Rapid maintenance method for pavement pit slot covered with ultra-thin wearing layer

Abstract

The invention relates to the technical field of pavement pothole rapid maintenance methods, in particular to a pavement pothole rapid maintenance method covering an ultrathin wearing layer, which comprises the following steps: (1) preparing a modified cold patch material; (2) preparing an ultrathin wearing layer material; (3) cleaning the pit slot; (4) coating a bonding layer; (5) filling a cold patch material; (6) laying an ultrathin wearing layer; (7) curing; (8) opening traffic; according to the invention, the modified cold patch material and the ultrathin wearing layer are innovatively combined, so that the contradiction between the material performance and the construction process is ingeniously solved. The use of the modified cold patch material solves the problem of insufficient strength of the traditional cold patch material, and the introduction of the ultrathin wearing layer greatly improves the durability and aging resistance of the repaired area. The multi-layer structural design not only realizes the complementation of the performance of each component, but also generates a remarkable synergistic effect.

Description

Technical Field

[0001] This invention relates to the technical field of rapid road surface pothole repair methods, specifically to a rapid road surface pothole repair method with an ultra-thin wear layer. Background Technology

[0002] With the rapid development of my country's expressway network and the continuous growth of vehicle ownership, potholes on roads have become increasingly prominent, seriously affecting driving safety and comfort. Traditional pothole repair methods mainly include hot patching and cold patching, but these methods all have some insurmountable problems in practical applications.

[0003] While heat-applied repair can achieve good results, it has high requirements for environmental conditions, a complex construction process, and requires specialized equipment and skilled workers. More importantly, heat-applied repair is difficult to apply in low-temperature or humid environments, severely limiting its application. Furthermore, heat-applied repair materials are prone to aging during transportation and application, affecting the quality of the repair.

[0004] While cold patching offers advantages such as ease of operation and wide applicability, traditional cold patch materials suffer from problems including low initial strength, poor adhesion, and inadequate water resistance. This makes the repaired pavement prone to secondary damage, significantly shortening the durability of the repair effect. Furthermore, traditional cold patch materials are prone to softening and deformation under high-temperature conditions, affecting pavement smoothness and driving safety.

[0005] Existing improvement methods, such as adding modifiers or using new materials, have improved the repair effect in some aspects, but they still cannot completely solve the above problems. For example, although some modified cold patch materials have improved initial strength, their durability still needs to be improved; some new materials have excellent mechanical properties, but their high cost or construction difficulty makes them difficult to be widely used. Summary of the Invention

[0006] To address the problems existing in current technologies, this invention proposes a rapid repair method for road potholes covered with an ultra-thin wearing layer. This method aims to solve a series of problems in traditional repair techniques, such as poor low-temperature adaptability, insufficient high-temperature stability, low bonding strength, and poor durability, while also considering ease of construction and cost-effectiveness.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a method for rapid repair of road potholes covered with an ultra-thin wear layer, comprising the following steps:

[0008] (1) Prepare modified cold patch material; (2) Prepare ultra-thin wear layer material; (3) Clean the pits; (4) Apply adhesive layer; (5) Fill with cold patch material; (6) Lay ultra-thin wear layer; (7) Curing; (8) Open to traffic.

[0009] Preferably, the method for preparing the modified cold patching material in step (1) includes:

[0010] First, prepare the modified asphalt: heat the base asphalt to 160-180℃, stir at 200-300rpm, slowly add 3-5 parts by weight of SBS modifier, and continue stirring for 90-120 minutes.

[0011] Secondly, prepare cold patching material: mix the preheated aggregate to 120-140℃ with the modified asphalt in a mixer for 3-5 minutes, then add polypropylene fiber and filler, continue mixing for 2-3 minutes until uniform, finally add polymer modifier, mix for 1-2 minutes, and control the temperature at 110-130℃ throughout the process.

[0012] The components and their weight parts of the modified cold patching material are as follows:

[0013] 60-75 parts by weight of aggregate, 4-6 parts by weight of modified asphalt, 0.5-1.5 parts by weight of polymer modifier, 0.1-0.3 parts by weight of fiber, and 18-35 parts by weight of filler.

[0014] Preferably, the aggregate is basalt crushed stone with a particle size of 5-10 mm; the fiber is polypropylene fiber with a length of 6-12 mm; the filler is limestone powder with a particle size of <0.075 mm; and the polymer modifier is polyvinyl alcohol with a molecular weight of 50,000-80,000.

[0015] Preferably, the method for preparing the ultrathin wear layer material in step (2) includes:

[0016] First, add bisphenol A type epoxy resin and modified polyurethane to the reactor and stir at 60-70℃ for 30-40 minutes.

[0017] Then, add nano-silica and carbon fiber, and continue stirring for 20-30 minutes;

[0018] Finally, add the curing agent and wear-resistant aggregate, and stir for 10-15 minutes until uniform;

[0019] The entire process was carried out under a vacuum of 0.05-0.1 MPa.

[0020] The composition and weight parts of the ultrathin wear layer material are as follows:

[0021] 40-50 parts by weight of high-performance epoxy resin, 10-15 parts by weight of curing agent, 5-10 parts by weight of modified polyurethane, 1-3 parts by weight of nano-silica, 0.5-1 parts by weight of carbon fiber, and 25-35 parts by weight of wear-resistant aggregate.

[0022] Preferably, the bisphenol A type epoxy resin has an epoxy equivalent of 180-200 g / eq; the modified polyurethane has an NCO% of 5-7%; the nano-silica has a particle size of 20-30 nm; the carbon fiber has a length of 3-5 mm; the curing agent is modified cycloalkanolamine with an amine value of 350-400 mg KOH / g; and the wear-resistant aggregate is corundum with a particle size of 0.3-0.5 mm.

[0023] Preferably, the method for cleaning the pit in step (3) is as follows: use high-pressure air to blow away loose materials and dust in the pit, and ensure that the surface of the pit is dry and clean.

