PAVING SYSTEMS AND METHODS OF FORMING A PAVING SYSTEM

Abstract

Outdoor paving systems and methods of installing paving systems are described herein. The paving systems have a drainage layer of drainage stones. The drainage layer has a top surface and a bottom surface. The paving systems also have a paving layer abutting the drainage layer and covering the top surface of the drainage layer. The paving layer includes a permeable material. The permeable material includes an aggregate material bonded together by an elastomeric binder. The paving layer forms a containment field surrounding a perimeter of the drainage layer to restrict movement of the drainage stones of the drainage layer outwardly towards the surrounding ground surface.

Claims

1. A paving system comprising: a drainage layer of drainage stones, the drainage layer having a top surface and a bottom surface; and a paving layer abutting the drainage layer and covering the top surface of the drainage layer, the paving layer comprising a permeable material, the permeable material including an aggregate material bonded together by an elastomeric binder, the paving layer forming a containment field surrounding a perimeter of the drainage layer to restrict movement of the drainage stones of the drainage layer outwardly towards a surrounding ground surface.

2. The system of claim 1, wherein the containment field has a height extending from an upper containment surface that is higher than the top surface of the drainage layer downwardly to a lower containment edge that is below the ground surface.

3. The system of claim 2, wherein the height of the containment field is one inch or greater.

4. The system of claim 1, wherein the top surface of the drainage layer is higher than a top surface of the ground surrounding the drainage layer.

5. The paving system of claim 1, wherein the containment field comprises the permeable material.

6. The paving system of claim 1, wherein the paving layer consists of the permeable material.

7. The paving system of claim 1, wherein the paving layer comprises the permeable material and one or more paving stones.

8. The paving system of claim 6, wherein the one or more paving stones are resting on the top surface of the drainage layer or the permeable material and each paving stone has: a top surface; a bottom surface opposed to the top surface; and a plurality of vertical edges extending between the top surface and the bottom surface, a plurality of vertical edges of adjacent paving stones defining each vertical channel of the series of vertical channels; and the permeable material is positioned within the series of vertical channels.

9. The system of claim 7, wherein the permeable material is adhered to a portion of the bottom surface of each paving stone.

10. The system of claim 1, wherein the elastomeric binder is a diphenylmethane diisocyanate-based polyurethane.

11. The system of claim 10, wherein the elastomeric binder comprises about 5 percent by volume of the permeable material.

12. The system of claim 1, wherein aggregate of the aggregate material has a distribution of particle sizes between 0.20 inches and 0.50 inches.

13. A method of installing a paving system, the method comprising: removing organic soil from a selected location for installing the paving system; placing a drainage layer of drainage stones on the ground, the drainage layer having a top surface and a bottom surface; placing a paving layer onto the top surface of the drainage layer, the paving layer comprising a permeable material, the permeable material including an aggregate material bonded together by an elastomeric binder, the paving layer forming a containment field surrounding a perimeter of the drainage layer to restrict movement of the drainage stones of the drainage layer outwardly towards the surrounding ground surface; and allowing the elastomeric aggregate mixture to cure.

14. The method of claim 13, wherein the containment field has a height extending from an upper containment surface that is higher than the top surface of the drainage layer downwardly to a lower containment edge that is below the ground surface.

15. The method of claim 14, wherein the height of the containment field is one inch or greater.

16. The method of claim 13, wherein the top surface of the drainage layer is higher than a top surface of the ground surrounding the drainage layer.

17. The method of claim 13, wherein the containment field comprises the permeable material.

18. The method of claim 13, wherein the elastomeric binder is a diphenylmethane diisocyanate-based polyurethane and the elastomeric binder comprises about 5 percent by weight of the permeable material.

19. The method of claim 13, wherein the step of placing the paving layer onto the top surface of the drainage layer includes placing one or more paving stones on the top surface of the drainage layer, each paving stone having: a top surface; a bottom surface opposed to the top surface; and a plurality of vertical edges extending between the top surface and the bottom surface, a plurality of vertical edges of adjacent paving stones defining each vertical channel of the series of vertical channels, each vertical channel having a width greater than 0.50 inches; and placing the permeable material within the series of vertical channels, aggregate of the aggregate material having an average particle size greater than 0.20 inches.

