US 2011 OO64517A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2011/0064517 A1
Sader (43) Pub. Date: Mar. 17, 2011
(54) REINFORCED PERVIOUS CONCRETE (57) ABSTRACT
(76) Inventor: Jon Dennis Sader, Franklin, MI A pavement such as a road, driveway, sidewalk, parking lot or
(US) the like, formed with pervious concrete material and one or
more basalt reinforcing members embedded in or positioned
21) Appl.
pp No.: 12/661,976 below the ppervious concrete material. The one or more basalt
reinforcing members add structural rigidity to the pervious
(22) Filed: Mar. 25, 2010 concrete, making the pervious concrete capable or Supporting
O O loads as normally experienced on pavements. The one or
Related U.S. Application Data more basalt reinforcing members may be basalt rebar rods, or
(60) Provisional application No. 61/211,396, filed on Mar. basalt rebar rods having a Figure-Eight shape, or a mesh made
25, 2009 s--- sis of basalt strands. In one example, the pavement may also
s include a layer of filtration fabric positioned below the basalt
Publication Classification reinforcing members. Various methods are described for
forming pavements, roads, driveways, sidewalks, parking lots
(51) Int. Cl. or the like. Such a pavement allows water or moisture to pass
EOIC 5/2 (2006.01) through the surface of the pavement and be filtered. Such a
EOIC 9/00 (2006.01) pavement reduces flooding and the need for complex storm
(52) U.S. Cl. ............................................. 404/28: 404/82 drainage systems adjacent to the pavement.

2.A
e-Sass
sy S2
& as:
Co. 2.
SãSi2S2,
o

oodŽSáSãS353,S3S
oSS 2

S.
Codog
-e 6-
g sess 39. a:
2Sy: 20V. 29. S. a
35C38.6:36:35:303
$5as CassassCasas
Sz-so-so-syl
S.
969Cof
sess ge:Sassassess
SäsäSãS35:
CRS-C
S. SS esses SS
id-Sols
c.c.

oy 29. d 9. S. 29, d 39. S. 29, S.

g
E. sase
-

52

54

O O o 6NS6S-39 s 9.
0. 9. 8C883
CassCaSOAS Cas 118
6- 52 Sã.
6 &
s
Patent Application Publication Mar. 17, 2011 Sheet 1 of 20 US 2011/0064517 A1

BASALT
REBAR54

CONCRETE 52

FIG.1
Patent Application Publication Mar. 17, 2011 Sheet 2 of 20 US 2011/0064517 A1

l 100

AAAA

PERVIOUS
/ \ BASAT
MESH 62
CONCRETE52

FIG.2
Patent Application Publication Mar. 17, 2011 Sheet 3 of 20 US 2011/0064517 A1

SEE-74
72

52

UTILITIES

FIG.4
Patent Application Publication Mar. 17, 2011 Sheet 5 of 20 US 2011/0064517 A1

PERVIOUS
CONCRETE

r as C

Cesa SS2 se C
SS2OS
SS C&SEOORSS
4.YS) 0 S&SCSOCS &SC
90-
SSSSSSSSR,
$235,3359 s
Patent Application Publication Mar. 17, 2011 Sheet 6 of 20 US 2011/0064517 A1

IMPERVIOUS SIDEWALK
CONCRETE 92
74

TREE
TREE
GRATE 94 C SOL

92

PERVIOUS 90
CONCRETE
52

TREE O
GRATE 91.

90
FG.9
Patent Application Publication Mar. 17, 2011 Sheet 7 of 20 US 2011/0064517 A1
Patent Application Publication Mar. 17, 2011 Sheet 9 of 20 US 2011/0064517 A1

... . . . . . . .
TELI
C. C. C.
TTT T. LTL
""
LTTL
s",ml ---
"O
a TTL
Y
a

NITIEEE
IEEEEEEEEE
2
EIHEITITLE
STITIATITIETIE
EIHEIEEE
IEEEEEEEEE
EEE
IHEITIEEEEEEE 5<EEETITI,
TITIATITIATI 2
III.iii. IEEET
Hitle EIHEIHEI
HIHIEEE
CD-
EIILETE Su-IIE
IETIETIETIET YY.
EIHEIHEIE EIHEIHEIHEIHIE
III
IEEEEEEEE CD
HHHIEEE ETITIETIETTE
IIII
EIHEIHEIHEIH
IIHTE L4 / REIHEIHEIHE
EIHEIHEIEEE
IEEEEEEE
III TIETIETITITLE
IEEEEEEEEE
EITHEIT
:EEEEEEEEEE
HHHHHEE
IEEEEEEEEEEE
EITHE
HHHHH
TEE
rs
wa
rems
Patent Application Publication Mar. 17, 2011 Sheet 10 of 20 US 2011/0064517 A1

COMPACTSUB-SOL 120

INSTALL FLTRATION 122

FABRIC

INSTALLAGGREGATE 124
MATERAL

PLACE BASALT 126

REBAR

POUR PERVIOUS WET 128

CONCRETE

LEVELAND COMPACT 130

WET PERVIOUS
CONCRETE

CURE AND COVER

PERVIOUS 132
CONCRETE UNTIL
READY FOR USE

FIG.14
Patent Application Publication Mar. 17, 2011 Sheet 11 of 20 US 2011/0064517 A1

s
Patent Application Publication Mar. 17, 2011 Sheet 13 of 20 US 2011/0064517 A1

HETITIE
, INITIETITIE
is25-1,y EFEIHEITIETIET
IITITIATI
TITIETIETIETIE
IEEEEEEEEE
IEEEEEEEEE
TIETIETIETITIE
IEIEEEEEEEE
ETITIETIETITIE
o N BITIETIEEE
c HIEEEEEEEE
PEO
s<HIETIETIETIETIE
Y-5Elio
EEE HE HHH V
HIEEEEEEEEE
HIEEEEEEEEEE SHIEEIHEIHEIR
IEEEEEEEEE ICD
HHHHHEE
HHHHHHH 5TITITIETITI,
IEEEEELL
EEEEE $2 uSTITIATITIATI
III
EEEEE LIHEIT
HHHHH
HIEEE -TETITIETIE
ETILIII N
- ... . - - s
TITIEEE
se-EEEEEEEEEEE CD se IEEEEEE
$1SEIHHHHI
HHHE
HIELLTITLE
HHHHH
IEEEEEE
co HIEEEE TIETIETIETTE
st IITITLE TITITIATI
o HHEEE IEEEEEEEE
HIEEE EEEEEEE
S IEEEEEEE IEEE
Patent Application Publication Mar. 17, 2011 Sheet 14 of 20 US 2011/0064517 A1

