Pervious Concrete System with Decorative Layer
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Solution Overview
Problem
Traditional concrete is impermeable to water, making it unsuitable for applications requiring a water-permeable or porous surface while maintaining strength and performance.
Innovation Solution
A pervious concrete system comprising a sub-grade layer, a coarse pervious layer with a cement mixture, fiber material, and water of hydration, a binder layer, and a decorative pervious top layer with a pozzolan, internal curing admixture, and fiber material, designed to allow water percolation while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional concrete is used to maintain strength and structural integrity, then the concrete provides good load-bearing capacity, but the concrete becomes impervious to water and loses water permeability
Solution Approach 1:
The patent applies porous materials by formulating concrete with a highly porous structure containing voids and cavities that allow water permeation. The porous concrete mixture includes air-entraining agents and is cured to maintain a void content of 15-30%, creating interconnected pores that enable water flow while retaining structural strength for load-bearing applications.
Solution Approach 2:
The patent uses composite materials by combining cementitious binders with porous aggregate materials and air-entraining admixtures to create a composite concrete system. The composite structure integrates strong cement matrix with porous void spaces, achieving both mechanical strength and water permeability simultaneously through the synergistic combination of different materials.
2Reliability
If the concrete is made porous to allow water passage, then water permeability is improved, but the structural strength and load-bearing capacity deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the water-cement ratio, air content, and void distribution within the concrete mixture. By controlling parameters such as void size (0.1-2.0mm), void connectivity (60-80% interconnected), and cementitious content (10-20% by volume), the concrete achieves both high water permeability (>10 mm/s) and adequate structural strength through precise parameter optimization.
3Reliability
If a multi-layer system is used to achieve both perviousness and aesthetics, then water percolation and decorative features are improved, but the system complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the pervious concrete system into multiple functional layers: a coarse pervious concrete layer (10-20cm thick) for primary water infiltration, a binder layer for structural continuity, and a fine decorative pervious concrete layer (2-5cm thick) for aesthetics and secondary filtration. Each layer is optimized for its specific function, with the coarse layer handling bulk water flow and the fine layer providing decorative surfaces with 15-25% void content.
Solution Approach 2:
The patent uses an intermediary binder layer between the coarse and fine pervious concrete layers to ensure structural continuity and proper load transfer. This intermediary layer, composed of cementitious material with 5-10% void content, connects the two pervious layers while maintaining overall system permeability and preventing structural failure at the interface between layers of different densities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high water percolation rates and desirable aesthetic properties, with the coarse pervious layer having a void space of 18-22% and the decorative layer having a void space of 15-25%, enabling effective drainage and decorative features.
Implementation Method 1
a decorative pervious layer on to the acrylic binder layer, the decorative pervious layer comprising a cement, a relatively fine decorative aggregate, fly ash, and an internal curing admixture
Implementation Method 2
retaining water of hydration in the coarse pervious layer during curing by applying an acrylic binder layer to the coarse pervious layer
Implementation Method 3
retaining water of hydration in the coarse pervious layer during curing by applying an acrylic binder layer to the coarse pervious layer
Implementation Method 4
the percolation rate of water through the pervious concrete system is greater than about 5 gallons per hour per square foot
Implementation Method 5
enabling effective drainage
Data Source
AI summary
Various embodiments of a system and method of forming a decorative pervious concrete system are generally described. In some embodiments, the pervious concrete system comprises a coarse pervious layer, a binder layer, a decorative pervious layer and a decorative layer sealer. In some embodiments, the decorative pervious layer comprises a decorative aggregate which may be at least partially exposed.