20. A method of building a stairway, the method comprising: removing organic soil from a selected location for building the stairway, the selected location being a sloped surface; placing a drainage layer of drainage stones on the ground, the drainage layer having a top surface and a bottom surface; positioning a plurality of first forms on the top surface, a rear surface and a top edge of each first form defining a respective first cavity with the sloped ground surface, each first form being level and vertically supported by at least one support member driven into the ground; positioning a plurality of second forms at a respective position where each second form is spaced apart from a respective first form, a rear surface of each second form and a front surface of each respective first form defining a second cavity therebetween, the second form: being coupled to the first form; having an uppermost edge that is higher than the uppermost edge of the first form; and having a lowermost edge vertically spaced apart from the sloped ground surface to form a gap between the lowermost edge and the sloped ground surface; filling the first cavity with an aggregate material to a height of an uppermost edge of the first form with an aggregate material; pouring an elastomeric aggregate composition into each second cavity to form a riser of each step of the stairway, the elastomeric aggregate composition passing through the gap between the lowermost edge of the second form and the sloped ground surface; pouring additional elastomeric aggregate composition onto a top surface of the aggregate material and over the uppermost edge of the first form to meet with the elastomeric aggregate composition filling the second cavity and form a paving layer; allowing the elastomeric aggregate composition to cure; and removing the second form.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] For a better understanding of the various embodiments described herein, and to show more clearly how these various embodiments may be carried into effect, reference will be made, by way of example, to the accompanying drawings which show at least one example embodiment, and which are now described. The drawings are not intended to limit the scope of the teachings described herein.

[0030] FIG. 1 is a photograph showing a finished stairway and a finished patio according to embodiments described herein.

[0031] FIG. 2A is a top view schematic of the patio of FIG. 1.

[0032] FIG. 2B is a cross-section view of the patio of FIG. 1.

[0033] FIG. 2C is a side view of a magnified portion of the patio of FIG. 1.

[0034] FIG. 2D is a cross-section view of a patio according to another embodiment described herein.

[0035] FIG. 3 is a photograph showing aggregate of an elastomeric aggregate composition, according to at least one embodiment described herein.

[0036] FIG. 4A is a photograph showing installation of drainage stones as a drainage layer, according to at least one embodiment described herein.

[0037] FIG. 4B is a photograph showing levelling one or more paving stones as a second step of constructing a stairway, according to at least one embodiment described herein.

[0038] FIG. 4C is another photograph showing levelling one or more paving stones as the second step of constructing a stairway.

[0039] FIG. 4D is a photograph showing a set of paving stones positioned on a drainage layer, according to at least one embodiment described herein.

[0040] FIG. 4E is a photograph showing forming a containment field around a set of paving stones, according to at least one embodiment described herein.

[0041] FIG. 4F is a photograph showing mixing of the elastomeric aggregate composition, according to at least one embodiment described herein.

[0042] FIG. 4G is a photograph showing placing the elastomeric aggregate composition in vertical channels between paving stones, according to at least one embodiment described herein.

[0043] FIG. 4H is a photograph showing levelling the elastomeric aggregate composition in vertical channels between paving stones, according to at least one embodiment described herein.

[0044] FIG. 4I is a photograph showing a paving stone system with the elastomeric aggregate composition within most of the vertical channels thereof.

[0045] FIG. 5A is a photograph of a finished stairway, according to at least one embodiment described herein.

[0046] FIG. 5B is a side view of the stairway of FIG. 5A.

[0047] FIG. 5C is a magnified side view of a portion of the stairway of FIG. 5A.

[0048] FIG. 5D is a magnified side view of another portion of the stairway of FIG. 5A.

[0049] FIG. 6A is a photograph of a selected location for a stairway having had organic soil thereof removed, according to at least one embodiment described herein.

[0050] FIG. 6B is another photograph of a selected location for a stairway having had organic soil thereof removed

[0051] FIG. 6C is a photograph showing installation of forms at the selected location for constructing a stairway.

[0052] FIG. 6D is a photograph showing forms being secured to a support member in the ground, according to at least one embodiment described herein.

[0053] FIG. 6E is a photograph showing a step having a first and second form spaced apart from each other by a cavity, according to at least one embodiment described herein.

[0054] FIG. 6F is another photograph showing a step having a first and second form spaced apart from each other by a cavity, according to at least one embodiment described herein.

[0055] FIG. 6G is a photograph showing mixing of the elastomeric aggregate composition, according to at least one embodiment described herein.

[0056] FIG. 6H is a photograph showing a gap beneath the second form, according to at least one embodiment described herein.

