Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
METHOD AND APPARATUS FOR SPREADING CHIPS ON ROADWAY
USING FOAMED ASPHALT CEMENT
FIELD OF TIIE INVENTION
The invention relates generally to a method and apparatus for carrying out a
chip sealing
operation on a roadway. More particularly, the invention relates to methods
and devices for use
in carrying out a chip sealing operation using foamed asphalt cement as a
binder.
BACKGROUND AND DESCRIPTION OF THE PRIOR ART
Roadway repair is often accomplished by overlaying the existing pavement
(whether of concrete
or asphalt paving material) with a new layer (often called a leveling course)
of concrete or
asphalt paving material. This is an expensive and time-consuming process and
is not always
necessary. An alternative is to employ a chip sealing process for extending
the useful life of the
existing roadway. The typical cost of a chip sealing process is 20-25% of the
cost of a
conventional asphalt overlay. In the chip sealing process, a binder
composition including asphalt
cement is applied to the surface of the existing roadway, and then a layer of
stone chips having
high durability and high fracture plane characteristics is spread over the
asphalt composition.
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A chip seal is designed to seal and protect a pavement from oxidation and
weathering by sealing
the small cracks in a pavement surface and thereby preventing the intrusion of
water into the
pavement surface. A chip seal can also be used to address raveling (loss of
aggregate), to correct
bleeding and flushing problems, to improve skid resistance and generally to
extend the pavement
life. Chip seals are not suited for all pavements: the existing structure
should be sound, with
only minor surface defects. Consequently, chip seals are typically applied to
pavements that are
in relatively good condition with no underlying structural damage. When a chip
seal is applied
to a pavement in relatively good condition, an additional six to eight years
of service may be
expected. For more distressed pavements, less service extension can be
expected (four to six
years on pavements in fair condition and three to four years for pavements in
poor condition).
Different types of asphalt cement binder compositions can be used in a chip
sealing process. The
composition may be applied with or without heating. Asphalt cement binder
compositions that
are applied without heating in conventional chip sealing operations include
modified and
unmodified asphalt cement emulsions. Compositions that are applied hot in
conventional chip
sealing operations can include polymer-modified asphalt cements, polymer-
modified asphalt
cements blended with rubber or crumb rubber and unmodified asphalt cements.
The appropriate
binder type is selected based on pavement condition, climate, aggregate
properties, and desired
service life and cost considerations.
The amount of binder that is applied must be carefully controlled to obtain
optimal results. It is
desirable to use sufficient binder to bond the chips to the roadway surface,
but not so much that
the binder bleeds to the upper surface of the roadway over time. When the
binder comprises a
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paving grade asphalt cement, it is difficult to apply enough binder to hold
the chips in place on
the roadway without significant bleed over. This allows the asphalt cement to
be tracked by the
wheels of the vehicles that are passing along the roadway. Consequently, in
many conventional
chip sealing processes, an emulsion is formed of asphalt cement and about 30%
water. This
emulsified mixture is then applied to the road using an asphalt emulsion
supply truck equipped
with a spray assembly. However, when the binder comprises an asphalt cement
emulsion, the
water in the emulsion begins to evaporate as soon as the emulsion meets the
road surface.
Furthermore, even if the chips are applied before much water has evaporated,
the emulsion will
tend to settle to the surface of the roadway, leaving much of the surface area
of the chips without
any binder material. Subsequent vehicular traffic will tend to dislodge the
chips from the thin
layer of emulsion on the roadway, resulting in an inferior and short-lived
repair. One solution to
these challenges is to apply a second layer of asphalt cement emulsion (i.e.,
a fog coat) over the
completed chip-sealed roadway.
It would be desirable if a chip sealing method and apparatus could be
developed that would
avoid the problems associated with conventional chip sealing operations.
ADVANTAGES OF THE PREFERRED EMBODIMENTS OF THE INVENTION
Among the advantages of the invention is that it provides a chip sealing
method that permits chip
sealing to be carried out in such a manner that the chips are substantially
coated with the asphalt
cement binder material without substantial bleed over of binder material.
