PAVING APPARATUS, SYSTEM AND METHOD
20250361683 ยท 2025-11-27
Inventors
Cpc classification
E01C11/221
FIXED CONSTRUCTIONS
E01C3/003
FIXED CONSTRUCTIONS
E01C5/001
FIXED CONSTRUCTIONS
E01C5/003
FIXED CONSTRUCTIONS
International classification
E01C11/22
FIXED CONSTRUCTIONS
Abstract
A paving system includes a base layer; a sand layer of coarse angular sand above the base layer: a tile layer of porcelain tiles above the sand layer; and a metal edge restraint staked down along an edge of the paved surface. The base layer may include a reinforcement grid. A tile edging apparatus includes an elongated tile edge restraint strip having a longitudinal axis extending between a first end and a second end and a vertical axis extending perpendicular to the longitudinal axis and between an upper end and a lower end: a fixation projection extending out from a first lateral side of the edge restraint strip, the fixation projection including an aperture extending generally vertically therethrough; and a tile support projection extending out from a second lateral side of the edge restraint strip opposite the first lateral side, the tile support projection including a tile support surface.
Claims
1. A paving system comprising: (a) a base layer, the base layer including a compacted aggregate; (b) a sand layer of coarse angular sand above the base layer; (c) a tile layer of ceramic tiles above the sand layer, the tile layer forming a paved surface; and (d) a metal edge restraint staked down along an edge of the paved surface.
2. The paving system of claim 1, wherein the tiles of the tile layer rest on the coarse angular sand of the sand layer.
3. The paving system of claim 1, wherein the base layer includes a reinforcement grid.
4. The paving system of claim 3, wherein the reinforcement grid is a polymeric grid filled with a grid aggregate.
5. The paving system of claim 1, wherein the coarse angular sand is a washed sand.
6. The paving system of claim 1, further comprising tile spacers installed between the tiles, wherein the tiles are adhered to the tile spacers.
7. (canceled)
8. The paving system of claim 1, wherein the edge restraint includes tile supports extending under adjacent ones of the tiles.
9. The paving system of claim 8, wherein the adjacent ones of the tiles are adhered to the tile supports of the edge restraint.)
10. (canceled)
11. (canceled)
12. (canceled)
13. A method of paving installing the paving system of claim 1, comprising: (a) installing the base layer; (b) installing the sand layer of coarse angular sand above the base layer; (c) laying the layer of ceramic tiles above the sand layer to form the paved surface; and (d) staking the metal edge restraint along the edge of the paved surface.
14. (canceled)
15. (canceled)
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. A tile edging apparatus, comprising: (a) an elongated tile edge restraint strip having a longitudinal axis extending between a first end and a second end and a vertical axis extending perpendicular to the longitudinal axis and between an upper end and a lower end; (b) a fastener support extending out from a first lateral side of the edge restraint strip, the fastener support including an aperture extending generally vertically therethrough for receiving a fastener for fixing the tile edging apparatus in place; and (c) a tile support extending out from a second lateral side of the edge restraint strip opposite the first lateral side, the tile support including a tile support surface extending generally perpendicular to the vertical axis.
26. The apparatus of claim 25, wherein the edge restraint strip includes a tile restraint surface extending generally parallel to the longitudinal axis and to the vertical axis, and the tile support surface is generally perpendicular to the tile restraint surface.
27. (canceled)
28. The apparatus of claim 25, wherein the edge restraint strip and the fastener support are a single integral body.
29. (canceled)
30. (canceled)
31. The apparatus of claim 25, wherein the tile support is formed by a first leg of a generally L-shaped plate and the tile edge restraint strip includes a cavity to receive a second leg of the plate.
32. The apparatus of claim 31, wherein the tile support is repositionable along the longitudinal axis and is removeable.
33. The apparatus of claim 32, further comprising a plurality of the tile supports, wherein the tile supports are independent from one another.
34. The apparatus of claim 33, wherein the cavity is a longitudinally extending cavity, and the tile support is repositionable along the longitudinal axis by sliding the first leg along the cavity, and all the tile supports are all received in the same cavity.
35. (canceled)
36. The apparatus of claim 25, wherein an upper rim of the aperture is recessed below a top surface of the fastener support, the fastener support includes a spaced-apart pair of parallel ridges flanking the aperture and spaced from the aperture to receive a head of the fastener between the ridges. and each ridge includes a groove facing the other ridge, and the apparatus further comprising a body slidably received in the grooves between the ridges, the body overlying the aperture.