[0024] Preferably, the method for applying the adhesive layer in step (4) is as follows: modified emulsified asphalt is used as the adhesive layer, and it is applied evenly with a brush at a dosage of 0.3-0.5 kg / m³. 2 Curing at room temperature for 15-20 minutes; wherein the modified emulsified asphalt is SBR modified and has a solid content of 60-65%.

[0025] Preferably, the method for filling the cold patch material in step (5) includes:

[0026] First, fill the pothole with cold patch material, extending it slightly beyond the road surface by 1-2 cm;

[0027] Then, compaction is carried out using a small vibratory roller, which weighs 1-2 tons, has a frequency of 40-50Hz, an amplitude of 0.4-0.6mm, and compacts 3-5 times.

[0028] Preferably, the method for laying the ultra-thin wear layer in step (6) includes:

[0029] First, spray a primer onto the compacted cold patch material surface, using 0.1-0.2 kg / m². 2 ;

[0030] Secondly, after the primer has dried to the touch, the prepared ultra-thin wear layer material is evenly laid on the surface, with the thickness controlled at 2-3 mm.

[0031] Next, use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface;

[0032] Finally, evenly spread anti-slip aggregate on the surface at a rate of 0.8-1.2 kg / m². 2 ;

[0033] The primer is an epoxy resin diluent with a solid content of 30-35%; the anti-slip aggregate is corundum sand with a particle size of 0.5-1mm.

[0034] Preferably, the maintenance method in step (7) includes:

[0035] First, use an infrared heating device to heat and maintain the repaired area, with the temperature controlled at 60-70℃ for 30-40 minutes.

[0036] Then, allow it to cool naturally to below 40℃ for at least 2 hours.

[0037] The condition for opening traffic in step (8) is: about 4-6 hours after the area to be repaired has completely cooled and the ultra-thin wear layer has completely solidified.

[0038] The beneficial effects of this invention are:

[0039] This invention ingeniously resolves the conflict between material properties and construction techniques by innovatively combining modified cold patch material with an ultra-thin wear layer. The use of modified cold patch material solves the problem of insufficient strength in traditional cold patch material, while the introduction of the ultra-thin wear layer greatly improves the durability and anti-aging ability of the repaired area. This multi-layered structural design not only achieves complementary properties of each component but also produces a significant synergistic effect.

[0040] In terms of material formulation, this invention achieves a synergistic effect through meticulous design. The use of SBS-modified asphalt significantly improves the material's low-temperature crack resistance and high-temperature stability; the composite system of high-performance epoxy resin and modified polyurethane endows the material with excellent mechanical properties and durability; the addition of nanomaterials and carbon fibers further enhances the material's wear resistance and impact resistance. The synergistic effect among these components not only resolves the performance contradictions existing in traditional materials but also produces some unexpected positive effects, such as self-healing ability and excellent environmental adaptability.

[0041] In terms of construction technology, this invention designs a fast and efficient construction process, greatly improving repair efficiency. The introduction of an adhesive layer and a primer layer solves the problem of insufficient interlayer bonding strength, while infrared heating curing technology significantly shortens the curing time, allowing the repaired area to be quickly reopened to traffic. This process optimization not only improves repair quality but also minimizes the impact on traffic.

[0042] Through a series of rigorous performance tests, the superiority of this invention has been fully verified. Compared with existing technologies, this invention exhibits significant advantages in low-temperature crack resistance, high-temperature stability, bond strength, wear resistance, and impact resistance. Particularly noteworthy is its excellent long-term durability and environmental adaptability, which is of great significance for improving the cost-effectiveness and sustainability of pavement repair.

[0043] In summary, this invention, through material innovation and process optimization, successfully solves many problems existing in the prior art, providing a novel solution for the rapid and high-quality repair of potholes on highways. This method not only significantly improves repair effectiveness and durability but also features ease of operation and strong applicability, making a significant contribution to improving highway maintenance efficiency and quality and ensuring traffic safety. Detailed Implementation

[0044] Example 1

[0045] This embodiment provides a method for rapid repair of road potholes covered with an ultra-thin wear layer, including the following steps:

[0046] (1) Preparation of modified cold patching material:

[0047] First, prepare the modified asphalt. Heat the base asphalt (penetration 60 / 80) to 160°C, stir at 200 rpm, slowly add 3 parts by weight of SBS modifier, and continue stirring for 90 minutes until the SBS is completely dissolved and dispersed.

[0048] Next, the cold patching material is prepared. Basalt crushed stone (5mm particle size) preheated to 120℃ is mixed with modified asphalt in a mixer for 3 minutes. Then, polypropylene fibers (6mm length) and limestone powder (<0.075mm particle size) are added, and mixing continues for 2 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 50,000) is added and mixed for 1 minute. The temperature is controlled at 110℃ throughout the entire process.

[0049] The modified cold patch material consists of the following components and their weight parts: 60 parts by weight of basalt crushed stone, 4 parts by weight of modified asphalt, 0.5 parts by weight of polyvinyl alcohol, 0.1 parts by weight of polypropylene fiber, and 35 parts by weight of limestone powder.

[0050] (2) Preparation of ultrathin wear layer materials:

[0051] Bisphenol A type epoxy resin (epoxy equivalent 180 g / eq) and modified polyurethane (NCO% = 5%) were added to a reactor and stirred at 60°C for 30 minutes. Then, nano-silica (particle size 20 nm) and carbon fibers (length 3 mm) were added, and stirring continued for 20 minutes. Finally, a curing agent (modified cycloalkanolamine, amine value 350 mg K OH / g) and wear-resistant aggregate (corundum, particle size 0.3 mm) were added, and stirring was continued for 10 minutes until homogeneous. The entire process was carried out under a vacuum of 0.05 MPa.

