Polymer Concrete with Plastic Aggregate and Fines

A composition that may include a resin, plastic aggregate, plastic fines, and optionally fly ash. The plastic aggregates and plastic fines may be formed from recycled plastic. The composition may be utilized to repair damaged surfaces, including damages concrete surfaces. The composition may further be used in pre-formed structures. The pre-formed structures may include panels that are assembled to form an upright enclosure, such as a shelter.

Not Applicable.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates generally to roadways, and more particularly, but not necessarily entirely, to the repair and maintenance of roadways.

2. Description of Related Art

The repair and maintenance of roadways is a costly and time-consuming endeavor. Pothole repair is particularly vexing as repairs tend to fail within a relatively short period of time making additional repairs necessary. Typical pothole repair includes the placement of a sufficient amount of a fill material into the pothole. For example, in the case of a pothole formed in an asphalt roadway, replacement asphalt-type material may be used to repair the pothole. In the case of a pothole formed in a concrete roadway, replacement concrete-type material may be used to repair the pothole.

As mentioned, pothole repairs tend to fail in relatively short amounts of time. Repair failure may be due to several reasons, the primary of which is that the repair material may not properly bond to the adjacent cured roadway. In some instances, the interface between the cured roadway adjacent the pothole and the repair material is porous such that moisture seeps into the repaired pothole. The moisture may lead to further erosion and damage in areas that have a freeze-thaw cycle. Further, automobile traffic may cause the formation of cracks at the repair-roadway interface that spread deep into the fill material. Such cracks may eventually lead to fragmenting of the fill material. It would be an advantage over the prior art to provide an improved repair method and system for repairing a pothole in a roadway.

The prior art is thus characterized by several disadvantages that are addressed by the present invention. The present invention minimizes, and in some respects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein. The features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention without undue experimentation. The features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

DETAILED DESCRIPTION

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. As used herein, the terms “comprising,” “including,” “containing,” “having,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps. As used herein, the term “about” means within 20% higher or lower than the stated value.

As used herein, the term “roadway” may refer to surfaces formed from asphalt or concrete and includes asphalt and concrete surfaces intended for all types of wheeled vehicles, including automobiles, bicycles, airplanes and the like. The term “roadway” may also refer to footpaths, trails and other surfaces intended for pedestrian traffic. The term “roadway” may include roads, highways, freeways, bridges, pathways, trails, parking lots, runways, sidewalks and the like.

The present disclosure is directed to a novel system and method for improved roadway repair. The present disclosure may be particularly suited for repairing damaged portions of roadways. As used herein, the term “damaged portion,” when used in reference to a roadway, may include potholes, cracks, voids, partially broken areas, scrapes, worn portions, and any other type of damage that occurs to roadways. The damaged portion may be caused by traffic and weather.

In an embodiment, the present disclosure provides a fill material with improved durability and life as compared to previous repair materials and methods.

In an embodiment, a method for repair of a roadway comprises clearing the damaged portion of loose debris. Boreholes are then formed in the interior surface of the damaged portion. One or more of the boreholes may undercut the non-damaged portion of the roadway. The boreholes may have a diameter between one-half inch and three inches. A depth of the boreholes may range from about six inches to three feet. The boreholes may be formed using a handheld or machine mounted drill having an auger type bit. The number of boreholes formed in the pothole may depend on the size of the pothole. In an embodiment, the number of boreholes may range from one to twenty. In an embodiment, the number of boreholes is two.

Once the boreholes are formed, a fill material may be placed into the damaged portion. The fill material may have a consistency such that it travels to the bottom of the boreholes. The fill material may be even with a top surface of a surface layer of the roadway. In an embodiment, the fill material may comprise a resin. In an embodiment, the fill material may comprise a resin and aggregate mixture. Suitable resins may include polymer-based resins. Once the fill material has been placed into the damaged portion, a friction enhancing topcoat may be installed onto the top of the fill material. In an embodiment, a pigment may be added to the fill material to match the color of the roadway.

