METHOD OF INSTALLING A MASTIC JOINT

Abstract

A method of installing mastic joints on a paved surface is described. The method of installing mastic joints may be used as a repair (i.e. erosion of the paved surface at the joint) or in connection with a new installation of the paved surface. The method of installing mastic joints made include installation with joints that have a structure at the joint terminus. The method produces a joint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic joint that is thermally resistant and produces longevity of use.

Claims

1. A method of installing a mastic joint that is water, fuel, salt, and temperature resistant at a paved surface, the method comprising: cutting the paved surface based on predetermined parameters forming a joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; preparing the joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the mastic joint.

2. The method of claim 1, wherein the paved surface is a surface material of concrete.

3. The method of claim 1, wherein the paved surface is a surface material of asphalt.

4. The method of claim 1, wherein preparing the joint comprises applying denatured alcohol to the adjacent paved surface.

5. The method of claim 2, wherein the minimum depth is equal to the depth of the paved surface.

6. The method of claim 1, wherein the width is from 0.9525 to 4.0 centimeters.

7. The method of claim 1, wherein the width is from 0.9525 to 3.175 centimeters.

8. The method of claim 1, further comprising cutting the paved surface based on predetermined parameters forming a second joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the second joint; preparing the second joint; applying hot mastic to the second joint to install a second mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the second mastic joint, wherein the application forms a mastic joint intersection between the mastic joint and the second mastic joint.

9. A method of installing a mastic joint that is water, fuel, salt, and temperature resistant at a paved surface where the mastic join has a structure at its terminus, the method comprising: forming the paved surface based on predetermined parameters forming a joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; preparing a joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 25% to 40% of the mastic joint.

10. The method of claim 9, wherein the paved surface is a surface material of concrete.

11. The method of claim 9, wherein the paved surface is a surface material of asphalt.

12. The method of claim 9, wherein preparing the joint comprises applying denatured alcohol to the adjacent paved surface and structure.

13. The method of claim 10, wherein the minimum depth is equal to the depth of the paved surface.

14. The method of claim 9, further comprising forming the paved surface based on predetermined parameters forming a second joint, the predetermined parameters comprising a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the second joint; preparing the second joint; applying hot mastic to the second joint to install a second mastic joint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 20% to 40% of the second mastic joint, wherein the application forms a mastic joint intersection between the mastic joint and the second mastic joint.

15. The method of claim 9, wherein the width is from 0.9525 to 4.0 centimeters.

16. The method of claim 9, wherein the width is from 0.9525 to 3.175 centimeters.

17. A mastic joint of a paved surface, the mastic joint comprising: parameters that provide water, fuel, salt and thermal resistance, where the parameters comprise a width from 0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimum surface area that contacts the adjacent paved surface and subbase from 7.62 square centimeters as measured based on a 2.54 centimeter vertical cross section of the joint; wherein the mastic joint is produced by making a joint of the paved surface to the parameters; preparing a joint; applying hot mastic to the joint to install the mastic joint, the applying comprising mixing a mastic base with a bulking stone, where the bulking stone is from 20% to 35% of the mastic joint.

18. The mastic joint of claim 17, wherein the width is from 0.9525 to 4.0 centimeters.

19. The mastic joint of claim 17, wherein the width is from 0.9525 to 3.175 centimeters.

20. The method of claim 4, wherein preparing the joint further comprises applying a primer to the adjacent paved surface.

Description

FIGURES

[0027] FIG. 1 is a method of installing a mastic joint for a paved surface.

[0028] FIG. 2 represents a mastic joint along the length of the mastic joint.

[0029] FIG. 3 represents a vertical cross section of a mastic joint showing the mastic joint is substantially level with the adjacent paved surface.

[0030] FIG. 4 represents mastic joints along the length of each respective joint showing an intersection of the mastic joints.

DETAILED DESCRIPTION

[0031] As used herein, the following terms have the accompanying defined meaning:

[0032] “Mastic” means a material for hot application that is a polymer binder with factory blended fillers, fine aggregate, and fibers, including reinforcing (bulking) stone (e.g. granite aggregate) having the capability of (1) withstanding motor vehicle (including semis) weight without deformation of the mastic, (2) adhering to surface material and any structure at the terminus of a joint, (3) preventing melting or deteriorating of the surface material or the plastic of any structure at the terminus of a joint, (4) resisting water, fuel, and salt (i.e. the mastic resists infiltration by water, fuel, salt, and mixtures thereof), (5) resisting thermal fluctuations (i.e. the mastic remain flexible under temperature changes to maintain adhesion to the surface material).