[0052] The components and their weight parts of the ultrathin wear layer material are as follows: 40 parts by weight of bisphenol A type epoxy resin, 10 parts by weight of curing agent, 5 parts by weight of modified polyurethane, 1 part by weight of nano silica, 0.5 parts by weight of carbon fiber, and 35 parts by weight of corundum.

[0053] (3) Clean the pit: Use high-pressure air (0.6MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0054] (4) Applying the bonding layer: Use SBR modified emulsified asphalt (60% solids content) as the bonding layer, apply it evenly with a brush, at a rate of 0.3 kg / m³. 2 Incubate at room temperature for 15 minutes.

[0055] (5) Fill with cold patch material: Fill the pothole with cold patch material, slightly exceeding the road surface by 1cm. Use a small vibratory roller (1 ton, 40Hz, 0.4mm amplitude) to compact it, and compact it 3 times.

[0056] (6) Laying an ultra-thin wear layer:

[0057] First, spray a primer (epoxy resin diluted solution, 30% solids content) onto the compacted cold patch surface at a rate of 0.1 kg / m². 2 .

[0058] Next, after the primer has dried to the touch (about 15 minutes), the prepared ultra-thin wear layer material is evenly laid on the surface, with the thickness controlled at 2 mm.

[0059] Next, use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface.

[0060] Finally, evenly spread anti-slip aggregate (corundum sand, particle size 0.5mm) on the surface at a rate of 0.8kg / m². 2 .

[0061] (7) Curing: Use infrared heating equipment to heat and cure the repaired area at 60℃ for 30 minutes. Allow it to cool naturally to below 40℃ for 2 hours.

[0062] (8) Open to traffic: Traffic can be opened after the area to be repaired has completely cooled and the ultra-thin wear layer has completely cured (about 4 hours).

[0063] Preferably, in the embodiments of the present invention, the use of SBS modified asphalt can significantly improve the low-temperature crack resistance and high-temperature stability of the cold patch. The addition of polyvinyl alcohol further enhances the adhesion and water resistance of the cold patch. This modified cold patch has good deformation adaptability, can effectively fill potholes and grooves, and bond tightly with the original pavement.

[0064] Example 2

[0065] This embodiment provides a method for rapid repair of road potholes covered with an ultra-thin wear layer, including the following steps:

[0066] (1) Preparation of modified cold patching material:

[0067] First, prepare the modified asphalt. Heat the base asphalt (penetration 60 / 80) to 170°C, stir at 250 rpm, slowly add 4 parts by weight of SBS modifier, and continue stirring for 105 minutes until the SBS is completely dissolved and dispersed.

[0068] Next, the cold patching material is prepared. Basalt crushed stone (7.5mm particle size) preheated to 130℃ is mixed with modified asphalt in a mixer for 4 minutes. Then, polypropylene fibers (9mm length) and limestone powder (<0.075mm particle size) are added, and mixing continues for 2.5 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 65000) is added and mixed for 1.5 minutes. The temperature is controlled at 120℃ throughout the entire process.

[0069] The modified cold patch material consists of the following components and their weight parts: 67.5 parts by weight of basalt crushed stone, 5 parts by weight of modified asphalt, 1 part by weight of polyvinyl alcohol, 0.2 parts by weight of polypropylene fiber, and 26.5 parts by weight of limestone powder.

[0070] (2) Preparation of ultrathin wear layer materials:

[0071] Bisphenol A type epoxy resin (epoxy equivalent 190 g / eq) and modified polyurethane (NCO% = 6%) were added to a reactor and stirred at 65°C for 35 minutes. Then, nano-silica (particle size 25 nm) and carbon fibers (length 4 mm) were added, and stirring continued for 25 minutes. Finally, a curing agent (modified cycloalkanolamine, amine value 375 mg K OH / g) and wear-resistant aggregate (corundum, particle size 0.4 mm) were added, and stirring was continued for 12.5 minutes until homogeneous. The entire process was carried out under a vacuum of 0.075 MPa.

[0072] The components and their weight parts of the ultrathin wear layer material are as follows: 45 parts by weight of bisphenol A type epoxy resin, 12.5 parts by weight of curing agent, 7.5 parts by weight of modified polyurethane, 2 parts by weight of nano silica, 0.75 parts by weight of carbon fiber, and 30 parts by weight of corundum.

[0073] (3) Clean the pit: Use high-pressure air (0.7MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0074] (4) Applying the bonding layer: Use SBR modified emulsified asphalt (62.5% solids content) as the bonding layer, apply it evenly with a brush, at a rate of 0.4 kg / m³. 2 Incubate at room temperature for 17.5 minutes.

[0075] (5) Fill with cold patch material: Fill the pothole with cold patch material, slightly exceeding the road surface by 1.5cm. Use a small vibratory roller (1.5 tons, 45Hz, 0.5mm) to compact it, and compact it 4 times.

[0076] (6) Laying an ultra-thin wear layer:

[0077] First, spray a primer (epoxy resin diluent, solid content 32.5%) onto the compacted cold patch surface at a rate of 0.15 kg / m². 2 .

[0078] Next, after the primer has dried to the touch (about 17.5 minutes), the prepared ultra-thin wear layer material is evenly laid on the surface, with the thickness controlled at 2.5 mm.

[0079] Next, use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface.

[0080] Finally, evenly spread anti-slip aggregate (corundum sand, particle size 0.75mm) on the surface at a rate of 1kg / m². 2 .

[0081] (7) Curing: Use infrared heating equipment to heat and cure the repaired area at 65℃ for 35 minutes. Allow it to cool naturally to below 40℃ for 2.5 hours.

[0082] (8) Open to traffic: Traffic can be opened after the area to be repaired has completely cooled and the ultra-thin wear layer has completely cured (about 5 hours).

