Note: Descriptions are shown in the official language in which they were submitted.
WO 2021/158605
PCT/US2021/016327
PAVER ADHESIVE AND METHOD OF LAYING PAVERS USING
SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
100011 This application is continuation-in-part and claims the benefit, under
35 U.S.C. 120,
of U.S. Patent Application No. 16/415,371, filed 17 May 2019 and entitled
"PAVER
ADHESIVE AND METHOD OF LAYING PAVERS," which is a continuation and claims the
benefit, under 35 U.S.C. 120, of U.S. Patent Application No. 15/845,809,
filed 18 December
2017 and entitled "PAVER ADHESIVE AND METHOD OF LAYING PAVERS," which is a
continuation and claims the benefit, under 35 U.S.C. 120, of U.S. Patent
Application No.
15/697,726, filed 7 September 2017 and entitled "PAVER ADHESIVE AND METHOD OF
LAYING PAVERS," which is a continuation and claims the benefit, under 35 U.S.0
120,
of U.S. Patent Application No. 15/288,433, filed 7 October 2016 and entitled
"PAVER
ADHESIVE AND METHOD OF LAYING PAVERS,- the entire contents and substance of
which are incorporated herein by reference in their entirety as if fully set
forth below.
FIELD OF THE DISCLOSURE
100021 The disclosed technology includes paver adhesives, such as dry concrete
mixes, as
well as methods for laying paver tiles using such paver adhesives. Each
disclosed paver
adhesive is configured to be distributed on a substrate (e.g., a sidewalk,
concrete pad, driveway,
stone, or other solid surface) while the paver adhesive is in a dry state,
such that bricks, paver
bricks, pavers, or paver tiles (referred to generally herein as "pavers" or
"paver tiles") can be
laid atop the paver adhesive while the paver adhesive is still in the dry
state, and the paver
adhesive can be hydrated after the pavers have been laid. Subsequent to
hydration and curing,
the disclosed paver adhesives can provide a strong and durable adhesion
between the pavers
and the substrate, and the paver adhesives can withstand vehicular traffic
without significant
cracking, releasing or otherwise degrading.
BACKGROUND
100031 Many homeowners or proprietors may wish to replace their old concrete
driveway
with a paver tile driveway. Conventionally, this process comprises breaking
and digging up the
1
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
existing concrete driveway and its base. The old concrete and base material
must then be
removed for disposal.
100041 The base material, typically a limestone gravel, can then be replaced
and compacted.
The base material is then typically covered with a layer of sand, which is
compacted and leveled
as a layer to support the pavers. The pavers can then be laid on top of the
leveled sand layer.
To prevent shifting or other movement of the pavers after placement, at least
some of the pavers
must be secured. It is commonplace to secure at least the pavers at the edges
of area being
paved, such as by a concrete edge, pavers set in concrete, or a metal or
plastic fixed edge.
Commonly, the pavers that are secured are thicker and more expensive than
typical pavers.
Accordingly, the process to convert a concrete (or any other material)
driveway, sidewalk, or
other area to one paved with pavers can be expensive, disruptive to existing
landscaping, and
time consuming.
100051 Further, there is no conventional method for reliably installing 075
inch to 1 5 inch
concrete pavers over a concrete driveway for use by vehicular traffic. Pavers
are not generally
designed to set in cement or mortar over existing concrete applications, and
relatedly, pavers
are not conventionally made or installed for vehicular applications. To that
end, the
International Concrete Paver Institute (ICPI), which governs, qualifies, and
mandates all
specifications for use of paver tiles, does not acknowledge driveway overlays
with paver tiles.
Thus, ICPI certified installers are unlikely to install pavers over existing
concrete pads.
100061 Because typical pavers were developed for pedestrian use and not
vehicular use,
pavers are generally seen as an approved or acceptable product for remodeling
pool decks,
backyard patios, walkways and courtyards. However, pavers are not typically
for vehicular
applications, such as installation as an overlay on a driveway or other
vehicular application.
