Permeable joint surface coating

Abstract

A process for manufacturing an exterior surface coating, comprising the following steps: - on a lower layer, placement of a matrix (2) comprising an upper face (4) and a lower face (6) connected by walls (8), the lower face (6) facing the bedding layer (1), the matrix (2) having compartments (10) delimited by walls (8), - application of a filler material into the matrix (2) until the compartments (10) are filled, - after solidification of the filler material, removal of the matrix (2) and obtaining a set of support elements formed by the in-situ applied filler material, - filling of spaces left free by the removal of the walls (8) of the matrix (2) with a water-permeable filler material. Figure for the abbreviation: Figure 2

Description

Title of the invention: Permeable joint surface coating technical field

[0001] The invention belongs to the field of surface coatings for the exterior, and relates more specifically to a surface coating configured to provide support for people or vehicles, while offering permeability to rainwater. Technological background

[0002] In order to facilitate the movement or parking of vehicles, it is common practice to lay a surface covering on the ground that provides a suitable support for these uses, is durable, and is not degraded by these uses. Bituminous surfaces have commonly been used for this purpose, covering, for example, parking spaces or sidewalks.

[0003] While such bituminous surfaces offer numerous advantages, particularly in terms of ease of installation, cost, flatness, and durability, they have the disadvantage of making surfaces impermeable, which poses both the problem of rainwater drainage and insufficient hydration of the underlying soils. Furthermore, these bituminous surfaces form mineral surfaces that do not offer the environmental and quality-of-life benefits of a vegetated surface.

[0004] Surface coverings consisting of a concrete grid with vegetated areas in the openings of the concrete grid have been proposed. However, this solution is not without its drawbacks. In particular, the installation of such surfaces is complicated and costly, since the concrete grid is prefabricated and must therefore be transported to the installation site, with significant logistical constraints, notably due to the grid's weight and fragility. Furthermore, installing the grid requires a perfectly flat surface, otherwise the grid may become unstable and / or weakened.

[0005] Another solution is to pave the surface with paving stones, for example, stone or bricks. The joints between the paving stones can be permeable, containing, for example, primarily sand or soil. However, laying these paving stones is a lengthy, delicate, and costly operation, since the bedding layer must be perfectly level and prepared to support the paving stones uniformly. Indeed, over time, any irregularity in the underlying layers will result in deformation of the paving. The same applies to the stresses on the paving stones, which vary greatly from one stone to another. This often results in deformed surfaces, or even the dislodging of paving stones. Presentation of the invention

[0006] The invention therefore aims to provide an exterior surface coating that is easy and inexpensive to implement, resistant to wear, and that limits the impermeability of the ground.

[0007] To this end, the invention proposes a method for manufacturing an exterior surface coating, comprising the following steps: - on a lower layer, the placement of a matrix comprising an upper face and a lower face connected by walls, the lower face facing the lower layer, the matrix having through voids between the upper face and the lower face, said voids being separated by walls of the matrix delimiting compartments, - application of a filler material into the matrix until the compartments are filled, - after solidification of the filling material, removal of the matrix and obtaining a monobloc piece formed from the in-situ applied filling material, said monobloc piece comprising support elements corresponding to the compartments and, - filling of spaces left free by the shrinkage of the matrix walls with a water-permeable filling material, allowing water to pass through said filling material to reach the lower layer.

[0008] The exterior surface coating, through the presence of the water-permeable filler material, allows water to infiltrate through this filler material and reach the lower layer. The in-situ application of the filler material allows for easy and rapid implementation at low cost, even over large surfaces.

[0009] Preferably, a plurality of walls each having a passage provided in said wall between two compartments delimited by said wall, and the application of the filling material in the matrix includes filling the passages between said compartments, and the assembly includes connections linking the support elements together and corresponding to the passages, the assembly forming a single piece, and the filling material covers the connections.

[0010] The connections linking the support elements together ensure the cohesion of the support elements and therefore the strength and durability of the surface coating. Preferably, the passages are provided at a distance from the upper face of the matrix. Preferably also, the passages are open on the lower face of the matrix.