37. (canceled)
38. (canceled)
39. (canceled)
40. (canceled)
41. A tile edging apparatus, comprising: (a) an elongated tile edge restraint strip having a longitudinal axis extending between a first end and a second end and a vertical axis extending perpendicular to the longitudinal axis and between an upper end and a lower end; (b) a fastener support extending out from a first lateral side of the edge restraint strip, the fastener support including an aperture extending generally vertically therethrough for receiving a fastener for fixing the tile edging apparatus in place, an upper rim of the aperture recessed below a top surface of the fastener support; and (c) a blocking body moveable between a first position overlying the aperture to prevent vertical movement of the fastener above the aperture and a second position spaced from the aperture such that the fastener can be vertically inserted down through the aperture.
42. The apparatus of claim 41, wherein the fastener support includes a spaced-apart pair of parallel ridges flanking the aperture and spaced from the aperture to receive a head of the fastener between the ridges.
43. The apparatus of claim 42, wherein each ridge includes a groove facing the other ridge, and the blocking body is slidably received in the grooves between the ridges in the first position.
44. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
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DESCRIPTION OF EXAMPLE EMBODIMENTS
[0064] Various apparatuses, methods and compositions are described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover apparatuses and methods that differ from those described below. The claimed inventions are not limited to apparatuses, methods and compositions having all of the features of any one apparatus, method or composition described below or to features common to multiple or all of the apparatuses, methods or compositions described below. It is possible that an apparatus, method or composition described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus, method or composition described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicant(s), inventor(s) and/or owner(s) do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.
[0065] The terms an embodiment, embodiment, embodiments, the embodiment, the embodiments, one or more embodiments, some embodiments, and one embodiment mean one or more (but not all) embodiments of the present invention(s), unless expressly specified otherwise.
[0066] The terms including, comprising and variations thereof mean including but not limited to, unless expressly specified otherwise. A listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms a, an and the mean one or more, unless expressly specified otherwise.
[0067] As used herein and in the claims, two or more parts are said to be coupled, connected, attached, or fastened where the parts are joined or operate together either directly or indirectly (i.e., through one or more intermediate parts), so long as a link occurs. As used herein and in the claims, two or more parts are said to be directly coupled, directly connected, directly attached, or directly fastened where the parts are connected in physical contact with each other. None of the terms coupled, connected, attached, and fastened distinguish the manner in which two or more parts are joined together.
[0068] Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the example embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the example embodiments described herein. Also, the description is not to be considered as limiting the scope of the example embodiments described herein.
[0069] Referring now to
[0070] Paving system 100 includes a plurality of layers. The layers extend generally horizontally, layered along a vertical axis 108 perpendicular to the transverse axis 106 and the longitudinal axis 104. The layers are provided to, e.g., support one another and allow for drainage. It will be appreciated that each layer may be leveled, angled to allow for surface drainage, and/or formed with a generally uniform surface planarity.
[0071] The paving system 100 includes a base layer 110. Base layer 110 includes a compacted aggregate. In some embodiments, the base layer 110 comprises granular A-gravel, or crusher run limestone material (e.g., inch), and/or an equivalent aggregate material. It will be appreciated that any suitable base that includes compacted aggregate may be used. As exemplified, the base layer 110 may include a sub-base layer 112 of compacted aggregate 114, and a grid layer 116 which includes a reinforcement grid 118 filled with compacted aggregate 120. The grid layer 118 may reduce the necessary depth of the base layer 110. The reinforcement grid 118 is a geogrid having vertically extending lateral walls that form cells which are open through the top and bottom ends. The geogrid may be a modular grid formed of interlocking modules, such as modules interlocking along lateral walls with adjacent modules. The reinforcement grid 118 may be a polymeric grid.
[0072] The compacted aggregate 120 of the grid layer 116 may be the same type of aggregate as the compacted aggregate 114 of the sub-base layer 112 or a different type of aggregate (e.g., the aggregate 120 may be finer than the aggregate 114). For example, the compacted aggregate 114 of the sub-base layer 112 may be A-gravel or crusher run limestone material, and the aggregate 120 of the grid layer 116 may be self-compacting material (e.g., since the cells of the grid interfere with compaction), such as a self-compacting limestone (e.g., inch clear chip) or equivalent.