Using existing methods, it is likely that any pavers installed atop a driver,
for example, would
crack and break apart from the weight of the vehicle, as well as the various
forces experienced
by the pavers, such as those provided by any twisting and turning of the
tires. Thus, using
current methods, it is difficult to install pavers on concrete for vehicular
use and provide a
durable final product.
100071 Moreover, regardless of the targeted use of the pavers (e.g.,
pedestrian, vehicular),
any adhesion of the pavers to the underlying substrate (e.g., a concrete pad)
typically requires
the adhesive¨typically, a concrete mix¨to be pre-mixed. Using conventional
practices, the
pre-mixed concrete mix or other adhesive is hydrated prior to application on
the ground or
substrate. For adhesion to occur, the hydrated mix must be permitted to cure,
which will
2
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
ultimately fixedly attach the pavers to the underlying surface. However, this
process can be
messy, difficult, and cumbersome. Further, the installer is afforded only a
certain amount of
the time to install the pavers atop the adhesive before the adhesive cures and
hardens. This
time-based issue can become a burden in and of itself and can cause the
installer to hurry the
installation, which can lead to shoddy or inferior installation.
100081 Accordingly, there is a need for a method of laying paver tiles over a
surface or
substrate such that the pavers will provide a durable and long-last surface
for vehicular use.
There is also a need for a paver adhesive for securely adhering pavers to a
substrate or
underlying surface.
SUMMARY
100091 These and other problems can be addressed by the technology disclosed
herein.
100101 The disclosed technology includes a dry concrete mix for dry setting
paver tiles, and
the dry concrete mix can include cement , silica sand, alumina silicate, and a
latex polymer
and/or acrylic polymer. The cement can be in a concentration range from
approximately 23
wt.% to approximately 70 wt.%. The cement can be in a concentration range from
approximately 23 wt.% to approximately 70 wt.%. The cement can be in a
concentration range
from approximately 25 wt.% to approximately 60 wt.%. The cement can be in a
concentration
range from approximately 20 wt.% to approximately 40 wt.%. The cement can be
in a
concentration range from approximately 21 wt.% to approximately 30 wt.%. The
cement can
be in a concentration range from 23 wt% to approximately 40 wt%.
100111 The silica sand can be in a concentration range from approximately 30
wt.% to
approximately 79 wt%. The silica sand can be in a concentration range from
approximately 30
wt.% to approximately 78 wt.%. The silica sand can be in a concentration range
from
approximately 30 wt.% to approximately 74 wt.%. The silica sand can be in a
concentration
range from approximately 30 wt.% to approximately 70 wt.%.
100121 The alumina silicate can be in a concentration range from approximately
0.5 wt.% to
approximately 6 wt.%.
100131 The latex polymer and/or acrylic polymer can be in a concentration
range from
approximately 0.5 wt.% to approximately 8 wt.% The latex polymer and/or
acrylic polymer
can be in a concentration range from approximately 0.5 wt.% to approximately 5
wt.%. The
latex polymer and/or acrylic polymer can be in a concentration range from
approximately 23
wt.% to approximately 70 wt.%;
3
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
[0014] The disclosed technology also includes methods for laying paver tiles
using the
disclosed paver adhesive or concrete mixes.
[0015] Additional features, functionalities, and applications of the disclosed
technology are
discussed in more detail herein.
BRIEF DESCRIPTION OF THE FIGURE
[0016] FIG. 1 shows a paver tile used in an embodiment of the method, wherein
the paver
tile comprises a bottom surface defining grooves.
DETAILED DESCRIPTION
[0017] Unless stated otherwise, such as in the examples, all amounts and
numbers used in
this specification are intended to be interpreted as modified by the term
"approximately" or the
term "about." Likewise, all elements or compounds identified in this
specification, unless stated
otherwise, are intended to be non-limiting and representative of other
elements or compounds
generally considered by those skilled in the art as being within the same
family of elements or
compounds.
[0018] While certain embodiments of the disclosed technology have been
described in
connection with what is presently considered to be the most practical
embodiments, it is to be
understood that the disclosed technology is not to be limited to the disclosed
embodiments, but
on the contrary, is intended to cover various modifications and equivalent
arrangements
included within the scope of the appended claims. Although specific terms are
employed
herein, they are used in a generic and descriptive sense only and not for
purposes of limitation.
