Method for constructing all-weather surface

Claim 3

The invention of claim 1, wherein said tack and second coatings are of emulsified asphalt material.

Claim 4

The invention of claim 2, wherein said emulsified asphalt is diluted by the addition of about 50% water to the emulsified asphalt to enhance the penetrating characteristics of the material.

Claim 5

The invention of claim 1, wherein the quantity of particulate rubber of each rubber layer is about 2 pounds per square yard.

Claim 6

The invention of claim 1, wherein the sizes of the rubber particules in the uppermost layer of rubber of the mat are finer than the particle sizes of one or more of the preceding layers of rubber.

Claim 7

The invention of claim 5, wherein the particle sizes of the rubber for one or more of the subsurface layers or rubber are such that 100% of the particles are retained on a 16 mesh screen and 100% pass a 3/8 inch mesh screen.

Claim 8

The invention of claim 6, wherein the particle sizes of the rubber for the uppermost layer of rubber are such that 100% of the particles are retained on a 16 mesh screen and 100% pass a 1/8 inch mesh screen.

Claim 9

The invention of claim 2, wherein said asphalt is type SS1H emulsified asphalt.

Claim 10

The invention of claim 8, wherein the emulsified asphalt for the tack coat is applied at a rate of not less than about 0.2 gallon per square yard of surface.

Claim 11

The invention of claim 9, wherein said second asphalt coat is applied at a rate of not less than about 0.3 gallon per square yard of surface.

Claim 12

The invention of claim 1, wherein the styrene butadiene contains approximately 50% solids by weight.

Claim 13

The invention of claim 11, wherein a color pigment is added to the styrene butadiene which is applied to at least one layer of rubber particles prior to the application thereof.

Claim 14

The invention of claim 12, wherein said color pigment is FeO 2 .

Claim 15

The invention of claim 11, wherein a surfactant is added to the styrene butadiene and water mixture to enhance the penetrating characteristics of the mixture.

Claim 16

The invention of claim 14, wherein the surfactant is a low sudsing detergent.

Claim 17

The invention of claim 15, wherein the detergent is added in a quantity of about one cup of detergent to 55 gallons of said mixture.

Claim 18

The invention of claim 1, wherein the rubber particles are strands of rubber removed from vulcanized tire carcasses by a stripping process, and wherein the strands are ground to a predetermined size gradation.

Claim 19

The invention of claim 1, wherein a sealing coat of rubberized coal tar emulsion sealer and water material is applied uniformly over the mat following application of the uppermost coating of styrene butadiene and water mixture, whereby to protect the mat from weather and ultra violet degradation.

Claim 20

The invention of claim 18, wherein said sealer and water material is applied in sufficient quantity to permit total permeation of the material throughout all previously applied layers of the mat.

Claim 21

A process for constructing an activity mat over a foundation comprising the steps of: spreading a tack coating comprising a mixture of about equal quantities of SS1H emulsified asphalt and water to the foundation surface at a rate of no less than 0.2 gallons of said mixture per square yard of foundation surface; spreading uniformly over the tack coating a first layer of strand rubber praticles having sizes such that 100% of said particles are retained on a 16 mesh screen and 100% pass a 3/8 inch screen, and in a quantity of about 2 pounds of particles per square yard of layer; spraying a second coating of said emulsified asphalt and water mixture over said first layer of rubber particles at a rate of no less than 0.3 gallons of mixture per square yard of surface; spreading successive layers of said rubber particles until the desired mat thickness is achieved with each layer being followed by the spraying of a liquid styrene butadiene containing 50% solids and diluted from about 30% to 50% with water over the immediately preceding layer of particles and in an amount sufficient to coat substantially all previously applied particles with the liquid, said liquid being permitted to dry until substantially no visible moisture is present before applying the next layer of rubber; applying a top layer of finer rubber particles uniformly over the mat; and spraying an emulsified coal tar sealer over the top layer of particles.

Claim 22

A process for constructing an activity mat over a foundation comprising the steps of: spreading a tack coating comprising a mixture of about equal quantities of SS1H emulsified asphalt and water to the foundation surface at a rate of no less than 0.2 gallons of said mixture per square yard of foundation surface; spreading uniformly over the tack coating a first layer of strand rubber praticles having sizes such that 100% of said particles are retained on a 16 mesh screen and 100% pass a 3/8 inch screen, and in a quantity of about 2 pounds of particles per square yard of layer; spraying a second coating of said emulsified asphalt and water mixture over said first layer of rubber particles at a rate of no less than 0.3 gallons of mixture per square yard of surface; spreading successive layers of said rubber particles until the desired mat thickness is achieved with each layer being followed by the spraying of a liquid styrene butadiene containing 50% solids and diluted from about 30% to 50% with water over the immediately preceding layer of particles and in an amount sufficient to coat substantially all previously applied particles with the liquid, said liquid being permitted to dry until substantially no visible moisture is present before applying the next layer of rubber; applying a top layer of finer rubber particles uniformly over the mat; and spraying an emulsified coal tar sealer over the top layer of particles.

Claim 23

The invention of claim 20, wherein said styrene butadiene and water liquid is sprayed over the rubber particles at pressure of from 10 to 40 pounds per square inch.