NZ587144A - Hydrocarbon-adsorbing porous pavement structure - Google Patents

Abstract

Disclosed is a water-pervious pavement structure comprising: (a) a wearing course comprising a water-pervious combination of recycled glass particles and aggregate particles bound together with a flexible adhesive binder and held within a plurality of connected, open grid pockets; (b) a layer of unbound recycled glass disposed under the wearing course capable of adsorbing contacting hydrocarbons carried with water through the wearing course; and (c) a caisson or aperture excavated under the layer of unbound recycled glass to a depth below a frost line to achieve a thermal moderating effect resulting from air rising through said caisson or aperture and into said unbound recycled glass layer. Also disclosed is a method of constructing said pavement comprising: applying a layer of recycled glass over a soil surface and providing a caisson or aperture under the layer of recycled glass to a depth below a frost line to achieve a thermal moderating effect resulting from air rising, through the aperture and into the recycled glass layer; compacting the applied layer of recycled glass to a modified Proctor of at least 90 percent; applying a fabric or mesh over the compacted layer of recycled glass; applying a structure containing a plurality of open-top grid pockets having rigid or semi-rigid upwardly-extending vertical grid walls for receiving and holding a wearing course composition; filling the grid pockets with a wearing course composition comprising a mixture of recycled glass, aggregate and flexible resin binder; curing the adhesive binder.

Description

WO 2009/1 (Will RECIEVED IPONZ 17 JUNE 2011 PCT/US2§»9/§33§45 HYDROCARBON-ADSORBING POROUS PAVEMENT STRUCTURE This application is being filed on 4 February 2009, as a PCX International Patent application in the name of Reynolds Consumer Products, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Joseph 5 B. Kaul, a citizen of the U.S., applicant for the designation of the US only, and claims priority to U.S. Utility Patent Application Serial No. 12/026,159, filed February 5,2008, which is a continuation-in-part of Application Serial No. 11/851,714, filed September 7,2007. Both applications are incorporated herein by reference.

' FIELD A heavy-duty porous pavement structure made from a composite composition of recycled glass, aggregate and an adhesive binding agent. The glass/aggregate composite is reinforced with the use of a recycled grid containing open-top pockets in various depths, depending upon the load and intended 15 application, for receiving the combination of recycled glass, aggregate and binder. In addition to being a strong and attractive parking lot surface, the glass, aggregate, binder composite works as an effective in-situ filter of hydrocarbons to prevent groundwater contamiiiatioii beneaflt the porous pavement staictwe and promote aquifer recharge. The porous pavement structure also acts as a Stormwater detention 20 basin, thereunder, capable of holding most 25 year storm events under the porous pavement structure.

BACKGROUND Increased concern is being given to non-point source pollution which originates from automobile fluids leaked onto pavement, such as parking surfaces 25 and subsequently carried by contaminated, surface heated rainwater into sensitive creeks and streams. Of additional concern is the increased amount of impermeable surfaces in urban areas which limit groundwater infiltration and increase velocities of runoff, thereby damaging nndtt-azed strain water conveyance infrastractore. Also of concern is the steady increase in non-porous Mack asphalt parking surfaces 30 which increase air temperatures and add to global warming. 1 w u mwyimm 1 i PCT/US2009/033045 RECIEVED IPONZ 17 JUNE 2011 He present invention relates to a high strength porous pavement structure that actively filters out hydrocarbon pollutants from Stormwater, and is capable of holding Hie filtered water in a lower layer of recycled glass. Water carrying hydrocarbons that penetrates an upper wearing course flows into a hydrocarbon-5 adsorbent recycled glass layer (filtration/water storage layer).

Current technology in porous pavements is limited to using mostly virgin construction materials and does not actively filter hydrocarbons from tine Stormwater prior to entering the underground aqmlfers. While the EPA encourages the use of porous pavements in their 1999 EPA fact sheet 11, "Porous Pavements", 10 they express concern of using the current technology over aquifers due to potential risk of contamination from oil and grease that can be leaked from vehicles. The present invention defuses this concern by providing a porous pavement composition and statctare that is able to remove hydrocarbons from water that passes therethrough so that underlying aquifer water quality is maintained.

The present invention utilizes recycled glass which is abundantly recycled, but has few commercial uses, diverting large volumes of glass from landfills. The recycled glass when mixed with aggregate and binder, creates a strong, attracti ve parking surface. The recycled glass actively adsorbs hydrocarbons while removing said hydrocarbons from polluted Stormwater before it enters underground aquifers. In addition to this environmental benefit, the porous parking surface will reduce flooding and promote groundwater recharge and allow for more efficient use of urban parking areas. The reflective nature of glass will also help keep the parking surface cool, reducing the urban heat island effect Increased water quality awareness and desire to use Green building materials mwfcr. the glass, aggregate and binder composite composition unique and attractive to envimntnentally conscious builders. Many slate and federal govemnmts are requiring the use of building products that offer Leadership in Energy and Environmental Design (LEED) points as regulated by the United States Green Building Council (USGBC) on municipal building projects. The present invention will rate higher in LEED points than any current porous pavement technology allowing architects and owners to achieve Gold and Platinum LEED standards more easily.