Other advantages of the invention include providing a chip sealing method and
apparatus that
permits chip sealing to be carried out without having the wheels of any
vehicle drive on the chip-
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free asphalt binder composition on the roadway surface. Furthermore, when a
chip sealing
operation is carried out according to an embodiment of the invention utilizing
a chip sealing train
that includes a chip supply dump truck, a modified chip spreader (as described
in some detail
hereinafter) and an asphalt cement supply truck, all three vehicles are able
to travel in a forward
direction, i.e., with the operator of each vehicle facing forward in the chip
spreading direction.
Still other advantages and features of this invention will become apparent
from an examination
of the drawings and the ensuing description.
NOTES ON CONSTRUCTION
The use of the terms "a", "an", "the" and similar terms in the context of
describing the invention
are to be construed to cover both the singular and the plural, unless
otherwise indicated herein or
clearly contradicted by context. The teims "comprising", "having", "including"
and "containing"
are to be construed as open-ended terms (i.e., meaning "including, but not
limited to,") unless
otherwise noted. The terms "substantially", "generally" and other words of
degree are relative
modifiers intended to indicate permissible variation from the characteristic
so modified. The use
of such terms in describing a physical or functional characteristic of the
invention is not intended
to limit such characteristic to the absolute value which the term modifies,
but rather to provide an
approximation of the value of such physical or functional characteristic.
Terms concerning attachments, couplings and the like, such as "attached",
"coupled",
"connected" and "interconnected", refer to a relationship wherein structures
are secured or
attached to one another either directly or indirectly through intervening
structures, as well as
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both moveable and rigid attachments or relationships, unless specified herein
or clearly indicated
by context. The terms "operatively attached" and "operatively connected"
describe such an
attachment, coupling or connection that allows the pertinent structures to
operate as intended by
virtue of that relationship. The term "fluid communication" refers to such an
attachment,
coupling or connection that allows for the flow of fluid from one such
structure or component to
or by means of the other.
The use of any and all examples or exemplary language (e.g., "such as" and
"preferably") herein
is intended merely to better illuminate the invention and the preferred
embodiments thereof, and
not to place a limitation on the scope of the invention. Nothing in the
specification should be
construed as indicating any element as essential to the practice of the
invention unless so stated
with specificity. Several terms are specifically defined herein. These terms
are to be given their
broadest reasonable construction consistent with such definitions, as follows:
The term "foamed asphalt cement" refers to an asphalt binder composition that
is made by
mixing hot liquid asphalt cement with cold water or with cold water and air in
a mixing or
foaming chamber. Foamed asphalt cement is characterized by a phase change of
the cold water
to steam when it comes into contact with the hot asphalt cement in the mixing
or foaming
chamber. Foamed asphalt cement is distinguishable from an emulsion of cold
asphalt cement
and water.
The term "chip sealing train" refers to a combination of a chip supply dump
truck, a chip
spreader and an asphalt cement supply truck that are used together in a chip
sealing operation.
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The term "chip spreading direction" is the direction of travel of the
components of the chip
scaling train during the chip sealing operation.
The term "in front of' and similar terms refer to an assembly, component or
portion of a chip
spreader or a component of a chip sealing train that is in the chip spreading
direction with respect
to a reference point, assembly, component or portion of the chip spreader or
component of the
chip sealing train.
The term "front end" and similar terms, when used with respect to a chip
sealing train or a
vehicular component of a chip sealing train, refer to a relative location or
direction towards the
leading end of the chip sealing train or a vehicular component thereof as it
travels in the chip
spreading direction.
The term "behind" and similar terms refer to an assembly, component or portion
of a chip
spreader or a component of the chip sealing train that is in the direction
opposite the chip
spreading direction with respect to a reference point, assembly, component or
portion of the chip
spreader or component of the chip sealing train.
The terms "rear end" and similar terms, when used with respect to a chip
sealing train or a
vehicular component of a chip sealing train, refer to a relative location or
direction towards the
trailing end of the chip sealing train or a vehicular component thereof as it
travels in the chip
spreading direction.
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The term "modified chip spreader" refers to a chip spreader which has been
modified: (a) by the
addition of an asphalt composition flow system including a foaming chamber and
a spray
assembly that is mounted in front of the chip spreader and is adapted to
dispense foamed asphalt
cement across the surface of the roadway; and (b) so that the operator of the
modified chip
spreader may face forward when the modified chip spreader travels in the chip
spreading
direction. Modified chip spreaders include retrofitted conventional chip
spreaders and new
machines that are designed to function as described herein.