[0019] In the following description, numerous specific details are set forth.
But it is to be
understood that examples of the disclosed technology can be practiced without
these specific
details. In other instances, well-known methods, structures, and techniques
have not been
shown in detail in order not to obscure an understanding of this description.
References to "one
embodiment," "an embodiment," "example embodiment," "some embodiments,"
"certain
embodiments," "various embodiments," etc., indicate that the embodiment(s) of
the disclosed
technology so described may include a particular feature, structure, or
characteristic, but not
every embodiment necessarily includes the particular feature, structure, or
characteristic.
Further, repeated use of the phrase "in one embodiment" does not necessarily
refer to the same
embodiment, although it may.
4
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
100201 Throughout the specification and the claims, the following terms take
at least the
meanings explicitly associated herein, unless the context clearly dictates
otherwise. The term
"or" is intended to mean an inclusive "or." Further, the terms "a," "an," and
"the" are intended
to mean one or more unless specified otherwise or clear from the context to be
directed to a
singular form.
100211 The disclosed technology includes a paver adhesive or dry concrete mix
that includes
Portland cement, silica sand, alumina silicate, and a latex polymer and/or an
acrylic polymer.
As discussed more fully below, the disclosed paver adhesives can be used in
methods for
installing paver tiles on a substrate, such as a concrete pad, an asphalt pad,
the ground, or some
other substrate. The method can include distributing the paver adhesive in a
dry form over an
area to covered with paver tiles (e.g., a substrate), positioning the paver
tiles over the paver
adhesive, and hydrating the paver adhesive subsequent to positioning the paver
tiles. Once
hydrated, the paver adhesive can be permitted to cure and harden
100221 As used herein, the term "dry" as used with respect to a dry paver
adhesive or a dry
concrete mix refers to the paver adhesive or concrete mix lacking added water.
That is, while
the dry paver mix or dry concrete mix may contain some moisture (e.g.,
depending on the
ambient humidity), the paver mix or dry concrete is still considered "dry" so
long as water or
hydrating fluids have not been added to the mix.
100231 The disclosed technology includes paver adhesives or concrete mixes
that are dry
(packaged), no-mix, polymer-modified, cement-based mortars. The paver
adhesives can be
configured to be distributed or applied in a dry state and hydrated in situ
subsequent to laying
paver tiles over the dry concrete mix. That is, the disclosed paver adhesives
are formulated
such that paver tiles can be laid over the paver adhesive while the paver
adhesive is in a dry
form, and the paver adhesive can then be hydrated after some or all of the
pave tiles are laid.
This is in contrast to conventional approaches that require shear mixing of
mortar with water
before placement of paver tiles. It is conventionally thought that the shear
mixing adds air to
the mortar to control the curing period, which is thought to be necessary for
ultimate strength
of the cured mortar and for developing a strong bond with abutting objects,
such as paver tiles.
100241 The dry concrete mix comprises cement (e.g., Portland cement), silica
sand, alumina
silicate (e.g., perlite), and/or latex polymer and/or acrylic polymer. The dry
concrete mix can
include calcium carbonate. The Portland cement can include Type I cement in a
concentration
range between approximately 40 wt. % and approximately 60 wt. % and Type III
cement in a
concentration range between approximately 40 wt. % and approximately 60 wt. %.
As will be
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
appreciated, alumina silicate, perlite, or another material for water
retention can promote water-
retention in the eventually hydrated paver adhesive or concrete mix, which can
aid in curing.
Further, the latex and/or acrylic polymers can also promote water-retention
and adhesion
between the paver tiles and the underlying substrate.