The object of the invention is to address or at least ameliorate one or more of the problems discussed above, or at least to provide the public with a useful choice. nu ^uuy/iuuin RECIEVED IPONZ 17 JUNE 2011 SUMMARY An upper porous pavement composition layer, also called the "wearing course", and abase layer of recycled glass thereunder, hereinafter called the "filtration/water storage layer" together are herein called the "pavement structure".

The wearing course layer comprises about 30 wt. % to about 80 wt. % recycled glass; about 20 wt. % to about 70 wt, % aggregate; and about 0.2 ounce to about 5 ounces of adhesive binder per ft2 of wearing course surface area. The filtration/water storage layer, disposed under the wearing layer, should be more than 80% recycled glass, preferably 100% recycled glass and optionally contains less that 10 20 wt. % fill®, such as aggregate. The filtration/water storage layer comprises recycled glass that is not coated with binder so that it adsorbs oil and other hydrocarbons that pass through the wearing course with rain water.

According to one exemplary embodiment, there is provided a water-pervious pavement structure comprising a wearing course comprising a water-pervious combination of recycled glass particles and aggregate particles bound together with a flexible adhesive binder and held within a plurality of connected, open grid pockets; a layer of unbound recycled glass disposed under the wearing course capable of adsorbing contacting hydrocarbons carried with water through the wearing course; and a caisson or aperture excavated under the layer of unbound recycled glass to a depth below a frost line to achieve a thermal moderating effect resulting from air rising through said caisson or aperture and into said unbound recycled glass layer.

According to another exemplary embodiment there is provided a method of constructing a porous pavement structure capable of capturing hydrocarbon contaminants carried by rain water comprising: applying a layer of recycled glass over a soil surface and providing a caisson or aperture under the layer of recycled glass to a depth below a frost line to achieve a thermal moderating effect resulting from air rising, through the aperture and into the recycled glass layer; compacting the applied layer of recycled glass to a modified Proctor of at least 90%; applying a fabric or mesh over the compacted layer of recycled glass; applying a structure containing a plurality of open-top grid pockets having rigid or semi-rigid upwardly-extending vertical grid walls for receiving and holding a wearing course composition; filling the grid pockets with a wearing course composition comprising a mixture of recycled glass, aggregate and flexible resin binder; curing the adhesive binder. 3 (followed by 3a) RECIEVED IPONZ 17 JUNE 2011 According to a further exemplary embodiment there is provided a water-pervious pavement structure comprising: a wearing course comprising a water-pervious combination of recycled glass particles and aggregate particles bound together with a flexible adhesive binder; the adhesive binder comprising polyurethanc; and a layer of unbound recycled glass disposed under the wearing course capable of adsorbing contacting hydrocarbons carried with water through the wearing course.

A primary aspect of the present invention is to provide a porous pavement structure formed from a readily available, strong and inert recycled glass material in 15 combination with an aggregate, such as chip seal aggregate, and a binder to form an upper wearing course portion of a porous pavement structure, and a layer of unbound recycled glass, disposed directly below the wearing course, that actively filters hydrocarbon pollutants from Stormwater that passes through the wearing course.

Another aspect of the present invention is to create a light reflecting, cool temperature parking surface to counteract the urban heat island effect. Another benefit is that the porous pavement structure described herein can be disposed over an underground Stormwater detention basin since any hydrocarbon leakage from the vehicles through the porous pavement structure will be adsorbed by the unbound 25 recycled glass portion of the pavement structure during penetration of storm water.

BRIEF DESCRIPTION OF PKAWIWGS Figure 1 is a cross sectional view of a porous pavement structure, taken along the line 1-1 of Figure 2, including a lower layer of unbound recycled glass (filtration/water storage layer) that is overlaid by a porous pavement composite 30 composition that fills a geosynthetic grid structure (wearing course) showing the 3a (foilowed by 4) RECIEVED IPONZ 17 JUNE 2011 grid strucute anchored to the prepared subgrade with an anchor, such as rebar, extending through the filtration/water storage layer; and Figure 2 is a partially broken-away top view of the porous pavement structure of Figure 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The preferred porous pavement structure described herein includes an upper wearing course comprising about 30 wt. % to about 80 wt. % recycled glass; about 20 wt. % to about 70 wt. % aggregate; and about 2 wt. % to about 6 wt. % of adhesive binder. Preferably, the wearing course includes about 50 wt % to about 70 10 wt % recycled glass; about 30 wt. % to about 50 wt. % aggregate; and about 3 wt, % to about 5 wt. % of binder, preferably a flexible polyurethane binder.

