OA19034A - Concrete based reinforced road structure covered by asphalt - Google Patents

Abstract

Concrete based reinforced road structure covered by asphalt that comprises a basic layer (1) made of concrete with a substantially horizontal upper surface and placed directly or through a subconstruction on the ground and at least one mould cover layer (2) thereon made of asphalt, and support elements (3) positioned between the basic layer (1) and the cover layer (2), wherein the support elements (3) are inserted in a predetermined depth in the basic layer (1) prior to the setting thereof so that they are partially projecting out of the basic layer (1) in normal direction to the upper surface, and the projecting portion provides protection to the cover layer (2) against being displaced relative to the basic layer (1) under loads to which the road is exposed, and the support elements (3) are flat stripes with walls being substantially normal to the surface of the basic layer (1) and comprising subséquent sections with differing directions to form respective meandering lines.

Description

Concrète based reinforced road structure covered by asphalt

The invention relates to a concrète based reinforced road structure covered by asphalt that comprises a basic layer made of concrète with a substantially horizontal upper surface and placed directly or through a subconstruction on the ground and at least one mould cover layer thereon made of asphalt, and support éléments positioned between the basic layer and the cover layer. This structure is capable of preventing or decreasing deformations in the asphalt layer under thermal effects and load coming from traffic.

Most versions of load bearing roads comprise several layers wherein the lower layer comprises at least one concrète base designed to resist the load and this is covered by one or more mould asphalt layer.

The asphalt layer that comprises elastic bitumen as binding material has physical and mechanical properties which substantially change within the température range characteristic to the temperate global zone. Because during the sudden température changes in summer owing to the fast relaxation of asphalt and the distribution of the generated tensions in ail directions no substantial thermal pressure or pulling tensions will take peace. The typical resuit will be the rutting or cave-ins of the pavement caused by the load of tires of heavy commercial vehicles i. e. by the uneven compression of the asphalt. In case of sudden drops of the température in winter the damages of the asphalt corne from thermal cracks.

In addition to thermal and mechanical pressure loads the road is also exposed to bending loads coming from the through going traffic. This load component dépends also on the thermal effects. Owing to the changing mechanical properties of the asphalt with time the bending type load will be the greater when the layers that constitute the road structure cannot cooperate because bending and pulling tensions can emerge therein which might be greater than the tension strength of the material of the given layer against pulling.

One way of designing pavements to these three kinds of loads is the choosing of appropriate materials and the use of structural solutions that prevent the road from the conséquences of these effects.

The main reason of the aforementioned triple problems lies in that there is no appropriately strong binding between the base layer made of concrète that has the task of receiving and resisting the load and the asphalt cover layer thereon therefore in most of the cases the asphalt layer gets displaced on the concrète or being cracked without displacement.

In US 7232276 B2 a road structure is described provided with a reinforcement layer, wherein under the usually applied upper asphalt layer a separate reinforcement layer is placed which comprises in a sandwich-like manner two asphalt layers and a binding layer between them made of glass fibers stabilized by a plastic binder. This structure has the drawback that its correct use requires high degree of skill and under temperate dimatic environment the plastic bound reinforcement layer will soon get destroyed. A further drawback lies in that this solution cannot render the coopération of the rigîd basic layer and the flexible cover layer(s).

In US 524 9883 a structure composed of four layers of asphalt and aggregate is disclosed, wherein a métal sheet is placed under the structure. In this case the loadability of this road is good and the four layers cooperate properly because of the use of modified elastomers, however, it has only a narrow field of use owing to the sophisticated and expensive technology, therefore it is mainly used on bridges and in garage buildings. When used on bridges the high traffic and the increased load because of the high speed of the vehicles the cohésion between the métal sheet and the asphalt layers can be insufficient and this coopération is adversely influenced by the high différence in the thermal conductivity of these layers.

In US 5009543 an asphalt correction method is disclosed for heavily worn roads with caves and/or rutting. Here a grid structure is built in the asphalt which has e.g. a honeycomb shape which has a strong withholding effect, whereby durable corrections can be made. A drawback of this solution is that there is no load bearing solid support layer under the asphalt and the grid structure is fully embedded in the asphalt layer, therefore it cannot solve the aforementioned problem Le. the displacement between the concrète base and the asphalt cover layer thereon.

In the document US 2008/0152436 Al a reinforcement structure is described that is built in the asphalt layer by zigzagged straps combined to form closed shapes. The publication describes several ways of such reinforcement structures but these are ail placed prior to the moulding of the asphalt layer on the underlying support surface (constituted mainly by the ground), therefore the grid structure can reinforce the asphalt layer only but has no effect on the quality of connection between the asphalt layer and the underlying support.

There are several other documents which deal with the connection of a concrète base and the asphalt layer placed thereon including e.g. CN 101109168A, CN 204662194 U, CN 102418309 A which hâve the common feature that the upper surface of the concrète base layer is shaped to hâve a periodic spatial profile (e.g. to hâve grooves) and in such cases there will be a form fitting connection with the overlying mould asphalt layer that prevents the displacement of the two layers.