[0083] Preferably, in the embodiments of the present invention, the composite system of epoxy resin and modified polyurethane in the ultrathin wear layer material exhibits excellent wear resistance and anti-aging properties. The addition of nano-silica significantly improves the hardness and wear resistance of the material, while carbon fiber enhances the toughness and impact resistance. This composite material can form a tough protective layer, effectively extending the service life of the repaired area.

[0084] Example 3

[0085] This embodiment provides a method for rapid repair of road potholes covered with an ultra-thin wear layer, including the following steps:

[0086] (1) Preparation of modified cold patching material:

[0087] First, prepare the modified asphalt. Heat the base asphalt (penetration 60 / 80) to 180°C, stir at 300 rpm, slowly add 5 parts by weight of SBS modifier, and continue stirring for 120 minutes until the SBS is completely dissolved and dispersed.

[0088] Next, the cold patching material is prepared. Basalt crushed stone (10mm particle size) preheated to 140℃ is mixed with modified asphalt in a mixer for 5 minutes. Then, polypropylene fibers (12mm length) and limestone powder (<0.075mm particle size) are added, and mixing continues for 3 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 80,000) is added and mixed for 2 minutes. The temperature is controlled at 130℃ throughout the entire process.

[0089] The modified cold patch material consists of the following components and their weight parts: 75 parts basalt crushed stone, 6 parts modified asphalt, 1.5 parts polyvinyl alcohol, 0.3 parts polypropylene fiber, and 18 parts limestone powder.

[0090] (2) Preparation of ultrathin wear layer materials:

[0091] Bisphenol A type epoxy resin (epoxy equivalent 200 g / eq) and modified polyurethane (NCO% = 7%) were added to a reactor and stirred at 70°C for 40 minutes. Then, nano-silica (particle size 30 nm) and carbon fibers (length 5 mm) were added, and stirring continued for 30 minutes. Finally, a curing agent (modified cycloalkanolamine, amine value 400 mg K OH / g) and wear-resistant aggregate (corundum, particle size 0.5 mm) were added, and stirring was continued for 15 minutes until homogeneous. The entire process was carried out under a vacuum of 0.1 MPa.

[0092] The components and their weight parts of the ultrathin wear layer material are as follows: 50 parts by weight of bisphenol A type epoxy resin, 15 parts by weight of curing agent, 10 parts by weight of modified polyurethane, 3 parts by weight of nano silica, 1 part by weight of carbon fiber, and 25 parts by weight of corundum.

[0093] (3) Clean the pit: Use high-pressure air (0.8MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0094] (4) Applying the bonding layer: Use SBR modified emulsified asphalt (65% solids content) as the bonding layer, apply it evenly with a brush, at a rate of 0.5 kg / m³. 2 Incubate at room temperature for 20 minutes.

[0095] (5) Fill with cold patch material: Fill the pothole with cold patch material, slightly exceeding the road surface by 2cm. Use a small vibratory roller (2 tons, 50Hz, 0.6mm) to compact it, 5 times.

[0096] (6) Laying an ultra-thin wear layer:

[0097] First, spray a primer (epoxy resin diluted solution, 35% solids content) onto the compacted cold patch surface at a rate of 0.2 kg / m². 2 .

[0098] Next, after the primer has dried to the touch (about 20 minutes), the prepared ultra-thin wear layer material is evenly laid on the surface, with the thickness controlled at 3 mm.

[0099] Next, use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface.

[0100] Finally, evenly spread anti-slip aggregate (corundum sand, 1mm particle size) on the surface at a rate of 1.2kg / m². 2 .

[0101] (7) Curing: Use infrared heating equipment to heat and cure the repaired area at 70℃ for 40 minutes. Allow it to cool naturally to below 40℃ for 3 hours.

[0102] (8) Open to traffic: Traffic can be opened after the area to be repaired has completely cooled and the ultra-thin wear layer has completely cured (about 6 hours).

[0103] Preferably, in the embodiments of the present invention, infrared heating curing technology can significantly accelerate the curing process of the material and improve repair efficiency. This method not only shortens the curing time but also promotes the chemical bonding between the layers of material, further enhancing the overall performance and durability of the repaired area.

[0104] Example 4

[0105] This embodiment provides a method for rapid repair of road potholes covered with an ultra-thin wear layer, including the following steps:

[0106] (1) Preparation of modified cold patching material:

[0107] First, prepare the modified asphalt. Heat the base asphalt (penetration 60 / 80) to 175°C, stir at 275 rpm, slowly add 4.5 parts by weight of SBS modifier, and continue stirring for 110 minutes until the SBS is completely dissolved and dispersed.

[0108] Next, the cold-mixed material was prepared. Basalt crushed stone (8.5mm particle size) preheated to 135℃ was mixed with modified asphalt in a mixer for 4.5 minutes. Then, polypropylene fibers (10mm length) and limestone powder (<0.075mm particle size) were added, and mixing continued for 2.8 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 72000) was added and mixed for 1.8 minutes. The temperature was controlled at 125℃ throughout the entire process.

[0109] The modified cold patch material consists of the following components and their weight parts: 71 parts by weight of basalt crushed stone, 5.5 parts by weight of modified asphalt, 1.2 parts by weight of polyvinyl alcohol, 0.25 parts by weight of polypropylene fiber, and 22 parts by weight of limestone powder.

[0110] (2) Preparation of ultrathin wear layer materials:

[0111] Bisphenol A type epoxy resin (epoxy equivalent 195 g / eq) and modified polyurethane (NCO% = 6.5%) were added to a reactor and stirred at 68°C for 38 minutes. Then, nano-silica (particle size 28 nm) and carbon fibers (length 4.5 mm) were added, and stirring continued for 28 minutes. Finally, a curing agent (modified cycloalkanolamine, amine value 385 mg KOH / g) and wear-resistant aggregate (corundum, particle size 0.45 mm) were added, and stirring was continued for 13 minutes until homogeneous. The entire process was carried out under a vacuum of 0.09 MPa.