[0011] The invention is advantageously complemented by the following various features taken alone or according to their various possible combinations: - the spaces left free leave the lower layer exposed over the majority of the surface area of ​​the spaces; - the filling material comes into contact with the lower layer over at least 50% of the surface area of ​​the spaces left free; - the filling material is a coating, a poured asphalt or a concrete; - the filling material essentially consists of gravel, sand or soil; - the upper face of the matrix is ​​flat, the application of the filling material includes flattening the filling material level with the upper face; - the matrix is ​​a single piece and comprises at least 4 compartments; -the spaces left free by the withdrawal of the walls of the matrix and filled by the filling material are continuous. - the process may then include planting vegetation on the filling material.

[0012] The invention also relates to an exterior surface coating comprising: - a set of support elements formed from a filling material applied in-situ, - a filling material filling the spaces between the support elements, the filling material being permeable to water and allowing the passage of water through said filling material to reach the lower layer. Presentation of the figures

[0013] Other features, objectives and advantages of the invention will become apparent from the following description, which is purely illustrative and not limiting, and which should be read in conjunction with the accompanying drawings on which:

[0014] - Fig. 1 illustrates, from a top view, an example of a matrix that can be used for setting up implementation of the process according to a possible embodiment of the invention;

[0015] - [Fig.2] shows the matrix of the figure in perspective;

[0016] - [Fig. 3] shows an example of filling the matrix compartments according to an embodiment of the invention;

[0017] - [Fig. 4] shows an example of an assembly formed from a filling material applied in-situ resulting from the removal of the matrix according to an embodiment of the invention;

[0018] - Figure 5 illustrates in perspective a detail showing a connection between two elements of the assembly according to an embodiment of the invention;

[0019] - Figure 6 shows a top view example of a surface coating according to a method of embodiment of the invention,

[0020] - Figure [Fig. 7] illustrates, from a top view, an example of a matrix that can be used for setting up implementation of the process according to a possible embodiment of the invention;

[0021] - [Fig.8] shows a detail of the matrix of [Fig.7],

[0022] - [Fig.9] shows an example of an assembly formed from a filling material applied in-situ resulting from the removal of the matrix from [Fig.7]. Detailed description

[0023] The exterior surface coating according to the invention can, in particular, be used to cover surfaces intended for pedestrian traffic or motor vehicle parking. However, other applications can be envisaged. An example of a method for manufacturing an exterior surface coating will now be described.

[0024] The outer surface coating is formed on a lower layer 1, which can be of any type and serves as a support for the outer surface coating. The lower layer is preferably permeable to water, such as a layer of gravel or soil. The lower layer 1 provides a flat and load-bearing surface for the outer surface coating. The lower layer 1 can be advantageously used to promote elevation adjustment and, if necessary, root development of any vegetation. In the latter case, it is preferably composed of a mixture of gravel and soil or a plant substrate.

[0025] The lower layer 1 can, for example, depending on the expected structure and traffic, be a base or subgrade layer, a bedding layer, and possibly a subgrade layer. A bedding layer is a layer of materials that allows for fine adjustment of elevation, the transmission of vertical forces to the lower layers, and may also provide drainage. A subgrade layer is a layer that allows for adapting the characteristics of the backfill materials or the existing ground.

[0026] However, unlike other approaches such as paving or grass grids, it is not necessary to have a perfectly flat bottom layer 1. If the bottom layer 1 is not perfectly flat, it may be advantageous to wedge the matrix 2. Preferably, the matrix 2 is arranged so that its upper face 4 is horizontal, or curved at a defined angle (<5°) with respect to the horizontal.

[0027] On this lower layer 1, a matrix 2 is placed, comprising an upper face 4 and a lower face 6 connected by walls 8, the lower face 6 facing the layer bed 1. Figures 1 and 2 show examples of such a matrix 2. The matrix 2 has through-holes between the upper face 4 and the lower face 6, said holes being separated by walls 8 of the matrix 2, delimiting compartments 10. In this example, the matrix 2 has an overall rectangular shape tangential, and the compartments 10 are square. Other shapes are possible for the compartments 10 or for the matrix 2, for example with sections according to geometric shapes such as rectangles, other preferably regular polygons, ellipses or circles, or even more complex shapes.

