Crack resistant coating and method of applying crack resistant coating

Abstract

The present invention relates to a method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface. The method comprises the steps of applying a binding material to the surface and applying an aggregate mixture within 15 seconds of applying the binding material to the surface, where the aggregate mixture comprises aggregate particles and an asphalt solution and where the aggregate mixture has a plurality of air voids, and where the binding material fills at least 15% of the air voids in the aggregate mixture (AVFA).

1 . A method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface, the method comprising the steps of:
 applying a binding material to the surface; and   applying an aggregate mixture within 15 seconds of applying the binding material to the surface, where the aggregate mixture comprises aggregate particles and an asphalt solution and where the aggregate mixture has a plurality of air voids;   
       where the binding material fills at least 15% of the air voids in the aggregate mixture (AVFA). 
     
     
         2 . The method of  claim 1  wherein the binding material fills at least 18% of the air voids in the aggregate mixture (AVFA). 
     
     
         3 . The method of  claim 1  where the aggregate mixture is applied within 10 seconds of applying the binding material to the surface. 
     
     
         4 . The method of  claim 1  where the aggregate mixture is applied within 5 seconds of applying the binding material to the surface. 
     
     
         5 . The method of  claim 1  where the binding material and the aggregate mixture comprise the crack resistant coating and where the crack resistant coating contains a total binding material in an amount greater than about 1.00 L/(m 2 -cm), where the total binding material is a sum of the net binding material and the asphalt solution. 
     
     
         6 . The method of  claim 5  where the total binding material is greater than about 1.30 L/(m 2 -cm). 
     
     
         7 . The method of  claim 5  where the total binding material is greater than about 1.51 L/(m 2 -cm). 
     
     
         8 . The method of  claim 1  further comprising allowing the binding material to fill some of the air voids in the aggregate mixture to form a substantially voidless layer with a height of at least 0.38 cm. 
     
     
         9 . The method of  claim 1  further comprising allowing the binding material to fill some of the air voids in the aggregate mixture to form a substantially voidless layer with a height of at least 0.46 cm. 
     
     
         10 . A method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface, where the crack resistant coating has binding material layers, aggregate mixture layers, and a wear surface for traffic, the method comprising the steps of:
 applying a first binding material layer of the crack resistant coating on the surface to provide a substantially impermeable moisture barrier to the surface;   applying a first aggregate mixture layer of the crack resistant coating on the first binding material layer, the first aggregate mixture layer providing support and structure to the crack resistant coating to resist rutting;   applying a second binding material layer of the crack resistant coating on the first aggregate mixture layer, the second binding material layer providing a second substantially impermeable moisture barrier to the surface; and   applying a second aggregate mixture layer of the crack resistant coating on the second binding material layer, the second aggregate mixture layer providing the wear surface of the coating and additional structure and support to the crack resistant coating to resist rutting.   
     
     
         11 . The method of  claim 10  further comprising the step of compacting the first aggregate mixture layer against the first binding material layer prior to the step of applying the second binding material layer, where the step of compacting the first aggregate mixture layer against the first binding material layer provides a substantially uniform thickness of the first aggregate mixture layer and the first binding material layer, reduces air void space in the first aggregate mixture layer, and promotes adhesion of the first aggregate mixture layer to the first binding material layer. 
     
     
         12 . The method of  claim 10  further comprising the step of compacting the second aggregate mixture layer against the second binding material layer to provide a substantially uniform thickness of the crack resistant coating, where the step of compacting the second aggregate mixture layer against the second binding material layer also reduces air void space in the second aggregate mixture layer, promotes adhesion of the second binding material layer to the first aggregate mixture layer, and promotes adhesion of the second aggregate mixture layer to the second binding material layer. 
     
     
         13 . The method of  claim 10  wherein the first aggregate mixture layer and the second aggregate mixture layer each comprise aggregate particles and an asphalt solution. 
     
     
         14 . The method of  claim 13  wherein the crack resistant coating contains a total binding material, where the total binding material is a sum of the asphalt solution of the first aggregate mixture layer, the asphalt solution of the second aggregate mixture layer, the net binding material of the first binding material layer, and the binding material of the second binding material layer. 
     
     
         15 . The method of  claim 14  wherein the total binder material of the crack resistant coating is greater than about 1.00 L/m 2 -cm. 
     
     
         15 . The method of  claim 13  wherein the total binder material of the crack resistant coating is greater than about 1.30 L/m 2 -cm. 
     