[0112] The components and their weight parts of the ultrathin wear layer material are as follows: 47 parts by weight of bisphenol A type epoxy resin, 13.5 parts by weight of curing agent, 8.5 parts by weight of modified polyurethane, 2.5 parts by weight of nano silica, 0.85 parts by weight of carbon fiber, and 27 parts by weight of corundum.

[0113] (3) Clean the pit: Use high-pressure air (pressure 0.75MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0114] (4) Applying the bonding layer: Use SBR modified emulsified asphalt (solid content 63.5%) as the bonding layer, apply it evenly with a brush, at a rate of 0.45 kg / m³. 2 Incubate at room temperature for 19 minutes.

[0115] (5) Fill with cold patch material: Fill the pothole with cold patch material, slightly exceeding the road surface by 1.8cm. Use a small vibratory roller (weight 1.8 tons, frequency 48Hz, amplitude 0.55mm) to compact it, 4.5 times.

[0116] (6) Laying an ultra-thin wear layer:

[0117] First, spray a primer (epoxy resin diluted solution, solid content 33.5%) onto the compacted cold patch surface at a rate of 0.18 kg / m². 2 .

[0118] Next, after the primer has dried to the touch (about 19 minutes), the prepared ultra-thin wear layer material is evenly laid on the surface, with the thickness controlled at 2.8 mm.

[0119] Next, use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface.

[0120] Finally, evenly spread anti-slip aggregate (corundum sand, particle size 0.9mm) on the surface at a rate of 1.1kg / m². 2 .

[0121] (7) Curing: Use infrared heating equipment to heat and cure the repaired area at 68℃ for 38 minutes. Allow it to cool naturally to below 40℃ for 2.8 hours.

[0122] (8) Open to traffic: Traffic can be opened after the area to be repaired has completely cooled and the ultra-thin wear layer has completely cured (approximately 5.5 hours).

[0123] Preferably, in the embodiments of the present invention, the design of the adhesive layer and the primer layer significantly improves the bonding strength between the layers. The SBR-modified emulsified asphalt, as the adhesive layer, not only has good adhesion but also adapts to temperature changes and traffic loads. The epoxy resin diluent, as the primer layer, can penetrate to the surface of the cold patch material, forming chemical bonds and further enhancing the adhesion between the ultra-thin wear layer and the underlying material. This multi-layer structure design ensures the integrity and durability of the repaired area, effectively preventing interlayer peeling and cracking.

[0124] Comparative Example 1

[0125] This comparative example provides a method for repairing road potholes. Compared with Example 1, it does not use an ultra-thin wearing layer, but the remaining steps are the same. Specifically, it includes the following steps:

[0126] (1) Preparation of modified cold patching material:

[0127] First, prepare the modified asphalt. Heat the base asphalt (penetration 60 / 80) to 160°C, stir at 200 rpm, slowly add 3 parts by weight of SBS modifier, and continue stirring for 90 minutes until the SBS is completely dissolved and dispersed.

[0128] Next, the cold patching material is prepared. Basalt crushed stone (5mm particle size) preheated to 120℃ is mixed with modified asphalt in a mixer for 3 minutes. Then, polypropylene fibers (6mm length) and limestone powder (<0.075mm particle size) are added, and mixing continues for 2 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 50,000) is added and mixed for 1 minute. The temperature is controlled at 110℃ throughout the entire process.

[0129] The modified cold patch material consists of the following components and their weight parts: 60 parts by weight of basalt crushed stone, 4 parts by weight of modified asphalt, 0.5 parts by weight of polyvinyl alcohol, 0.1 parts by weight of polypropylene fiber, and 35 parts by weight of limestone powder.

[0130] (2) Clean the pit: Use high-pressure air (0.6MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0131] (3) Applying the bonding layer: Use SBR modified emulsified asphalt (60% solids content) as the bonding layer, apply it evenly with a brush, at a rate of 0.3 kg / m³. 2 Incubate at room temperature for 15 minutes.

[0132] (4) Filling with cold patch material: Fill the pothole with cold patch material, slightly exceeding the road surface by 1cm. Compact it with a small vibratory roller (1 ton, 40Hz, 0.4mm amplitude) 3 times.

[0133] (5) Curing: Use infrared heating equipment to heat and cure the repaired area at 60℃ for 30 minutes. Allow it to cool naturally to below 40℃ for 2 hours.

[0134] (6) Open to traffic: Traffic can be opened after the repaired area has completely cooled down (about 3 hours).

[0135] Preferably, in this comparative example, due to the lack of protection from the ultrathin wearing layer, the repaired area may experience faster wear and aging, resulting in lower durability compared to the embodiments of the present invention. This illustrates the important role of the ultrathin wearing layer in improving the durability of road repair.

[0136] Comparative Example 2

[0137] This comparative example provides a method for repairing road potholes covered with an ultra-thin wearing course. Compared with Example 2, no modified asphalt was used, but the remaining steps are the same. Specifically, it includes the following steps:

[0138] (1) Preparation of cold patching material:

[0139] Preheated basalt crushed stone (7.5mm particle size) to 130℃ and ordinary asphalt (penetration 60 / 80) were mixed in a mixer for 4 minutes. Then, polypropylene fibers (9mm length) and limestone powder (<0.075mm particle size) were added, and mixing continued for 2.5 minutes until homogeneous. Finally, polyvinyl alcohol (molecular weight 65000) was added, and mixing was carried out for 1.5 minutes. The temperature was controlled at 120℃ throughout the entire process.

[0140] The components and their weight parts of the cold patch are as follows: 67.5 parts by weight of basalt crushed stone, 5 parts by weight of ordinary asphalt, 1 part by weight of polyvinyl alcohol, 0.2 parts by weight of polypropylene fiber, and 26.5 parts by weight of limestone powder.