100251 The latex polymer and/or acrylic polymer can be a powder, such as a
dry,
redispersible powder. The latex polymer and/or acrylic polymer can include,
but is not limited
to, poly(ethylene-vinyl acetate), poly(vinyl acetate-ethylene) (VAE, VAc/E),
poly(vinyl
acetate/vinyl ester of versatic acid) (VAENeoVa, VAM/VeoVa), poly(styrene
acrylate),
poly(ethylene-vinyl acetate), acrylic homopolymer, acrylic copolymers, acrylic
terpolymers,
poly(acrylic esters), polyvinylidene chloride (PVAC), poly(styrene-butadiene),
poly(styrene-
butadi en e) copolymers, poly (styrene-butadiene)terpolymers, or any useful
combination
thereof. Various types (chemical families) and grades of dry, redispersible
latex and/or acrylic
polymer powders can conceivably be used in the disclosed paver adhesive
formulations without
departing from the spirit of the disclosed technology. The combination of
components in the
disclosed paver adhesives and dry cement mix can provide ease of use and
sufficient adherence
between an underlying substrate and the paver tiles to prevent cracking of the
tiles (e.g., due to
vehicular use). As will be appreciated, the dry paver adhesives of the present
disclosure can be
spread more easily and conveniently as compared to wet mortars.
100261 Qualities of the formulations can be influenced as desired by the
concentration of
certain materials. For example, increased concentrations of latex and/or
acrylic polymers can
improve adherence and ultimate performance of the paver adhesive, but this may
also increase
the cure time of the paver adhesive. Thus, it may be beneficial to increase
the concentration of
a component (e.g., alumina silicate) to regulate water evaporation and offset
the increased cure
time.
100271 An example dry concrete mix can include Portland cement, silica sand,
alumina
silicate, and as poly(ethylene-vinyl acetate) As a more specific example, the
dry concrete mix
can include Portland cement in a concentration range from approximately 30
wt.% to
approximately 60 wt.%, silica sand, alumina silicate (perlite) in a
concentration range from
approximately 1 wt.% to approximately 6 wt.%, and poly(ethylene-vinyl acetate)
in a
concentration range from approximately 1 wt.% to approximately 30 wt.%. As
another
example, the dry concrete mix can include Portland cement in a concentration
range from
approximately 30 wt.% to approximately 60 wt.%, silica sand in a concentration
range from
approximately 25 wt.% to approximately 60 wt.%, alumina silicate (perlite) in
a concentration
6
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
range from approximately 1 wt.% to approximately 6 wt.%, and poly(ethylene-
vinyl acetate)
in a concentration range from approximately 1 wt.% to approximately 30 wt.%.
100281 As yet another example, the dry concrete mix can include Portland
cement in a
concentration range from approximately 40 wt.% to approximately 60 wt.%,
silica sand,
alumina silicate (perlite) in a concentration range from approximately 0.5
wt.% to
approximately 3 wt.%, and poly(ethylene-vinyl acetate) in a concentration
range from
approximately 0.5 wt.% to approximately 5 wt.%. For certain applications, the
dry concrete
mix can include Portland cement in a concentration range from approximately 40
wt.% to
approximately 60 wt.%, silica sand in a concentration range from approximately
40 wt.% to
approximately 60 wt.%, alumina silicate (perlite) in a concentration range
from approximately
0.5 wt.% to approximately 3 wt.%, and pol y (ethyl en e-vi nyl acetate) in a
concentration range
from approximately 0.5 wt.% to approximately 1.0 wt.%.
100291 As an example that may be particularly useful for use in colder
climates, the dry
concrete mix can include Portland cement in a concentration range from
approximately 30
wt.% to approximately 60 wt.%, silica sand, alumina silicate (perlite) in a
concentration range
from approximately 0.5 wt.% to approximately 3 wt.%, and poly(ethylene-vinyl
acetate) in a
concentration range from approximately 15 wt.% to approximately 30 wt.%. For
certain
applications, the dry concrete mix can include Portland cement in a
concentration range from
approximately 40 wt.% to approximately 60 wt.%, silica sand in a concentration
range from
approximately 25 wt.% to approximately 50 wt.%, alumina silicate (perlite) in
a concentration
range from approximately 4 wt.% to approximately 6 wt.%, and poly(ethylene-
vinyl acetate)
in a concentration range from approximately 15 wt.% to approximately 30 wt.%.