Aspects of the present disclosure contemplate using a plastic aggregate in the fill material as well as plastic fines.

Referring now toFIG. 1, there is depicted a roadway100according to an embodiment of the present disclosure. The roadway100may be formed of any suitable material. The roadway100may include a surface layer102formed on a base material104as is known to those of ordinary skill. The surface layer102may be formed of any suitable material, including, but not limited to, asphalt or concrete. The base material104may be formed of aggregate or some other crushed material, such as crushed stone.

A damaged portion106may be formed in the roadway100. The damaged portion106may be caused by several factors, including the wear and tear of traffic as well as seasonal freeze-thaw cycles. The damaged portion106may take any shape or form, including cracks or other types of damage in the roadway100. The damaged portion106may have an interior surface108that defines a cavity or void that extends below the surface layer102and into the base material104. Loose debris109may be present in the bottom of the damaged portion106. The loose debris109may include fragmented pieces of the surface layer102.

As shown inFIG. 2, where like reference numerals depict like components, the first step in patching the damaged portion106is to remove the loose debris to expose the interior surface108. This may be done using handheld or powered tools, including shovels.

As shown inFIG. 3, where like reference numerals depict like components, the next step in patching the damaged portion106is to form at least one borehole110in the interior surface108. In an embodiment, the at least one borehole110may be formed using a powered tool, such as a drill112having a bit114. In an embodiment, the drill112may be one of electric and hydraulic. In an embodiment, the drill112may be handheld or mounted to an arm of a machine.

In an embodiment, the diameter of the bit114is between one-half inch and three inches. In an embodiment, the diameter of the bit114is about one inch. In an embodiment, a length of the cutting surface of the bit114is between six inches to three feet. In an embodiment, a length of the cutting surface of the bit114may be about one foot, or between ten inches and fourteen inches. In an embodiment, a length of the cutting surface of the bit114may be about two feet.

The at least one borehole110may have a diameter between one-half inch and three inches. In an embodiment, the diameter of the at least one borehole110is one inch. A depth of the at least one borehole110may range from about six inches to three feet. In an embodiment, the depth of the at least one borehole110may be about one foot, or between ten inches and fourteen inches. In an embodiment, the depth of the at least one borehole110may be about two feet.

The number of boreholes110formed in the damaged portion106may depend on the size void formed by the damaged portion106. In an embodiment, the number of boreholes110may range from about one to twenty, or two boreholes. In an embodiment, some of the at least one borehole110may undercut the surface layer102. In an embodiment, the boreholes110may extend into the base material104.

As shown inFIG. 4, the next step for repairing the damaged portion106is to install a fill material120. The fill material120may have a consistency such that it flows into the at least one borehole110. The fill material120may comprise a mixture of a binding agent and an aggregate. In an embodiment, the binding agent is a resin, such as a polymer resin. In an embodiment, the resin may be a two-part resin that includes the use of a curing agent.

In an embodiment, the aggregate is a plastic aggregate. Plastic fines and optionally cenosphere may also be added to the resin along with the plastic aggregate.

The resin, plastic aggregate, and plastic fines and optionally cenosphere may be mixed in a mixer115having a mixing container, drum or tub. In an embodiment, the mixer115may include a combustion engine powered by a fuel that mixes the binding agent and aggregate and fines. In an embodiment, the mixer115may include an electric motor.

In an embodiment, a carbon fiber material may be added to the fill material120during the mixing process to provide additional strength to the repair. In an embodiment, shredded carbon fiber material may be added to the fill material120.

As shown inFIG. 4, the fill material120is placed into the damaged portion106until it is about even with the top of the surface layer102. As shown inFIG. 5, a friction enhancing material122may be placed or sprinkled onto the top of the fill material120. The friction enhancing material122may comprise a crushed material, such as crushed stone.