[0073] It will be appreciated that the compacted aggregate 114 and/or the compacted aggregate 120 may be compacted to any suitable degree of compaction. In some embodiments, the compacted aggregate 114 and/or the compacted aggregate 120 is compacted to a proctor density co-efficient of at least 75%, at least 85%, or at least 90%. It will be appreciated that the compacted aggregate 114 may be compacted more or less than the compacted aggregate 120.
[0074] In some embodiments, the base layer 110 includes at least one further layer. For example, in some embodiments the base layer 110 includes an intervening layer 122 between the sub-base layer 112 and the grid layer 116. The intervening layer 122 may be a different type of aggregate than the sub-base layer 112. For example, the intervening layer may be a layer of a finer aggregate than the aggregate 114 of the sub-base layer 112. The intervening layer 122 may be formed of compacted fine gravel. In some examples, the paving system 100 includes an intervening layer 122 of chip limestone (e.g., inch) or stone dust. The intervening layer 122 may be a skim coat.
[0075] The paving system 100 also includes a sand layer 130. The sand layer 130 is above the base layer 110. The sand layer 130 may be supported by the base layer 110. The sand layer 130 may rest on the base layer 110, as exemplified. The sand layer 130 is a layer of coarse angular sand, such as concrete sand. In some embodiments, the coarse angular sand is a washed sand. In some embodiments, the coarse angular sand is a manufactured sand and/or pit sand. The coarse angular sand may have an average particle size that is between 0.01 and 0.08 inches, 0.02 and 0.08 inches, 0.02 and 0.06 inches, or 0.02 and 0.04 inches. The sand layer 130 may have a thickness of between 0.25 and 2 inches, 0.5 and 1 inch, or about inch.
[0076] The paving system 100 includes a tile layer 140 above the sand layer. In some embodiments, as exemplified, the tile layer 140 rests on the sand layer 130. The tile layer 140 forms the paved surface 102. The paved surface 102 may be smaller than the horizontal extent of one or more of the sub layers. For example, one or more sub layers (e.g., the base layer 110) may extend out at least 2 inches, at least 5 inches, or at least 10 inches from the lateral edges of the paved surface 102.
[0077] It will be appreciated that any suitable tiles may be used. In some embodiments, the tile layer 140 includes ceramic tiles 144 (also referred to as ceramic pavers). For example, the ceramic tiles 144 may be porcelain tiles. The ceramic tiles 144 may be arranged in a regular grid to form the paved surface 102. In some embodiments, the tiles 144 are two foot by four foot tiles. It will be appreciated that other sizes may also or alternatively be used.
[0078] Ceramic tiles 144, particularly porcelain tiles, provide a wear-resistant and aesthetically pleasing surface. Tiles, such as ceramic tiles and particularly porcelain tiles, may be susceptible to breakage. The paved surface 102 may be used by heavy vehicular traffic, and the sand layer 130 assists in preventing tile breakage. The sand layer 130 may act as a cushioning layer. The coarse angular sand may provide many points of contact against the tiles 144. The coarse angular sand may be compressed when weight is applied to a tile above the sand, and then return to an uncompressed distribution when weight is removed from the tile above the sand (i.e., unlike smooth sand, which may stay compressed or stay more compressed than coarse angular sand). It will be appreciated that in some embodiments one or more intervening layer may be between the sand and the tiles, e.g., if the intervening layer does not interfere with the cushioning function (e.g., a layer of geotextile).
[0079] Referring now to
[0080] It will be appreciated that an edge restraint 150 assists in holding the paved surface 102 together. The edge restraint 150 may assist in preventing lateral (i.e., perpendicular to the vertical axis 108) shifting of the tiles 144. In some embodiments, the edge restraint 150 is a metal edge restraint. For example, the edge restraint 150 may be formed of aluminum (e.g., an extruded aluminum strip). A metal edge restraint may provide for a durable, easy to work with, easy to manufacture, and/or aesthetically pleasing edge restraint. An edge restraint 150, particularly a metal edge restraint, may result in additional risk of tile breakage when weight is applied to the tiles 144. However, as discussed above, a sand layer 130 may assist in preventing tile breakage. The metal edge restraint 150 combined with the layer of coarse angular sand may assist in allowing for a metal-edged paved surface 102 for supporting heavy vehicular traffic without breakage.