As yet another
example, the dry concrete mix can include Portland cement in a concentration
range from
approximately 35 wt.% to approximately 45 wt.%, silica sand in a concentration
range from
approximately 30 wt.% to approximately 40 wt.%, alumina silicate (perlite) in
a concentration
range from approximately 4 wt.% to approximately 6 wt%, and poly(ethylene-
vinyl acetate)
in a concentration range from approximately 15 wt.% to approximately 25 wt.%.
100301 As yet another example, the dry concrete mix can include Portland
cement in a
concentration range from approximately 40 wt.% to approximately 60 wt.%,
silica sand in a
concentration range from approximately 25 wt.% to approximately 50 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 4 wt.% to approximately
6 wt.%, and
poly(ethylene-vinyl acetate) in a concentration range from approximately 15
wt.% to
approximately 30 wt.%.
7
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
100311 Yet another example of the dry concrete mix can include Portland
cement, silica sand,
alumina silicate, and poly(ethylene-vinyl acetate). As a more specific
example, the dry concrete
mix can include Portland cement in a concentration range from approximately 30
wt.% to
approximately 60 wt.%, silica sand, alumina silicate (perlite) in a
concentration range from
approximately 1 wt.% to approximately 6 wt.%, and a latex and/or acrylic
polymer, such as
poly(ethylene-vinyl acetate) powder in a concentration range from
approximately 1 wt.% to
approximately 30 wt.%. As another example, the dry concrete mix can include
Portland cement
in a concentration range from approximately 30 wt.% to approximately 60 wt.%,
silica sand in
a concentration range from approximately 25 wt.% to approximately 60 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 1 wt.% to approximately
6 wt.%, and
poly(ethylene-vinyl acetate) or a latex and/or acrylic polymer powder in a
concentration range
from approximately 1 wt .% to approximately 30 wt
100321 As a further example, the dry concrete mix can include Portland cement
in a
concentration range from approximately 40 wt.% to approximately 60 wt.%,
silica sand,
alumina silicate (perlite) in a concentration range from approximately 0.5
wt.% to
approximately 3 wt.%, and a dry, redispersible latex polymer powder, such as
poly(ethylene-
vinyl acetate), in a concentration range from approximately 0.5 wt.% to
approximately 3 wt.%.
For certain applications, the dry concrete mix consists essentially of
Portland cement in a
concentration range from approximately 40 wt.% to approximately 60 wt.%,
silica sand in a
concentration range from approximately 40 wt.% to approximately 60 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 0.5 wt.% to
approximately 3 wt.%, a
latex and/or acrylic polymer (e.g., dry, redispersible powders), such as
poly(ethylene-vinyl
acetate), in a concentration range from approximately 0.5 wt .% to
approximately 1.0 wt.%.
100331 As another example that can be useful in colder climates for example,
the dry concrete
mix can include Portland cement in a concentration range from approximately 30
wt.% to
approximately 60 wt %, silica sand, alumina silicate (perlite) in a
concentration range from
approximately 0.5 wt.% to approximately 3 wt.%, and latex and/or acrylic
polymers such as,
but not limited to, poly(ethylene-vinyl acetate), in a concentration range
from approximately 5
wt .% to approximately 30 wt.% As another example, for example for use in
colder climates,
the dry concrete mix can include Portland cement in a concentration range from
approximately
30 wt.% to approximately 60 wt.%, silica sand, alumina silicate (perlite) in a
concentration
range from approximately 0.5 wt.% to approximately 3 wt.%, and dry, latex
polymer powders
such as, but not limited to, poly(ethylene-vinyl acetate) in a concentration
range from
8
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
approximately 20 wt.% to approximately 30 wt.%. For certain applications, the
dry concrete
mix consists essentially of Portland cement in a concentration range from
approximately 40
wt.% to approximately 60 wt.%, silica sand in a concentration range from
approximately 25
wt.% to approximately 50 wt.%, alumina silicate (perlite) in a concentration
range from
approximately 4 wt.% to approximately 6 wt.%, and poly(ethylene-vinyl acetate)
in a
concentration range from approximately 10 wt.% to approximately 19 wt.%. In
still another
example, the dry concrete mix can include Portland cement in a concentration
range from
approximately 35 wt.% to approximately 45 wt.%, silica sand in a concentration
range from
approximately 30 wt.% to approximately 40 wt.%, alumina silicate (perlite) in
a concentration
range from approximately 4 wt.% to approximately 6 wt.%, and poly(ethylene-
vinyl acetate)
in a concentration range from approximately 15 wt % to approximately 25 wt.%.
