Epoxy asphalt modified concrete (EAMC) overlays system for rigid and flexible pavements for road construction and maintenance

Abstract

The present invention relates to epoxy asphalt modified concrete (EAMC)bituminous overlays on rigid and flexible pavements for road construction and maintenance. The pavement structure (100 A and 100 B) with an overlay of an epoxy asphalt (102 A and 102B), in accordance with an embodiment of the present invention. In an embodiment, EAMC overlays system over the Rigid Pavement- The Pavement structure (100 B) with an overlay of an epoxy asphalt modified concrete (102B) over the rigid pavement, in accordance with an embodiment of the present invention. The pavement structure includes a first layer (106) of a tack coat sprayed on a surface of an existing pavement structure (104A), a third layer (110) of reflective crack relief interlayer (RCRI) sandwiched between a second layer of a first paving fabrics provided over the first layer and a fourth layer (112) of a second paving fabrics (108) provided over the third layer such that the third layer is provided over second layer, and a fifth layer (114) of a binder having a combination of an epoxy, asphalt and a bitumen provided over the fourth layer, wherein the fifth layer operates as a top surface of the pavement structure on rigid pavements. In another embodiment, EAMC overlays system over the Flexible Pavement, the Pavement structure (100 A) with an overlay of an epoxy asphalt modified concrete (102A) over the flexible pavement, in accordance with an embodiment of the present invention. This includes a first layer (112) of Glass fibre Geo grid (self-adhesive backing / tack coat) surface of an existing pavement structure (104 A); and a second layer (114) of a binder having combination of an epoxy, asphalt and a bitumen provided over the first layer, wherein the second layer operates as a top surface of the pavement structure.

Description

EPOXY ASPHALT MODIFIED CONCRETE (EAMC) OVERLAYS SYSTEM FOR RIGID AND FLEXIBLE PAVEMENTS FOR ROAD CONSTRUCTION AND MAINTENANCETECHNICAL FIELD

[0001] The invention relates to the technical field of road construction and maintenance, in particular to overlays system for a top layer surface of roads and a construction method thereof. More specifically, the invention relates to epoxy asphalt modified bituminous (EAMC) overlays on rigid and flexible pavements for road construction and maintenance.BACKGROUND

[0002] The following are two pavement types used in road construction.1. Flexible Pavement2. Rigid Pavement

[0003] Both Pavements (Flexible and Rigid Pavement) are built up in several layers, consisting of: 1. Sub-grade, 2. Sub-base, 3. Base and 4. Surface layer / Top layer.

[0004] These layers together. Constitute the pavement. The number of layers and their thickness can vary depending on the type of road, traffic load, soil condition, and other factors. The road surface / top layer is not only subjected to the action of wheel load, but also affected by natural environmental factors.

[0005] The influence of traffic load and atmospheric factors on the road surface is generally gradually weakened along with the depth, so that the road surface is usually of a multilayer structure, the material with good quality is laid on the upper layer with larger stress, and the material with lower quality is laid on the lower layer with smaller stress, thereby forming a road surface structure form that the material with different specifications and requirements is adopted on the roadbed, and the cushion layer, the base layer and the surface layer are respectively laid.

[0006] Conventionally bitumen / modified plastic / polymer / rubberized bitumen has been using for resurfacing of road for existing flexible pavements, however the biggest downside of conventional bituminous overlay is that it cannot correct any underlying problems of existing subgrade such as: frost heaves road, shear failure cracking in pavement, settlement of fill material, potholes on road, contraction and expansion movement during the climatic changes, and nonbonding of overlay with existing surface,

[0007] Also, there are certain limitations of the existing rigid pavements (cement concrete road) such as but not limited to:• Rigid pavement requires frequent joint maintenance. - They are liable to crack and warp due to temperature variations;• Rigid pavement cannot be opened to traffic shortly after construction;• It creates noise, as tired vehicles cause lot of noise while moving on rigid pavement;• Rigid pavement does lose non-skid surface with time;• The rigid pavement is Low and very rough riding quality; and• Any excessive deformations occurring due to heavier wheel loads are not recoverable in this rigid pavement.• Heating of tyres due to excessive friction due to high roughened surface, tyre bursts.• Demolishing and re -construction of complete new rigid pavement with subgrade is only one solution for above problems of rigid pavement, but it is not feasible as well as it is very costly and time taking activity for running expressway / roads to demolish and reconstruct the rigid pavement.SUMMARY

[0008] An object of the present invention is to solve at least the above problems and to provide at least the advantages described later.