[0081] It will be appreciated that the edge restraints 150 may be of any suitable shape. In some embodiments, the edge restraint 150 is part of an edging apparatus 240 which includes a tile support 156 (e.g., as described further below) extending under an adjacent one 158 of the tiles 144. The tile support 156 may provide more stability for the tile edging 150, may help to prevent rollout of the tile edging 150, may provide a place for an adhesive to be applied, and/or may aid in preventing the tile edging 150 being hammered below the bottom surface of the tile 144 when stakes 154 are being hammered into the edging 150. For example, the adjacent ones 158 of the tiles 144 may be adhered to the edging 150. For example, an adhesive may be applied to the tile support 156 and/or the tile 144 during installation, and the tile 144 placed against the tile support 156.
[0082] In some embodiments, as exemplified, the paving system 100 also includes tile spacers 160 installed between tiles 144. It will be appreciated that any suitable tile spacers may be used. As exemplified, in some embodiments the tile spacers 160 each include a support base 162 forming a tile receiving surface 164 (e.g., a generally planar surface) on which a tile 144 may rest, and spacing projections 166 extending out (e.g., perpendicular) from the tile receiving surface 164 to abut lateral edges of the tiles 144 to keep the lateral edges of the tiles 144 from touching. The tile spacers 144 may be spacer discs (e.g., as exemplified in
[0083] In some embodiments, the paving system 100 also includes polymeric sand 170 filling joints 172 between the tiles 144.
[0084] Referring now to
[0085] At step 204, method 200 includes installing a base layer (e.g., base layer 110). The base layer may be installed in the excavated area excavated in step 202. The base layer includes a compacted aggregate. The base layer may include a layer of compacted aggregate and a grid layer including a reinforcement grid (e.g., grid 118) filled with compacted aggregate. Step 204 may include compacting the aggregate (e.g., the aggregate of the layer of compacted aggregate) to a proctor density co-efficient of at least 75%, at least 85%, or at least 90%. Step 204 may include installing a skim coat of fine aggregate between the compacted aggregate layer and the grid layer, such as installing a skim coat of fine inch chip limestone or stone dust. Installing a layer of aggregate may include using leveling and/or screeding tools to, e.g., achieve a graded layer.
[0086] Step 204 may include leveling the base layer (e.g., the layer of compacted aggregate and/or the grid layer), and may include ensuring the base layer is level, allowing for surface drainage, and that the base layer has a strong degree of uniform surface planarity. Step 204 may include eliminating any high spots and filling any low spots. The base layer may be built up to a level of between 2 and 5 inches, 3 to 4 inches, or about 3.5 inches below the desired paved surface.
[0087] Method 200 includes, at step 206, installing a sand layer (e.g., sand layer 130) above the base layer. The sand layer 130 may be resting on the base layer 130. The sand layer is a layer of coarse angular sand, such as the coarse angular sand discussed above. Step 206 may include screeding a layer of coarse angular sand. The sand layer may have a thickness of between 0.25 and 2 inches, 0.5 and 1 inch, or about inch. Installing the sand layer may include using leveling and/or screeding tools to, e.g., achieve a graded layer.
[0088] At step 208, the method 200 includes laying tiles (e.g., tiles 144) above the sand layer to form a paved surface (e.g., surface 102). Step 208 may include laying the tiles directly on the sand layer. Step 208 may include installing tile spacers (e.g., spacers 160) between the tiles. In some embodiments, step 208 includes adding adhesive to the tile spacers to adhere the tiles to the tile spacers. For example, step 208 may include adding adhesive to a spacer and/or a tile and then bringing the spacer and tile together in position to form the paved surface.
[0089] At step 210, the method 200 includes staking an edge restraint (e.g., edge restraint 150) along an edge of the paved surface. The edge restraint may be a metal edge restraint (e.g., made from aluminum).
[0090] In some embodiments, step 210 includes positioning a tile support (e.g., tile support 156) of the edge restraint under a tile of the tiles. In some embodiments, step 210 includes positioning a plurality of independent tile support projections under a tile, e.g., each tile support projection under a different portion of the tile. For example, where a tile includes a two foot long edge against the edge restraint step 210 may include positioning two tile support projections under the tile, and where a tile includes a four foot long edge against the edge restraint step 210 may include positioning three tile support projections under the tile.