[0057] FIG. 6I is a photograph showing installation of the elastomeric aggregate composition into the cavity between the first and second form, according to at least one embodiment described here.

[0058] FIG. 6J is a photograph showing a stairway having the elastomeric aggregate composition installed on treads of the stairway, according to at least one embodiment described herein.

[0059] FIG. 6K is another photograph showing a stairway having the elastomeric aggregate composition installed on treads of the stairway, according to at least one embodiment described herein.

[0060] FIG. 6L is another photograph showing a stairway having the elastomeric aggregate composition installed on treads of the stairway, according to at least one embodiment described herein.

[0061] FIG. 6M is a photograph showing a finished stairway having the second form removed, according to at least one embodiment described herein.

[0062] FIG. 7A is a top view of a paving, according to at least one embodiment described herein.

[0063] FIG. 7B is a side view of the paving of FIG. 7A.

[0064] FIG. 7C is a side view of a retaining wall paving, according to at least one embodiment described herein.

[0065] FIG. 7D is a side view of another retaining wall paving, according to at least one embodiment described herein.

[0066] FIG. 8A is a photograph showing a gravel driveway having a containment field formed by an elastomeric aggregate composition, according to at least one embodiment described herein.

[0067] FIG. 8B is another photograph of a gravel driveway having a containment field formed by an elastomeric aggregate composition, according to at least one embodiment described herein.

[0068] FIG. 9 is a photograph showing a paving of an elastomeric aggregate composition at a top of a stairway, according to at least one embodiment described herein.

[0069] FIG. 10 is a photograph showing a paving of an elastomeric aggregate composition in front of a garage door, according to at least one embodiment described herein.

[0070] FIG. 11 is a photograph showing a paving of an elastomeric aggregate composition in front of a door, according to at least one embodiment described herein.

[0071] FIG. 12 is a photograph showing a paving of an elastomeric aggregate composition around a field of tiles, according to at least one embodiment described herein.

DETAILED DESCRIPTION

[0072] Various systems, apparatus, compositions and processes will be described below to provide an example of one or more embodiments. No embodiment described below limits any claimed embodiment and any claimed embodiment may cover systems, apparatus, compositions or processes that differ from those described below. The claimed embodiments are not limited to systems, apparatus, compositions or processes having all of the features of any one system, apparatus, composition or process described below or to features common to multiple or all of the systems, apparatus, compositions or processes described below. It is possible that a system, apparatus, composition or process described below is not an embodiment of any claimed embodiment. Any embodiment disclosed 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 applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such embodiment by its disclosure in this document.

[0073] Outdoor paving systems, including but not limited to patios and stairways, and methods of installing outdoor paving systems are described herein.

[0074] Herein, the term paving system refers to two layers of material(s) working together to provide a firm surface for travel. The firm surface may be level, such as but not limited to the firm surface of a walkway, or may be uneven, such as the firm surface of a stairway. The paving systems described herein generally include a top layer of a hard material forming the firm surface that that covers an underlying layer of aggregate stone or a material like stone.

[0075] Herein, the term drainage layer refers to the underlying layer of the paving systems described herein.

[0076] Herein, the term paving or paving layer refers to the top layer having the hard material forming the firm surface.

[0077] Herein, the term paving stone means a singular, large, flat piece of stone, tile or other similar material used in a paving.

Outdoor Paving Systems

[0078] In accordance with a broad aspect, paving systems are described herein. These paving systems are intended to be installed outdoors on a ground and provide rigidity that enables the paving system to support foot traffic and/or vehicular traffic. The paving systems described herein are flexible to adapt and/or accommodate to changing underground conditions, including but not limited to ground movement that is caused by freezing and thawing of the ground in cold climate regions. The paving systems described herein are also permeable to provide for water to evacuate the system and pass downwardly and outwardly therefrom and permeate into the ground under and around the paving system. These paving systems are appropriate for travel, for example, on-ground applications such as a patio, a sidewalk, a walkway, a pathway, a driveway or a parking lot, among other surfaces.

[0079] Turning now to the drawings, FIG. 1 is a picture showing an example of a finished patio 100 and a finished stairway 200, according to embodiments described herein. Each of patio 100 and stairway 200 are example embodiments of a paving system described herein.

[0080] Each paving system described herein includes a drainage layer 101 underlying a paving layer 103. Different embodiments of each of these layers is described in greater detail below.