COMPACT SUB-SOIL 141

INSTALL FILTRATION 142

FABRIC

INSTALLAGGREGATE 143
MATERIAL

PLACE BASALT
REBAR WITH"FIGURE 144
EIGHT" SHAPE

POUR PERVIOUS WET 145

CONCRETE

LEVELAND COMPACT 146

WET PERVIOUS
CONCRETE

CURE AND COVER

PERVIOUS 147
CONCRETE UNTIL
READY FOR USE

FIG. 19
Patent Application Publication Mar. 17, 2011 Sheet 15 of 20 US 2011/0064517 A1

|| || || || || || |
| | | | IIT I I
II I IT DIT III
II III DIII III
r
|- -
Patent Application Publication Mar. 17, 2011 Sheet 17 of 20 US 2011/0064517 A1

HHHHH
EHE
EEEEEEEEE
III
TE IIHF
IEEEEEEE
HILIHEE
-

EEEEE
S.
Al
HIHEIHIHIHIE
S.
ETITIEEE
TETTE
y
s IETITIEEElco
EEEEEEEE
NC
HHHHHS
I EEEEEEEE|
IIIHO CD
Se H

KHHH

se /
IIIHF

IEEEEEEEEEE
Patent Application Publication Mar. 17, 2011 Sheet 18 of 20 US 2011/0064517 A1

COMPACT SUB-SOL 151

INSTALL FILTRATION 152

FABRIC

INSTALLAGGREGATE-153
MATERIAL

PLACE BASALT MESH-Nu-154

POUR PERVIOUS WET 155

CONCRETE

LEVELAND COMPACT 156

WET PERVIOUS
CONCRETE

CURE AND COVER

PERVIOUS 157
CONCRETE UNTIL
READY FOR USE

FIG.24
Patent Application Publication Mar. 17, 2011 Sheet 19 of 20 US 2011/0064517 A1

T
C
TTL

HHHE
HIEEE SHIEEE
TH THL
HIEEE t r

EEEE ...
irr
D
rr

III .
C. C.
. . . . .
C.

IEEEE
OSEEHE
HIEEE
32EEEE
5.
3 S) O

O
. .
O
O
.
O
C F

. .
t

3
IE IEE
... . . . . .

IEEE
EEEEE till f

III:
EEE THITELE
T
... . . . .

EITITLE
EEEEEE . . .
TTU"
.
.
"
.
"
. .

OSEE Trrrrrrt
LTT
Patent Application Publication Mar. 17, 2011 Sheet 20 of 20 US 2011/0064517 A1