[0028] Since the matrix 2 is intended to be removed after the application and solidification of a filler material 14, the walls 8 of the matrix 2 are shaped to allow this removal. The walls 8 are preferably straight between the upper face 4 and the lower face 6, and typically perpendicular to these parallel faces 4 and 6. Thus, in the case of compartments 10 having a square or rectangular cross-section, the compartments 10 form cubes or cuboids, respectively. The walls 8 may, however, have a positive draft angle. The matrix 2 is made of a rigid material capable of withstanding the stresses and temperatures to which the matrix 2 may be subjected. Preferably, the matrix 2 is metallic, and generally made of steel.

[0029] In the illustrated example, matrix 2 has 20 compartments 10, but any number of compartments 10 can be considered. However, matrix 2 preferably has at least 4 compartments 10, and preferably at least 8 compartments 10.

[0030] As shown in [Fig. 2], a plurality of walls 8 preferably each have a passage 12 formed in said wall 8 between two compartments 10 delimited by said wall. Preferably, each compartment 10 communicates with at least one other compartment 10 via a passage, and preferably each compartment 10 communicates with at least two other compartments 10.

[0031] To allow the removal of the matrix 2, the passages 12 are opened on the side of the lower face 6 of the matrix 2. Preferably, the passages 12 are located at a distance from the upper face 4 of the matrix 2, and therefore do not extend over the entire height of the walls 8. Typically, each passage 12 represents less than 40%, and preferably less than 20%, of the wall 8 in which said passage 12 is located, in terms of wall area, and preferably less than 15% of the wall 8 in which said passage 12 is located. Preferably, the passages 12 extend over less than 50% of the length of the walls 8 of a compartment 10, parallel to the upper face 4, and preferably over less than 30%. Put another way, the walls 8 of a compartment 10 extend, over the majority of their length, from the upper face 4 to the lower layer 1, without any passage 12 crossing them.

[0032] With the matrix 2 now resting on the lower layer 1, a filling material 14 is applied to the matrix 2 until the compartments 10 and the passages 12 between said compartments 10 are filled, as illustrated in [Fig. 3]. Depending on the nature of the material, the application may be a casting or a molding, or any other action that allows the matrix to be filled.

[0033] The filler material 14 can be of any type that can be applied in situ and solidify while allowing the matrix 2 to be removed. Once solidified, the filler material 14 provides support for foot traffic or vehicular traffic on the surface pavement. Typically, the filler material 14 is a mix, a poured asphalt, or concrete. A mix is ​​defined as a product comprising a hydrocarbon binder and solid particles, in particular mineral solid particles.

[0034] The term "hydrocarbon binder" or "binder" as used in this description refers to any hydrocarbon binder of fossil or vegetable origin, or synthetic, or bio-based, usable for the production of so-called "bituminous" products. The binder may also be non-bituminous.

[0035] The hydrocarbon binder can be pure, additized, in particular by adding additives commonly used in the road sector, for example adhesion enhancers or vegetable or petrochemical waxes, or be modified, in particular by adding polymers.

[0036] Examples of solid particles include mineral solid particles such as natural mineral aggregates (gravel, sand, fines) for example from quarries or gravel pits, recycled products such as asphalt aggregates, for example resulting from the recycling of materials recovered during road repairs or surpluses from asphalt plants, manufacturing waste, shingles (from the recycling of roofing membranes), aggregates from the recycling of road materials including concrete, slags in particular slag, shales in particular bauxite or corundum, rubber powders from the recycling of tires in particular, artificial aggregates of any origin and aggregates from for example bottom ash from municipal solid waste incineration (MSWI), as well as mixtures thereof in all proportions.

[0037] Solid particles, in particular mineral solid particles, for example natural mineral aggregates, typically include:

[0038] - elements smaller than 0.063 mm (filler or fines);

[0039] - sand whose elements are between 0.063 mm and 4 mm;

[0040] - gravel or aggregates, the elements of which have dimensions

[0041] * between 2 mm and 6 mm;

[0042] * greater than 6 mm.