A common drawback of such solutions is that the formation of a spatially structured upper surface for the base layer can be provided only by using very big tools and this is an expensive job, and water can collect in the deeper parts of the grooves which when getting frozen causes cracks, furthermore the grooves hâve generally a single main direction and the protection against displacement is efficient only normal to this direction, although the aforementioned loads can corne from any direction.

The object of the present invention is to provide a reinforced road structure that has a concrète base and a mould asphalt layer thereon which can provide and efficient protection against ali the three listed deforming load effects and can prevent the asphalt layer(s) from being dispiaced relative to the concrète base layer.

This objective has been reached by providing a concrète based reinforced road structure covered by asphalt that comprises a bastc layer made of concrète with a substantially horizontal upper surface and placed directly or through a subconstruction on the ground and at least one mould cover layer thereon made of asphalt, and support éléments positioned between the basic layer and the cover layer, and according to the invention the support éléments are inserted in a predetermined depth in the basic layer prior to the setting thereof so that they are partially projecting out of the basic layer in normal direction to the upper surface, and the projecting portion provides protection to the cover layer against being dispiaced relative to the basic layer under loads to which the road is exposed, and the support éléments are fiat stripes with walls being substantially normal to the surface ofthe basic layer and comprising subséquent sections with differing directions to form respective meandering lines.

It is preferred if the meandering stripes formed of the support éléments are extending beside each other so that along certain sections they are interconnected to form together an array of closed shapes.

The positioning will become easier if respective openings are provided in the support éléments that extend till the upper surface of the basic layer and at the lower edges of the openings respective eut tabs are folded out to prevent the support éléments from immersing in the material of the basic layer when it is still rn a pasty state.

It is preferred if the closed shape is triangle, square, circle or hexagon.

In a preferred embodiment the cover layer comprises gravel pièces made of stone, and the support éléments extend out from the upper surface of the basic layer at least as high as the half of the average size of said gravel pièces.

For the sake of easier handling it is preferred if the upper sides of the support éléments hâve a wider upper rim, and it is more preferred if such wider rims are provided also on their lower edges.

It is also preferred if that the support éléments are arranged beside each other to form respective regular shapes which are connected to each other.

The invention will now be described in connection with préférable embodiments thereof, in which reference will be made to the accompanying drawings. In the drawing:

Fig. 1 shows a preferred embodiment of the road structure according to the invention in half ready state in a stepped section;

Fig. 2 shows an enlarged detail similar to Fig, 1;

Fig. 3 shows the enlarged cross sectional profile of a preferred embodiment of the support éléments 3;

Fig. 4 shows an alternative design of the support éléments 3; and

Fig. 5 shows the enlarged cross sectional view of the road structure.

Fig. 1 shows the simplified stepped sectional view of the first embodiment of the road structure according to the invention in which at the bottom a solid basic layer 1 is arranged made of concrète. Below the basic layer 1 the ground is prepared for instance by compaction or with a different way or there can be a coarser grained concrète. The basic layer 1 has a design which can take and resist taking static and dynamic loads typically present at the road under construction, and the basic layer 1 has preferabiy a planar or slightly bowed upper surface which is preferred for leading water away and for its much cheaper manufacture as if it was an articulated structure. The basic layer 1 is preferabiy strengthened by a steel reinforcement which need not be indicated separately as it is not required for understanding the present invention.

When the road is constructed, an asphalt cover layer 2 is provided on the top of the basic layer 1 by moulding. The asphalt layer 2 comprises as shown in the sectional view of Fig. 5 gravel with small pièces of different size and bitumen that fills the gaps between the pièces. In Fig. 1 the cover layer 2 has been shown in a partially removed state for the sake of illustrating the structure prior to the placement of the cover layer 2.

Before the setting of the basic layer 1 support éléments 3 are positioned from above which hâve spécial shape and iayout as illustrated in Fig. 1 in such a way that the support éléments 3 extend out from the upper surface of the basic layer 1 in a predetermined height normal to the surface, whereas the support éléments 3 are at the same time sunken in a predetermined depth also in the basic layer 1. The support éléments 3 are made preferabiy but not necessarily from iron, steel, or they can be made from a material designed to take the expected load. This task can also be taken by an appropriately chosen plastic material.

Fig. 2 shows the design of a preferred embodiment of the support éléments 3 in an enlarged view, in which the support éléments 3 hâve the shape of stripes formed of half hexagons positioned normal to the surface and arranged opposite to each other and they are connected to each other at their contacting surface areas by means of bolts, rivets or by welding, whereby they constitute a closed arrangement of stable closed polygons e.g. form hexagonal grids that extend out of the surface to a predetermined height. This design is preferred because the closed polygons are interconnected with force fitting attachments, whereby they can resist forces coming from any direction that act on the cover layer 2 mould later thereon, whereby they prevent any displacement of the asphalt.