[0009] The invention also aims to provide a highway pavement structure and a construction method thereof.

[0010] The present invention addresses the problem by providing epoxy asphalt modified concrete overlays system for road constructions and maintenance work for low noise, less friction, smooth riding quality as well as extremely durable roads.

[0011] Epoxy Asphalt Modified bituminous overlays system is designed for overlaying rigid and flexible pavements in road construction and maintenance work for low noise, less friction, smooth riding quality as well as extremely durable roads.

[0012] The system of present invention includes:

[0013] Layer of Epoxy Asphalt Modified Concrete by using 3 components modified binder, Component of modified binder as follows: Epoxy Asphalt, Asphalt, and Bitumen from Indian Refinery;

[0014] Glass Fibre Geogrid Mats;

[0015] Layer of RCRI ((reflective cracks relief interlayer) by using Polymer modified Binder; and

[0016] Tack coat of Bitumen Emulsion.

[0017] The System is invented by using Epoxy Asphalt (2 Component Binder). Epoxy Asphalt has a history 53 years as a binder for airfield pavements, bridges, and roadways.

[0018] A concrete made with an Epoxy Asphalt Binder that, unlike conventional concrete, having many advantages as follows:■ Does not become brittle at low temperature■ Does not melt at high temperature.■ Epoxy Asphalt pavements have much higher stability, much less susceptibility to cracking,■ Less permeable and maintain skid resistance much longer than conventional pavements

[0019] To make the feasible and affordable price of binder for pavement concrete in India, Epoxy Asphalt is being modified with Indian refinery Bitumen.

[0020] The Results of specimens along with epoxy asphalt modified binder are much better than required parameters in Indian Specifications for Roads.

[0021] Additionally, 2 layers of paving mats and a layer of RCRI (reflective cracks relief interlayer) has been incorporated to stop the refective cracks, settlement due to subgrade failure of existing roads, tensile stresses on rigid pavements.

[0022] 1 layer of paving mat with tack coat has been incorporated before layer of epoxy asphalt modified concrete to address the tensile stresses and existing cracks on flexible roads.

[0023] Accordingly, the present invention provides a pavement overlay structure for rigid pavement with an overlay of epoxy asphalt modified concrete. The overlay pavement structure comprising in five layers for rigid pavements, as follows: i. A first layer of a tack coat sprayed on a surface of an existing rigid pavement structure. ii. A second layer of fiber glass geogrid paving mat having 50KN Tensile strength iii. A third layer of 25 mm thick reflective crack relief interlayer (RCRI) iv. A fourth layer of self-adhesive backing fiber glass geogrid paving mat having 100KN Tensile strength v. A fifth / top layer of 35 mm Epoxy Asphalt Modified Concrete (EAMC).

[0024] Also, the present invention provides a pavement overlay structure for flexible pavement with an overlay of epoxy asphalt modified concrete (EAMC). The overlay pavement structure comprising in two layers, as follows: i. A First layer of self-adhesive backing fiber glass geogrid paving mat having 100KN Tensile strength ii. A Second / top layer of 35 mm Epoxy Asphalt Modified Concrete (EAMC).

[0025] The present invention further provides a detailed method for overlay system for Rigid and Flexible Pavements, as follows:

[0026] Rigid Pavement- Constructing a overlay pavement structure on rigid pavement with an overlay of epoxy asphalt modified concrete. The method includes the steps of spraying a first layer of a tack coat on a surface of the rigid pavement structure, overlaying a second layer of a paving fabrics provided over the first layer, a third layer of 25 mm thick reflective crack relief interlayer (RCRI), and a fourth layer of a paving fabrics provided over the third layer, wherein the third layer is sandwiched between the second layer and the fourth layer; and overlaying a fifth layer of 35 mm thick epoxy asphalt modified concrete with a binder wherein the binder having a combination of an epoxy asphalt and a bitumen of Indian Refinery over the fourth layer.

[0027] Flexible Pavements - Constructing a pavement structure on flexible pavements with an overlay of epoxy asphalt modified concrete. The method includes the steps of overlaying a fiber glass geogrid pavement mat (self- adhesive backing / by using tack coat bitumen emulsion, overlaying a second / top layer of 35 mm thick epoxy asphalt modified concrete with a binder wherein the binder having a combination of an epoxy asphalt and a bitumen of Indian Refinery over the fourth layer.BRIEF DESCRIPTION OF DRAWINGS

[0028] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0029] The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:

[0030] FIG. 1A illustrates a sectional view of pavement structure with an overlay of epoxy asphalt modified concrete over the flexible pavements, in accordance with an embodiment of the present invention.