[0043] The size of solid particles, in particular mineral solid particles, for example mineral aggregates, is measured by the tests described in standard NF EN 933-2 (version May 1996).

[0044] The term "aggregates of asphalt" refers to fragments of asphalt (a mixture of aggregates and bituminous binders) from milling asphalt layers, crushing slabs extracted from asphalt pavements, pieces of asphalt slabs, asphalt waste, or surplus asphalt production (production surpluses are materials coated or partially coated at the plant resulting from the transitional phases of manufacturing). These elements and other recycled products can reach dimensions of up to 31.5 mm.

[0045] Asphalt mixes can be hot mix, warm mix, cold-applied bituminous materials, porous asphalt, colored asphalt, light-binder asphalt, plant-binder asphalt, shot-blasted asphalt, or surface dressings. Such bituminous products are well known in road construction and can be prepared using conventional techniques. For example, it is possible to use a Décovia® type asphalt mix, which is a range of cold mixes based on the use of translucent, non-bituminous binders that enhance the natural color of the aggregates used. Décovia® asphalt is applied at an average thickness of 40 mm using the usual methods for applying bituminous materials. The grading curve of Décovia® formulas is continuous. The most common particle size is 0 / 10 mm.

[0046] Other materials could however be used depending on the intended use of the surface coating.

[0047] Preferably, the upper face 4 of the die 2 is flat, and the application of the filler material 14 includes leveling the filler material 14 to be level with the upper face 4. Typically, if the filler material 14 is asphalt, poured asphalt, or concrete, it is sufficient to level the filler material 14 by passing it over the upper face 4 of the die 2, for example, with a hand tool such as a scraper or a simple straightedge. If the filler material 14 is asphalt, the process advantageously also includes a step of compacting the asphalt. After solidification of the filling material 14, it reaches a consistency allowing the removal of the matrix 2 while retaining the shape of the compartments 10. The duration of solidification can range from one or two hours, for example in the case of cooling a material such as a poured asphalt or asphalt mix, or can be longer for the setting of concrete.

[0048] The matrix 2 is then removed, typically by an upward translation. This yields an assembly 16 formed from the in-situ applied filling material 14, as in the example of [Fig. 4]. In this example, the assembly 16 is a single piece, and therefore forms a single unit. The single-piece assembly 16 comprises support elements 18 corresponding to the compartments 10 and connections 20 linking the support elements 18 together and corresponding to the passages 12 between the compartments 10. Thus, the support elements 18 are linked together, ensuring the The monolithic nature of the assembly 16 is achieved, and therefore the cohesion of the support elements 18 is ensured, which is not possible with the installation of independent pavers. The support elements 18 rest on the lower layer 1, and their underside 6 adopts the shape of the lower layer due to the application of the filler material 14, thus compensating for any irregularities in the lower layer 1. The support elements 18 provide support for foot traffic or vehicular traffic on the surface, and their thickness and size are chosen for this purpose. In particular, the thickness must be sufficient to ensure good durability, and the upper surface of each support element 18 must be large enough to stably accommodate objects that will rest upon it.

[0049] The support elements 18 are separated from each other by spaces 22 left free by the shrinkage of the walls 8 of the matrix 2. In one embodiment, the spaces 22 extend mainly from the lower layer 1 to the upper face of the support elements 18. Thus, the spaces 22 leave the lower layer 1 exposed over the majority of the surface of the spaces 22. This then maximizes the passage of water to reach the lower layer 1.

[0050] When the matrix 2 includes passages 12, the spaces 22 are traversed by the connections 20 between the support elements 18. Preferably, the connections 20 linking the support elements 18 to each other extend over less than 50% of the area of ​​the spaces 22 on the lower layer 1, and preferably over less than 30%. This allows for maximizing the water flow to reach the lower layer 1.

[0051] These spaces 22 are then filled with a filling material 24, resulting in a surface coating as illustrated in [Fig. 5]. The filling material comes into contact with the lower layer 1 over at least 40% of the area of ​​the spaces 22, and preferably over at least 55%, and even more preferably over at least 70%.