Referring now toFIG. 6, a method of repairing a damaged portion is disclosed. At step200, debris is cleared from the damaged portion in order to expose an interior surface of the damaged portion. At step202, at least one borehole is formed in the interior surface of the damaged portion. The at least one borehole may have a diameter between about one half inch and three inches. In an embodiment, the at least one borehole may have a diameter of about one inch. It will be appreciated that the at least one borehole may have any diameter. The at least one borehole may be formed by a bit mounted on a drill. In an embodiment, the depth of the at least one borehole may be about two feet. It will be appreciated that at least one borehole may have any depth.

At step204, a binding agent and plastic aggregate and plastic fines and optionally cenosphere are added to a mixer. The binding agent and aggregate and fines are mixed together to form a fill material. In an embodiment, the fill material comprises a binding agent and an aggregate and fines mixture that are combined in the mixing container on site. In an embodiment, the binding agent and the aggregate and fines mixture are pre-mixed offsite and transported to the site of the damaged portion.

In an embodiment, the binding agent is a resin, such as is a polymer resin. In an embodiment, the binding agent is an epoxy resin. In an embodiment, the aggregate is a plastic aggregate and the fines are plastic fines In an embodiment, carbon fiber, such as shredded carbon fiber, is mixed into the fill material. Pigment may also be added to the fill material to match the color of the roadway.

In an embodiment, the fill material may be mixed by an auger mixer. The aggregate may be fed from a hopper into the auger mixer. The binding agent, such as a thermosetting resin, may be injected into the auger mixer. A curing agent or hardener (polymerization catalyst) may be injected into the auger mixer.

At step206, the fill material is installed into the damaged portion and the at least one borehole. In an embodiment, the fill material may be poured or pumped from the mixer. A top surface of the fill material may be about even with the top of the roadway. At step208, a friction enhancing material is placed onto the top surface of the fill material. It will be appreciated that the friction enhancing material may include a granular material, such as crushed stone, sand, or any other substance.

Referring now toFIG. 7, according to an embodiment of the present disclosure, a cured binding agent250suitable for use in the repair as described above may be deformable under tension, either plastically or elastically. It will be appreciated that the deformability of the cured binding agent250improves the life of the repair, especially when subject to the impact forces of vehicle traffic. The binding agent250may be deformed by a tension force to a new shape shown by the dashed line252. As shown, length D1represents the original length of the binding agent250, length D3represents the stretched length of the binding agent250, and D2is the difference between D3and D2. When the tension force is removed, the binding agent250may or may not return to its original shape due to its elasticity. In some cases, the stretched binding agent will not return to its original shape as it is plastically deformable. In an embodiment, the binding agent250is deformable under tension to a percentage of its original length.

In an embodiment, a “percentage of deformability” is a property of the cured binding agent250and is defined by Equation 1, below:

Where D1is an original length of the cured binding agent and D3is a stretched length of the cured binding agent. The percentage of deformability defined by Equation 1 represents the amount of deformation under which the binding agent250undergoes without failing. As used herein, the term “failure” may mean the cured binding agent250breaks into two pieces. For example, if the binding agent250is deformable under a tension force from an original length of 4 units (D1) to a length of 6 units (D3) without failure, the percentage of deformability is at least 50%. By way of another example, if the binding agent250is deformable under a tension force from an original length of 4 units (D1) to a length of 5 units (D3) without failure, the percentage of deformability is at least 25%.

In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 15%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 20%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 25%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 30%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 35%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 40%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 45%. In an embodiment, the percentage of deformability of the binding agent250suitable for roadway repair as described herein is at least 50%. In an embodiment, the percentage of deformability is between 15% and 50%. It will be appreciated that the binding agent250may be a polymer resin suitable for use in roadway repair as described above.

Referring now toFIGS. 8A, 8B and 8C, there is depicted an exemplary embodiment of a mixer300suitable for use with the present disclosure. The mixer300may be utilized to mix a binding agent and aggregate as disclosed herein. The mixer300may include a mixing tub302. The mixer300may further include a first mixing blade assembly304and a second mixing blade assembly306. The mixer300may further include a scraper308.