The recycled glass/aggregate/binder composite of the wearing course should have the recycled glass and aggregate homogeneously mixed such that thane is a surface percentage of recycled glass and surface percentage of aggregate that is 15 within about 10 wt. % of the overall percentage of recycled glass and aggregate that forms the wearing course. In the preferred embodiment, the wearing course has a compressive strength of at least about 800 psi, more preferably at least about 900 psi.

The wearing course is provided with sufficient strength and stability for 20 years of structural integrity by disposing the recycled glass/aggregate/binder composition in a metal, ceramic, or polymeric grid structure, such as that described in Boinhoff U.S. Patent No. 5,250,340, hereby incorporated by reference. Other suitable grid structures are available aid are nsefol having depths of about 1 inch to about 10 inches. Preferred grid structures include interconnected pockets or grids 25 having shaped reservoirs that are open at their upper surfaces for receiving the recycled glass/aggregatotoinder composition, and are liquid-porous at their bottom surfaces, but include structure, such as an underlying water-pervious felt or mat (woven or non-woven) layer, or contain horizontal bottom cross or grid structure that will retain the recycled glass/aggregate/binder composition within the pockets. 30 Alternatively, a separate mesh, e.g., metal or plastic, preferably plastic, can be disposed under the grid structure pockets. The grids or pockets that are filled with RECIEVED IPONZ 17 JUNE 2011 the wearing course composition preferably should have dimensions (in any shape) that measure about I in2 to about 30 in2 (regardless of depth), e.g., 3 inch by 3 inch, squares, in their open top surface area to provide sufficient strength and stability to the wearing course composition.

The recycled glass is glass that has been crushed, tumbled and heated to round its edges aid remove non-glass impurities. A suitable recycled glass is described in Arnott U.S. Patent No. 7,041,221, which is hereby incorporated by reference. Waste glass is prepared by crushing the glass to desired dimensions, e.g., above 200 mesh, U.S. Seive Series, to about 2 inches in diameter, preferably about 10 1/4 inch to about 1/2 inch, more preferably about 3/8 inch.

The glass may be crushed using an impact crusher, hammer mill, cone crusher or a roller crusher. Preferably, the recyclable glass is crushed using roller crusher. Inventor has further observed that better oil adsorption occurs when the glass is crushed using a roller crusher.

Any order of pre-crushing, pre-screening, crushing, cleaning and drying may be used. In a preferred embodiment however, the crushed glass is first pre-crushed and pie-screeoed. If the glass is clean, no pro-crushing or pre-screening is required. The pre-cruabed glass is pre screened through a mesh, which may include an inch mesh, a combination of double or triple deck screens or at least two meshes. Once 20 pre-screened through the mesh, preferably the glass is further crushed using a roller crusher and subsequently, the crushed glass is dried, after cleaning, preferably at a temperature of at least 100° F. or, more preferably, at a temperature of at least 350° F. Subsequently, the crushed glass is screened, preferably through at least a 40 mesh screen, or more preferably through a 30 mesh screen, or most preferably 25 through a 20 mesh screen.

The crushed, screened and heated recycled glass is washed prior to applying the binder to its surfaces in forming the wearing course of the pavement structure. The binder preferably is applied to an upper surface of the wearing course after filling a grid structure with the mixture or recycled glass and aggregate that is 30 disposed over a filtration/water storage layer of clean recycled glass that contains no binder or other coating material. The binder preferably is applied to the surface of RECIEVED IPONZ 17 JUNE 2011 the recycled glass/aggregate wearing course by spraying, but any other method, e.g., pouring binder over the upper surface of the wearing course also is effective to provide sufficient binding of contacting or closely adjacent glass and aggregate binding surfaces to bind the recycled glass to contacting or closely adjacent 5 aggregate and/or other glass particles. Alternatively, the glass and aggregate can be mixed together and the binder applied to the mixture, prior to filling the grid pockets, or the binder can be applied only to the aggregate prior to mixing the recycled gjass and aggregate.

One hypothetical wearing course composition includes 60 wt % recycled 10 glass and 40 wt. % aggregate in a plastic (polymeric grate) having adjacent pockets having a 9.0 in2 horizontal cross-sectional area (3 inch by 3 inch squares) and a depth, of 2 inches, using a flexible polyurethane resin (ELASTOTRAK 62001T from BASF — a diphenylmethaiie — 4,4HJid80cyanatc/p0lymeric diphenylmethane-4,4'-diisocyanate polyurethane from BASF) at 3-6% the total weight of aggregate and 15 glass (mixed by tumbling the glass, aggregate and resin in a paddle, drum or screw auger mixer. An underlying filtration/water storage layer of recycled glass retains maximum hydrocarbon adsotbency since it contains essentially no binder.