[0031] FIG. IB illustrates a sectional view of pavement structure with an overlay of epoxy asphalt modified concrete over the rigid pavements, in accordance with an embodiment of the present invention.

[0032] FIG. 2 illustrates a method for constructing a pavement structure with an overlay of epoxy asphalt, in accordance with an embodiment of the present invention.

[0033] FIG. 3 shows results of a standard test method for Marshall stability and flow of asphalt mixtures - ASTM D6927-15.

[0034] FIGs. 4A-4C shows results of permanent deformation behavior and rutting resistance of compacted asphalt mix in the modified loaded wheel tracker test utilizing controlled confining pressure - ASTM D8292 -20.

[0035] FIGs. 5A-5E shows results of design of flexible pavement with epoxy modified binder - IRC 37: 2018.

[0036] FIGs. 6A-5H shows results of mix trials for epoxy asphalt modified concrete by using 3 component binder i.e epoxy, asphalt and Bitumen of Indian refinery (VG40)

[0037] FIG. 7A shows a sectional view of pavement structure with an overlay of an epoxy asphalt for flexible pavement, in accordance with an embodiment of the present invention.

[0038] FIG. 7B shows a sectional view of pavement structure with an overlay of an epoxy asphalt for rigid pavement, in accordance with an embodiment of the present invention

[0039] FIGs. 8A-5G shows result of Reflective Crack Relief Interlayer (RCRI) mixture - 6 % and 7 % of PMB.DETAILED DESCRIPTION OF DRAWINGS

[0040] The present invention is described in detail below with reference to the attached drawings so that those skilled in the art can implement the invention by referring to the description.

[0041] The invention relates to the technical field of road construction and maintenance, in particular to overlays system for a top layer surface of roadsand a construction method thereof. More specifically, the invention relates to epoxy asphalt modified bituminous overlays on rigid and flexible pavements for road construction and maintenance.

[0042] In a preferred embodiment, FIG. 1A illustrates a sectional view of pavement structure (100A) with an overlay of an epoxy asphalt modified concrete over the flexible pavements (102A), in accordance with an embodiment of the present invention. i. A first layer of self-adhesive backing fiber glass geogrid paving mat having 100KN Tensile strength (112); ii. A second / top layer of 35 mm Epoxy Asphalt Modified Concrete (EAMC) (114).

[0043] In a preferred embodiment, FIG. IB illustrates a sectional view of pavement structure (100B) with an overlay of an epoxy asphalt modified concrete over the rigid pavements (102B), in accordance with an embodiment of the present invention. i. A first layer of a tack coat sprayed on a surface of an existing rigid pavement structure. (106); ii. A second layer of fiber glass geogrid paving mat having 50KN Tensile strength (108); iii. A third layer of 25 mm thick reflective crack relief interlayer (RCRI) (HO); iv. A fourth layer of self-adhesive backing fiber glass geogrid paving mat having 100KN Tensile strength (112); v. A fifth / top layer of 35 mm Epoxy Asphalt Modified Concrete (EAMC) (114).

[0044] It may be appreciated by a person skilled in the art that the pavement (existing pavement structure (104 A and 104 B), in construction, is an outdoor floor or superficial surface covering. Paving materials include asphalt, concrete, stones such as flagstone, cobblestone, and setts, artificial stone, bricks, tiles, and sometimes wood. In landscape architecture, pavements are part of the hardscape and are used on sidewalks, road surfaces, patios, courtyards, etc. Thepavement structure is a combination of subbase, base course, and surface course placed on a subgrade to support the traffic load and distribute it to the roadbed. The pavement structure can be of the following types: a cross section of modem pavements, a flexible asphalt-based pavement, and a rigid Portland cement concrete pavement. In other words, pavement is a structure consisting of superimposed layers of processed materials above the natural soil sub-grade, whose primary function is to distribute the applied vehicle loads to the sub-grade.

[0045] Also, it may be appreciated that the tack coat sprayed application of bitumen emulsion binder upon an existing flexible or Cement concrete pavement surface prior to an overlay, or between layers of bituminous concrete.

[0046] It may be further appreciated by a person skilled in the art that an overlay is any operation that consists of overlaying system either on Pavement Quality Concrete (PQC) pavement or Bituminous i.e., flexible pavement over an existing pavement structure.

