System and method for roadway pavement restoration

Abstract

Embodiments of the present invention are generally related to roadway maintenance and repair, and, in particular, to a system and method for restoring asphalt surfaces such as asphalt roadways. In one embodiment, an asphalt restoration system comprising a vehicle with a loading arm, a heater, a heater power generator, a road roller, and an asphalt processor is disclosed. The asphalt restoration system is positioned at a repair site, wherein the heater is offloaded from the vehicle by the vehicle arm and positioned over a repair area. After the repair area is heated, the asphalt processor tills and levels the area, producing a seamless and restored area.

What is claimed is: 
     
         1 . A method of restoring asphalt in a road surface, comprising:
 providing an asphalt restoration system comprising a vehicle with a loading arm, a heater, a heater power generator configured to communicate with the heater, a road roller, and an asphalt processor, wherein the vehicle is configured to simultaneously transport the heater, heater power generator, road roller, and asphalt processor;   transporting the asphalt restoration system to a repair site comprising a repair area;   offloading the heater from the vehicle using the vehicle loading arm;   positioning the heater over the repair area;   heating the repair area using the heater to produce a heated repair area;   re-positioning the heater away from the heated repair area;   applying rejuvenation material to the heated repair area;   tilling the heated repair area with the asphalt processor to break up the heated repair area and form a beveled edge on opposing sides of the heated repair area;   leveling the heated repair area with a screed of the asphalt processor;   compacting the heated repair area with the road roller;   loading the heater onto the vehicle using the vehicle loading arm; and   loading the road roller and asphalt processor onto the vehicle.   
     
     
         2 . The method of  claim 1 , wherein the heater is an infrared heater. 
     
     
         3 . The method of  claim 1 , wherein the heater comprises wheels to facilitate positioning of the heater. 
     
     
         4 . The method of  claim 1 , further comprising connecting the heater power generator with the heater. 
     
     
         5 . The method of  claim 4 , wherein the heater power generator is an electrical power generator fueled by a hydrocarbon. 
     
     
         6 . The method of  claim 1 , wherein the asphalt processor comprises:
 a rotatable shaft member having a first end and a second end; and   a plurality of tines extending outwardly from the rotatable shaft member comprising a first and second set of outermost tines and a set of inner tines positioned between the first and second set of outmost tines, each of the first and second set of outermost tines comprising a portion that angles inwardly toward the inner set of tines and configured to form the respective first and second beveled edges in the heated repair area.   
     
     
         7 . The method of  claim 6 , wherein the asphalt processor comprises a tiller operable in a first position of use and a screed operable in a second position of use. 
     
     
         8 . The method of  claim 7 , wherein the screed comprises at least two outwardly extending arm structures. 
     
     
         9 . The method of  claim 1 , further comprising a temperature sensor in proximity to the heated repair area, wherein the repair area is heated to a temperature of at least about 325 degree Fahrenheit. 
     
     
         10 . The method of  claim 9 , wherein the heater is in operable communication with a controller, the controller controlling a level of power of the heater power generator based on a temperature measurement from the temperature sensor. 
     
     
         11 . The method of  claim 1 , wherein the heater is operated on at least one of propane and a natural gas. 
     
     
         12 . The method of  claim 1 , further comprising a remote control device configured to remotely control the asphalt processor. 
     
     
         13 . A method of repairing a void in an asphalt road surface, comprising:
 providing an asphalt restoration system comprising a heater, a heater power generator configured to communicate with the heater, and an asphalt processor;   transporting the asphalt restoration system to a repair site comprising the void in an asphalt road surface;   positioning the heater in proximity to the void;   heating asphalt in proximity to the void using the heater to produce a heated repair area;   re-positioning the heater away from the heated repair area;   tilling the heated repair area with the asphalt processor to break up the heated repair area;   leveling the heated repair area with a screed of the asphalt processor; and   compacting the heated repair area to create a repaired asphalt road surface with a substantially uniform surface;   wherein the asphalt processor is controlled remotely by a remote control device.   
     
     
         14 . The method of  claim 13 , wherein the asphalt processor comprises a tiller operable in a first position of use and a screed operable in a second position of use, wherein the tiller forms a beveled edge on opposing sides of the heated repair area. 
     
     
         15 . The method of  claim 14 , wherein the screed comprises at least two outwardly extending arm structures. 
     
     
         16 . The method of  claim 15 , wherein the heated repair area is heated to a temperature of at least 325 degree Fahrenheit. 
     
     
         17 . The method of  claim 16 , further comprising applying rejuvenation material to the heated repair area. 
     
     
         18 . An asphalt restoration system for repairing a void in an asphalt road surface, comprising:
 a heater configured to heat asphalt in proximity to the void to produce a heated repair area;   a generator configured to provide power to the heater;   an asphalt processor configured to: i) till the heated repair area with a tiller to break up the heated repair area, and ii) level the heated repair area with a screed, the asphalt processor configured to till with the tiller in a first position of use and configured to level with a screed in a second position of use;   a remote control device configured to remotely control the asphalt processor;   a road roller configured to pinch the heated repair area;   a vehicle with a loading arm, the vehicle configured to simultaneously transport the heater, the heater power generator, the asphalt processor, and the road roller; and   wherein the loading arm is configured to offload the heater from the vehicle.   
     
     
         19 . The system of  claim 18 , wherein the heater is in operable communication with a controller, the controller controlling a level of power of the heater power generator based on a temperature measurement from the temperature sensor. 
     
     
         20 . The system of  claim 19 , wherein the heater is an infrared heater configured to heat the heated repair area to a temperature of at least about 325 degree Fahrenheit.