[0033] “Bulking stone” means a fine aggregate that provides volume when added to the mastic, where the fine aggregate is from 0.3175 to 0.635 centimeters (0.125 to 0.25 inches). The bulking stone may be of any material that is non-reactive with the mastic, such as, granite, quartz, limestone, pea gravel, and the like.

[0034] “Joint” means the area between portions of a paved surface.

[0035] “Surface material” means the material of a paved surface and includes concrete or asphalt.

[0036] “Structure” means a fabricated installation that includes steel and may include concrete, where the steel and/or concrete is in contact with the surface material concrete or asphalt. For example, structures include manholes, spill buckets, and fuel islands, where the fuel island includes canopy column(s), fuel pump island, and bumper posts.

[0037] A method of installing mastic joints on a paved surface is described. The method of installing mastic joints may be used as a repair (i.e. erosion of the paved surface at the joint) or in connection with a new installation of the paved surface. The method of installing mastic joints made include installation with joints that have a structure at the joint terminus. The method produces a joint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic joint that is thermally resistant (i.e. the mastic remains flexible at varying temperatures such that adherence of the mastic to the adjacent surface material is maintained). In repairs, the mastic joint of the method provides longevity of use of at least one year and up to 5 years prior to any repair or replacement. In new installations, the mastic joint provides longevity of use of at least 1 year and up to 10 years prior to any repair or replacement when in regions having a freeze and thaw cycle similar to that of the Midwest region. Finally, the method of installing a mastic joint does not affect the structural integrity of the adjacent or surrounding paved surface, where the adjacent or surrounding surface material does not require repair or replacement sooner than if the method had not been deployed.

[0038] FIG. 1 represents a method 100 of installing a mastic joint on a paved surface. In 102, the paved surface is prepared. When installing a mastic joint as a repair, the paved surface is cut with a saw or router configured for cutting the surface material type according to predetermined parameters of the mastic joint. When installing a mastic joint as part of a new installation, the paved surface may be prepared as described in connection with a repair, or the surface material of the paved surface is prepared (e.g. concrete is poured) according to predetermined parameters of the mastic joint. The parameters of the mastic joint include placement of the joint to provide that the joint is water, salt, fuel (including mixtures of water, salt, and fuel thereof) and thermally resistant, which provide longevity of use as erosion is significantly delayed or prevented by such resistances. The parameters of the mastic joint also require the mastic joint to not adversely affect the adjacent and surrounding surface material of the paved surface. The parameters of the mastic joint further provide placement of the joint to prevent cracking and peeling of the mastic from the joint.

[0039] The parameters of the mastic joint that provide water, salt, fuel (and mixtures thereof) and thermal resistance are a width and depth of the mastic joint. The width of the mastic joint is from 0.9525 to 5.080 centimeters (0.375 to 2.00 inches (in.)). Preferably, the width of the mastic joint is from 0.9525 to 4.0 centimeters (0.375 to 1.5748 in.), and most preferably, the width of the mastic joint is from 0.9525 to 3.175 centimeters (0.375 to 1.25 in.). The width (in connection with the depth) ensures that there is sufficient area between the adjacent surface material to install the mastic joint according to the method 100 for adherence of the mastic joint to the adjacent surface material, including the surface material or subbase below the joint. For example, the width 204 of the mastic joint of FIGS. 2 and 4 is from 0.9525 to 3.175 centimeters for the mastic joint 200.

[0040] The width is also determined by correcting any existing erosion while not exceeding the maximum width of 5.080 centimeters (2.00 inches), while selecting a width as close to the preferred widths as possible to still correct the erosion. For example, in a repair if erosion of the joint is of a width greater than 2.54 cm (1 in.) a width greater than 2.54 cm and less than 5.080 centimeters (2.00 inches) is selected, most preferably of 3.175 cm (1.25 in.) if this preferred width will remove erosion of the paved surface. If the most preferred width will not remove erosion of the paved surface the preferred width is evaluated to determine if this preferred width will remove erosion.