[0047] This is different than a total replacement of the structure and is typically done when there is only minor to modest damage to the existing pavement structure where top layer / surface layer of pavement has to be changed.

[0048] In this embodiment, the pavement structure is a rigid pavement or a flexible pavement in road construction. It may be noted that, the flexible pavements tend to have more layers and are therefore much thicker by default, whereas the rigid pavement are those pavements that have fewer layers and are thinner than flexible pavements, which makes them susceptible to more repairs overtime.

[0049] In this embodiment, the tack coat includes an adhesive material applied between one or more surfaces of a concrete laid down for road construction.

[0050] In this embodiment, the tack coat includes an asphalt emulsion applied between one or more hot mix asphalt layers laid down for road construction.

[0051] In an exemplary embodiment, this adhesive when applied correctly, helps to prevent the degradation of the road by keeping the asphalt concrete layers together.

[0052] In an exemplary application, a sprayer typically applies the tack coat with a multitude of different nozzles and nozzle angles. Most likely, the many ways that the sprayers are configured and made directly affect the amount of tack coat put down and directly affect the durability of the road. When applying the tack coat, the trucks must go at a constant speed to get a uniform application of the tack coat on to the asphalt concrete pavement. If too little is applied, then the tack coat is not sufficient but add too much and it gets expensive.

[0053] It may be appreciated that, the tack coat (also known as bond coat) is a light application of asphalt emulsion between hot mix asphalt layers designed to create a strong adhesive bond without slippage. Heavier applications may be used under porous layers or around patches where it also functions as a seal coat. The type of emulsion used for tack coats varies from country to country. Normal practice in the USA is to use a slow-setting emulsion that is diluted with water before application. In many European countries cationic rapid setting or specially designated low viscosity medium setting emulsions are used, which are applied undiluted.

[0054] In this embodiment, the first paving fabric comprises a Glass Fiber Geogrid paving mat. It may be appreciated that the Glass Fiber Geogrid paving mat is a type of paving mat. The product is also known as Paving mat, glass geogrid mat etc.

[0055] In this embodiment, the second paving fabric comprises a fiberglass geogrid. It may be appreciated that the fiberglass geogrid is a new type of geosynthetic material. It is made from fiberglass filament. This product adopts a unique woven technique. It is coated with a special solution. Fiberglass geogridhas strong tension. It can largely increase the bearing capacity of the ground and prolongs the service life of the road. This material has high tensile strength and good wear resistant performance. It is suitable for the reinforcement of soft soil, cement, concrete, asphalt and so on. Compared with steel plastic geogrid, fiberglass geogrid has better heat resistance. This material is characterized by excellent thermal stability. It performs well under high temperatures.

[0056] Fiberglass geogrid has long term structural stability. It is suitable for permanent projects. Fiberglass geogrid is extensively used in asphalt pavement, soil stabilization and embankment reinforcement. It can effectively prevent the ground from cracking and subsiding. Applying this product can reduce the overlay thickness of asphalt, thereby, fiberglass geogrid can greatly reduce the construction cost and project investment.

[0057] In an example, the paving fabrics (first and second) which is paving fabrics interlayer is a needle-punched nonwoven fabric weighing a minimum of 4.1 oz. per square yard, which, when embedded in a field applied asphalt cement tack coat becomes an asphalt saturated fabric membrane. Properly installed it is a pavement moisture barrier and a stress absorbing interlayer which retards crack reflection and extends pavement life. It is then covered with an asphalt overlay or a surface maintenance treatment such as chip or cape seal.

[0058] In this embodiment, the reflective crack relief interlayer (RCRI) comprises a polymer modified asphalt binder mixed with a dense fine aggregate mixture made primarily from manufactured sand. In another embodiment, the RCRI includes a Polymer Modified Bitumen (PMB).

[0059] It may be further appreciated that the reflective crack relief interlayer (RCRI) is used for the construction of composite pavements composed of Pavement Quality Concrete (PQC) with some thickness of hot mix modified asphalt (HMA). The reflective cracking relief interlayer is a low stiffnesspavement layer that relieves the stresses and strains built up in an underlying pavement layer by dissipating energy during vertical and horizontal deformations. Typically, these layers are less than two inches and do not increase the structural value of the pavement, but they are designed to reduce reflective cracking. In an example, the RCRI is a modified asphalt-cement concrete material, comprising gravel, aggregate, sand, bitumen, optional modified polymer binders, and — significantly — aramid fibers to allow the RCRI to meet performance specifications chosen to ensure proper performance and long life in view of the loads that the finished restored pavement is designed to support.