     
         16 . The method of  claim 9  wherein the step of applying the first binding material layer further comprises applying the first binding material layer on the surface in an amount of from about 0.09 L/m 2 -cm to about 0.533 L/m 2 -cm. 
     
     
         17 . The method of  claim 9  wherein the step of applying the first binding material layer further comprises applying the first binding material layer on the surface in an amount of about 0.28 L/m 2 -cm. 
     
     
         18 . The method of  claim 12  wherein the asphalt solution included in the first aggregate mixture layer is present in an amount of from about 0.71 L/m 2 -cm to about 1.95 L/m 2 -cm. 
     
     
         19 . The method of  claim 18  wherein the amount of the asphalt solution is about 1.16 L/m 2 -cm. 
     
     
         20 . The method of  claim 9  wherein the step of applying the second binding material layer further comprises applying the second binding material layer on the first aggregate mixture layer in an amount of from about 0.18 L/m 2 -cm to about 1.07 L/m 2 -cm. 
     
     
         21 . The method of  claim 9  wherein the step of applying the second binding material layer further comprises applying the second binding material layer on the first aggregate mixture layer in an amount of about 0.57 L/m 2 -cm. 
     
     
         22 . The method of  claim 9  wherein the asphalt solution included in the second aggregate mixture layer is present in an amount of from about 0.18 L/m 2 -cm to about 1.07 L/m 2 -cm. 
     
     
         23 . The method of  claim 22  wherein the amount of the asphalt solution is about 0.57 L/m 2 -cm. 
     
     
         24 . A crack resistant coating disposed on a surface to provide resistance to high vertical and horizontal movements and high shear stresses, the coating comprising:
 a first binding material layer disposed on the surface to provide a substantially impermeable moisture barrier to the surface;   a first aggregate mixture layer disposed on the first binding material layer, the first aggregate mixture layer providing support and structure to the coating to resist rutting;   a second binding material layer disposed on the first aggregate mixture layer, the second binding material layer further providing another substantially impermeable moisture barrier to the surface; and   a second aggregate mixture layer disposed on the second binding material layer, the second aggregate mixture layer providing a wear surface of the coating and additional structure and support to the crack resistant coating to resist rutting.   
     
     
         25 . The coating of  claim 24  wherein the first and second aggregate mixtures comprise a plurality of air voids and where the first and second binding material fills a percentage of the air voids, and wherein the percentage of air voids filled with binding material is greater than about 15%. 
     
     
         26 . The coating of  claim 25  wherein the percentage of air voids filled with binding material is greater than about 18%. 
     
     
         27 . The coating of  claim 24  wherein the crack resistant coating has a depth that is flooded with binding material, and wherein the depth flooded with binding material is greater than about 0.38 cm. 
     
     
         28 . The coating of  claim 27  wherein the crack resistant coating has a depth that is flooded with binding material, and wherein the depth flooded with binding material is greater than about 0.46 cm. 
     
     
         29 . A crack resistant coating disposed on a surface, the coating comprising:
 a first layer comprising aggregate mixture and binding material, where the aggregate mixture comprises a plurality of air voids and where the binding material fills substantially all of the air voids such that the first layer resists cracking; and   a second layer atop the first layer, the second layer comprising aggregate mixture and binding material, where the aggregate mixture comprises a plurality of air voids and a sufficient quantity of the air voids are not filled with binding material such that the second layer resists deformation and rutting;   
       where the first layer and the second layer are created simultaneously by first applying the binding material on the surface and then applying the aggregate mixture on the binding material. 
     
     
         30 . The crack resistant coating of  claim 29  where the aggregate mixture is applied within 15 seconds of applying the binding material to the surface. 
     
     
         31 . The crack resistant coating of  claim 29  where the aggregate mixture is applied within 10 seconds of applying the binding material to the surface. 
     
     
         32 . The crack resistant coating of  claim 29  where the aggregate mixture is applied within 5 seconds of applying the binding material to the surface. 
     
     
         33 . The crack resistant coating of  claim 29  where the first layer has a depth greater than about 0.38 cm. 
     
     
         34 . The crack resistant coating of  claim 29  where the first layer has a depth greater than about 0.46 cm. 
     
     
         35 . The crack resistant coating of  claim 29  where greater than about 15% of the air voids in the first layer and in the second layer combined are filled with binding material. 
     
     
         36 . The crack resistant coating of  claim 29  where greater than about 18% of the air voids in the first layer and in the second layer combined are filled with binding material.