[0034] As an additional example, the dry concrete mix can include Portland
cement in a
concentration range from approximately 25 wt % to approximately 60 wt %,
silica sand in a
concentration range from approximately 25 wt.% to approximately 60 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 0.5 wt.% to
approximately 5 wt.%, and
latex and/or acrylic polymers in a concentration range from approximately 0.5
wt.% to
approximately 8 wt.%. As another example, the dry concrete mix can include
Portland cement
in a concentration range from approximately 40 wt.% to approximately 65 wt.%,
silica sand in
a concentration range from approximately 40 wt.% to approximately 65 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 0.5 wt.% to
approximately 5 wt.%, and
latex and/or acrylic polymers in a concentration range from approximately 0.5
wt.% to
approximately 8 wt.%.
[0035] As an additional example, the dry concrete mix can include Portland
cement in a
concentration range from approximately 20 wt% to approximately 40 wt.%, silica
sand in a
concentration range from approximately 30 wt.% to approximately 79 wt.%,
alumina silicate
(perlite) in a concentration range from approximately 0.5 wt.% to
approximately 6 wt %, and
latex and/or acrylic polymers in a concentration range from approximately 0.5
wt.% to
approximately 5 wt.%. As yet another example, the dry concrete mix can include
Portland
cement in a concentration range from approximately 20 wt.% to approximately 30
wt.%, silica
sand in a concentration range from approximately 30 wt.% to approximately 79
wt.%, alumina
silicate (perlite) in a concentration range from approximately 0.5 wt.% to
approximately 6
wt.%, and latex and/or acrylic polymers in a concentration range from
approximately 0.5 wt.%
to approximately 5 wt.%. As yet another example, the dry concrete mix can
include Portland
9
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
cement in a concentration range from approximately 21 wt.% to approximately 40
wt.%, silica
sand in a concentration range from approximately 30 wt.% to approximately 78
wt.%, alumina
silicate (perlite) in a concentration range from approximately 0.5 wt.% to
approximately 6
wt.%, and latex and/or acrylic polymers in a concentration range from
approximately 0.5 wt.%
to approximately 5 wt.%. As yet another example, the dry concrete mix can
include Portland
cement in a concentration range from approximately 25 wt.% to approximately 35
wt.%, silica
sand in a concentration range from approximately 30 wt.% to approximately 74
wt.%, alumina
silicate (perlite) in a concentration range from approximately 0.5 wt.% to
approximately 6
wt.%, and latex and/or acrylic polymers in a concentration range from
approximately 0.5 wt.%
to approximately 5 wt.%.
100361 As an additional example, the dry concrete mix can include Portland
cement in a
concentration range from approximately 23 wt.% to approximately 70 wt.%,
silica sand in a
concentration range from approximately 30 wt % to approximately 75 wt %,
alumina silicate
(perlite) in a concentration range from approximately 0.5 wt.% to
approximately 6 wt.%, and
latex and/or acrylic polymers in a concentration range from approximately 0.5
wt.% to
approximately 8 wt.%.
100371 While the various example formulations or compositions are expressly
described
herein as "comprising" or "including" certain materials (often in relation to
certain
concentration ranges), it is to be understood that the disclosure fully
contemplates formulations
or compositions that "consist essentially of' the described combinations
and/or concentration
ranges of materials.
100381 The disclosed technology includes methods for installing paver tiles
using the
disclosed paver adhesives. The method can include cleaning the substrate or
area where the
paver tiles are to be installed (e.g., concrete pad), such as by power washing
the surface of the
substrate. It is preferable to wait for the surface to become substantially
dry before continuing
the method.