[0091] In some embodiments, step 210 includes adding adhesive to the tile support projection and/or the tile to adhere the tile to the tile support projection. For example, adhesive may be added to tile support projection and/or the bottom of the tile and then the tile may be laid on the tiles support projection.
[0092] Method 200 also includes, at step 212, filling joints between the tiles with polymeric sand.
[0093] Referring now to
[0094] The edge restraint strip 180 has a longitudinal axis 184 extending between a first end 186 and a second end 188. The edge restraint strip 180 has a vertical axis 190 extending perpendicular to the longitudinal axis 184 and between an upper end 192 and a lower end 194. The edge restraint strip 180 has a transverse axis 220 extending between a first lateral side 222 and a second lateral side 224 opposite the first lateral side 222. The transverse axis 220 is perpendicular to the longitudinal axis 184 and to the vertical axis 190.
[0095] As exemplified, the edge restraint strip 180 includes a tile restraint surface 230. The tile restraint surface 230 extends generally parallel to the longitudinal axis 184 and to the vertical axis 190. The tile restraint surface 230 is provided to hold the tiles 144 in place. The exemplary surface 230 is on the second lateral side 224, but it will be appreciated that the tile restraint surface 230 may be on either lateral side. As exemplified, the strip 180 may have a generally vertical and longitudinal surface on each lateral side, e.g., to allow the strip to be arranged with either side against the tiles 144. The strip 180 may be a generally flat strip, as in the exemplary embodiment. The strip 180 may be bendable (e.g., as in
[0096] As exemplified in
[0097] In some embodiments, an angle 232 between the fastener support 182 (e.g., a plane perpendicular to an axis of the aperture) and the tile support surface 230 is generally fixed. The angle 232 may be about 90 degrees, such as 70 to 110 degrees, or 80 to 100 degrees. In some embodiments, the edge restraint strip 180 and the fastener support 182 are a single integral body (e.g., an aluminum body). As exemplified, the fastener support 182 may be a flange projecting from the strip 180.
[0098] Referring now to
[0099] In some embodiments, an angle 246 between the tile support surface 244 and the tile restraint surface 230 is generally fixed. The angle 246 may be about 90 degrees, such as 70 to 110 degrees, or 80 to 100 degrees. As exemplified, the tile support 156 may be a removeable body. The tile support 156 may be removably received in a longitudinally extending cavity 250 (
[0100] Referring now to
[0101] Referring again to
[0102] As exemplified, the cavity 250 may be open through the first end 186 and/or the second end 188. The tile support 156 may be inserted into the cavity 250 longitudinally from the first end 186 or the second end 188.
[0103] In some examples, the cavity 250 is shaped to prevent the tile support 156 from being removed vertically. As exemplified in
[0104] In some embodiments, the tile edging apparatus 240 includes a plurality of the tile supports 156. The tile support 156 may be independent from one another. The plurality of tile supports 156 may be held in a common cavity 250. For example, the longitudinally extending cavity 250 may hold two or more tile supports 156 end to end or spaced from one another along the longitudinal axis 184.
[0105] Referring now to
[0106] Referring now to
[0107] The fixation flange 1182 may include a spaced-apart pair of parallel ridges 1286 flanking the aperture 1226 and spaced from the aperture 1226 to receive a head 1288 of the fastener between the ridges 1286. The ridges 1286 may provide a surface on which tile or other material can rest without resting on the head 1288 of the fastener 1152. In some embodiments, each ridge may include a groove 1290 facing the other ridge. The blocking body 1280 may be slidably received in the grooves 1290 between the ridges 1286, the body 1280 overlying the aperture 1226 as exemplified in
[0108] As used herein, the wording and/or is intended to represent an inclusive-or. That is, X and/or Y is intended to mean X or Y or both, for example. As a further example, X, Y, and/or Z is intended to mean X or Y or Z or any combination thereof.
[0109] While the above description describes features of example embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. For example, the various characteristics which are described by means of the represented embodiments or examples may be selectively combined with each other. Accordingly, what has been described above is intended to be illustrative of the claimed concept and non-limiting. It will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the invention as defined in the claims appended hereto. The scope of the claims should not be limited by the preferred embodiments and examples, but should be given the broadest interpretation consistent with the description as a whole.