Drainage Layer

[0081] Drainage layer 101 includes drainage stones. In some embodiments, drainage layer 101 consists of drainage stones. In some embodiments, drainage layer 101 includes drainage stones as well as other stones to provide for water to permeate therethrough. Drainage layer 101 readily accepts and then disperses water (such as rain, snow melt, etc.) to the ground 107 below the patio 100.

[0082] Herein, the term drainage stones refers to a porous gravel material designed to manage the flow of water therethrough. Drainage stones can come in a variety of sizes, such as but not limited to having an average diameter in a range of about of an inch to 1 inch, or in a range of about 3/16 to of an inch, or of about of an inch, or of about of an inch, or of about of an inch, or of about of an inch, or of about of an inch, or of about of an inch, or of about of an inch, or of about 1 inch.

[0083] In at least one embodiment, drainage layer 101 is an unpacked layer of drainage stones, where each of the stones within the layer is substantially unadhered to neighboring or adjacent drainage stones. For instance, in traditional construction methods or methods of installing pavings, it is essential to have a strong, solid foundation that provides stability and support for upper layers. Herein, the drainage layer 101 is intended to be a loose layer that allows water to permeate down through. Generally, drainage layer 101 is more flexible than, for instance, concrete, and able to flex slightly upwardly and downwardly to accommodate small movements in the ground 107.

[0084] Turning to FIGS. 2A-2D, drainage layer 101 has a top surface 104, a bottom surface 105 and a thickness TT. Drainage layer 101 generally has a thickness TT in a range of about 0.5 inches to about 4 inches, or in a range of about 0.5 inches to about 2 inches, in a range of about 1 inches to about 4 inches, in a range of about 1 inches to about 2 inches, or of about 0.5 inches, or about 1 inch, or about 1.5 inches, or about 2 inches, or about 2.5 inches, or about 3 inches, or about 3.5 inches, or about 4 inches.

[0085] In at least one embodiment, top surface 104 of drainage layer 101 is higher than a top surface 107a of ground 107 that surrounds at least a portion of the drainage layer 101. The drainage layer 101 acts to both provide for water to pass downwardly from its top surface 104 through bottom surface 105 into the ground 107. Being as the drainage layer 101 is comprised of at least primarily drainage stones, drainage layer 101 is also flexible and able to accommodate minor shifts in the portion of ground 107 underlying bottom surface 105 of drainage layer 101, as is common in ground freezing and thawing, for example.

[0086] For greater certainty, it should be understood that top surface 104 of drainage layer 101 includes any surface of drainage layer 101 that is spaced apart from bottom surface 105. It should also by understood that that bottom surface 105 of drainage layer 101 is a horizontal surface that abuts either ground 107 (as shown in FIG. 2B) or an intermediate layer 109 (as shown in FIG. 2D).

[0087] In at least one embodiment, top surface 104 is higher than a ground surface 107a of ground 107 (see FIG. 2C) surrounding the paving system 100. More specifically, as further described below, when preparing the patio 100 shown in FIGS. 2A-2D, a portion of ground 107 is excavated and drainage layer 101 is placed into a c.

[0088] Ground 107 below drainage layer 101 is prepared to provide stability for paving system 100. In one example, ground 107 underneath drainage layer 101 is prepared by compacting the ground 107. In another example, as shown in FIG. 2D, intermediate layer 109 may be placed in the cavity remaining after the portion of ground 107 is excavated, and optionally compacted. Once the drainage layer 101 is placed either directly on ground 107 or on intermediate layer 109, at least a portion of top surface 104 of drainage layer 101 may higher than top surface 107a of existing ground 107 that surrounds the patio 100. In at least one embodiment, top surface 104 may be 0.5 inches, or 1 inch, or 2 inches, or more than 2 inches higher than ground surface 107a.

Paving Layer

[0089] Paving layer 103 covers top surface 104 of drainage layer 101 to form a containment field 112 around a perimeter of the drainage layer 101. By forming a containment field 112 around a perimeter of the drainage layer 101, the paving layer 103 restricts lateral movement of the drainage stones of the drainage layer 101 outwardly towards the surrounding ground 107 to ensure that the permeability and flexibility of the drainage layer 103 is maintained and the rigidity of the paving layer 103 is not compromised by shifts in the ground underlying the drainage layer 103 (e.g., the paving layer 103 doesn't crack as traditional concrete cracks).