In accordance with another important embodiment, a "thermal moderating effect" on the pavement surface is achieved by excavating the soil to below the frost 20 line. This thermal moderating effect cools the pavement surface in the summer and warms the surface in the winter aiding to melt surface ice and snow. The soil excavation below the frost line can be accomplished under the entire pavement area (at great expense) or can be accomplished by drilling 2 inch to 12 inch diameter caissons to a depth of at least 12 inches below the frost line depth at spaced locations 25 under the base (e.g., at 4 foot intervals under the entire base of the pavement structure). The holes or caissons can be filled with an air-permeable material, such as one inch squares of polymeric foam material, that will allow air from below the frost line to rise through the caissons and enter the base material, thereby providing the above-described thermal moderating effect to the pavement surface. 30 ADHESIVE BINDERS Any known flexible polymeric binder is suitable for binding the recycled glass to the aggregate to manufacture the wearing course composition described RECIEVED IPONZ 17 JUNE 2011 PCT/U52§«9/®33045 herein. Suitable adhesive resin binders including polyurethane; epoxy binders, e.g., Bisphenol A and Bisphenol F based epoxies; phenoxy resins; polyester resins; vinyl ester resins; phenolic resins; novolac resins; phenol/novolac resins; polyamide, e.g., nylon resins; and the like. The flexible (elastomeric) polyurethane resins are 5 preferred since they have the highest adhesion values under extensive loads, e„g.„ vehicles in parking lots.

The preferred elastomeric polyurethane is BASF ELASTOTRAK 62001T isocyanate that is a combination of 3 8 wt. % CAS Number 101-68-8 and about 60 wt % CAS Number 9016-87-9 with less tian 3 wt. % mixed isomers of CAS 10 Number 101 -68-8 and less than 2% isocyanate prepolymers.

Other useful polyurethanes include the reaction product of any of the following aliphatic or aromatic diisocyanates with one or more of the following dialcohols and crossJinking agents, wherein the cross-linking agent is used in an amount that results in a flexible (elastomeric) polyurethane having an elongation at 15 break of at least about 50% preferably at least about 100%, more preferably at least about 200%, and not a rigid polyurethane: disocvanate poMs 1,2-ethylene disocyanate; 1 ,&-hexytene disocyanate; Ipine diisocyanate; bis(2-isocyanabethyl) ftmarafe; 1,4-cyctohsxytene dfeocyanafe; melhyicycbhexytene disocyanate; 2,2»4-trimeiifl-1I6»liexflene dfeocyanate; 2,64oiyfeoe iiisocjfanate; 4»4'-^iSKpnatrtiphenyl ether; 4,4'<Bsocyanak)cBphenylmethane; S.Mfchlo^.f-iiwpnatodiphenylmetiane; 4,4'-tf phenyl disocyanate; 4,4'-disocyanaWiphenyl,-3,3'-{imethyl4,4'-^isocpn8Miphenfl; 2,Z-dimeft^4,4'-dIisocyanattiphenyl; 3,f-dinBB»xy4,4'^lB0cyaiiaWIphirifI; 2,2»dBhlwo»-5>5'-difnettoxy4I4'-Ji»cpnatotliplieii|l; 3»3'-dichbro4,4'»iiis«pnatrfiplieiifl; 1 .S-diwcpnatoberizeme; ethylene glycol propylene glycol trimefftolpropane Mmefftylolefliane 1,2-propanedioI 1,4-butanediol iethffene glycol pofyoxypropytene tools dihydroxy polptfws trftiydraxy polyBthers poly {tetfamefcflene glycol) ply {ethylene glycol) poly {propylene glycol) pertaerythritol pofy (caprotactons did) pofpter/poiyrefer polyo/hybrids polyester diets extended with propylene axkte; polyethertriols 1 »4-disocyanatoben®ne; 1,2-maphiybne disocyanate; cross-linking agents 4-chi0ro-t,2-naphfleme dfeocyanate; 4-methyU ,2-napMhylene disocyanate; ethylene diamine.