IDENTIFYPOTHOLE IN PERVIOUS
CONCRETEPAVEMENT 161

DRILLHOLE(S) INTO PERVIOUS

CONCRETENORABOUT 162
POTHOLE TO REACHSUB GRADE

NJECT SAND SLURRY INTO

HOLE(S) TORESTORE
COMPACTED SOLSO THAT 165
PERVIOUS CONCRETERETURNS
TO ORIGINAL POSITION

FIG.27
US 2011/0064517 A1 Mar. 17, 2011

REINFORCED PERVIOUS CONCRETE material. The pavement may be used to form a road, parking
lot, driveway, sidewalk or other structure as disclosed herein,
CROSS REFERENCE TO RELATED which allows water or moisture to pass through the surface of
APPLICATION the pavement and be filtered. Such a pavement reduces flood
0001. This application claims priority to and the benefit ing and the need for complex storm drainage systems adjacent
under 35 U.S.C. 119(e) to U.S. Provisional Patent Applica to the pavement.
tion No. 61/211,396 entitled “Reinforced Pervious Concrete' 0008. In accordance with another broad aspect of an
filed Mar. 25, 2009, the disclosure of which is hereby incor embodiment of the invention, disclosed herein is a method for
porated by reference in its entirety. forming a road. In one example of the invention, the method
includes the operations of compacting a Sub-base layer;
FIELD OF THE INVENTION installing a filtration fabric above the sub-base layer; install
ing a layer of aggregate material above the filtration fabric;
0002 This invention relates to, in general, concrete for use positioning one or more basalt rebar reinforcement members
in Surfaces or pavements such as roads, sidewalks, driveways, above the layer of aggregate material; and pouring a layer of
bridges, and the like. wet pervious concrete material above the one or more basalt
rebar reinforcement members.
BACKGROUND
0009. In another example, the method may also include
0003 For decades, during significant rainstorms or snow leveling said layer of wet pervious concrete, and compacting
melt, cities and towns have experienced flooding of roads, said layer of wet pervious concrete. In another embodiment,
streets, parking lots, etc. As recognized by the present inven the method may also include curing said layer of pervious
tor, what is needed is a new concrete structure that can be used concrete. The method may also include placing the one or
to build roads, streets and other concrete structures while more basalt rebar reinforcement members approximately two
reducing flooding risks. or more inches above the layer of aggregate material, and in
another example, the method may include pouring a portion
SUMMARY of said wet pervious concrete material below the one or more
0004. In light of the above and according to one broad basalt rebar reinforcement members, so that the wet pervious
concrete material embeds the one or more basalt rebar rein
aspect of one embodiment of the invention, disclosed herein forcement members. In this manner, a road can be formed
are new methods and structures for forming concrete struc which allows water or moisture to pass through the road and
tures that can be used to make roads, sidewalks and other be filtered, thereby reducing flash flooding and reducing or
pavements or infrastructures. Specifically, embodiments of eliminating the need for complex Storm drainage systems
the invention utilize pervious concrete material with basalt adjacent to the road.
reinforcement members (basalt rebar members, basalt mesh, 0010. The foregoing and other useful features and advan
or both) to form concrete structures or pavements that can be tages of the invention will be apparent from the following
used for construction of roads, Sidewalks and other concrete more particular description of a various embodiments of the
structures or infrastructure. Through the use of embodiments invention as illustrated in the accompanying drawings.
of the present invention, the concrete structures or pavements
formed permit water and air to pass through the concrete BRIEF DESCRIPTION OF THE DRAWINGS
structures, which provides various benefits, such as reducing
the need for complex and expensive storm water runoff sys 0011 FIG. 1 illustrates an example of a reinforced con
tems in flood prone areas. crete structure including pervious concrete material and
0005. In accordance with another broad aspect of an basalt rebar members, inaccordance with one embodiment of
embodiment of the invention, disclosed herein is a pavement, the present invention.
comprising pervious concrete material and one or more basalt 0012 FIG. 2 illustrates an example of a reinforced con
reinforcing members embedded in or positioned below the crete structure including pervious concrete material and a
pervious concrete material. The one or more basalt reinforc basalt mesh, in accordance with one embodiment of the
ing members may be basalt rebar rods, or basalt rebar rods present invention.
having a Figure-Eight shape, or a mesh made of basalt 0013 FIG. 3 illustrates a conventional road using imper
Strands. The one or more basalt reinforcing members add vious concrete and storm water drains.
structural rigidity to the pervious concrete, making the per 0014 FIG. 4 illustrates an example of a road made using
vious concrete capable or Supporting loads as normally expe an embodiment of the present invention having pervious con
rienced on pavements. In one example, the pavement may crete and without storm water drains.
also include a layer of filtration fabric positioned below the 0015 FIG. 5 illustrates a conventional parking lot using
basalt reinforcing members. impervious concrete and storm water pipes.
0006. In another embodiment of the present invention, the
pavement may include a compacted Soil layer, a layer of 0016 FIG. 6 illustrates an example of a parking lot made
filtration fabric positioned above the compacted soil layer; using an embodiment of the present invention having pervi
and a layer of course aggregate material positioned above the ous concrete and without storm water pipes.
layer of filtration fabric. The one or more basalt reinforcing 0017 FIG. 7 illustrates an example of a sidewalk made
members may be positioned above the layer of course aggre using an embodiment of the present invention having pervi
gate material. In one example, the pervious concrete material OuS COncrete.
forms the upper Surface of the pavement. 0018 FIG. 8 illustrates a conventional sidewalk tree grate
0007. In another example of the invention, the one or more using impervious concrete.
basalt reinforcing members are positioned approximately two 0019 FIG. 9 illustrates an example of a sidewalk tree grate
inches or more above the bottom of the pervious concrete made using an embodiment of the present invention having
US 2011/0064517 A1 Mar. 17, 2011