SUMMARY OF THE INVENTION
The invention comprises a method and apparatus for carrying out a chip sealing
process using
foamed asphalt cement. A first embodiment of the apparatus comprises a chip
sealing train
including a chip supply dump truck, a conventional chip spreader, and an
asphalt cement supply
truck that is modified to permit the dispersal of foamed asphalt cement on the
roadway. In this
embodiment of the invention, the asphalt cement supply truck includes a cement
tank for
containing hot asphalt cement, a water tank, and a foam dispersal assembly
comprising a spray
bar that extends across the roadway. The foam dispersal assembly includes a
foaming chamber,
an asphalt cement supply line from the cement tank to the foaming chamber and
a water supply
line from the water tank to the foaming chamber. The chip spreader in this
embodiment of the
invention is a self-propelled vehicle that has a receiving hopper on its rear
end, a spreader
assembly including a spreader hopper on its front end, and a conveyor assembly
for conveying
stone chips from the receiving hopper to the spreader assembly. When the chip
supply dump
truck is operatively attached to the chip spreader, and the dump bed of the
chip supply truck is
raised, stone chips will fall into the receiving hopper of the chip spreader.
The modified asphalt
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cement supply truck is operated to drive along the roadway dispensing foamed
asphalt cement
onto the roadway. The foaming process greatly increases the volume of the
asphalt cement
binder. As the chip spreader is driven along the roadway in the chip spreading
direction, closely
behind the modified asphalt cement supply truck, the conveyor assembly is
operated to convey
stone chips to the spreader assembly which dispenses stone chips on the newly
applied foamed
asphalt cement on the roadway. Because the foamed asphalt cement on the
roadway has a much
greater volume than liquid asphalt cement or an asphalt cement emulsion, it
will engulf the chips
on the roadway. Furthermore, because the foamed asphalt cement has a greater
viscosity than
does an asphalt cement emulsion, it will tend to cling to the chips on the
roadway even as the
foam breaks down. What results is a chip seal that is more durable and less
likely to bleed over
than conventional chip seals.
In a second embodiment of the invention, the chip sealing train includes a
modified chip spreader
that is adapted to be used in a chip sealing train including a chip supply
dump truck and an
asphalt cement supply truck. The modified chip spreader is a self-propelled
vehicle that has a
receiving hopper on its front end, a spreader assembly on its rear end and a
conveyor assembly
for conveying stone chips from the receiving hopper to the spreader assembly.
In this
embodiment of the invention, the asphalt cement supply truck includes a cement
tank for
containing hot asphalt cement, and either the asphalt cement binder supply
truck or the modified
chip spreader includes a water tank. The modified chip spreader also includes
a foam dispersal
assembly comprising a foaming chamber and a spray bar that extends across the
roadway. An
asphalt cement supply line provides fluid communication from the cement tank
to the foaming
chamber and a water supply line provides fluid communication from the water
tank to the
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foaming chamber. Either the asphalt cement supply truck or the modified chip
spreader has an
asphalt cement pump that is adapted to pump the hot asphalt cement from the
cement tank to the
foaming chamber and a water pump that is adapted to pump water from the water
tank to the
foaming chamber. It is also preferred that the modified chip spreader have a
tow bar on its rear
end that is operatively attached to a tow-bar hitch assembly on the front end
of the asphalt
cement supply truck, and a hitch assembly on its front end for coupling it to
rear end of the chip
supply dump truck. When the chip supply dump truck and the asphalt cement
supply truck are
operatively attached to the preferred modified chip spreader according to this
embodiment of the
invention, and the dump bed of the chip supply truck is raised, stone chips
will fall into the
receiving hopper of the modified chip spreader. As the preferred modified chip
spreader is
driven along the roadway in the chip spreading direction, pushing the chip
supply dump truck
and pulling the asphalt cement supply truck, the conveyor assembly is operated
to convey stone
chips to the spreader assembly, the foam dispersal assembly is operated to
dispense foamed
asphalt cement on the roadway in front of the spreader assembly, and the
spreader assembly is
operated to dispense stone chips onto the newly applied foamed asphalt cement
on the roadway.
