Thin Polymer Concrete Coating for Traffic Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for resurfacing concrete structures require demolition and removal of existing concrete, plumbing, and electrical wiring, making the process labor-intensive, time-consuming, and expensive.
Innovation Solution
A system and method for applying an exposed aggregate architectural coating to existing concrete structures, using a modified, cement-based, two-part polymer that is thinner than standard concrete finishing materials, allowing for installation without demolition of existing structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard concrete finishing materials are used, then durability and traffic resistance are improved, but installation time and labor intensity increase
Solution Approach 1:
The patent changes the thickness parameter of the concrete coating from traditional 4 inches or greater to less than one-fourth of an inch. This parameter change enables faster installation and reduced labor while maintaining durability through the use of polymer-modified cement-based materials that provide strength at reduced thickness.
Solution Approach 2:
The patent uses polymer-modified cement-based materials that combine organic polymers with inorganic cement. This composite material approach maintains the durability and traffic resistance of traditional concrete while enabling thinner application thickness, thereby reducing installation time and labor requirements.
2Shape
If new concrete finish is installed by demolishing existing concrete, then aesthetic quality is improved, but installation time and cost increase
Solution Approach 1:
The patent applies a bonding agent to the existing concrete surface before applying the new thin-layer coating. This preliminary action ensures proper adhesion of the new material to the old surface, eliminating the need for demolition while maintaining aesthetic quality. The existing concrete is prepared and treated in advance to receive the new finish.
Solution Approach 2:
The patent creates a new aesthetic finish that copies or replicates the appearance of traditional exposed aggregate concrete but applies it as a thin coating over existing concrete. This copying approach achieves the desired aesthetic without the time-consuming demolition and reinstallation process.
3Reliability
If thick concrete coating is applied, then durability under traffic is improved, but material cost and installation complexity increase
Solution Approach 1:
The patent changes the thickness parameter from traditional thick applications (4 inches or more) to thin applications (less than one-fourth of an inch). This parameter change reduces installation complexity and material costs while maintaining traffic resistance through polymer modification and proper surface preparation.
Solution Approach 2:
The patent employs a thin-film approach using polymer-modified cement-based coating that provides the necessary durability and flexibility to withstand traffic loads. The thin film structure, reinforced by polymer additives, achieves traffic resistance without requiring thick applications that会增加 installation complexity.
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 solution provides a durable, aesthetically pleasing exposed aggregate finish that can withstand high vehicular and pedestrian traffic, while being less labor-intensive and time-consuming to install, and is cost-efficient due to its thinner composition.
Implementation Method 1
a modified, cement-based, two-part polymer... applied to existing concrete structures... to preserve the integrity of the pre-existing concrete structures
Data Source
AI summary
The invention involves an exposed aggregate architectural coating to be applied to existing concrete structures. The invention includes a method of preparing and roughening an existing concrete structure surface, mixing the components of the exposed aggregate architectural coating, applying the coating to the existing concrete structure, spreading the coating to a thickness of one-fourth of an inch or thinner, using a trowel, gauge rake, or other method to smoothen the coating, allowing the coating to cure, applying a surface retarder once the exposed aggregate architectural coating has stiffened, allowing the surface retarder to cure for twenty-four hours, and washing the surface with a pressure-washer to remove the surface retarder, then “acid-washing” the surface to remove residue and create a desired texture. The resulting applied exposed aggregate architectural coating will have an exposed aggregate finish that is durable and suitable for high vehicular and pedestrian traffic areas.