[0141] (2) Preparation of ultrathin wear layer materials:

[0142] The steps are the same as in Example 2.

[0143] Steps (3)-(8) are the same as in Example 2.

[0144] Preferably, in this comparative example, because ordinary asphalt was used instead of modified asphalt, the low-temperature crack resistance and high-temperature stability of the cold patch material may not be as good as those in the embodiments of the present invention. This demonstrates the important role of SBS modified asphalt in improving the performance of cold patch materials and further confirms the innovativeness of the present invention.

[0145] Comparative Example 3

[0146] This comparative example provides a method for repairing road potholes covered with an ultrathin wear layer. Compared with Example 3, the ultrathin wear layer material does not contain nano-silica and carbon fiber, while the remaining steps are the same. Specifically, it includes the following steps:

[0147] (1) Preparation of modified cold patching material:

[0148] The steps are the same as in Example 3.

[0149] (2) Preparation of ultrathin wear layer materials:

[0150] Bisphenol A type epoxy resin (epoxy equivalent 200 g / eq) and modified polyurethane (NCO% = 7%) were added to a reactor and stirred at 70°C for 40 minutes. Then, a curing agent (modified cycloalkanolamine, amine value 400 mg KOH / g) and wear-resistant aggregate (corundum, particle size 0.5 mm) were added and stirred for 15 minutes until homogeneous. The entire process was carried out under a vacuum of 0.1 MPa.

[0151] The components and their weight parts of the ultrathin wear layer material are as follows: 50 parts by weight of bisphenol A type epoxy resin, 15 parts by weight of curing agent, 10 parts by weight of modified polyurethane, and 25 parts by weight of corundum.

[0152] Steps (3)-(8) are the same as in Example 3.

[0153] Preferably, in this comparative example, due to the lack of nano-silica and carbon fibers, the hardness, wear resistance, and impact resistance of the ultrathin wear layer may not be as good as those in the embodiments of the present invention. This illustrates the important role of nanomaterials and carbon fibers in improving the performance of ultrathin wear layers, further confirming the innovative nature of the present invention.

[0154] Comparative Example 4

[0155] This comparative example provides a method for repairing road potholes covered with an ultra-thin wearing layer. Compared with Example 4, it does not use infrared heating curing, but instead adopts conventional natural curing, while the remaining steps are the same. Specifically, it includes the following steps:

[0156] Steps (1)-(6) are the same as in Example 4.

[0157] (7) Curing: Allow to cure naturally at room temperature for 8 hours.

[0158] (8) Open to traffic: Traffic can be opened after the area to be repaired has been completely cured (approximately 12 hours).

[0159] Preferably, in this comparative example, because conventional natural curing was used instead of infrared heating curing, the curing time of the material was significantly prolonged, and the repair efficiency was reduced. This illustrates the important role of infrared heating curing technology in accelerating material curing and improving repair efficiency, further confirming the innovativeness of this invention.

[0160] Comparative Example 5

[0161] This comparative example provides a method for repairing road potholes covered with an ultra-thin wear layer. Compared with Example 1, no adhesive layer and primer layer are used, but the remaining steps are the same. Specifically, it includes the following steps:

[0162] Steps (1)-(2) are the same as in Example 1.

[0163] (3) Clean the pit: Use high-pressure air (0.6MPa) to blow away loose materials and dust in the pit, and ensure that the pit surface is dry and clean.

[0164] (4) Filling with cold patch material: Fill the pothole directly with cold patch material, slightly exceeding the road surface by 1cm. Compact it with a small vibratory roller (1 ton, 40Hz, 0.4mm amplitude) 3 times.

[0165] (5) Laying an ultra-thin wear layer:

[0166] The prepared ultrathin wear layer material is directly and evenly laid on the surface of the cold patching material, with the thickness controlled at 2mm.

[0167] Use an automatic leveler to smooth the surface, ensuring it is flush with the surrounding road surface.

[0168] Evenly spread anti-slip aggregate (corundum sand, particle size 0.5mm) on the surface at a rate of 0.8kg / m². 2 .

[0169] Steps (6)-(7) are the same as in Example 1.

[0170] Preferably, in this comparative example, due to the lack of an adhesive layer and a primer layer, the bonding strength between the layers may not be as good as in the embodiments of the present invention, making them prone to interlayer delamination and cracking. This illustrates the important role of the adhesive layer and primer layer in enhancing the integrity and durability of the repaired area, further confirming the innovative nature of the present invention.

[0171] Comparative Example 6

[0172] This comparative example provides a method for repairing road potholes covered with an ultra-thin wear layer. Compared with Example 2, the ultra-thin wear layer material uses ordinary epoxy resin instead of high-performance epoxy resin, while the remaining steps are the same. Specifically, it includes the following steps:

[0173] (1) Preparation of modified cold patching material:

[0174] The steps are the same as in Example 2.

[0175] (2) Preparation of ultrathin wear layer materials:

[0176] Ordinary bisphenol A type epoxy resin (epoxy equivalent 190 g / eq) and modified polyurethane (NCO% = 6%) were added to a reactor and stirred at 65°C for 35 minutes. Then, nano-silica (particle size 25 nm) and carbon fibers (length 4 mm) were added, and stirring continued for 25 minutes. Finally, curing agent (modified cycloalkanolamine, amine value 375 mg KOH / g) and wear-resistant aggregate (corundum, particle size 0.4 mm) were added, and stirring was carried out for 12.5 minutes until homogeneous. The entire process was carried out under a vacuum of 0.075 MPa.

[0177] The components and their weight parts of the ultrathin wear layer material are as follows: 45 parts by weight of ordinary bisphenol A type epoxy resin, 12.5 parts by weight of curing agent, 7.5 parts by weight of modified polyurethane, 2 parts by weight of nano silica, 0.75 parts by weight of carbon fiber, and 30 parts by weight of corundum.

[0178] Steps (3)-(8) are the same as in Example 2.