[0052] The backfill material 24 is water-permeable. Water-permeable means a material that allows water to pass through it, and more specifically in this intended application, that allows rainwater to infiltrate into the underlying soil, typically within minutes, for example, in less than an hour after rainfall of at least 1 mm. Preferably, the backfill material 24 essentially comprises gravel, sand, or a plant substrate such as soil, which may optionally be enriched with seeds or fertilizer. The water permeability of the backfill material 24 makes the surface pavement permeable by allowing water to penetrate it. Advantageously, the backfill material 24 can be vegetated, typically with grass, which provides better resistance to compaction and This improves permeability. It is therefore possible for the fill material 24 to contain seeds. The fill material 14 is considered vegetated when at least 25%, and preferably 50%, of its surface is covered by vegetation growing on it. Vegetation may simply consist of waiting for vegetation to grow. Typically, the fill material 14 is vegetated in less than a year, or even in a few months or weeks if conditions are favorable.

[0053] Due to the shrinkage of the matrix 2, the spaces 22 open laterally from the assembly 16, and the filling material 24 could protrude unsightly. It is possible to frame the surface covered by the surface coating with a containment solution, such as a frame of another material, for example, asphalt or soil. Typically, the surface coating fills a gap, such as a hole, made to accommodate it, so that the periphery of the surface coating abuts the frame of this gap.

[0054] The permeable filling material 24 fills the spaces 22 between the support elements 18 and covers any connections 20 between the support elements 18. Preferably, the filling material 24 fills these spaces 22 until it is level with the upper surface of the support elements 18, possibly after settling. The spaces 22 left free by the shrinkage of the walls 8 of the matrix 2 and filled by the filling material 24 are continuous and interconnected, resulting in surface continuity of the filling material 24. In this way, the upper surface of the filling material 24 also serves as a water drainage channel in case of excessive rainfall and runoff. If this upper surface is sown with grass, the surface continuity of the filling material 24 also allows for gradual plant colonization, facilitating the resilience of the vegetation.

[0055] The surface area covered by the filler material 24 is preferably sufficient to significantly improve permeability and potentially ensure the survival of plant species. Preferably, however, the support elements 18 are not separated from each other by more than a few centimeters, so that they can fulfill their support function despite the presence of the surface covered by the filler material 24 between them. Thus, the surface area of ​​the filler material is preferably less than 50% of the surface area of ​​the surface covering, and preferably less than 40% of the surface area of ​​the surface covering. However, the surface area of ​​the filler material is preferably more than 5% of the surface area of ​​the surface covering, and preferably even more than 10% of the surface area of ​​the surface covering.

[0056] As already visible in the example of [Fig.2], but even more clearly visible in the example of [Fig.7], [Fig.8], and [Fig.9], the walls 8 of the matrix 2 com They take first parts 8a of the wall and second parts 8b of the wall, the first parts 8a not extending over the entire height between the upper face 4 and the lower face 6, while the second parts 8b extend over the entire height between the upper face 4 and the lower face 6. In the illustrated example, the first parts 8a are straight, and the second parts 8b are cylindrical. Other shapes can, however, be considered.

[0057] The first portions 8a may extend from the upper face 4 to only 75% or less, preferably only 50% or less, and even more preferably only 30% or less of the height between the upper face 4 and the lower face 6. For example, over a height of approximately 5 to 6 cm between the upper face 4 and the lower face 6, the first portions 8a may extend for approximately 1 cm. The area below the first portions 8a is left free, and thus constitutes a passage 12 between two compartments 10. As before, the passage 12 allows the filling material to connect two compartments 10, forming connections 20.

[0058] After the removal of matrix 2, some of the spaces 22 left free are then separated from the lower layer 1 by the filling material constituting material 20: these are the first spaces 22a resulting from the removal of the first wall sections 8a. Conversely, the second wall sections 8b leave second spaces 22b which extend down to the lower layer 1. It should be noted that the passages 12 can then represent more than 20% of the walls 8 of a compartment 10, but preferably less than 50% of this area.