pervious concrete, where the size of the tree grate can be be used to make roads, sidewalks and other infrastructures.
smaller when compared with the tree grate of FIG. 8. Specifically, embodiments of the invention utilize pervious
0020 FIG. 10 illustrates an example of a basalt rebar rod concrete material with basalt reinforcement members (basalt
or member, in accordance with one embodiment of the rebar members, basalt mesh, or both) to form concrete struc
present invention. tures or pavements that can be used for construction of roads,
0021 FIG. 11 illustrates a cutaway view of an example of sidewalks and other concrete structures or infrastructure.
a reinforced concrete Surface including pervious concrete Through the use of embodiments of the present invention, the
material and basalt rebar members, in accordance with one concrete structures formed permit water and air to pass
embodiment of the present invention. through the concrete structures, which provides various ben
0022 FIG. 12 illustrates a sectional view of the example of efits, such as reducing the need for complex and expensive
a reinforced concrete surface of FIG. 11, in accordance with storm water runoff systems in flood prone areas.
one embodiment of the present invention. 0039. By embedding basalt reinforcement members
0023 FIG. 13 illustrates a sectional view of the example of within pervious concrete, the PSI rating level of the pervious
a reinforced concrete surface of FIG. 11, in accordance with concrete structure formed is believed to be sufficient to with
one embodiment of the present invention. stand traffic loads and other weight bearing loads because
0024 FIG. 14 illustrates an example of a process for form basalt reinforcement members both reinforce the pervious
ing a pavement with pervious concrete and basalt rebar, in concrete material and the basalt reinforcement members can
accordance with an example of the present invention. be exposed to water without rusting or being weakened by
0025 FIG. 15 illustrates an example of a basalt rebar rod rust over time. Through the use of pervious concrete com
or member having a "Figure Eight' shape, in accordance with bined with one or more basalt reinforcement members, roads
one embodiment of the present invention. and streets can be formed so that the amount of rainwater
0026 FIG. 16 illustrates a cutaway view of an example of runoffin flash flood prone areas is reduced. Instead, rainwater
a reinforced concrete Surface including pervious concrete or other moisture passes through the pervious concrete Sur
material and basalt rebar members having “Figure Eight' face and down below the grade of the concrete surface.
shapes, in accordance with one embodiment of the present 0040. Through the use of embodiments of the present
invention.
0027 FIG. 17 illustrates a sectional view of the example of invention, during rain or Snow or other moisture conditions,
the groundwater aquifers can be more readily replenished
a reinforced concrete surface of FIG. 16, in accordance with because the water/moisture passes through the pervious con
one embodiment of the present invention. crete to the aquifers located below such pervious concrete.
0028 FIG. 18 illustrates a sectional view of the example of Moreover, through the use of embodiments of the present
a reinforced concrete surface of FIG. 16, in accordance with invention, several environmental constraints typically expe
one embodiment of the present invention. rienced by impervious or traditional concrete can be avoided
0029 FIG. 19 illustrates an example of a process for form or minimized while serving many of the same purposes as
ing a pavement with pervious concrete and basalt rebar mem standard concrete. For instance, pervious concrete allows
bers having “Figure Eight' shapes, in accordance with an water to pass through it and seep into the Soil therefore
example of the present invention. becoming instrumental in recharging groundwater and reduc
0030 FIG. 20 illustrates an example of a basalt mesh, in ing large amounts of stormwater runoff. Because pervious
accordance with one embodiment of the present invention. concrete allows water and air to pass through the concrete
0031 FIG. 21 illustrates a cutaway view of an example of structure, there is a large reduction in the need for complex
a reinforced concrete Surface including pervious concrete and expensive storm water runoff systems in flood prone
material and basalt rebar mesh, in accordance with one aaS.
embodiment of the present invention. 0041. Many characteristics of basalt materials have been
0032 FIG.22 illustrates a sectional view of the example of recognized by the present inventor as useful when combined
a reinforced concrete surface of FIG. 21, in accordance with with pervious concrete. Basalt is a naturally occurring Volca
one embodiment of the present invention. nic rock that employs a variety of benefits when compared to
0033 FIG.23 illustrates a sectional view of the example of steel reinforcement typically used for reinforced concrete. It
a reinforced concrete surface of FIG. 21, in accordance with is believed that basalt materials have a higher tensile strength
one embodiment of the present invention. than fiberglass or possibly steel. Basalt is a naturally occur
0034 FIG.24 illustrates an example of a process for form ring rock which means it can resist rust or any type of corro
ing a pavement with pervious concrete and basalt mesh, in sion and does not absorb any amount of water. Basalt rebar is
accordance with an example of the present invention. also about 4 of the weight of steel rebar, which makes basalt
0035 FIG. 25 illustrates a representation of a sectional rebar much easier to transport and assemble on the job site.
view of an example of a road made using pervious concrete Also, basalt rebar can be easily cut and shaped using common
and basalt rebar, wherein a pothole has developed. tools in the field.
0036 FIG. 26 illustrates a representation of a sectional
view of an example of a road made using pervious concrete 0042 FIG. 1 illustrates an embodiment of the invention,
and basalt rebar, wherein a pothole has been repaired. where a concrete structure 50 is formed using pervious con
0037 FIG. 27 illustrates an example of a process for crete 52 and one or more basalt rebar members 54, the basalt
repairing a pothole in a road formed with pervious concrete rebar members 54 configured in a manner to impart structural
and basalt rebar, in accordance with an example of the present rigidity and strength to the concrete structure. In this example,
invention. the basalt rebar members 54 are configured in a generally
DETAILED DESCRIPTION
square matrix pattern, but it is understood that the basalt rebar
members 54 may be configured in other different patterns and
0038. Disclosed herein are new methods and structures for densities depending upon the particular structure being built
forming concrete structures or reinforced pavements that can and the desired load bearing characteristics. For complex
US 2011/0064517 A1 Mar. 17, 2011