100391 The method can include distributing the paver adhesive on the substrate
while the
paver adhesive is in a dry state (e.g., in powder form). For example, the
method can include
spreading a layer of the paver adhesive over a concrete pad. The paver
adhesive can be
distributed or spread to have a substantially uniform depth. Any useful amount
of dry paver
adhesive can be applied. For example, the layer of the applied paver adhesive
can have a depth
in the range between approximately 0.25 inch to approximately 0.5 inch.
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
[0040] It can be helpful to apply additional paver adhesive (e.g., a thicker
layer), for example,
in areas of the substrate that are uneven, have dips, or other deformities. It
is preferable to not
exceed a dry paver adhesive thickness of 1.5 inches. Additional paver adhesive
can be applied,
but this may increase the difficulty or amount of water required for
subsequently hydrating the
paver adhesive (as explained more fully below) and/or the amount of time
required for the
paver adhesive to cure and/or harden.
[0041] The method can include covering any existing expansion joints or cracks
of the
substrate with the paver adhesive. Small cracks (e.g., up to 0.75 inch) can be
covered with the
paver adhesive. If the substrate is damaged to a greater extent than small
cracks, it may be
necessary to cut out the corresponding portion of the substrate to the full
depth of the substrate
and repair the corresponding portion of the substrate prior to continuing the
disclosed method.
For example, repairing a portion of the substrate can include refilling the
removed portion of
the substrate with concrete or the like using rebar, which can help provide
adequate strength
for the substrate.
[0042] The method can include laying (e.g., setting, positioning) paver tiles
over or atop the
dry paver adhesive. It may be helpful to lay paver tiles to track any outer
edges of the substrate
and/or to abut any structures adjacent to the substrate (e.g., a house, a
building, a retaining
wall). That is, it may be helpful to create a border of paver tiles.
Optionally, the method can
include cutting a groove in the substrate at or near the border. The groove
can provide a channel
for increased paver adhesive depth, which can help enhance bond strength
between the border
tiles and the substrate. Similarly, it may be beneficial to cut two
substantially parallel grooves
at or near the border of the substrate.
[0043] If desired, it can be helpful use a wet mortar to lay the border tiles.
For example, the
method can include mixing a latex modifier and/or hydrating the paver adhesive
to create a wet
mortar and spreading the wet mortar along the border area of the substrate.
The corresponding
border tiles can then be laid atop the wet mortar bed and permitted to cure
and/or harden. This
can enable a user to create a solidified border without wetting the interior
area where the dry
paver adhesive is located or will be applied.
[0044] Once paver tiles have been placed atop the dry paver adhesive, the
method can include
hydrating the dry paver adhesive, which can include spraying or otherwise
applying water atop
the installed paver tiles and the underlying paver adhesive. Once the paver
adhesive has been
sufficiently hydrated, the method can include spreading or distributing mason
sand over the
installed paver tiles to fill joints. Once hydrated, the method can include
permitting the paver
11
CA 03166803 2022- 8-2
WO 2021/158605
PCT/US2021/016327
adhesive to cure and/or harden and to gain strength before beginning normal
use. For example,
it may be necessary to wait approximately 24 hours to approximately 72 hours
before beginning
normal use.
100451 The disclosed technology can enable secure adhesion of paver tiles to a
substrate. As
will be appreciated, the layer of paver tiles above the hydrated paver
adhesive can serve as a
curing membrane to prevent rapid evaporation of the water in the hydrated
paver mix. Further,
any border construction made by laying down a wet mortar bed and a layer of
paver tiles can
serve to contain the hydrating water subsequently applied to the interior
portion of paver tiles
laid atop the dry paver adhesive and thus preventing hydraulic pressure from
"washing out"
the dry paver adhesive from beneath the interior paver tiles.
100461 While certain embodiments of the disclosed technology have been
described in
connection with what is presently considered to be the most practical
embodiments, it is to be
understood that the disclosed technology is not to be limited to the disclosed
embodiments, but
on the contrary, is intended to cover various modifications and equivalent
arrangements
included within the scope of the appended claims. Although specific terms are
employed
herein, they are used in a generic and descriptive sense only and not for
purposes of limitation.
12
CA 03166803 2022- 8-2