In order to facilitate an understanding of the invention, the preferred
embodiments of the
invention, as well as the best modes known by the inventors for carrying out
the invention, are
illustrated in the drawings, and a detailed description thereof follows. It is
not intended,
however, that the invention be limited to the particular embodiments described
or to use in
connection with the apparatus illustrated herein. Therefore, the scope of the
invention
contemplated by the inventors includes all equivalents of the subject matter
described herein, as
well as various modifications and alternative embodiments such as would
ordinarily occur to one
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skilled in the art to which the invention relates. The inventors expect
skilled artisans to employ
such variations as seem to them appropriate, including the practice of the
invention otherwise
than as specifically described herein. In addition, any combination of the
elements and
components of the invention described herein in any possible variation is
encompassed by the
invention, unless otherwise indicated herein or clearly excluded by context.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently preferred embodiment of the invention is illustrated in the
accompanying
drawings, in which like reference numerals represent like parts throughout,
and wherein:
Figure I is a perspective view of a conventional chip spreader that may be
employed in a first
embodiment of the invention.
Figure 2 is a side view of a chip sealing train according to a first
embodiment of the invention.
Figure 3 is an enlarged view of a portion of the chip sealing train
illustrated in Figure 2.
Figure 4 is a side view of a chip sealing train according to a second
embodiment of the invention.
Figure 5 is a perspective view of the chip sealing train illustrated in Figure
4.
Figure 6 is an illustration of chips on a roadway that are partially engulfed
by foamed asphalt
cement immediately after being deposited on a roadway according to the
invention.
CA 3023700 2018-11-09
Figure 7 illustrates the partial coverage of the chips by foamed asphalt
cement even after the
foam has begun to break down.
Figure 8 illustrates the chip arrangement shown in Figures 6 and 7 after the
chips have been
pressed into the roadway surface by a mechanical roller.
DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
This description of preferred embodiments of the invention is intended to be
read in connection
with the accompanying drawings, which are to be considered part of the entire
written
description of this invention. The drawing figures are not necessarily to
scale, and certain
features of the invention may be shown exaggerated in scale or in somewhat
schematic foini in
the interest of clarity and conciseness.
As shown in Figure 1, conventional chip spreader 10 is a self-propelled
vehicle that is adapted to
be driven in chip spreading direction "C" by an operator who is seated at
operator's station 11.
Chip spreader 10 is adapted to follow a conventional asphalt cement supply
truck (not shown in
Figure 1) which is dispensing an asphalt cement binder composition from a
spray assembly
located at the rear end of the asphalt cement supply truck. Chip spreader 10
has receiving hopper
12 on its rear end and spreader assembly 13 on its front end. Receiving hopper
12 is adapted to
receive chips from a chip supply dump truck (also not shown in Figure 1), and
conveyor
assembly 14 is adapted to convey these chips from receiving hopper 12 to
spreader assembly 13,
which disperses the chips across the roadway. Hitch assembly 15 is located on
the rear end of
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chip spreader 10 for coupling the chip spreader to the rear end of a chip
supply dump truck.
Since the receiving hopper can only accommodate a portion of the load of the
chip supply truck,
the dump bed of the chip supply truck is raised and the chip spreader is
coupled to the chip
supply truck for a period of time sufficient to unload the chips from the dump
truck as chip
spreader 10 travels in direction "C" pulling the dump truck backwards, and as
chips are conveyed
from the receiving hopper to the chip spreader assembly on the front end of
this conventional
chip spreader.
A first embodiment 16 of a chip sealing train that is adapted to operate
according to the invention
is illustrated in Figures 2 and 3. Chip sealing train 16 includes modified
liquid asphalt cement
supply truck 17, conventional chip spreader 18 (which is substantially similar
to chip spreader
10) and conventional chip supply dump truck 19. Modified liquid asphalt cement
supply truck
17 includes asphalt cement tank 20 for containing hot liquid asphalt cement,
water tank 21 and a
foam dispersal assembly comprising spray bar 22 that extends across the
roadway (perpendicular
to the plane of Figures 2 and 3). The foam dispersal assembly includes foaming
chamber 23,
asphalt cement supply line 24 that is in fluid communication with asphalt
cement tank 20 and the
foaming chamber, and water supply line 25 that is in fluid communication with
water tank 21
and foaming chamber 23. Modified liquid asphalt cement supply truck 17 also
includes means
for heating the foaming chamber and suitable valves and pumps to pump the
water and asphalt
cement into the foaming chamber at a desired ratio.