[0059] In order to maintain the capacity for water to infiltrate down to the lower layer 1, it is preferable that, at the level of the upper face 4, the surface area of ​​the first wall sections 8a represents less than 100% of the surface area of ​​the second wall sections 8b, preferably less than 75%, and even more preferably less than 50%. Thus, the gaps 22 left free expose the lower layer 1 over the majority of the area of ​​the gaps 22. This then maximizes the water penetration to reach the lower layer 1. Similarly, the connections 20 linking the support elements 18 together preferably extend over less than 50% of the area of ​​the gaps 22 on the lower layer 1, and preferably over less than 30%.

[0060] These spaces 22 are then filled with a water-permeable filling material 24. The filling material comes into contact with the lower layer 1 over at least 40% of the surface area of ​​the filled spaces 22, and preferably over at least 55%, and even more preferably over at least 70%. More specifically, the filling material 24 covers the connections 20 in the first spaces 22a, and comes into contact with the lower layer 1 in the second spaces 22b. The invention is not not limited to the embodiment described and shown in the attached figures. Modifications remain possible, particularly with regard to the constitution of the various technical characteristics or by substitution of technical equivalents, without departing from the scope of protection of the invention.

Claims

Demands

1. A method for manufacturing an exterior surface coating, comprising the following steps: - on a lower layer (1), placement of a matrix (2) comprising an upper face (4) and a lower face (6) connected by walls (8), the lower face (6) facing the lower layer (1), the matrix (2) having through voids between the upper face (4) and the lower face (6), said voids being separated by walls (8) of the matrix (2) delimiting compartments (10), - application of a filler material (14) into the matrix (2) until the compartments (10) are filled, - after solidification of the filler material (14), removal of the matrix (2) and obtaining an assembly (16) formed of the filler material (14) applied in-situ, said assembly (16) comprising support elements (18) corresponding to the compartments (10) and,- filling of spaces (22) left free by the shrinkage of the walls (8) of the matrix (2) with a filling material (24), characterized in that the filling material (24) is permeable to water, allowing the passage of water through said filling material to reach the lower layer.

2. A method according to the preceding claim, wherein a plurality of walls (8) each having a passage (12) formed in said wall (8) between two compartments (10) delimited by said wall, and the application of the filling material in the matrix includes filling the passages (12) between said compartments (10), and the assembly (16) includes connections (20) linking the support elements (18) together and corresponding to the passages (12), the assembly (16) forming a single piece, and the filling material (24) covers the connections (20).

3. A method according to any one of the preceding claims, wherein the spaces (22) left free leave the lower layer (1) exposed over the majority of the area of ​​the spaces (22).

4. A method according to any one of the preceding claims, wherein the filling material comes into contact with the lower layer (1) over at least (50%) of the area of ​​the spaces (22) left free.

5. A method according to any one of claims 2 to 4, wherein each passage (12) represents less than 20% of the wall (8) in which said passage (12) is provided.

6. A method according to any one of the preceding claims, wherein the filling material (14) is a coated asphalt, a cast asphalt or a concrete.

7. A method according to any one of the preceding claims, wherein the filling material (24) essentially comprises gravel, sand or earth.

8. A method according to any one of the preceding claims, wherein the upper face (4) of the die (2) is flat, the application of the filling material (14) comprising flattening the filling material (14) to be level with the upper face (4).

9. A method according to any one of the preceding claims, wherein the matrix (2) is monobloc and comprises at least 4 compartments (10).

10. A method according to any one of the preceding claims, wherein the spaces (22) left free by the withdrawal of the walls (8) of the matrix (2) and filled by the filling material (24) are continuous.

11. Method according to any one of the preceding claims, subsequently comprising vegetation of the filling material (24).

12. Exterior surface coating comprising, on a lower layer (1): - a set (16) of support elements (18) formed of a filler material (14) applied in-situ, - a filler material (24) filling the spaces (22) between the support elements (18), the filler material being permeable to water and allowing the passage of water through said filler material to reach the lower layer.

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