RECIEVED IPONZ 17 JUNE 2011 1,3-napMhytene disocyanate; diethytene, tnamine, 1,4-naphthyiene disocyanate; n methyl ethylene diamine, tfmethflpropne, 1,5-naphttiyIene diisocyanate; Wmethftoletharie, 1,8-naphtfffene diisocyanate; glyceiaol, 1,7-naphthfIene disocyanate; 1,2,8-h«ane triol, 1 ,8-naphthylene disocyanate; cyciopentane-tetracarboxyic acid, 4-chloro-l,8-na^ifiylene diisocyanate; 1,3,5-benzene tricarboxylic acid, 2,3-naphfty bne disocyanate; citric acid, 2,7-naphthytene cfcocyanate; frimefffGlprapne WsfP- mercaptopropionate) and 1»8-dintro-2,7-naphthffene diisocyanate; pentaerythritot ietrafcisf mercaptopropionate. 1 -meJhyt-2,4maphtiylene diisocyanate; triethylenetatramine, 1 -mettiyl-5»7-naphtfiylerie disocyanate; tstrasthyienepentamine, §-metf»fl-1,3-!iaphttfIene diisocyanate pdyethyfeneimine. and 7-methyl-1,3-naphthylene dssocyanste. perrtaerythritol, p-phenytene diisocyanate; tolylene-2»4,6-triaroirie1 toluene disocyanate; arainfr€thanol, 4,4'-iiethflenebis-(ptei|li»CfariMe); trintethyienedtemins, potymethytene potyphenyi isocyanate; tetramefhylenediamfne, blolylene diisocyanate; pertamethytenediamine, irv^Btramathyt-xytytene; haxamethylenediamine, hexamethytene disocyanate; ethanolamine, 1,6-ii8ocyanato-2,2,4,4-tetra-mettiyIhexarie; diethanolamine, 1,6-difsroyan ato-2»4»4-'Wrfieiiyl-hexanB»- hydrazine, trans-cyctohexane-l ,4-disocyanate; Mettianolamine, 1 >bis(isw|an*-mef!|l)cplAexare; benz»r»-1,2,4-tricaiboxyiic acid. 3-isocpnato-methfl-3,5,5-triiietiylcfcIo-hexfImyarate; nMloWacefc acid dk^otexytmeftane diisocyanate 4»4'-meth^enebisCo-chIoroanilne) Examples of other suitable adhesive resins include: binders comprising carboxylic acid and anhydride polymers and j5-hydroxyalkyiamides as crosslinkers. The molar ratio of carboxyl groups to hydroxy! groups is preferably 1:1. Examples 5 are described in U.S. Patent No, 4,076,917, Imcoipomted herein, by reference. Other suitable adhesive binders are mixtures ofhigh molecular weight polycarboxylic adds and polyhydric alcohols, alkanolamio.es or polyacid amines. Suitable high molecular weight polycarboxylic acids are polyacrylic acid, copolymers of methyl methacrylate/n-butyl acryiate/methaoryli c acid and of methyl 10 methacrylate/methacrylic acid. The polyhydric alcohols and aDcanolamines include 2-hydroxymethyl-l ,4-botanediol, trimefhylolpropane, glycerol, poly(mefhylmelhflciylate-co-hydroxypropyl acrylate), cftethanolamine and triethannlamine- Maleic acid can be included as a possible comonomer for preparing the high molecular weight polycarboxylic acids. Additional examples of « RECIEVED IPONZ 17 JUNE 2011 these adhesive binders are described in EP 445 578, incorporated herein by reference.

Suitable formaldehyde-free aqueous Mutes are described in EP 583 086, incorporated herein by reference. These binders require a phosphorus-containing 5 reaction accelerant to provide adequate reinforcing fiber web strengths. The binders comprise a polycarboxylic acid having at least 2 carboxyl groups and optionally also anhydride groups. Polyaaylic acid is preferred, but copolymers of acrylic acid with maldc anhydride are also useful. The binder further comprises a polyol, for example glycerol, bis[N,N-di(^-liydroxyrfiyl)adipamide, pentaerythritol, diethyl ene 10 glycol, ethylene glycol, gluconic acid, /S-D-lactose, sucrose, polyvinyl alcohol, diisopropaitolamine, 2-(2-amim)ethyIamino)etbanoI, triethanolamine, tris(hydraKymcthylammo)methane and diethanolamine. A phosphorus-containing reaction accelerant is omitable only if a highly reactive polyol is used such as j^HHHydroxyalkylamides.

Additional examples of useful adhesive binders include a condensation product of a methylene donor and a methylene acceptor, either pro-condensed, or condensed in-situ while in contact with the basalt particles. The term "methylene donor" is intended to mean a compound capable of reacting with a methylene acceptor (such as resordmol or its equivalent containing a reactive hydroxy! group) 20 and generate the resin outside of contact with the basalt particles, or in-situ. Preferably, the components of the condensation product include a methylene acceptor and a methylene donor. The most commonly employed methylene acceptor is a phenol, such as resorcinol, while the most commonly employed methylene donor is a melamine, such as N-(substituted oxymethyl)melamine. The 25 effect achieved is resin formation in-situ while in contact with the basalt particles, creating a bond between the basalt particles, irrespective of whether the basalt particles have been pretested with an additional adhesive, such as a polyopoxides or the like. Examples of other methylene donors which are suitable for use in the basalt powder compositions described herein include melamine, 30 hexamethylenetetramme, hexaethoxymethylmelarairie, hexamethoxyme&ylmelamine, lauryloxymethyl-pyridinium chloride, ethoxy-methylpyridinium chloride, trioxan hexamethoxy-methylmelarnine, the hydroxy! RECIEVED IPONZ 17 JUNE 2011 groups of which may be esrterificd or partly esterified, a&d polymers of formaldehyde, such as paraformaldehyde. In addition, the methylene donors may be N-substituted oxymethyhnelamines, of the general formula* wherein X is an alkyl having from I to 8 carton atoms R3, R4, R5, R6 and R7 are individually selected from the group consistiiig of hydrogen, an alkyl having from 1 to 8 carbon atoms and the group -CH2OX. Specific methylene donors include hexaMs (m<^hoxymethyl)m6t amine; N,N'^ntrimethyl/N^N'^sl "-trimethylol-melamine; heumethytohndamine; N,N',N"-dimc4iylolmelainine; N-methyiol-mdamine; NN'-dimethylolmelamlne; N,N',M"-Ms(metioxpneftiyl)iiielaniine; and N^N'-Mbutyl-N^N'-MinefhyM-melmiiie. TheN-methylolderivatives of melamine are prepared by known methods.

