxy 32 and sand 15 pre-mixed in a ratio of 2:1 by weight. Part B comprises hardener 33 and synthetic resin 34 pre-mixed in a ratio of 1:1 by weight. The epoxy 22, sand 15, hardener 23 and resin 24 35 are similar to those of the previous embodiments. Where the aggregate 3,13 is to be resin-bound, aggregate 3,13 is mixed with parts A and B 36,37 in the bucket 38. Where the aggregate 3,13 is to be resin-bonded to the surface 4, the aggregate 3,13 is broadcast over the surface treatment after the surface treatment has been applied to the surface 4. 05/06/2020 Providing the surface treatment in a kit comprising separate pre-mixed parts A and B 36,37 saves time at a site where a road or surface is to be repaired. Part A 36 and part B 37 are provided in separate containers which can be individually transported to site. Once mixed, the surface treatment is curable in the presence of water and/or at temperatures below 5 °C. Unlike 5 many prior art systems, no heating of the parts or the surface treatment itself is required.

As will be understood by the skilled person, the example embodiments presented above can be modified in a number of ways without departing from the scope of the invention. For example, the surface treatment 1,11 can be applied to the surface of any suitable substrate for pedestrian or vehicular traffic such as a driveway, roadway, highway, street, paving or pavement 10 surface, deck, platform, stairwell or mezzanine surface. The substrate may be an asphalt or Stone Mastic Asphalt (SMA) road, roadway or pavement, or may be of concrete, steel or wood. The surface to which the surface treatment 1,11 is to be applied may already be at least partially covered by a surface treatment of a same, similar or different type.

In optional embodiments the curing agent includes a hardener only and/or does not 15 include synthetic resin. The hardener may be an aliphatic hardener, such as DETA manufactured by Delamine ltd. The curing agent may comprise a diluent such as benzyl alcohol which alters the viscosity thereof, increasing the ease with which the curing agent can be manipulated, mixed, spread and/or poured.

The average aggregate particle size may be greater than 0.1 mm or 0.5 mm and less 20 than 20 mm, less than 10 mm or less than 5 mm. In preferred embodiments consistent with the present invention the aggregate particle size is anywhere in the range of 0.5-20 mm. The binder layer can have a thickness in the range of 0.5-50 mm or 0.5-10 mm, the resin bonded binder can form a layer having a thickness of 1-20 mm, 1-5 mm or 1-2 mm, and the aggregate and binder may be used to form a layer having a thickness of 1-50 mm or 5-20 mm.

The curing of binder 2,12 may take less than one hour or less than half an hour. It is possible for a further amount of aggregate 3,13 to be broadcast over the surface treatment 1,11 during curing of the binder 2,12. This increases the concentration of aggregate 3,13 at the surface of the surface treatment 1,11, thereby improving the microtexture at the surface.

In alternative embodiments the surface repair kit 21,31 comprises 1-10 kg or 1-3 kg of 30 epoxy, 0.2-4 kg or 0.4-1.2 kg of hardener, 0.3-6 kg or 0.6-1.8 kg of synthetic resin, 1-50 kg or 125 kg of aggregate and 1-20 or 1-6 kg of sand. The surface repair kit 21,31 may contain sufficient material to cover a surface of 0.25-10 m2 in area with the surface treatment 1,11. The mixing bucket(s) 28,38 can have a volume of anywhere within the range of 1-10 litres and the curing agent bucket(s) 29 can have any volume in the range of 1-5 litres.

In optional embodiments either of the surface repair kits 21,31 may not include sand 15 and/or aggregate 3,13. Optionally, sand 15 can be supplied in the kit 21,31 pre-mixed with the epoxy and/or hardener (e.g. in part B 37). Part A in repair kit 31 may include only epoxy 22 and part B may include only hardener 23. Where a surface repair kit 21,31 is to be used to produce jointing material 11 (or other surface treatment which does not include aggregate) steps 103/203 may be omitted may be omitted from methods 100/200.