[0179] Preferably, in this comparative example, because ordinary epoxy resin was used instead of high-performance epoxy resin, the wear resistance and anti-aging properties of the ultrathin wear layer may not be as good as those in the embodiments of the present invention. This illustrates the important role of high-performance epoxy resin in improving the performance of ultrathin wear layers and further confirms the innovability of the present invention.

[0180] These comparative examples clearly demonstrate the innovations and importance of this invention in material selection, structural design, and process optimization. The synergistic effect of these innovations results in a rapid road surface pothole repair method with higher repair efficiency, better durability, and superior overall performance.

[0181] To comprehensively evaluate the effectiveness and superiority of the present invention, "A method for rapid repair of road potholes covered with an ultra-thin wearing layer," we designed the following series of test experiments:

[0182] 1. Low-temperature crack resistance test

[0183] Experimental conditions: temperature -10℃, loading rate 50mm / min;

[0184] Experimental method: Low temperature bending test was adopted. The specimen with a size of 250mm×30mm×35mm was placed in an environment of -10℃ and kept for 4 hours. Then, a three-point bending test was carried out, and the failure load and deflection were recorded.

[0185] 2. High-temperature stability test

[0186] Experimental conditions: temperature 60℃, loading frequency 0.7Hz;

[0187] Experimental method: Dynamic creep test was adopted. A cylindrical specimen with a diameter of 100 mm and a height of 60 mm was placed in an environment of 60℃ and kept for 5 hours. Then, dynamic creep test was carried out, and the deformation within 60 minutes was recorded.

[0188] 3. Bond strength test

[0189] Experimental conditions: temperature 25℃, tensile rate 50mm / min;

[0190] Experimental method: Tensile bond test was adopted. Two cylindrical specimens with a diameter of 100 mm and a height of 50 mm were bonded together with an adhesive layer and cured at 25℃ for 24 hours. Then, a tensile test was carried out and the maximum tensile force was recorded.

[0191] 4. Abrasion resistance test

[0192] Experimental conditions: temperature 25℃, rotation speed 30r / min, load 500N, grinding wheel H-22;

[0193] Experimental method: A rotary drum abrasion test was used. The specimen with dimensions of 100mm×100mm×15mm was subjected to abrasion test of 1000 revolutions on a rotary drum abrasion tester, and the mass loss was recorded.

[0194] 5. Impact resistance test

[0195] Experimental conditions: temperature 25℃, drop weight mass 4.5kg, drop weight height 50cm;

[0196] Experimental method: Drop hammer impact test was adopted. The specimen with a size of 500mm×500mm×50mm was subjected to drop hammer impact test, and the destructive energy was recorded.

[0197] Based on the above testing methods, we conducted a comprehensive performance evaluation of Examples 1-4 and Comparative Examples 1-6, and the results are shown in the table below:

[0198] Table 1 Performance test results of each embodiment and comparative example

[0199]

[0200] The test results show that Example 3 exhibits the best overall performance and can be considered the best embodiment of the present invention. Compared with the comparative example, the embodiments of the present invention show significant superiority in all indicators:

[0201] 1. Low-temperature crack resistance: The low-temperature crack resistance of the examples was generally higher than that of the comparative examples, mainly due to the use of SBS modified bitumen. The styrene blocks in the SBS molecule provide good rigidity, while the butadiene blocks endow the material with excellent elasticity. The synergistic effect of the two significantly improves the low-temperature crack resistance of the material.

[0202] 2. High-Temperature Stability: The high-temperature deformation of the embodiment was significantly lower than that of the comparative example, which is attributed to the composite system of high-performance epoxy resin and modified polyurethane. The epoxy resin provides excellent thermal stability, while the modified polyurethane enhances the elastic recovery of the material. The synergistic effect of the two greatly improves the high-temperature stability of the material.

[0203] 3. Bond Strength: The bond strength of the embodiment is significantly higher than that of the comparative example, mainly due to the multi-layer structure design of the adhesive layer and the primer layer. The SBR-modified emulsified asphalt, as the adhesive layer, not only provides good initial adhesion but also adapts to temperature changes and traffic loads. The epoxy resin diluent, as the primer layer, can penetrate to the surface of the cold patch material, forming chemical bonds and further enhancing the interlayer bond strength.

[0204] 4. Abrasion Resistance: The abrasion resistance of the embodiments was significantly better than that of the comparative examples, mainly due to the addition of nano-silica and carbon fibers. Nano-silica improves abrasion resistance by enhancing the surface hardness and internal structure of the material, while carbon fibers reduce wear by providing internal support and stress dispersion. The synergistic effect of the two significantly improves the abrasion resistance of the material.

[0205] 5. Impact Resistance: The impact resistance of the embodiments is also superior to that of the comparative examples, mainly due to the addition of carbon fibers and the design of the epoxy-polyurethane composite system. Carbon fibers can effectively absorb and disperse impact energy, while the epoxy-polyurethane composite system provides good toughness. The synergistic effect of the two greatly improves the impact resistance of the material.

[0206] Through in-depth analysis of the test data, we discovered that this invention also has some unexpected technical effects:

[0207] 1. Self-healing ability: During high-temperature stability testing, we unexpectedly discovered that the prototype exhibited a certain degree of self-healing ability after unloading. This may be due to the fluidity and molecular chain rearrangement of the SBS modified bitumen and modified polyurethane at high temperatures, enabling the material to recover its original shape and properties to some extent.

[0208] 2. Fatigue Resistance: During repeated impact tests, we found that the performance degradation rate of the embodiment was significantly lower than that of the comparative example. This indicates that the material of the present invention has excellent fatigue resistance, possibly due to the enhanced internal structural stability of the material resulting from the addition of nanomaterials and carbon fibers.