[0090] Paving layer 103 has an outer surface 110 that is a top surface of the paving system that can be, for example, walked on by a person. Paving layer 103 also has an inner surface 111 that abuts top surface 104 of drainage layer 101.

[0091] Paving layer 103 includes a permeable material 108 that is described in greater detail below. Permeable material 108 generally includes an aggregate material bonded together by an elastomeric binder. Permeable material 108 may be present anywhere in the paving layer 103. For example, paving layer 103 may consist of the permeable material 108. Conversely, permeable material 108 may be present in defined portions of paving layer 103, such as but not limited to around flagstone and/or tiles 102 as is shown in FIGS. 2A-2D. In at least one embodiment, paving layer 103 may have at least one paving stone 102 or a set of paving stones. For example, the patio 100 shown in FIG. 1, which is shown in cross-section in FIGS. 2B and 2C, includes a paving layer 103 having plurality of paving stones 102. The paving stones can be matted or unmated paving stones (i.e. the pavers may be individual pavers or may be connected to each other with a grid to form an articulating mat of paving stones). Other matted or unmated paving stones can be used, such as for example, bricks, natural stones, flagstones, river rock, artificial stones, tiles, landscape edgers, and any other paving stones forming a surface covering, wall or other structure. The paving stone systems disclosed herein may alternatively be polymer-based (e.g. rubber). In another example, the paving stones may be stone. Each paving stone 102 may be a flagstone paver. Each flagstone paver may, optionally, have an irregular shape or a regular shape, as desired.

[0092] In this embodiment, drainage layer 101 abuts the bottom surface of each paver 102 and extends below the joints, or gaps, 113 between the pavers 102.

[0093] Paving stones 102 of paving layer 103 rest on the top surface 104 of the drainage layer 101 and, optionally, are laterally spaced apart from each other by a series of vertical channels 115. Although the patio 100 shown in FIG. 1 is shown with paving stones 102 being laterally spaced apart from each other, it should be understood that other embodiments of paving systems having other embodiments of paving layer 103 are also possible, such as but not limited to the paving systems shown in FIGS. 7A-12,

[0094] Returning to the paving layer 101, each paving stone 102 therein has a top surface 112, a bottom surface 114 opposed to the top surface 112 and a plurality of vertical edges 116 extending between the top surface 112 and the bottom surface 114. The plurality of vertical edges 116 define a shape of each paving stone 102. As noted above, each paving stone 102 may have a unique and/or irregular shape or, alternatively, may have a same shape like man-made tile.

[0095] The plurality of vertical edges 116 of each tile 102 co-operate with adjacent vertical edges 116 of adjacent paving stones 102 to define channels 115.

[0096] As noted above, paving layer 103 of patio 100 also includes a permeable material. In the embodiment shown in FIG. 2A-2D. the permeable material 108 is positioned within the series of channels 115. Permeable material includes aggregate material bonded together by an elastomeric composition, as described in greater detail below.

[0097] The permeable material, in addition to be placed within channels 115, may also be placed around a perimeter 122 of the plurality of pavers 102 and form containment field 112 surrounding drainage layer 101.

[0098] Containment field 112 around perimeter 126 (see FIG. 2C) of the drainage layer 101 may restrict movement of the drainage stones of the drainage layer 101 outwardly towards the surrounding ground surface. This then provides for drainage layer 101 to be a permeable and flexible layer in that the drainage stones of the drainage layer 101 may move relative to each other within the containment field 112 without moving out of the containment field 112. FIG. 2C shows how permeable material 108 may form at least a part of the containment field 112. Containment field 112 has a height extending from an upper containment surface that is higher than the top surface 104 of the drainage layer 101 downwardly to a lower containment edge that is below at least a portion of the ground surface 107. In at least one embodiment, the height of the containment field is one inch or greater, such as but not limited to two inches, three inches or four inches or more than four inches.

[0099] In other examples, paving layer 103 may include other materials beyond permeable material 108. For example, of the materials may for part of the containment field 112, such as but not limited to boulders, rocks, buildings, and the like. One example is shown in FIG. 1, where the stairway 200 includes a plurality of boulders forming a portion of the paving layer 101.

[0100] FIG. 3 shows one example of an aggregate material for use in forming the permeable material 108. Permeable material 108 forms at least one layer between the pavers 102 and, in some embodiments, may co-operate with the top surface 104 of the pavers 102 to define a paved surface of the paver system 100.