[0060] In an implementation, the interlayer includes a polymer modified asphalt binder mixed with a dense fine aggregate mixture containing a substantial amount of manufactured sand. The interlayer mix is designed using a rutting performance and a stability test. Preferably, a hot mix asphalt overlay that is compatible with the interlayer, as well as the demands of local traffic and climate, is placed over the interlayer so that a protected, smooth paved surface is provided. The interlayer may delay the first appearance of cracks and the severity of cracks for several years compared with traditional hot mix overlays and extend pavement service life.

[0061] This interlayer may include an aggregate comprised of no more than about 15% by weight manufactured sand, wherein said aggregate that is not natural sand is manufactured sand with an angularity of at least 38%, and wherein said aggregate is comprised of about 80% by weight to about 100% by weight aggregate having a sieve size of less than about 4.75 mm; and an asphalt binder, wherein said interlayer has a Hveem Stability at 60° C. and 50 gyrations of at least about 22 and a Flexural Beam Fatigue of at least about 50,000 cycles at 2000 microstrains, 10 Hz, 3.0±2.0% air voids, at 0-30° C.

[0062] In this embodiment, the binder has 3 (Three) parts of epoxy, asphalt and 1 (one) part of Indian bitumen. In another embodiment, the binder has 6% epoxy, 24% asphalt and 70% of Indian bitumen.

[0063] FIG. 2 illustrates a method (200) for constructing a pavement structure with an overlay of epoxy asphalt, in accordance with an embodiment of the present invention.

[0064] At step 202, a first layer of a tack coat is sprayed on the surface of the pavement structure. The tack coat is coated using a rapid setting emulsion.

[0065] At step 204, a second layer of the first paving fabrics overlayed over the first layer, a third layer of reflective crack relief interlayer (RCRI) over the second layer, and a fourth layer of a second paving fabrics over the third layer. The third layer is sandwiched between the second layer and the fourth layer. In an exemplary implementation, the second layer achieves a tensile strength of 50 kN / m, the third layer achieves is of a 25 mm RCRI layer provided using polymer modified binder (PMB)

[0066] At step 206, a fifth layer of a binder is overlayed over the fourth layer as a top surface of the pavement structure. The binder has a combination of epoxy asphalt and bitumen provided over the fourth layer. The fifth layer is 35 mm formed of a mixture of epoxy asphalt and bitumen

[0067] FIG. 3 shows results of a standard test method for Marshall stability and flow of asphalt mixtures - ASTM D6927-15.

[0068] FIGs. 4A-4C shows results of permanent deformation behavior and rutting resistance of compacted asphalt mix in the modified loaded wheel tracker test utilizing controlled confining pressure - ASTM D8292 -20.

[0069] FIGs. 5A-5E shows results of design of flexible pavement with epoxy modified binder - IRC 37: 2018.

[0070] FIGs. 6A-5H shows results of mix trials for epoxy asphalt concrete with VG 40.

[0071] FIG. 7A shows a sectional view of pavement structure with an overlay of an epoxy asphalt for flexible pavement, in accordance with an embodiment of the present invention.

[0072] FIG. 7B shows a sectional view of pavement structure with an overlay of an epoxy asphalt for rigid pavement, in accordance with an embodiment of the present invention.

[0073] FIGs. 8A-5G shows result of Reflective Crack Relief Interlayer (RCRI) mixture - 6 % and 7 % of PMB.

[0074] To summarize the results, M / s SSPI Industrial Products LLP and Structural Specialties and Projects (India) Pvt Ltd have done detailed trials, research and investigation of Epoxy Asphalt with available Indian raw material such as Indian Domestic bitumen (VG30 / 40 from HPCL Refinery, Aggregates etc.) at NABL lab such as Bureo Veritas & Bharat Textile Research Association (BTRA). The Results of Epoxy asphalt Modified Concrete are as follows:Also, complete design / section of epoxy asphalt modified concrete has been checked and verified from BTRA lab.

[0075] It is additionally noted and anticipated that although the adjustable transducer speaker-based assembly is shown in its most simple form, various components and aspects of the device may be differently shaped or slightly modified when forming the invention herein. As such those skilled in the art will appreciate the descriptions and depictions set forth in this disclosure or merely meant to portray examples of preferred modes within the overall scope and intent of the invention and are not to be considered limiting in any manner. While all of the fundamental characteristics and features of the invention have been shown and described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instances, some features of the invention may be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should also be understood that various substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention.

