Coating processes – Solid particles or fibers applied
Reexamination Certificate
1999-11-09
2003-01-07
Parker, Fred J. (Department: 1762)
Coating processes
Solid particles or fibers applied
C427S136000, C427S202000, C427S359000, C427S403000
Reexamination Certificate
active
06503558
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a fluid surface texturing device, apparatus incorporating the same and a kit of parts, the use thereof in texturing a fluid surface and a process for texturing a fluid surface.
BACKGROUND OF THE INVENTION
Concrete has been used for many years to provide the wearing surface on highways. The popularity of the technique varies from country to country, and even within countries, for example between UK Highway Authorities, for the reasons given below.
Concrete is perhaps the most durable, and easily repaired of all materials for highways etc., but there are three interrelated drawbacks:
1. The surface's natural smoothness requires texturing for increased friction, and water drainage for the avoidance of skidding and “aquaplaning” when wet;
2. This “texturing” is usually carried out by a stiff brushing or raking as the concrete sets, which is prone to failure, since all texture surface is lost if there is rain at any time in the first 10 hours or so, of the setting process, or by cutting with diamond-tipped rotary blades which is extremely costly and justified only for retexturing runways for example, and leads to excessive, unpleasant audible noise emission as a driving surface;
3 Texturing produced by these methods rapidly wears under traffic, particularly so in areas where high friction is most needed, at corners and, junctions and the like, hence this is not a long term solution.
Asphalt finishes are less durable and need great care to repair properly, but the random surface pattern of particle size, position and gap widths of the surface layer of aggregate, provides a much quieter driving surface, greater friction naturally, and channels for surface water to occupy if not excessive, and to drain in heavy falls.
As a compromise, many roads are laid with a concrete substructure, and an Asphalt topping.
Much research has gone into trying to get concrete surfaces to imitate the performance of asphalt, resulting in the recent successful trials on UK motorways, of so-called “whisper” concrete. A special, aggregate rich surface layer is laid, but the top few millimeters of concrete are given a set-inhibitor, so that the concrete can be removed, this exposing the tips of the aggregate whilst leaving it partially embedded. This apparently provides a dramatic improvement in the required properties.
Unfortunately this chemical technique requires specialised equipment and trained operatives, and due attention to timing, dispersal of inhibitor, removal of the surface cement binder etc. For this reason the application is limited by cost and convenience.
There is therefore a need for a cost effective and convenient apparatus and method for producing a similar result to that of the chemical technique, and in a wide variety of applications, from footpaths, to motorways; for ornamental addition to concrete surfaces, or for discouraging pedestrians from walking in unsafe locations such as roundabout centres and the like.
Moreover there is a need for an apparatus and method for texturing concrete surfaces with acceptable surface flattener and levelness. A standard test method for determining surface flatness and levelness is given in astmE 1155-87. In particular there is a need for an apparatus and method which is self-regulating in terms of surface flatness and levelness produced for a textured surface, for high quality, efficient and reproduceable operation.
We have now surprisingly found a cost effective and convenient apparatus and method for texturing a concrete surface by mechanical means to produce a similar result to that of the chemical technique.
SUMMARY OF THE INVENTION
In its broadest aspect there is provided according to the present invention a device for association with a rotatable powered roller having an elongate cylindrical roll surface adapted to be moved over a surface of newly laid fluid and surrounding formwork, wherein the manner of association is such that the roller surface comprises an elongate substantially cylindrical texturing portion and at least two guide portions, the guide portions being adapted to support the texturing portion at a required level with respect to the fluid surface in manner to ensure partial embedding of texturing material distributed thereon.
Reference herein to formwork is to any vertical surround as necessary in the art to provide a boundary for casting a setable fluid, and includes an edge, cutaway or section of existing surface which is to be infilled or repaired.
Reference herein to a fluid is to any setting, curing or solidifiable fluid commonly used in the construction of load bearing surfaces such as footpaths, roads and the like. In particular, the fluids may include concrete and mixtures thereof with other construction materials.
Reference herein to texturing is to incorporation of a solid aggregate for the purpose of inducing a friction, drainage, decorative or ornamental, obstructive, guiding or marking surface and the like.
The aggregate material as hereinbefore defined may be any solid particulate or shaped object. The material may be comprised of any desired wearing, friction inducing, decorative, obstructive or non-obstructive material such as stone or gravel chippings which may be natural or coloured, depending on the effect required, glass fragments, ground glass, concrete or other composite blocks or formed objects and the like. The aggregate material may be of substantially uniform size or may be of a size distribution selected for graded or random texturing.
A device as hereinbefore defined may be integral or non-integral with a powered roller as hereinbefore defined. A non-integral device may be adapted to engage with or to be attached to the roller. The device may be of fixed or variable nature, or may be one of a plurality of super-imposable devices, whereby the required level of the texturing portion may be selected as desired. It will be appreciated that the required level may vary widely according to the desired purpose and function of texturing, but is generally determined to be in the range of 50 to 80% of the average dimension of the aggregate material to be employed. A desired level may therefore be in the range of 2 mm-200 mm.
For example the required level for providing friction or drainage to a surface may be in the range of 2 mm-10 mm, preferably 3 mm-8 mm, whereas the required level for the purpose of introducing a barrier or obstruction to discourage access by humans or vehicles maybe of the order of 10-200 mm, and the required level for introducing guiding or marking texturing, for example to provide a footpath direction strip for the blind or a visible direction marker to indicate or segregate the paths may be in the region of 5 mm-20 mm, for example 7 mm-15 mm.
In a first aspect of the invention a device comprises two substantially identical sleeves which may be fitted around the rolling surface at either end thereof, the sleeves being constructed of any rigid load bearing material and having a sleeve-wall thickness corresponding to the required level as hereinbefore defined. Preferably each sleeve includes a base of one end having an aperture to receive the supporting axis of the roller, and adapted to abut against the end of the roller thereby maintaining the sleeve in place. The sleeve may include additional projections, attachments and the like for the same purpose, and preferably being readily engaged or released by hand or by simple tool.
A plurality of sleeves may be provided of different internal and external diameters, whereby a required level of the texturing portion of the roller may be obtained by means of placing one or a plurality of sleeves one about the other at each end of the roller. Alternatively a set of sleeves may be of similar internal diameter and of different external diameters, whereby a pair of sleeves may be selected to provide the required level.
In a second embodiment a device comprises a pair of support carriageways adapted to ride on, or near the formwork, and having a vertical aperture or the like to receive the en
Errut Product Limited
Fulbright & Jaworski LLP
Parker Fred J.
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