In the preceding discussion of the invention, unless stated to the contrary, the disclosure of alternative values for the upper or lower limit of the permitted range of a parameter, coupled 5 with an indication that one of the values is more highly preferred than the other, is to be construed as an implied statement that each intermediate value of the parameter, lying between the more preferred and the less preferred of the alternatives, is itself preferred to the less preferred value and also to each value lying between the less preferred value and the intermediate value.

The features disclosed in the foregoing description or the following drawings, expressed 10 in their specific forms or in terms of a means for performing a disclosed function, or a method or a process of attaining the disclosed result, as appropriate, may separately, or in any combination of such features be utilised for realising the invention in diverse forms thereof.

Claims (25)

1. A surface treatment for a surface arranged to carry vehicular or pedestrian traffic, the surface treatment comprising a binding means and a particulate material wherein the 5 binding means comprises at least an epoxy and a curing agent and the binding means is curable in the presence of water and/or at temperatures below 5 °C.

2. A surface treatment according to claim 1 wherein the curing agent comprises a hardener. 10

3. A surface treatment according to claim 2 wherein the curing agent comprises a mannich base hardener.

4. A surface treatment according to claim 2 wherein the curing agent comprises an aliphatic, phenolic or polymercaptan hardener.

5. A surface treatment according to any previous claim wherein the curing agent comprises synthetic resin.

6. A surface treatment according to claim 5 wherein the synthetic resin comprises styrenated 20 phenol and/or gum rosin.

7. A surface treatment according to claim 1 wherein the epoxy has at least 1.5 epoxy groups per molecule. 25

8. A surface treatment according to claim 1 wherein the epoxy has an epoxy group content of 5260-5420 mmol/kg.

9. A surface treatment according to claim 1 wherein the epoxy is a Bisphenol A epoxy resin or a Bisphenol F epoxy resin.

10. A surface treatment according to claim 1 wherein the epoxy is an epichlorohydrian-based epoxy, a novalac epoxy, a cycloaliphatic epoxy, an epoxy diluent or a glycidylamine epoxy.

11. A surface treatment according to any previous claim wherein the particulate material 35 comprises aggregate. 05/06/2020

12. A surface treatment according to claim 11 wherein the aggregate comprises particles of calcined bauxite or steel slag.

13. A surface treatment according to claim 11 wherein the aggregate comprises particles of 5 sandstone, tuff, flint, basalt or granite.

14. A surface treatment according to any one of claims 11-13 wherein the aggregate is a mixture of two or more aggregate materials. 10

15. A surface treatment according to any one of claims 11-14 wherein the aggregate is resin bound or resin bonded in the surface treatment.

16. A surface treatment according to any previous claim wherein the surface treatment is a high friction surface treatment.

17. A surface treatment according to claim 16 wherein the surface treatment is applied to a surface for vehicular or pedestrian traffic.

18. A surface treatment according to any previous claim wherein the surface treatment is a 20 jointing material for a road, pavement or similar surface.

19. A surface treatment according to claim 18 wherein the surface treatment is located in a crack, hole or defect on a road, pavement or similar surface. 25

20. A method of applying a surface treatment to a surface, the method comprising: mixing at least an epoxy and a curing agent to form a binding means; applying the binding means to a surface; and curing the binding means such that the binding means bonds to the surface, wherein the binding means is curable in the presence of water and/or at temperatures below 5 °C.

21. A method according to claim 20 comprising forming the curing agent comprises by mixing at least a mannich base hardener and synthetic resin.

22. A method according to claim 21 comprising at least partially embedding particulate 35 material in the binding means.

23. A method according to claim 19 or 20 wherein the method comprises broadcasting aggregate over the binding means after the binding means has been applied to the surface. 5

24. A surface repair kit comprising an epoxy and a curing agent wherein the epoxy and curing agent are mixable to form a binding means and the binding means is curable in the presence of water and/or at temperatures below 5 °C.

25. A surface repair kit according to claim 24 wherein the curing agent comprises a mannich 10 base hardener and synthetic resin.