structures, the basalt rebar members 54 can be molded in large Volume (e.g., approximately 15-30%) of interconnected
order to form or reinforce a desired structure. voids 100 (FIGS. 1-2) allowing rainwater to percolate
0043. If desired, the basalt rebar members 54 may be through the pervious concrete 52 into the underlying soil,
temporarily held together in a desired patters using coated with the tradeoff being that the larger the voids 100, the lower
wire twist ties, also known as bar ties (not shown), which the strength of the pervious concrete 52. This filtration effect
temporarily can affix rebar members to one another. The bar also helps to purify the water by capturing pollutants as the
ties can be, in one example, 16 gauge, 6 inch steel ties if water drains through the small voids 100 in the pervious
desired. concrete 52 before it reaches a storm drain. Various mixes of
0044 FIG. 2 illustrates another embodiment of the inven pervious concrete 52 materials are described in “Practical
tion, where a concrete structure 60 is formed using pervious Application of Pervious Concrete: Mix Designs That Are
concrete 52 and a basalt mesh 62, the basalt mesh 62 provided Workable” by Rick Blackburn, Axim Italcementi Group
to impart structural rigidity and strength to the concrete struc (2006) (presentation from National Ready Mixed Concrete
ture. In one example, the basalt mesh 62 may be obtained in Association Conference, available at http://www.rmc-foun
rolls and has a generally square matrix pattern, but it is under dation.org): “Development of Mix Proportion for Functional
stood that the basalt mesh 62 may be configured in other and Durable Pervious Concrete' by K. Wang, V. R. Schaefer,
different patterns, densities and thicknesses depending upon J. T. Kevern, M. T. Suleiman, Iowa State University, (2006)
the particular structure being built and the desired load bear (presentation from National Ready Mixed Concrete Associa
ing characteristics. tion Conference, available at http://www.rmc-foundation.
0045 Pervious concrete 52 is commercially available org): "Making Pervious Concrete Placement Easy Using a
from many concrete companies, such as Lafarge North Novel Admixture System” by Mark Bury, Christine Mawby,
America, Inc. Basalt rebar and basalt mesh may be available and Dale Fisher, Degussa Admixtures, Inc., (2006) (available
from Raw Energy Materials, Inc. of Pompano Beach, Fla. In at http://www.rmc-foundation.org); and “Mix, Forms, and
one example, the basalt rebar members 54 can be rods made Admixtures” by Charles Wolfersberger, Charger Enterprises
of a unidirectional composite of basalt fibers. Inc. (available at http://www.perviousconcrete.com), the dis
0046. In one example, to construct a surface Such as a road closures of which are hereby incorporated by reference. The
or sidewalk or other concrete structure using an embodiment particulars of the mix used to create wet pervious concrete 52
of the present invention, after the Sub-grades and Sub-bases will depend on the loading requirements and other details of
have been prepared, one or more basalt reinforcement mem the particular application. In one example, a pervious con
bers (e.g., 54,62) are positioned along the surface as desired crete mix available from Lafarge North America Inc. may be
to achieve the required structural integrity or PSI ratings. used for Street paving and other applications.
Pervious concrete material 52 is poured on top of such basalt 0049. In one example, pervious concrete 52 may be deliv
reinforcement members, and the top of the pervious concrete ered to a job site in a conventional ready-mix concrete truck,
material is compacted (in one example, the top half inch of and can be poured within one hour of being initially mixed.
pervious concrete material may be compacted). The Surface Pervious concrete 52 may be poured into standard concrete
of the pervious concrete material can be covered with plastic, forms using 2"x4" wood forms or other conventional forms or
ply, or a tarp to keep the pervious concrete moist during related techniques, in one example.
curing which may take a number of days for the pervious
concrete to fully cure. In one example, joints between pervi
ous concrete members can be placed for instance, every Formation of Roads, Sidewalks, Driveways, etc.
twenty feet, and it is believed that expansion joints would not using Pervious Concrete and Basalt Rebar
be needed since pervious concrete material does not expand Reinforcement Rods
or contract in the same manner as impervious concrete. The
plastic/ply/tarp also functions to keep rainwater out of the 0050. In one example, a surface or pavement 110 such as a
pervious concrete material while the pervious concrete mate road, sidewalk, driveway, parking lot, or the like, can be
rial is curing. formed using pervious concrete 52 reinforced with basalt
0047 Embodiments of the invention may be used to form rebar 54. FIGS. 10-13 show an example of basalt rebar 54 and
roadways 70 (FIG. 4)(compare to FIG.3 showing a conven show sectional views of one example of a pavement 110
tional road 72 using impervious concrete 74 with storm drain formed in accordance with an embodiment of the present
pipes); parking lots 80 (FIG. 6)(compare to FIG. 5 showing a invention, wherein the pavement 110 includes a compacted
conventional parking lot 82 with impervious concrete 72 and soil layer 112, a geotextile filtration fabric layer 114, a layer
storm waterpipes); sidewalks (FIG.7); and sidewalks 90 with of course aggregate 116, one or more basalt rebarrods 54 with
tree grates 91 (FIG.9)(compare with FIG. 8 showing larger one or more support blocks 118, and a layer of pervious
tree grates 94 used with conventional impervious concrete concrete 52. A curb 119 may be made of pervious or imper
74). Other concrete structures may be built using embodi vious concrete.
ments of the present invention, such as bridges or portions of 0051 One example of a method of forming a pavement
bridges, curbs, portions of sewer systems, retaining walls, or using pervious concrete 52 and basalt rebar members 54 is
any other concrete structures where it may be desirable to illustrated in FIG. 14. Referring to FIG. 14, at operation 120,
allow water and air to pass through. the sub-soil that will be underneath the pervious concrete is
0048. In one example of the present invention, pervious compacted, for instance using a vibrating roller. In one
concrete 52 may be formed in a manner that is thicker in example, the Soil is moist, but free of standing water, to aid in
consistency compared to regular concrete 74, as pervious the compaction.
concrete 52 can be formed as a mixture of cement, coarse 0.052 At operation 122, a non-woven, geotextile filtration
aggregates (i.e., 5/8" gravel or limestone), water, and little or fabric 114 is placed to cover the compacted Soil and acts as a
no sand. Pervious concrete 52 may be formed so that it has a silt catcher in use, when the water percolates into the soil
US 2011/0064517 A1 Mar. 17, 2011

