Method of making and use of a heavy duty pavement structure

Abstract

The present invention is directed to a heavy duty pavement structure comprising an open-graded asphalt layer fortified with a non-segregating grout mixture. The heavy duty pavement structure is made through the steps including forming an open-graded asphalt layer and then fortifying the layer with a non-segregating grout mixture that includes a predetermined amount of portland cement, sand and cement binder system.

1 . A method of making a heavy duty pavement structure comprising:
 a. forming an open-graded asphalt mixture layer wherein the layer includes a predetermined percentage of air voids; and,   b. filling air voids formed within the open-graded asphalt layer with a non-segregating grout mixture comprising portland cement, sand and a cement binder system.   
     
     
         2 . The method of  claim 1 , wherein the open-graded asphalt mixture comprises a mineral aggregate and an asphalt binder system. 
     
     
         3 . The method of  claim 2 , wherein the open-graded asphalt mixture comprises at least 75% crushed faces of aggregate and wherein each aggregate particle is no more than 1 inch in diameter. 
     
     
         4 . The method of  claim 1 , wherein the air voids within the open-grade asphalt range in volume from 20% to 35% after compaction. 
     
     
         5 . The method of  claim 1 , wherein the air voids within the open-grade asphalt range in volume from 25% to 30% after compaction. 
     
     
         6 . The method of  claim 2 , wherein the open-grade asphalt mixture comprises 2.5% to 4.5% asphalt binder system based on the total weight of the mixture. 
     
     
         7 . The method of  claim 1 , wherein the open-grade asphalt mixture comprises one sized aggregate. 
     
     
         8 . The method of  claim 1 , wherein the cement binder system comprises a combination of inorganic binders and organic binders. 
     
     
         9 . The method of  claim 8 , wherein the inorganic binders comprise hydraulically reactive materials including calcium silicate, calcium aluminate, magnesium phosphate, or partially hydrolyzed forms of calcium oxide, calcium sulphate and combinations thereof. 
     
     
         10 . The method of  claim 8 , wherein the organic binders comprise polymers having at least one monomer including vinyl esters, (meth)acrylates, vinyl aromatics, olefins, 1,3-dienes and vinyl halides. 
     
     
         11 . A method of making a heavy duty pavement structure comprising:
 a. preparing an open-graded asphalt mixture;   b. laying the open-graded asphalt mixture in place to form a layer;   c. compacting the open-graded asphalt layer;   d. allowing the open-graded asphalt layer to cool to a predetermined temperature;   e. preparing a non-segregating grout mixture;   f. placing the grout mixture on top of the previously laid open-graded layer; and,   g. filling air voids within the open-graded asphalt layer with the grout mixture through vibratory compaction.   
     
     
         12 . The method of  claim 11 , wherein the grout mixture comprises portland cement, sand and a cement binder system. 
     
     
         13 . The method of  claim 12 , wherein the cement binder system comprises a combination of inorganic binders in combination with organic binders. 
     
     
         14 . The method of  claim 11 , wherein the open-graded asphalt mixture comprises a mineral aggregate and an asphalt binder system. 
     
     
         15 . The method of  claim 11 , wherein the open-graded asphalt mixture comprises at least 75% crushed faces of aggregate and wherein each aggregate particle is no more than 1 inch in diameter. 
     
     
         16 . The method of  claim 11 , wherein the air voids within the open-grade asphalt range in volume from 20% to 35% after compaction. 
     
     
         17 . A heavy duty pavement composite comprising:
 an open-graded asphalt layer, wherein the total volume of the asphalt layer comprises between 20% to 35% air voids; and,   a non-segregating grout that fills the air voids in the asphalt layer   
     
     
         18 . The heavy duty pavement composite of  claim 17 , wherein the non-segregating grout comprises portland cement, sand and a cement binder system. 
     
     
         19 . The heavy duty pavement composite of  claim 17 , wherein the open-graded asphalt layer comprises at least 75% crushed faces of aggregate and wherein each aggregate particle is no more than 1 inch in diameter. 
     
     
         20 . The heavy duty pavement composite of  claim 17 , wherein the non-segregating grout comprises portland cement, sand, water, and a cement binder system including a combination of inorganic binders in combination with organic binders.