The first mixing blade assembly304may rotate about a first axis304A and the second mixing blade assembly306may rotate about a third axis306A. In addition, the first mixing blade assembly304and the second mixing blade assembly306and the scraper may rotate about a second axis310. It will be appreciated that the first mixing blade assembly304may include a plurality of blades304B and the second mixing blade assembly306may include a plurality of blades306B.

It will be appreciated that the use of the boreholes in the interior surface of the damaged portions, as described herein, provide a more secure repair that is able to withstand traffic as well as inclement weather. In particular, the fill material in the boreholes provides an anchor for the main portion of the pothole repair. The present disclosure may be utilized with both asphalt and concrete roadways.

Referring now toFIG. 9, there is depicted a metal cover500installed over a utility access tunnel. Surrounding the cover500is a concrete apron502. As can be seen, the apron502is damaged and includes cracks, pits and voids. A process of repairing the apron502is as follows. First, the apron502is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the apron502. Next, a protective overlay and composite material504is installed onto the apron502to effectuate the repair. In an embodiment, the protective overlay material504is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the apron502. The material504is then finished by using a hand trowel as shown inFIG. 23. The repaired apron502is shown inFIG. 10.

Referring now toFIG. 11, there is depicted a concrete pedestrian ramp510having a damaged surface512. The damage to the surface512includes cracks, pits and voids. A process of repairing the surface512is as follows. First, the surface512is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the surface512. Next, a protective overlay and composite material514is installed onto the surface512to effectuate the repair. In an embodiment, the protective overlay material514is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the surface512. The material514is then finished by using a hand trowel as shown inFIG. 23. The repaired ramp510is shown inFIG. 12.

Referring now toFIG. 13, there is depicted a concrete trough520having a damaged surface522. The damage to the surface522includes cracks, pits and voids. A process of repairing the surface522is as follows. First, the surface522is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the surface522. Next, a protective overlay and composite material524is installed onto the surface522to effectuate the repair. In an embodiment, the protective overlay material524is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the surface522. The material524is then finished by using a hand trowel as shown inFIG. 23. The repaired trough520is shown inFIG. 14.

Referring now toFIG. 15, there is depicted a manhole cover530installed over a utility access tunnel. Surrounding the cover530is a concrete apron532. As can be seen, the apron532is damaged and includes cracks, pits and voids. A process of repairing the apron532is as follows. First, the apron532is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the apron532. Next, a protective overlay and composite material534is installed onto the apron532to effectuate the repair. In an embodiment, the protective overlay material534is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the apron532. The material534is then finished by using a hand trowel as shown inFIG. 23. The repaired apron532is shown inFIG. 16.

Referring now toFIG. 17, there is depicted a metal grate540installed over a drain pipe. Surrounding the grate540is a concrete trough542. As can be seen, the trough542is damaged and includes cracks, pits and voids. A process of repairing the trough542is as follows. First, the trough542is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the trough542. Next, a protective overlay material544is installed onto the trough542to effectuate the repair. In an embodiment, the protective overlay material544is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the trough542. The material544is then finished by using a hand trowel as shown inFIG. 23. The repaired trough542is shown inFIG. 18.

Referring now toFIG. 19, there is depicted a concrete pad550. As can be seen, the pad550is damaged and includes cracks, pits and voids. A process of repairing the pad550is as follows. First, the pad550is cleared of debris. Next, as shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the pad550. Next, a protective overlay and composite material552is installed onto the pad550to effectuate the repair. In an embodiment, the protective overlay material552is mixed in a mixer as shown inFIG. 22and then placed onto the damaged surface of the pad550. The material552is then finished by using a hand trowel as shown inFIG. 23. The repaired pad550is shown inFIG. 20.