Chip spreader 18 is a self-propelled vehicle having frame 26 that is supported
by front wheel
assembly 27 and rear wheel assembly 28. The wheel assemblies are operatively
connected to an
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engine 29 that is located beneath operator's station 30. Suitable controls and
controllers are
provided in the operator's station to operate all of the components of chip
spreader 18 and to
drive it in chip spreading direction "C" by an operator in operator's station
30 who is facing in
the chip spreading direction. Chip spreader 18 has receiving hopper 31 on its
rear end and
spreader assembly 32 on its front end. Receiving hopper 31 is adapted to
receive chips from chip
supply dump truck 19, and conveyor assembly 33 is adapted to convey these
chips from
receiving hopper 31 to spreader assembly 32, which disperses the chips across
the roadway atop
the newly discharged foamed asphalt cement. A conventional hitch assembly (not
shown) may
be located on the rear end of chip spreader 18 for coupling the chip spreader
to the rear end of
chip supply dump truck 19. Since the receiving hopper can only accommodate a
portion of the
load of the chip supply dump truck, the dump bed 34 of supply truck 19 is
raised and the chip
spreader is coupled to the supply truck for a period of time sufficient to
unload the chips from the
dump truck as chip spreader 18 travels in chip spreading direction "C" pulling
the dump truck
backwards and as chips are conveyed from the receiving hopper to the chip
spreader assembly on
the front end of chip spreader 18.
A second embodiment 35 of a chip sealing train that is adapted to operate
according to the
invention is shown in Figures 4 and 5. This embodiment of the invention
employs a modified
chip spreader 36 that permits chip sealing to be carried out without having
the wheels of any
vehicle drive on the chip-free asphalt composition on the roadway surface,
while allowing all
three vehicles in the chip sealing train to travel with the operator of each
vehicle facing forward
in the chip spreading direction "C". As shown in Figures 4 and 5, chip sealing
train 35 includes,
in addition to modified chip spreader 36, chip supply dump truck 37 and liquid
asphalt cement
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supply truck 38. Modified chip spreader 36 is a self-propelled vehicle having
frame 39 that is
supported by front wheel assembly 40 and rear wheel assembly 41. The wheel
assemblies are
operatively connected to an engine 42 that is located beneath operator's
station 43. Suitable
controls and controllers are provided in the operator's station to operate all
of the components of
modified chip spreader 36 and to drive it in chip spreading direction "C" by
an operator who is
facing forward as the machine moves in the chip spreading direction. Modified
chip spreader 36
also has receiving hopper 44 on its front end, a spreader assembly including a
spreader hopper 45
on its rear end, and conveyor assembly 46 for conveying stone chips from
receiving hopper 44 to
the spreader assembly.
Modified chip spreader 36 includes water tank 47 and a foam dispersal assembly
comprising
spray bar 48 that extends across the roadway (perpendicular to the plane of
Figure 4) near the
rear end of modified chip spreader 36. The foam dispersal assembly includes
foaming chamber
49 and a water supply line (not shown, but substantially similar to water
supply line 25 shown in
Figures 2 and 3) that is in fluid communication with water tank 47 and the
foaming chamber.
The foam dispersal assembly also includes asphalt cement supply line 50 that
is in fluid
communication with asphalt cement tank 51 on asphalt cement supply truck 38
and foaming
chamber 49. Modified chip spreader 36 also includes asphalt cement pump 52 for
pumping
asphalt cement from asphalt cement tank 51 into foaming chamber 49 and water
pump 53 for
pumping water from water tank 47 into the foaming chamber. Modified chip
spreader 36 also
includes means for heating the foaming chamber and suitable valves and
controls to permit the
introduction of water and asphalt cement into the foaming chamber at a desired
ratio. In other
embodiments of the invention (not shown), the asphalt cement pump may be
located on asphalt
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cement supply truck 38 instead of on chip spreader 36. Spray bar 48 is located
in front of
spreader hopper 45, and is adapted to dispense foamed asphalt cement onto the
surface of a
roadway in advance of the discharge of stone chips on the roadway.