In Fig, 1 it is illustrated schematically that the support éléments 3 comprise respective openings made close to the height of the upper surface of the basic layer 1 which hâve been eut out of the material of the support éléments 3 and bent outwardly relative to the original plane of the stripes (which plane is now vertical) to form tabs 4 that provide increased horizontal surfaces that prevent the support element 3 from being immersed in the material of the basic layer 1 when it is still in pasty state. The presence of the tabs 4 and the associated opening is also preferred because in this way in spite of the presence of the support éléments 3 there will be a free flow of water through the openings of the support éléments 3, and when the cover layer 2 is mould bitumen can flow in the openings causing a further stabilizing effect for the cover layer 2.

The enlarged detail of Fig. 3 shows that in a preferred embodiment the stripes constituting the support éléments 3 hâve an upper rim 5 with rounded and increased cross section i.e. the stripes do not hâve sharp edges but upper surfaces with an increased thickness. Such a design is préférable from the point of view of minimizing the hazard of accidents and following the setting of the lower basic layer 1 that fixes the lower portion of the support éléments 3 this upper rim 5 makes it possible that prior to the placement of the cover layer 2 vehicles can move on their surface without the danger of their tires being eut by the sharp upper edges of the support éléments 3. It is also preferred if the support éléments 3 hâve a symmetric cross section i.e. provided with a similarly wide lower rim 5 as it is shown in Fig. 3 which reinforces their sit in the basic layer 1.

Fig. 4 shows stripes 6 (or straps) which constitute the support éléments 3 positioned in a spaced arrangement to illustrate that the formation of a closed structure defining hôtes is not an indispensable condition because the stripes 6 with their meandering lines can be sufficientîy stable after the setting of the basic layer 1 in which their lower parts are inserted. In case of roads designed for lower load such an open design can also provide the required stability. If needed, the support éléments 3 can also be made as stripes without having the widened rims 5 positioned normal to their plane surfaces in the basic layer 1.

Reference is made now to Fig. 5 showing the cross section of the road after it has been finished. As described earlier following the setting of the basic layer 1 with the support éléments 3 previously inserted therein, the cover layer 2 will be positioned from above by moulding in a soft, pasty state. The height of the projection of the support éléments 3 above the basic layer 1 is not critical, whereas it is preferred if this height is at least as high as the half of the average size of the stone pièces 7 that constitute the gravel in the cover layer 1 so that the walls of the support éléments 3 can provide sufficient résistance against the pressure of these pièces 7. The depth in which the support éléments 3 should be inserted in the basic layer 1 can be determined 5 only in the knowledge of the required loadability, but it is also preferred if the depth is at least the half of the average size of the grave! pièces in the basic layer 1. Fig. 5 shows the support éléments 3 with different projecting heights. In any given actual embodiment only a single projecting height is chosen.

From the examples shown it can be understood there are several ways for supporting the 10 cover layer 2 made of asphalt, and of these possibilities the chotce should be made according to the local conditions at the particular site, to the budget limitations or to other conditions. The essence lies only in that the support éléments 3 inserted in and bound to the basic layer 1 stabilize the asphalt cover layer 2 and prevent it from getting displaced even under the simultaneous effect of the previously mentioned three types of load.

Claims (7)

1. Claims

   1. Concrète based reinforced road structure covered by asphalt comprising a basîc layer (1) made of concrète with a substantially horizontal upper surface and placed directiy or through a subconstruction on the ground and at least one mould cover layer (2) thereon made of asphalt, and support éléments (3) positioned between the basic layer (1) and the cover layer (2), characterized in that the support éléments (3) are inserted in a predetermined depth in the basic layer (1) priorto the setting thereof so that they are partially projecting out of the basic layer (1) in normal direction to the upper surface, and the projecting portion provides protection to the cover layer (2) against being displaced relative to the basic layer (1) under loads to which the road is exposed, and the support éléments (3) are fiat stripes with walls being substantially normal to the surface of the basic layer (1) and comprising subséquent sections with differing directions to form respective meandering lines.
2. 2. The road structure as claimed in claim 1, characterized in that the meandering stripes formed of the support éléments (3) are extending beside each other so that along certain sections they are interconnected to form together an array of ctosed shapes.
3. 3. The road structure as claimed in claims 1 or 2, characterized in that respective openings are provided in the support éléments (3) that extend till the upper surface of the basic layer (1) and at the lower edges of the openings respective eut tabs (4) are fotded out to prevent the support éléments (3) from getting immersed in the material of the basic layer (1) when it is still in a pasty state.
4. 4. The road structure as claimed in claims 2 or 3, characterized in that the closed shape is triangle, square, circle or hexagon.
5. 5. The road structure as claimed in any of claims 1 to 4, characterized in that the cover layer (2) comprises gravel pièces made of stone, and the support éléments (3) extend out from the upper surface of the basic layer (1) at least as high as the half of the average size of said gravel pièces.
6. 6. The road structure as claimed in any of claims 1 to 5, characterized in that the upper sides of the support éléments (3) hâve a wider upper rim (5).
7. 7. The road structure as claimed in any of claims 1 to 6, characterized in that the support éléments (3) are arranged beside each other to form respective regular shapes which are connected to each other.