[0101] Permeable material 108 includes an aggregate material bonded together by an elastomeric composition. The elastomeric portion of the elastomeric aggregate composition is a non-cement binder. For example, the elastomeric portion (e.g. binder) of the elastomeric aggregate composition may comprise a polyurethane-based liquid, such as but not limited to a diphenylmethane diisocyanate-based polyurethane. In at least one embodiment, the elastomeric portion of the elastomeric aggregate composition is a polyurethane-based liquid. In at least one embodiment, the polyurethane-based liquid is a diphenylmethane diisocyanate-based polyurethane liquid. The aggregate material of the permeable material 108 may have an average particle size (e.g. diameter) in a range of about 0.25 inches to about 1.00 inch. The aggregate material may have an average aggregate size (e.g. diameter) in a range of about 0.20 inches to 0.50 inches.

[0102] In at least one embodiment, the elastomeric portion of the elastomeric aggregate composition may be about 5% by volume or 3% by weight when mixed with stone aggregate of the permeable material. In another example, the elastomeric portion of the elastomeric aggregate composition may be about 5% by volume or 3% by weight of the permeable material 108 and have an average diameter in a range of about 0.20 inches to about 0.50 inches for common pedestrian applications.

[0103] In at least one embodiment, as the average size (e.g. particle size) of the aggregate increases, the ratio of binder to aggregate will decrease. Also, as the average size (e.g. particle size) of the aggregate increases, the thickness of the permeable material 108 within paving layer 103 will also increase.

[0104] It should be understood that each piece of aggregate of the aggregate material may be within a distribution of particle sizes. This distribution of particle sizes provides at least two advantages.

[0105] First, as each piece of aggregate is coated with the elastomeric binder, aggregates with smaller particle sizes within the distribution increase a number of contact points with other neighboring aggregates, thereby increasing a strength of the permeable and flexible material 108. Second, aggregates with larger particle sizes within the distribution provide for larger distances between contact points with neighboring aggregates, thereby increasing void spaces within the permeable and flexible material that are used by water to pass through the permeable and flexible material. By changing the particle size distribution of the aggregate, water flow rates through the permeable and flexible material can be controlled so the permeable and flexible material can be used in different applications (i.e., erosion control).

[0106] The elastomeric aggregate composition is formed by mixing the aggregate material with the elastomeric portion of the composition. The mixing occurs over a pre-determined period of time with proper process and equipment and provides for the elastomeric composition to coat at least a portion of the surface of each stone of the aggregate material to encourage the aggregate material to stick together. After mixing the elastomeric portion of the composition and the aggregate together, the elastomeric aggregate composition can be poured or troweled onto a surface, such as but not limited to the ground 107. In one embodiment, the elastomeric aggregate composition can be poured within the vertical channels 115 and/or around perimeter 122 of pavers 102 and/or perimeter 126 of drainage layer 101 after the pavers 102 have been positioned on the top surface of drainage layer 101 and spaced apart from each other. Pavers 102 may be spaced apart from each other using physical spacers, or spaced apart by hand or other means

Method of Forming a Paving System

[0107] As noted above, the patio 100 and the stairway 200 shown in FIG. 1 are both examples of paver systems described herein. The following paragraphs describe steps of forming patio 100 shown in FIG. 1.

[0108] At a first step, as is noted above, organic soil is removed from a selected location for installing the paving system. By removing the organic soil and optionally preparing the ground at the selected location (e.g., by compacting the ground and/or installing an intermediate layer 109 (with or without compaction), ground 107 is suitable for supporting the paving system 100.

[0109] At a third step, drainage layer 101 of drainage stones is placed on the ground 107.

[0110] At a fourth step, paving layer 103 is placed onto the top surface 104 of the drainage layer 101. In one example of this step, FIGS. 4A, 4B and 4C show an installer placing pavers 102 on a drainage layer 101. Pavers 102 may optionally be leveled (see FIGS. 4B and 4C).

[0111] As noted above, the paving layer 103 includes a permeable material and the permeable material includes an aggregate material bonded together by an elastomeric binder. FIGS. 4D and 4E show installation of patio 100 when the pavers 102 are positioned on drainage layer 101 and spaced apart from each other. Typically, the pavers 102 are spaced apart from each other by a distance of about -inch to about 5 inches, and more preferably from about 0.5 inches to about 3 inches, apart. However, it should be understood that the spacing of the pavers 102 may vary, for example based on the size of the pavers. For example, for larger pavers 102, the pavers 102 may be spaced apart as much as 8 inches or more. The space between adjacent pavers 102 forms an open joint or void for receiving the elastomeric aggregate composition.