[0041] The parameter of depth of the mastic joint provides water, fuel, salt, and thermal resistance is determined based on the surface material depth. The mastic joint may be full depth of the paved surface (i.e. the depth down to the subbase). The mastic joint may be partial depth of the paved surface. In instances where the mastic joint is partial depth, the minimum depth of the mastic is at least and including 2.54 centimeters (1 inch) to provide the water, fuel, salt and thermal resistances. When the mastic joint is used as a repair, partial depth repair is not done when the surface material that would be directly below the mastic joint shows signs of erosion or damage, such that the surface material directly below the joint must be intact without erosion for a partial depth replacement. Preferably, when the mastic joint is installed as part of a new installation, the mastic joint depth is at least from 2.54 centimeters (1 inch) or greater. For example, FIG. 3 shows the mastic depth 206 of the joint 200.

[0042] The parameter of width and depth must also provide a minimum surface area of contact with the adjacent paved surface to ensure proper adhesion of the mastic to the paved surface to prevent water, salt, fuel, and combinations thereof from infiltrating the seam between the mastic joint and the paved surface. Preferably, the minimum surface area of all sides of the mastic joint (both sides and bottom) in contact with the adjacent paved surface or subbase, as measured on a 2.54 centimeters (1 inch) cross section is 7.62 square centimeters (3 square inches). Thus, the width and depth of the mastic joint must be determined to meet this minimum surface area. For example the sides making up the surface area are represented by 308 in FIG. 3.

[0043] The parameter of levelness of the mastic joint with the paved surface provides protection from cracking and peeling of the mastic joint from the joint. Levelness of the mastic joint means that the mastic joint is substantially flush with the paved surface, where substantially means that the mastic joint extends from 0 to 5 millimeters above the paved surface. For example, FIG. 3 represents the joint 200 being substantially flush with the paved surface 202, where the joint 200 is flush (level with) the paved surface.

[0044] In 104, a joint is prepared for receiving the mastic. The joint preparation may include ensuring the subbase is level at the predetermined depth, which may include removing debris, adding subbase material and/or smoothing the subbase. Preparation of the joint may further include removal of any rust, dirt, or debris from the adjacent paved surface, such as through sandblasting.

[0045] Preparation of the joint further includes ensuring the joint and adjacent paved surface is dry and the pores of the surface material and structure are clean to create binding elasticity between the mastic and the surface material and structure. Preparation of the joint includes application of denatured alcohol, which may be followed by application of a primer (e.g. mastic primer, water-based elastomeric coating and sealant that is acrylic resin) to the adjacent paved surface and structure to promote adherence of the mastic to the adjacent paved surface. Preparation of the joint provides for maximum adherence of the mastic to the adjacent paved surface and subbase, while using the least amount of mastic, thus increasing the efficiency of the installation process.

[0046] In 106, the mastic is applied to the prepared joint forming the mastic joint. The mastic is applied in accordance with mastic manufacturer specifications. The application of the mastic includes applying the mastic to the joint hot, while mixing the mastic base (i.e. mastic without bulking stone added) with bulking stone, where from 20%-40% of the mastic is bulking stone (i.e. bulking stone percentage). More preferably the bulking stone is from 20-35% of the mastic. The percentage of bulking stone in the mastic is dependent on the width and volume of the joint, where a joint having a greater width or volume requires a higher percentage of bulking stone of the mastic. Preferably, the mastic is not placed in lifts exceeding 7.62 centimeters (3 inches) in height to speed with cooling. Applying the mastic may include phased application. Cooling of the mastic in partial depth applications to cure for receiving traffic takes approximately 1 hour for foot traffic and all vehicle traffic. Cooling of the mastic in full depth application to cure for receiving foot traffic takes approximately 30 minutes to 2 hours for foot traffic and all vehicle traffic.

[0047] Preferably, the mastic is applied to the entire length of the joint, including where joints intersect. For example, as represented in FIG. 4 the mastic joints are applied to the entire length of the joint, including formation of a mastic joint intersection 406. Applying mastic along the entire length of the joint reduces likelihood and speed of erosion of the adjacent paved surface.