[0076] Embodiments of the present invention include various steps, which will be described below. The steps may be performed by hardware components or may be embodied in machine- executable instructions, which may be used to cause a general-purpose or special-purpose processor programmed with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, and firmware and / or by human operators.

[0077] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention.

Claims

WE CLAIM:

1. A pavement structure (100A, 1OOB) with an overlay of an epoxy asphalt modified concrete (102 A, 102 B), the pavement structure characterized by comprising: a paving fabric (108, 112) provided over a surface of an existing pavement structure (104); and a layer (114) of a binder having a combination of an epoxy 6% , asphalt 24% by weight and a bitumen 70% by weight provided over the fourth layer, wherein the fifth layer operates as a top surface of the pavement structure.

2. A pavement structure (100 B) with an overlay of an epoxy asphalt (102 B) for rigid / concrete pavement, the pavement structure characterized by comprising: a first layer (106) of a tack coat sprayed on a surface of an existing pavement structure (104 B); a third layer (110) of reflective crack relief interlayer (RCRI) sandwiched between a second layer (108) of a first paving fabrics provided over the first layer and a fourth layer (112) of a second paving fabrics provided over the third layer, wherein the third layer is provided over second layer; a fifth layer (114) of a binder having a combination of an epoxy, asphalt and a bitumen provided over the fourth layer, wherein the fifth layer operates as a top surface of the pavement structure.

3. A pavement structure (100 A) with an overlay of an epoxy asphalt (102 A) for flexible pavement, the pavement structure characterized by comprising: a first layer (112) of glass fibre geo grid (self-adhesive backing / tack coat) surface of an existing pavement structure (104 A); a second layer (114) of a binder having combination of an epoxy, asphalt and a bitumen provided over the first layer, wherein the second layer operates as a top surface of the pavement structure.

4. The pavement structure as claimed in claims 1 and 2, wherein the pavement structure is a rigid pavement or a flexible pavement in road construction.

5. The pavement structure as claimed in claims 1 and 2, wherein the tack coat comprises: an adhesive material applied between one or more surfaces of a concrete laid down for road construction; or an asphalt emulsion applied between one or more hot mix asphalt layers laid down for road construction.

6. The pavement structure as claimed in claim 1, wherein the first paving fabrics comprises a glass fiber geo grid; and the second paving fabrics comprises a fiberglass geogrid.

7. The pavement structure as claimed in claim 1, wherein the reflective crack relief interlayer (RCRI) comprises: a polymer modified asphalt binder mixed with a dense fine aggregate mixture made primarily from manufactured sand; or a Polymer Modified Bitumen8. The pavement structure as claimed in claim 1, wherein the binder having:3 (parts) parts modified binder of an epoxy-6%, asphalt-24% and 30% part of a bitumen; or3 Parts- 1 part of Epoxy, 1 part of Asphalt and 1 part of Bitumen.

9. A method (200) for constructing a pavement structure with an overlay of an epoxy asphalt, the method characterized by comprising:spraying (202) a first layer of a tack coat on a surface of the pavement structure; overlaying (204): a second layer of a first paving fabrics over the first layer; a third layer of reflective crack relief interlayer (RCRI) over the second layer; and a fourth layer of a second paving fabrics over the third layer, wherein the third layer is sandwiched between the second layer and the fourth layer; and overlaying (206) a fifth layer of a binder over the fourth layer as a top surface of the pavement structure, wherein the binder having a combination of an epoxy asphalt and a bitumen provided over the fourth layer.

10. The method as claimed in claim 7, wherein the tack coat comprises: an adhesive material applied between one or more surfaces of a concrete laid down for road construction; or an asphalt emulsion applied between one or more hot mix asphalt layers laid down for road construction.

11. The method as claimed in claim 7, wherein: the first paving fabrics comprises a fibreglass Geo grid- Tensile Strength- 100 KN; and the second paving fabrics comprises a fiberglass Geo grid- Tensile Strength- 50 KN12. The method as claimed in claim 7, wherein the reflective crack relief interlayer (RCRI) comprises a polymer modified asphalt binder mixed with a dense fine aggregate mixture made primarily from manufactured sand, and wherein the binder having 2 (two) parts of an epoxy asphalt and 1 (one) part of a bitumen.

Images