The amount of methylene donor and methylene acceptor, pro-condensed or condensed in-situ, that are present in the basalt powder composition may vary. Typically, die amount of pro-condensed methylene donor and methylene acceptor is present will range from about 0.1% to about 15.0%; or each can be added separately in an amount of about 0.1% to about 10.0%, based on the weight of basalt powder in the composition. Preferably, the amount of each of a methylene donor and methylene acceptor added for in-situ condensation ranges from about 2.0% to about 5.0%, based on the weight of basalt powder in the composition, to obtain the maximum basalt content for greater ballistic protection.

The weight ratio of methylene donor to the methylene acceptor may vary. Generally speaking, tbe weight ratio will range from about 1:10 to about 10:1. Preferably, the weight ratio ranges from about 1:3 to 3:1.

Resorcinol-free adhesive resins also are useful in the basalt compositions described herein. For example, U.S. Patent No. 5,298,539, incorporated herein by RECIEVED IPONZ 17 JUNE 2011 reference, discloses at least one additive selected from the group consisting of derivatives of melamine, acetoguanamine, benzoguanamine, cydohexylguanamine and glycoluril monomer and oligomers of these monomers. These derivatives are substituted on average at two or more positions on the monomer or each unit of the 5 oligomer with vinyl terminated radicals and the composition is free of resorcinol.

Other resorcmol-free adhesive resins and adhesive compounds that are useful in the basalt compositions include those described in U.S. Patent Nos. 5,891,938 and 5,298,539, both hereby incorporated by reference. The *938 patent discloses a self-oondetising alkylated txiazine resin having high imino and/or methylol fimctionality. U.S. Patent No. 5,298,539 discloses substituted derivatives based on cyclic nitrogen compounds such as melamine, acetoguanamine, cyclohexjlguanamine, benzoguanamine, and similar alkyl, aryi or aralkyl substituted melamines, glycoluril and oligomers of these compounds. In particular, the adhesive resins and adhesive compounds which are useful as the adhesive resins in the basalt compositions described herein include the following: adhesive resins selected from the group consisting of derivatives of melamine, acetoguanamie, benzoguanamine, cyclohexylguanamine and glycoluril monomers and oligomers of these monomers, which have been, substituted on. average at two or more positions on the monomer or on each unit of the oligomer with vinyl terminated radicals, the adhesive being free of resorcinol; and, these derivatives which have been further substituted on average at one or more positions with a radical which comprises oubamylmethyl or amidomethyi.

Further, the adhesive resin can be any of the compounds of the following formulas: /R 11 RECIEVED IPONZ 17 JUNE 2011 T ■Nv "L' rr ^ A r r T \ y M-^Sl ,c—n: 1 s /c\ ^ Jf R ch-ch ft— R f 12 RECIEVED IPONZ 17 JUNE 2011 PC F/US2009/033045 fi _ o __ and positional isomers thereof, wherein, in each monomer and in each polymerized unit of the oligomers, Y is selected from methyl, phenyl and cyclohexyl, and, on average, at least two R are -CHz-R1, aad any remaining R are H, and at least 2 R1 are radicals selected from Q32==C(1.2)—C(0) —O—» CH2= C(R2>-<XO) —Z, 10 CH2= C{R2)—€(0) —NH —»and CH2= C(R2>—CH2 —O—, wherein R2 is hydrogen or Cj-Cu alkyl, and Z is a radical selected from —O—CHj—CHy—O—, —O—CHa—CHfCHs)—O—, 15 —O-—CH.2—CH2—CH2O—, and —O—CHCCzHj)—O—, and any remaining R1 radicals are selected from —O—RJ, —NH—C(0>—OR4, and 20 —NH—C(0)—R4, and wherein 1.3 is hydrogen or R*, and 13 RECIEVED IPONZ 17 JUNE 2011 PCT/US2Q«f/§33A45 R4 is a Cj-Cig alkyl, alicyclic, hydroxyalkyl, alkoxyalkyl or aromatic radical, and in the oligomers, P is 2 to about 10, and L is methylene or the radical —CHa—O—CH2—.

These adhesive compounds are particularly useful, wherein on average at least one R1 in each monomer or in each oligomerized unit is —NH—C(0)—OR4, particularly the compounds of the following formulas: \ / /* l * r -n.