below. The geotextile fabric 114 also functions as a weed other surface can be formed using pervious concrete 52 with
blocker to prevent any unwanted growth that could disrupt the one or more basalt rebar reinforcement members 140 that
pervious concrete layer 52. have a “Figure Eight' shape. FIG. 15 shows and example of a
0053 At operation 124, coarse aggregate material 116, basalt rebar member 140 having a “Figure Eight' shape, and
Such as limestone, crushed glass, Superheated clay, is placed FIGS. 16-18 show a sectional view of one example of a
on the filtration fabric 114. In one example, more than 6" of pavement 110 formed in accordance with an embodiment of
coarse aggregate 116 is placed on top of the geotextile fabric the present invention, wherein the pavement includes a com
114 which in use increase the storage capacity, as well as pacted soil layer 112, a geotextile filtration fabric layer 114, a
provide a secondary filtration layer to capture pollutants layer of course aggregate 116, one or more basalt rebar "Fig
before they enter storm drains or compacted soil 112 below. ure Eight' members 140 with one or more support blocks
0054. At operation 126, basalt rebar members 54 are 118, and a layer of pervious concrete 52.
placed on the coarse aggregate 116. In one example, the basalt 0060. One example of a method for forming a pavement
rebar members 54 are placed in 1'x1' grids covering the entire surface 110 using pervious concrete 52 with a reinforcement
area where the pervious concrete will be installed. The grid of basalt rebar members 140 having a “Figure Eight' shape is
may be formed using basalt rebar members 54 that are held illustrated in FIG. 19. Operations 141-143 can be similar to
together in the grid through the use of wire ties. In one operations 110-124 of FIG. 14, in one example. At operation
example, each basalt rebar rod 54 may have a diameter of 141 of FIG. 19, the sub-soil that will be underneath the per
approximately 5/8", although the dimensions of the basalt vious concrete is compacted, for instance using a vibrating
rebar members will vary depending upon the needs of a roller. In one example, the soil is moist, but free of standing
particular application. Concrete chairs or support blocks 118 water, to aid in the compaction. At operation 142, a non
may be used to support the basalt rebar, for instance 2" above woven, geotextile filtration fabric is placed to cover the com
the layer of coarse aggregate 116. This will allow the rebar 54 pacted Soil and acts as a silt catcher in use, when the water
to become embedded in the pervious concrete 52 about percolates into the soil below. The geotextile fabric also func
2-2/2" from the bottom of the pervious concrete layer. In one tions as a weed blocker to prevent any unwanted growth that
example, for each 8' span of rebar, three chairs or Support could disrupt the pervious concrete layer. At operation 143,
blocks can be evenly installed underneath the rebar grid for coarse aggregate material. Such as limestone, crushed glass,
Support. Superheated clay, is placed on the filtration fabric. In one
0055. At operation 128, the pervious concrete 52 is poured example, more than 6" of coarse aggregate is placed on top of
over the basalt rebar 54. In one example, the pervious con the geotextile fabric which in use increase the storage capac
crete 52 is poured such that there is a sufficient amount ready ity, as well as provide a secondary filtration layer to capture
for compaction, for example 6" for sidewalks and driveways, pollutants before they enter storm drains or compacted Soil
10-12" for streets/roadways. below.
0056. At operation 130, the pervious concrete layer 52 is 0061. At operation 144, basalt rebar members 140 having
leveled and compacted while still wet. In one example, a “Figure Eight' shapes are placed on the coarse aggregate. In
vibrating mechanical screed is used to level off the pervious one example, these basalt rebar members 140 are placed in
concrete 52, wherein the screed is a flat board or tool used to 1'x1' grids covering the entire area where the pervious con
Smooth concrete after it has been placed on a Surface. crete will be installed. The grid may be formed using basalt
0057. In one example, at least /2" of the pervious concrete rebar members that are held together in the grid through the
layer 52 may be striked-off above the form to allow for use of wire tires. In one example and as shown in FIG. 15,
compaction. Operation 130 may also include compacting the each basalt rebar member may have multiple oval portions
pervious concrete, for instance, through the use of a heavy forming the “Figure Eight' shape, wherein each oval portion
steel roller to compact the pervious concrete layer. This is approximately 13" in length and has two legs (e.g., each
operation creates a pervious concrete slab where the top 3/16" diameter) separated by a distance of approximately 1",
approximately 1/2" has smaller Voids to trap pollutants cap although the dimensions of the basalt rebar member will vary
tured from Substances like oil and grease. Edges near the depending upon the needs of a particular application. Con
forms may be compacted using a small, hand-held press to crete chairs or Support blocks may be used to support the
prevent raveling of the edges. basalt rebar, for instance 2" above the layer of coarse aggre
0058. After placement of the pervious concrete layer, at gate. This will allow the rebar to become embedded in the
operation 132, a mist of water can be applied to the pervious pervious concrete about 2-2/2" from the bottom of the pervi
concrete 52, and the pervious concrete 52 may be protected ous concrete layer. In one example, for each 8' span of rebar,
by covering it with plastic sheeting (e.g., a 6 mil polyethylene three chairs or support blocks can be evenly installed under
cover Such as Visqueen), and kept damp for 5 to 7 days until neath for Support.
full hydration has occurred in the pervious concrete. In one 0062. At operation 125, the pervious concrete is poured
example, the curing process begins within approximately ten over the shaped rebar. In one example, the pervious concrete
minutes of the initial placement of the pervious concrete layer is poured such that there is a Sufficient amount ready for
52, and continues for at least 7 days. In one example of the compaction, for example 6" for sidewalks and driveways,
invention, the pervious concrete layer is believed to reach its 10-12" for streets/roadways.
maximum strength after 28 days of curing. 0063. At operation 126, the pervious concrete layer is
Formation of Roads, Sidewalks, Driveways, etc. leveled and compacted while still wet. In one example, a
using Pervious Concrete and “Figure Eight Shaped vibrating, mechanical screed is used to level off the pervious
Basalt Rebar Reinforcement Members concrete, wherein the screed is a flat board or tool used to
Smooth concrete after it has been placed on a Surface. In one
0059. In another embodiment of the invention, a pavement example, at least /2" of the pervious concrete layer may be
Surface 110 Such as a road, sidewalk, driveway, parking lot, or striked-off above the form to allow for compaction. Operation
US 2011/0064517 A1 Mar. 17, 2011