[0209] 3. Environmental adaptability: When tested under different temperature and humidity conditions, we found that the performance of the embodiment fluctuated little, demonstrating excellent environmental adaptability. This may be due to the complex network structure formed by the synergistic effect of multiple components, which enables the material to maintain stable performance under various environmental conditions.

[0210] 4. Long-term durability: Through accelerated aging tests, we found that the tested samples maintained a high performance level even after long-term use. This is likely due to the excellent anti-aging properties of the high-performance epoxy resin and modified polyurethane, as well as the free radical scavenging effect of the nanomaterials, which together improve the long-term durability of the material.

[0211] 5. Interface compatibility: In the microscopic analysis, we found that the components of the embodiment formed good interface compatibility. This may be due to the complex physical and chemical interactions between the multiple components, such as hydrogen bonds and van der Waals forces, thus forming a highly integrated composite system.

[0212] These unexpected technical effects further confirm the innovation and superiority of the invention, providing more comprehensive and reliable technical support for the rapid, efficient, and durable repair of potholes on highways.

[0213] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A method for rapid repair of a road surface pit covered with an ultra-thin wearing layer, characterized in that ,including the following steps: (1) preparing modified cold patch material; (2) preparing ultra-thin wearing layer material; (3) cleaning the pit; (4) applying the bonding layer; (5) filling the cold patch material; (6) laying the ultra-thin wearing layer; (7) curing; (8) opening to traffic.

2. The method of claim 1, wherein The method for preparing the modified cold patch material in step (1) comprises: First, prepare the modified asphalt: heat the base asphalt to 160-180℃, stirring speed 200-300rpm, slowly add 3-5 parts by weight of SBS modifier, continue stirring for 90-120 minutes; Second, prepare the cold patch material: preheat the aggregate to 120-140℃, stir in the mixer for 3-5 minutes, then add polypropylene fiber and filler, continue stirring for 2-3 minutes until uniform, finally add the high molecular modifier, stir for 1-2 minutes, the whole process temperature control at 110-130℃; The components of the modified cold patch material and their parts by weight are: aggregate 60-75 parts by weight, modified asphalt 4-6 parts by weight, high molecular modifier 0.5-1.5 parts by weight, fiber 0.1-0.3 parts by weight, filler 18-35 parts by weight.

3. The method of claim 2, wherein The aggregate is basalt gravel, particle size 5-10mm; the fiber is polypropylene fiber, length 6-12mm; the filler is limestone powder, particle size <0.075mm; the high molecular modifier is polyvinyl alcohol, molecular weight 50000-80000.

4. The method of claim 1, wherein The method for preparing the ultra-thin wearing layer material in step (2) comprises: First, add bisphenol A type epoxy resin and modified polyurethane in the reaction kettle, stir at 60-70℃ for 30-40 minutes; Then, add nano-silicon dioxide and carbon fiber, continue stirring for 20-30 minutes; Finally, add curing agent and wear-resistant aggregate, stir for 10-15 minutes until uniform; The whole process is carried out under vacuum degree 0.05-0.1MPa; The components of the ultra-thin wearing layer material and their parts by weight are: high-performance epoxy resin 40-50 parts by weight, curing agent 10-15 parts by weight, modified polyurethane 5-10 parts by weight, nano-silicon dioxide 1-3 parts by weight, carbon fiber 0.5-1 parts by weight, wear-resistant aggregate 25-35 parts by weight.

5. The method of claim 4, wherein The epoxy equivalent weight of the bisphenol A type epoxy resin is 180-200g / eq; the NCO% of the modified polyurethane is 5-7%; the particle size of the nano-silicon dioxide is 20-30nm; the length of the carbon fiber is 3-5mm; the curing agent is modified naphthenic amine, amine value 350-400mgKOH / g; the wear-resistant aggregate is corundum, particle size 0.3-0.5mm.

6. The method of claim 1, wherein The method for cleaning the pit in step (3) is: use high-pressure air blowing, pressure 0.6-0.8MPa, remove loose materials and dust in the pit, ensure the pit surface is dry and clean.

7. The method of claim 1, wherein , the method of applying the adhesive layer in step (4) is: using modified emulsified asphalt as the adhesive layer, uniformly applying with a brush, the amount being 0.3-0.5 kg / m 2 , curing at room temperature for 15-20 minutes; wherein the modified emulsified asphalt is SBR modified, the solid content being 60-65%.

8. The method of claim 1, wherein The method for filling the cold patch material in step (5) comprises: First, fill the cold patch material into the pit, slightly exceeding the road surface by 1-2cm; Then, compacting is performed using a small vibrating roller, wherein the small vibrating roller has a weight of 1-2 tons, a frequency of 40-50 Hz, an amplitude of 0.4-0.6 mm, and is compacted for 3-5 times.

9. The method of claim 1, wherein The method for laying the ultra-thin wearing layer in step (6) comprises: First, spray the surface of the compacted cold patch material with a primer, the amount of which is 0.1-0.2 kg / m 2 ; Secondly, after the primer is dry, the prepared ultra-thin wearing layer material is uniformly laid on the surface, and the thickness is controlled to be 2-3 mm; Thirdly, the surface is smoothed using an automatic screed to ensure that the surface is flush with the surrounding pavement; Finally, anti-skid aggregate is evenly spread on the surface, with a dosage of 0.8-1.2 kg / m 2 ; The primer is an epoxy resin diluent, and the solid content is 30-35%; the anti-skid aggregate is corundum sand, and the particle size is 0.5-1 mm.

10. The method of claim 1, wherein The method for curing in step (7) comprises: Firstly, the repaired area is heated and cured using an infrared heating device, the temperature is controlled to be 60-70℃, and the time is 30-40 minutes; Then, the temperature is naturally cooled to below 40℃, and the curing time is not less than 2 hours; The condition for opening the traffic in step (8) is that the repaired area is completely cooled and the ultra-thin wearing layer is completely cured, and the time is about 4-6 hours.

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