Nr f T vrN I /N\ -J r r Other useful adhesive resins include the above foxmulas wherein on average, at least one R radical in each monomer or in each oligomerized unit is _CH2= NH- C(0) —OR4, wherein R4 is a Cj-Cig alkyl, alicyclic, hydroxyalkyl, alkoxyalkyl or aromatic radical, and wherein, 011 average, at least two R radicals are selected from CH2= CCCH3)—€(0)0—CjH« —O-CHr- and CH2= CHr—C(0)0—CiH —O—CHz— and at least one R radical is selected from —CHz== NH—C(0>-4)—CH3» aid 14 WO 2009/10®! 11 RECIEVED IPONZ 17 JUNE 2011 —CHz— NH—C(0)—O—CjH7.

These adhesive rains and compounds can include additional additives, particularly those selected from hyiroxyraeftylated and alkoxymethylated (alkoxy having 1-5 carbon atoms) derivatives of melamine, acetoguanamine, 5 benzoguanamine, cyclohexylguanamme and glycoluril and their oligomers.

Additional adhesive resins useful in the recycled glass/aggregate wearing couse compositions described herein include self-condensing alkylated triazine resins selected from the group consisting of (i), (ii), and (Mi): (i) a self-condensing alkylated triazine resin having at least one of imino 10 or meftiyM functionality and represented by formula (1) (ii) an oligomer of (i), or (ii) a mixture of (i) and (ii), wherein Z is -N (RXCH2OR1), aryl having 6 to 10 carbon atoms, alkyl having 1 to 20 15 carbon atoms or an acetyl group, each R is independently hydrogen or -CH2OR1, and each R1 is independently hydrogen or an alkyl group having 1 to 12 carbon atoms, provided that at least one R is hydrogen or -CH2OH and at least one R1 is 20 selected from the alkyl group; and wherein the basalt powder-containing composition is substantially free of methylene acceptor coreactants.

These adhesive resins are particularly useful wherein at least one R group is hydrogen and/or wherein at least one R1 group is a lower alkyl group having 1 to 6 RECIEVED IPONZ 17 JUNE 2011 PCT/US2009/U33045 carbon atoms, particularly where the adhesive resin is a derivative of melamine, benzoguanamine, cyclohexylguanamine, or acetoguanamine, or an oligomer thereof.

One particularly useful alkylated triazine adhesive resin of the above formula is wherein Z is -N(RXCH20R1).

The compositions containing an adhesive such as a cobalt salt of an organic acid, hydroxybenzwie odd, and resorcinol, also function to increase the adhesion between the basalt powder particles.

Another adhesive resin useful herein, is N-(substituted oxymefhyl)melamine and at least one of a- or ff-naphfhol. This adhesive resin employs the monohydric 10 phenols, a- or naphthol, as methylene acceptors in the resin forming reaction (hiring vulcanization in the absence of resorcinol.

Another suitable class of adhesive resins useful herein to adhere the recycled glass and aggregate particles together, are those which are applied in multi-stage processes, for instance a Mocked isocyanate "being applied in combination with 15 polyepoxide and the material then, bang treated using customary resorcmol-fbrmaldehyde resins. Additional useful adhesive resins include, for example, a reaction, product of triallyl cyanurate, resorcinol and formaldehyde or p-chlorophenol, resorcinol and formaldehyde.

Other suitable adhesive resins include polyurethane resins, phenol aldehyde 20 resins, polyhydiic phenol aldehyde resins, phenol fiirforal resins, xylene aldehyde resins, urea formaldehyde resins, melamine formaldehyde resins, alkyd resins, polyester resins, and the like.

PREFERRED CONSTRUCTION OF PAVEMENT STRUCTURE Referring now to the drawings showing the porous pavement structure 10, the filtration/water storage lower layer 12 of recycled glass particles 14 is deposited in a defined, excavated area 16 in a soil surface 18 in a desired depth, e.g., 2 inches to about 30 inches, preferably about 12 inches, compacted to at least 90%, preferably at least 95% Modified Proctor (ASTM D1557) before applying the wearing course 20 thereover. Before laying the grid structure 22 on the recycled glass lower layer 12 (filtration/water storage layer), preferably a fabric or plastic 16 RECIEVED IPONZ 17 JUNE 2011 PCT/US2O09/O33O45 mesh 24 is disposed over the recycled glass layer 12 to hold the recycled glass particles 14, aggregate particles 26 and binder composition of the wearing course 20 in place within the grid structure 22. The preferred grid structure is GEO-BLOCK® of Presto Products Company having a 2 inch height of individual, adjacent 3 inch by 5 3 inch rectangular pockets 28 of adjacent interlocking grid units 30 of semi-rigid high density polyethylene. The GEOBLOCK® grid units 30 then are interlocked together to create an integral holding structure for the recycled glass/aggregate/bmder wearing course 20 composition forming an upper portion of the pavement structure 10 having the desired dimensions. Optionally, the grids 30 10 may be anchored to the soil with spaced anchors 3 3.

In accordance with a preferred embodiment, the wearing course 20, disposed over the filtration/water storage layer 12 of recycled glass particles 14, is supported at its edges 34 or perimeter with a structural border material, such as cement border 36, so that vehicle traffic on the wearing course 20 edges 34 does not force 15 separation of the bound recycled glass/aggregate composition from the grid pockets 28 at the edges 34 of the pavement structure 10.