Although it is not essential that modified chip spreader 36 be operatively
attached to chip supply
dump truck 37 and to asphalt cement supply truck 38, such a configuration of
the chip sealing
train is preferred. Such a configuration will permit the operator of the
modified chip spreader to
easily control the rate of advance of the vehicular components of the chip
sealing train as it
carries out a chip sealing operation.
Chip supply dump truck 37 is a conventional dump truck having a front end 54
adjacent to which
is an operator's cab. Chip supply dump truck 37 is adapted to haul stone chips
and is preferably
equipped with a conventional hitch coupler (not shown) for attachment to a
hitch assembly (also
not shown, but similar to hitch assembly 15 on chip spreader 10) on the front
end of modified
chip spreader 36. Asphalt cement supply truck 38 is a conventional tanker
truck having a front
end 55 adjacent to which is an operator's cab. Asphalt cement supply truck 38
is adapted to haul
hot liquid asphalt cement that is suitable for foaming. Preferably, modified
chip spreader 36 is
equipped with tow bar 56 on its rear end that is attached to a tow-bar hitch
assembly on front end
55 of asphalt cement supply truck 38. It is also preferred that modified chip
spreader 36 be
equipped with a roller assembly 57 on its front end (similar to those found on
asphalt paving
machines) that can be engaged by rear wheel assembly 58 of chip supply truck
37 as dump bed
59 is raised to discharge stone chips into receiving hopper 44. As chip supply
truck 37 unloads
CA 3023700 2018-11-09
stone chips into receiving hopper 44, conveyor assembly 46 will carry the
stone chips upwardly
and off upper end 60 of conveyor assembly 46 into spreader hopper 45 of the
spreader assembly.
When the chip supply dump truck and the asphalt cement supply truck are
operatively attached
to the preferred modified chip spreader, and dump bed 61 of chip supply truck
37 is raised, stone
chips will slide and/or fall into receiving hopper 44 of modified chip
spreader 36. As the
preferred modified chip spreader is driven along the roadway in the chip
spreading direction,
pushing the chip supply dump truck and pulling the asphalt cement supply
truck, conveyor
assembly 46 on the modified chip spreader is operated to convey stone chips
from receiving
hopper 44 to the spreader assembly, and asphalt cement pump 52 and water pump
53 are
operated to pump asphalt cement from supply tank 51 of the asphalt cement
supply truck and
water from water tank 47 to foaming chamber 49 of the spray assembly. The
spray assembly
will dispense foamed asphalt cement on the roadway and the spreader assembly
will dispense
stone chips out of spreader hopper 45 onto the newly applied foamed asphalt
cement across the
roadway.
Figures 6-8 illustrate a chip seal that may be obtained according to the
invention. Because the
foamed asphalt cement on the roadway surface "S" has a much greater volume
than asphalt
cement or asphalt cement emulsions, its initial depth on the roadway, defined
by the dimension
"F", will engulf the chips 62 on the roadway, as shown in Figure 6.
Furthermore, because the
foamed asphalt cement has a greater viscosity than does an asphalt cement
emulsion, it will tend
to cling to chips 62 on the roadway, as shown by the hatched areas 63, even as
the foam breaks
down to its base level defined by the dimension "B", as shown in Figure 7.
Even when the chip
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seal is rolled by a mechanical roller, as shown in Figure 8, sufficient binder
63 remains on the
chips so that any that are dislodged by traffic on the roadway will quickly
reattach themselves to
the chip sealed road. What results from the invention, therefore, is a chip
seal that is more
durable and less likely to bleed over than conventional chip seals.
Although this description contains many specifics, these should not be
construed as limiting the
scope of the invention but as merely providing an illustration of the
presently preferred
embodiments thereof, as well as the best mode contemplated by the inventors of
carrying out the
invention. The invention, as described and claimed herein, is susceptible to
various
modifications and adaptations as would be appreciated by those having ordinary
skill in the art to
which the invention relates.
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