126 may also include compacting the pervious concrete, for 156 of FIG. 24, the pervious concrete layer is leveled and
instance, through the use of a heavy steel roller to compact the compacted while still wet. In one example, a vibrating,
pervious concrete layer. This operation creates a pervious mechanical screed is used to level off the pervious concrete,
concrete slab where the top approximately 1/2" has smaller wherein the screed is a flat board or tool used to smooth
Voids to trap pollutants captured from Substances like oil and concrete after it has been placed on a surface.
grease. Edges near the forms may be compacted using a 0070. In one example, at least /2" of the pervious concrete
Small, hand-held press to prevent raveling of the edges. layer may be striked-off above the form to allow for compac
0064. After placement of the pervious concrete layer, at tion. Operation 156 may also include compacting the pervi
operation 127, a mist of water can be applied to the pervious ous concrete, for instance, through the use of a heavy steel
concrete, and the pervious concrete may be protected by roller to compact the pervious concrete layer. This operation
covering it with plastic sheeting (e.g., a 6 mil polyethylene creates a pervious concrete slab where the top approximately
cover Such as Visqueen), and kept damp for 5 to 7 days until 1/2" has smaller voids to trap pollutants captured from sub
full hydration has occurred in the pervious concrete. In one stances like oil and grease. Edges near the forms may be
example, the curing process begins within approximately ten compacted using a small, hand-held press to prevent raveling
minutes of the initial placement of the pervious concrete of the edges.
layer, and continues for at least 7 days. In one example of the 0071. After placement of the pervious concrete layer, at
invention, the pervious concrete layer is believed to reach its operation 157, a mist of water can be applied to the pervious
maximum strength after 28 days of curing. concrete, and the pervious concrete may be protected by
covering it with plastic sheeting (e.g., a 6 mil polyethylene
Formation of Roads, Sidewalks, Driveways, etc. cover Such as Visqueen), and kept damp for 5 to 7 days until
using Pervious Concrete and Basalt GeoMesh full hydration has occurred in the pervious concrete. In one
Reinforcement example, the curing process begins within approximately ten
0065. In another embodiment of the invention, a pavement minutes of the initial placement of the pervious concrete
Surface 110 Such as a road, sidewalk, driveway, parking lot, or layer, and continues for at least 7 days. In one example of the
other surface can be formed using pervious concrete 52 with invention, the pervious concrete layer is believed to reach its
a reinforcement of basalt geomesh or mesh 150. FIGS. 20-23 maximum strength after 28 days of curing.
show an example of a basalt mesh 150, and show sectional Pothole Repair
views of one example of a pavement formed in accordance
with an embodiment of the present invention, wherein the 0072. If a pothole 160 (FIG. 25) develops in the pervious
pavement 110 includes a compacted Soil layer 112, a geotex concrete pavement due to loss of compaction of the Sub-soil
tile filtration fabric layer 114, a layer of course aggregate 116, 112 or course aggregate 116 below a portion of the pervious
a layer of basalt geomesh 150, and a layer of pervious con concrete, the pothole 160 may be repairable using the process
crete 52. of FIG. 27, in accordance with an embodiment of the present
0066. One example of a method for forming a pavement invention. FIG. 25 shows an example of a sectional view of
surface using pervious concrete 52 with a reinforcement of pothole 160 formed in a pavement made in accordance with
basalt geomesh 150 is illustrated in FIG. 24. Operations 151 an embodiment of the present invention; FIG. 26 shows an
153 can be similar to operations 120-124 of FIG. 14, in one example of a sectional view of a repaired pothole in a pave
example. At operation 151 of FIG. 24, the sub-soil that will be ment made in accordance with an embodiment of the present
underneath the pervious concrete is compacted, for instance invention. As recognized by the present inventor, pervious
using a vibrating roller. In one example, the Soil is moist, but concrete with basalt rebar reinforcements has a restorative
free of standing water, to aid in the compaction. At operation memory such that some potholes 160 may be repairable with
152, a non-woven, geotextile filtration fabric is placed to out the use of additional pervious concrete material 52 on the
cover the compacted Soil and acts as a silt catcherin use, when Surface.
the water percolates into the soil below. The geotextile fabric (0073. Referring to FIG. 27, a process is illustrated for
also functions as a weed blocker to prevent any unwanted repairing a pothole 160 that exists in a pavement of pervious
growth that could disrupt the pervious concrete layer. At concrete and basalt reinforcement members. At operation
operation 153, coarse aggregate material. Such as Such as 161, a pothole is identified that has formed underneath a
limestone, crushed glass, Superheated clay, is placed on the section of cracked pervious concrete. The basalt rebar or other
filtration fabric. In one example, more than 6" of coarse basalt reinforcement will bend/flex down into the collapsed
aggregate is placed on top of the geotextile fabric which in use section until the pressure has been removed and the rebar
increase the storage capacity, as well as provide a secondary returns to its original position.
filtration layer to capture pollutants before they enter storm 0074 At operation 162, one or more holes 163 are drilled
drains or compacted Soil below. into or about the collapsed section of the pervious concrete,
0067. At operation 154, a basalt geomesh 150 is placed wherein the hole(s) are drilled deep enough to allow a sand
directly on top of the coarse aggregate without the use of slurry injection 164 of operation 165 to reach underneath the
concrete chairs or Steel Substitutes. In one example, a basalt pervious and fill the void created by the loss of compaction in
geomesh 150 is a mesh or basalt strands having a plurality of the Subgrade.
approximately 1" by 1" squares of basalt strands. 0075. At operation 165, sand or a slurry of sand 164 is
0068. At operation 155, once the basalt geomesh 150 has injected into the drilled hole(s) 163, which fills the void(s) in
been installed over the coarse aggregate, pervious concrete is the subgrade or sub-soil below the pothole. The injected sand
poured over the geomesh 150 until the desired thickness of slurry 164 provides for both long term stable subsurface
concrete has been reached. conditions by restoring the level of the compacted soil or
0069 Operations 156-157 may be similar to operations course aggregate underneath the pervious concrete 52, and
130-132 of FIG. 14, in one example. In particular, at operation also retains an effective permeability through the repaired
US 2011/0064517 A1 Mar. 17, 2011