After the grid structure 22 is disposed over the plastic mesh or fabric 24, the grids 30 are filled with a homogeneous mixture of recycled glass particles 14 and aggregate particles 26 coated with a flexible polyurethane resin, preferably having a 20 percent elongation at break of at least 50% ,more preferably at least 100%, even more preferably at least 200%. The recycled glass, aggregate and resin are compacted in the grids 30, in individual, adjacent grid pockets 28. Sufficient adhesive binder is coated onto the recycled glass and aggregate to adhere all glass and aggregate particles together. 17 RECIEVED IPONZ 17 JUNE 2011

Claims (18)

WHAT IS CLAIMED:

1. A water-pervious pavement structure comprising: (a) a wearing course comprising a water-pervious combination of recycled glass particles and aggregate particles bound together with a flexible adhesive binder and held within a plurality of connected, open grid pockets; (b)a layer of unbound recycled glass disposed under the wearing course capable of adsorbing contacting hydrocarbons carried with water through the wearing course; and (c) a caisson or aperture excavated under the layer of unbound recycled glass to a depth below a frost line to achieve a thermal moderating effect resulting from air rising through said caisson or aperture and into said unbound recycled glass layer.

2. The pavement structure of claim 1, wherein the wearing course comprises about 30 wt.% to about 80 wt.% recycled glass and about 20 wt.% to about 70 wt.% aggregate bound together by a cured resin binder within the grid pockets.

3. The pavement structure of claim 2, wherein the resin binder is applied to an upper surface of the wearing course after filling the grid pockets with the recycled glass and aggregate combination, wherein the resin binder is applied in an amoimt in the ■j range of about 0,2 ounce to about 10 ounces per ft of wearing course surface area.

4. The pavement structure of claim 3, where the resin binder is applied to the upper surface of the wearing course in an amount in the range of about 0.5 ounces to about 5 ounces per ft2 of wearing course surface area.

5. The pavement structure of any of claims 1-4, wherein the wearing course has a compressive strength of at least 800 psi.

6. The pavement structure of any of claims 1-5, wherein the wearing course has a compressive strength of at least 900 psi. 18 RECIEVED IPONZ 17 JUNE 2011

7. The pavement structure of any of claims 1 -6, wherein the layer of unbound recycled glass disposed under the wearing course has a thickness and sufficient void space between unbound recycled glass particles to provide a detention basin for storm water that penetrates the wearing course.

8. The pavement structure of claim 1, wherein tie aggregate is cMp seal aggregate.

9. The pavement structure of claim 1, including a stormwater detention basin disposed directly below the layer of unbound recycled glass.

10. The pavement structure of claim 1, wherein the recycled glass particles have a size in the range of about 1/16 inch to about 2 inches.

11. The pavement structure of claim 10, wherein both the glass particles and the aggregate particles have a size of about 3/8 inch.

12. A method of constructing a porous pavement structure capable of capturing hydrocarbon contaminants carried by rain water comprising: applying a layer of recycled glass over a soil surface and providing a caisson or aperture under the layer of recycled glass to a depth below a frost Ike to achieve a thermal moderating effect resulting from air rising, through the aperture and into the recycled glass layer; compacting the applied layer of recycled glass to a modified Proctor of at least 90%; applying a fabric or mesh over the compacted layer of recycled glass; applying a structure containing a plurality of open-top grid pockets having rigid or semi-rigid upwardly-extending vertical, grid walls for receiving and holding a wearing course composition; filling the grid pockets with a wearing course composition comprising a mixture of recycled glass, aggregate and flexible resin binder; curing the adhesive binder. 19 RECIEVED IPONZ 17 JUNE 2011

13. The method of claim 12, wherein the mixture of recycled glass and aggregate comprises about 30 wt.% to about 80 wt.% recycled glass and about 20 wt.% to about 70 wt.% aggregate; and the adhesive binder is a resin binder applied in an amount in the range of about 2 wt. % to about 6 wt. %, based on the combined weight of recycled glass and aggregate.

14. The method of claim 12, wherein the layer of recycled glass is disposed over the soil surface and has a thickness and sufficient void space between recycled glass particles to provide a detention basin for storm water that penetrates the bound mixture of recycled glass and aggregate.

15. A water-pervious pavement structure comprising: (a) a wearing course comprising a water-pervious combination of recycled glass particles and aggregate particles bound together with a flexible adhesive binder; (i) the adhesive binder comprising polyurethane; and (b) a layer of unbound recycled glass disposed under the wearing course capable of adsorbing contacting hydrocarbons carried with water through the wearing course.

16. A water-pervious pavement structure substantially as herein described with reference to the accompanying drawings.

17. A method as claimed in claim 12 substantially as herein described.

18. A porous pavement structure formed by the method of any one of claims 12 to 14 and 17. 20