[0112] After the pavers 102 are laid out on the drainage layer 101, the elastomeric aggregate composition is installed into the spaces, or joints, or channels 115 between adjacent pavers. FIG. 4F shows mixing of the elastomeric aggregate composition.

[0113] FIGS. 4G and 4H show an installer placing the elastomeric aggregate composition between adjacent pavers 102 and levelling the elastomeric aggregate composition. Permeable material 108 serves as a structural layer of the system holding the pavers 102 together and provides permeability to the system. As opposed to a pervious concrete formed of aggregate and cement, the permeable material 108, which is made up of large aggregates and a non-cement binder, forms an open-celled matrix that is flexible, permeable and strong to allow water to flow through it and to provide a stable spacer between all pavers. FIG. 4I shows a partially complete patio 100.

[0114] Once the elastomeric aggregate composition has been placed to form the permeable material 108, permeable material 108 cures for a period of time in a range of about two hours to about 24 hours. Once cured, the paver system can be used.

Stairways

[0115] As noted above, the stairway 200 shown in FIG. 1 is another example of a paver systems described herein. The following paragraphs describe stairway 200 (see FIGS. 5B-5D) and steps of forming stairway 200 (see FIGS. 6A-6M) shown in FIG. 1 and in FIG. 5A according to at least one embodiment described herein. The stairway 200 may include paving stones 102 on the treads or can be made entirely of permeable material 108.

[0116] Permeable outdoor stairway 200 is formed using an aggregate material bonded together by an elastomeric composition, as described above.

[0117] FIGS. 5B to 5D are diagrams showing side views of a permeable stairway 200 formed on a ground surface 107, according to at least one embodiment described here. Permeable stairway 200 includes a paving layer 103 and a drainage layer 101. FIG. 5B also shows a first form 206, one or more pins 208 and a second form 210 that are used to shape at least a portion of paving layer 103 of stairway 200.

[0118] It should be understood that the paving layers 103 described herein may also include more than one plane of materials. For example, referring to FIGS. 5B and 6F, paving layer 103 may include a plane of permeable material 108 supporting a plane of paving stones 102 placed thereon. In this case, the paving stones 102 on top of the permeable material 108 will be adhered to the permeable material 108.

[0119] Turning now to FIGS. 6A to 6M, steps of a method of forming a permeable outdoor stairway 200 are shown. The method provides for an installer to start and stop installation of the paving layer, as described below, at self-directed moments without compromising an integrity of the paving layer.

[0120] To form permeable stairway 200, at a first optional step organics such as topsoil should be excavated from a selected portion of ground 107. For example, in some embodiments, it may be undesirable to have organic materials beneath the permeable outdoor stairway 200. In these examples, the topsoil underneath the stairway 200 may need to be removed. In some examples, clay underneath the stairway may also need to be removed. Removing clay beneath the permeable outdoor stairway 200 may provide for water passing through the permeable outdoor stairway 200 to pass directly into the ground thereunder and not be diverted by clay beneath the stairway. For further clarity, any soil that may stop water from penetrating ground 107 should be removed and replaced with a drainage layer 101 as described above. Drainage layer 101 will absorb the micromovements in the ground 107 that occur, for example, in colder climates during a typical freeze/thaw cycle. An intermediate layer 109 may also be included in stairway 200, optionally, if the topsoil is deep, for example greater than 6 inches or greater than 12 inches. In this embodiment, the intermediate layer 109 may stabilize the drainage layer 101 and paving layer 103. As noted above, the intermediate layer 109 is more stable than drainage layer 101 as, for example, intermediate layer 109 is more packed together (e.g., has less void space) than drainage layer 101.

[0121] At a second step, a drainage layer 101 is placed on the ground 107 to establish a base for the permeable outdoor stairway 200. For example, in at least one embodiment, drainage stone, as described above, may be placed on the ground 107 to establish a base for the permeable outdoor stairway 200. This is shown in FIG. 6B

[0122] At a third step, a first form 206, or a plurality of first forms 206, is positioned on or slightly below the drainage stone forming drainage layer 101 for building a first step, as well as subsequent steps, of the staircase 200. First form 206 is intended to hold additional drainage stone that is positioned behind the form 206. An example of the additional drainage stone of drainage layer 101 is shown in FIG. 6E.