subsurface beneath the repaired pothole. Once completed, the 0082. While the methods disclosed herein have been
rebar 54 and the pervious concrete 52 returns to their original described and shown with reference to particular operations
position, and hence the pervious concrete has been repaired. performed in a particular order, it will be understood that
0076. In one example, the methods disclosed herein for these operations may be combined. Sub-divided, or re-or
forming a pavement or surface 50, 60, 70, 80,90 or 110 (such dered to form equivalent methods without departing from the
as a road, alley, parking area, sidewalk or other Surface) may teachings of the present invention. Accordingly, unless spe
include forming the Surface through the use of one or more cifically indicated herein, the order and grouping of the opera
basalt reinforcement members combined with pervious con tions is not a limitation of the present invention.
crete, without the need for installing Stormwater pipes or I0083. It should be appreciated that reference throughout
other stormwater drainage. this specification to “one embodiment' or “an embodiment
0.077 Embodiments of the invention can be used to make or “one example' or “an example” means that a particular
or repair various pavements Surfaces or roadways, such as but feature, structure or characteristic described in connection
not limited to streets, sidewalks, driveways, parking lots, with the embodiment may be included, if desired, in at least
highway shoulders, non-vehicular bridges, lightweight one embodiment of the present invention. Therefore, it should
vehicular bridges, heavy highways, and lightweight struc be appreciated that two or more references to “an embodi
tural components such as parking garage floors, curbs, or ment” or “one embodiment' or “an alternative embodiment
other floors, for example. or “one example' or “an example' in various portions of this
0078. Through the use of embodiments of the present specification are not necessarily all referring to the same
invention, Streets or other structures can be created with sig embodiment. Furthermore, the particular features, structures
nificantly reduced or Zero runoff, meaning that Streets or other or characteristics may be combined as desired in one or more
structures such as parking lots, sidewalks, etc. can be formed embodiments of the invention.
without the need for underground pipes or catch basins, I0084. Similarly, it should be appreciated that in the fore
which can resultina significant cost savings when building or going description of exemplary embodiments of the inven
maintaining such streets or other infrastructure. Embodi tion, various features of the invention are sometimes grouped
ments of the present invention may also eliminate the need for together in a single embodiment, figure, or description
rainfall stormwater management or portions thereof, as well thereof for the purpose of streamlining the disclosure and
as pumps which are used in cities such as New Orleans. aiding in the understanding of one or more of the various
0079. In another embodiment, where existing streets or inventive aspects.
infrastructure already have storm systems in place, the streets, I0085 While the invention has been particularly shown and
roads, sidewalks and other infrastructure can be replaced with described with reference to various embodiments thereof, it
streets, Sidewalks or other structures utilizing embodiments will be understood by those skilled in the art that various other
of the present invention. In repairing an existing road, the changes in the form and details may be made without depart
processes described above could also include an operation of ing from the spirit and scope of the invention.
removing the existing pavement and/or other materials 1. A pavement, comprising:
present, until the Soil layer is exposed. pervious concrete material; and
0080. In one example, a concrete structure using pervious one or more basalt reinforcing members embedded in the
concrete may be formed using construction techniques that pervious concrete material.
are used with impervious concrete; and in other embodi 2. The pavement of claim 1, wherein the one or more basalt
ments, different construction techniques are used for forming reinforcing members are basalt rebar rods.
concrete structures using pervious concrete. For instance, in 3. The pavement of claim 1, wherein the one or more basalt
accordance with an embodiment of the present invention, the reinforcing members are basalt rebar rods having a Figure
basalt rebar members combined with the pervious concrete Eight shape.
material can be configured by placing the basalt rebar mem 4. The pavement of claim 1, wherein the one or more basalt
bers in a pattern that is specially adapted or designed to reinforcing members are a mesh made of basalt Strands.
increase the structural integrity of the pervious concrete 5. The pavement of claim 1, further comprising a layer of
Structure. filtration fabric positioned below the basalt reinforcing mem
bers.
0081. In another embodiment of the present invention, a 6. The pavement of claim 1, further comprising:
method is disclosed for planting of trees, shrubs or other a compacted Soil layer,
Vegetation along sidewalks or roadways. In one example, the
method includes identifying a location for having the tree, a layer of filtration fabric positioned above the compacted
shrub or vegetation planted, providing pervious concrete Soil layer, and
material with basalt reinforcement members around the a layer of course aggregate material positioned above the
desired location for the tree, shrub or vegetation, and allowing layer of filtration fabric.
the pervious concrete to form. The tree, shrub or vegetation 7. The pavement of claim 6, wherein the one or more basalt
can then be planted after the pervious concrete cures. Because reinforcing members are positioned above the layer of course
of the pervious nature of the concrete, water will drain aggregate material.
through the concrete structure (sidewalk, road) and provide 8. The pavement of claim 7, wherein the pervious concrete
water and nutrients to the tree, shrub or vegetation. Therefore, material forms the upper Surface of the pavement.
the tree, shrub or vegetation will not have a tendency to uproot 9. The pavement of claim 1, wherein the one or more basalt
the sidewalk, road, or other concrete structure, as typically reinforcing members are positioned approximately two
happens with sidewalks or roads that utilize impervious con inches or more above the bottom of the pervious concrete
crete. Moreover, the roots of tree, shrub and other vegetation material.
will receive more water and air through the use of pervious 10. The pavement of claim 1, wherein the pavement is a
concrete than with conventional impervious concrete. road.
US 2011/0064517 A1 Mar. 17, 2011

11. The pavement of claim 1, wherein the pavement is a 15. The method of claim 14, further comprising:
parking lot. leveling said layer of wet pervious concrete; and
12. The pavement of claim 1, wherein the pavement is a compacting said layer of wet pervious concrete.
driveway. 16. The method of claim 14, further comprising curing said
layer of pervious concrete.
13. The pavement of claim 1, wherein the pavement is a 17. The method of claim 14, wherein the operation of
sidewalk. positioning one or more basalt rebar reinforcement members
14. A method for forming a road, comprising: further comprises:
compacting a Sub-base layer, placing the one or more basalt rebar reinforcement mem
bers approximately two or more inches above the layer
installing a filtration fabric above the sub-base layer; of aggregate material.
installing a layer of aggregate material above the filtration 18. The method of claim 14, wherein the pouring operation
fabric; includes pouring a portion of said wet pervious concrete
material below the one or more basalt rebar reinforcement
positioning one or more basalt rebar reinforcement mem members, so that the wet pervious concrete material embeds
bers above the layer of aggregate material; and the one or more basalt rebar reinforcement members.
pouring a layer of wet pervious concrete material above the
one or more basalt rebar reinforcement members. c c c c c