[0123] First form 206 is held in place by one or more support members (e.g. pins or rebar stakes) 208, that are driven into the ground to support the first form 206. Pins 208 are shown in FIGS. 6E and 6F. Support members 208 are positioned to rest against an outer surface of the first form 206.

[0124] After positioning the first form 206, as shown in FIG. 6C, and supporting the first form 206 with one or more pins 208, as shown in FIG. 6D, a second form 210 is positioned to be laterally spaced apart from a front face 212 of the first form 206. Second form 210 being laterally spaced apart from front face 212 of first form 206 creates a gap 214 for forming a riser of the stairway 200. FIG. 6H also shows gap 218 ensuring the riser and an adjacent tread of the paving layer 101 of the stairway 200 are continuous.

[0125] Second form 210 is positioned such that a lower edge 216, as shown in FIGS. 6H and 6I, is vertically spaced apart from a top surface 104 of the drainage stone 101 filling a space behind a lower first form 206. The space 218 created below the lower edge 216 provides for elastomeric aggregate composition to be poured into the gap 214, as shown in FIG. 6I, and form a continuous paving layer 103 of elastomeric aggregate composition with an adjacent tread covering the top surface 104 of the drainage stone 101 to form the stairway 200.

[0126] As shown in FIG. 6J, when pouring the elastomeric aggregate composition onto the top surface 104 of the drainage layer 101 to form the paving layer 103 of the stairway 200, the elastomeric aggregate composition is poured on top of a top edge 219 of the first form 206 (shown in FIG. 6F) to bury the first form 206. The second form 210 remains visible and, after allowing the elastomeric aggregate composition to cure, the second form 210 is removed (e.g. screws that act as spacers to form the gap 214 can be removed from the elastomeric aggregate composition after the elastomeric aggregate composition has been poured).

[0127] In at least one embodiment, after the drainage layer 101 has been placed behind the first form 206 to form a base for each tread of the permeable stairway 200, a wire (or chain) may be added to the first form 206 to help the elastomeric aggregate composition be anchored in place and reduce potential for the elastomeric aggregate composition to shift after curing. The wire may extend along a length of the stairway 200 and pass underneath the first form 206 and/or the second form 210 of each step of the stairway 200.

[0128] After placing the paving layer 103 onto the top surface 104 of the drainage layer 101, the elastomeric aggregate mixture is allowed to cure and form the stairway 200.

Other Paving Systems

[0129] Turning now to FIGS. 7-12, other embodiments of paving systems are shown therein.

[0130] For example, a paving system 300 is shown in FIGS. 7A-7C. In this paving system 300, paving layer 103 consists of the permeable material comprising the elastomeric aggregate composition described herein. Drainage layer 101 underlies the paving layer 103 consisting of the permeable material comprising the elastomeric aggregate composition. System 400 of FIG. 7D is similar to system 300, however in system 400, paving layer 101 includes paving stones 102.

[0131] Photographs of examples of system 500 are provided in FIGS. 8A and 8B, where paving layer 103 comprises the permeable material 108 comprising the elastomeric aggregate composition forming at least a portion of containment field 112 and a second aggregate material 501 is included in paving layer 103.

[0132] FIG. 9 is a photograph showing a system 300 having a paving layer 103 consisting of an elastomeric aggregate composition at a top of a stairway.

[0133] FIG. 10 is a photograph showing a system 300 having a paving layer 103 consisting of an elastomeric aggregate composition in front of a garage door.

[0134] FIG. 11 is a photograph showing a system 300 having a paving layer 103 consisting of an elastomeric aggregate composition in front of a person door.

[0135] FIG. 12 is a photograph showing a system 400 having a paving layer 103 including an elastomeric aggregate composition 108 and a plurality of tiles 102.

[0136] In each of these cases, the paving systems may be installed by applying an elastomeric aggregate composition onto a drainage layer 101 (not shown) as described above, the elastomeric aggregate composition comprising an aggregate material bonded together by an elastomeric composition; and allowing the elastomeric aggregate composition to cure.

[0137] While the above description provides examples of one or more apparatus, methods, or systems, it will be appreciated that other apparatus, methods, or systems may be within the scope of the claims as interpreted by one of skill in the art.