Referring now toFIG. 24, there is depicted a manhole vault assembly600. The assembly600comprises a cap602, mid-risers604and606, and a base member608. In an embodiment, the manhole vault assembly600is formed of concrete. The assembly600may be buried underground and provide access to a sewage system through an opening formed in the cap602. In particular, the base member608may include a trough610for directing sewage as is known to one having ordinary skill in the art. As can be observed, an inner surface612of the base member608may include damaged portions in the nature of pitting and corrosion caused by the toxic sewer gases.

A process of repairing the inner surface612of the base member608is as follows. First, the inner surface612is cleared of debris. Next, as illustratively shown inFIG. 21, a grinder is used to remove rough edges and loose edges on the inner surface612. Next, a protective overlay and composite material614is installed onto the inner surface612to effectuate the repair. In an embodiment, the protective overlay material614is mixed in a mixer as shown inFIG. 22and then placed onto the inner surface612. The material614is then finished by using a hand trowel as illustratively shown inFIG. 23. The repaired inner surface of the base member608is shown inFIG. 25.

In embodiments of the present disclosure, a plastic material, such as plastic aggregate and plastic fines, may be included in Part A (or Part B) of the composition in lieu of rock aggregate and sand, or in addition to rock aggregate and sand. As used herein, “plastic aggregate” means a plastic material formed from a loosely compacted mass of fragments, pellets, granules or particles. The plastic aggregate may have a size greater than one of 0.420 mm, 0.5 mm, 0.595 mm, 0.707, mm, 0.841 mm, 1.0 mm, 2.0 mm, 3.0 mm, 4.0 mm, 5.0 mm, 6.0 mm and 7.0 mm. As used herein, “plastic fines” means very small plastic particles, including a plastic powder and pulverized plastic. The plastic fines may have a size less than one of 0.420 mm, 0.354 mm, 0.297 mm, 0.250 mm, 0.210 mm, 0.177 mm, 0.149 mm, 0.125 mm, 0.105 mm, 0.088 mm, 0.074 mm, 0.063 mm, 0.053 mm, 0.044 mm, and 0.037 mm.

It will be appreciated that plastic aggregate and plastic fines may be formed from one of virgin plastic, recycled plastic, and certified recycled plastic. It will be appreciated that the plastic fines may comprise any recycled plastic. In an embodiment, the recycled plastic fines may be created by grinding, cutting, or pulverizing recycled plastic.

As used herein, the plastic material may be sized by sieve size as is known to one of ordinary skill. As is known to one of ordinary skill, the sieve size may correspond to mesh openings as shown in the attached Appendix A. For example, plastic aggregate may have, without limitation, a mesh size between No. 4 (4.76 mm) and No. 40 (.420 mm), or any size or size range in between shown in Appendix A. The plastic fines may have, without limitation, a sieve size of between No. 40 (.420 mm) and No. 400 (.037 mm), or any size or size range in between as shown in Appendix A.

In an embodiment, a compound according the present disclosure may comprise a resin, plastic aggregates, and plastic fines and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin, recycled plastic aggregates, and recycled plastic fines and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin and plastic aggregates but not plastic fines and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin and plastic fines but not plastic aggregates and optionally cenosphere. The compounds disclosed herein may be mixed with a hardener (Part B) as is known to one of ordinary skill to cause the resin to harden into a rigid structure.

In an embodiment, a compound according the present disclosure may comprise a resin, plastic aggregates, and a plastic powder and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin, recycled plastic aggregates, and recycled plastic powder and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin and plastic aggregates but not plastic powder and optionally cenosphere. In an embodiment, a compound according the present disclosure may comprise a resin and plastic powder but not plastic aggregates and optionally cenosphere. The compounds disclosed herein may be mixed with a hardener (Part B) as is known to one of ordinary skill to cause the resin to harden into a rigid structure.

The compounds disclosed herein may be utilized to form structures, including, without limitation, flat work, walls, supports, beams, surface repairs, roadways, sidewalks, buildings, houses, pipes, conduits, and sewers. It will be further appreciated that the compounds formed herein may be utilized in any application that previously used concrete. In embodiments of the present disclosure, a rigid structure may comprise a resin, plastic aggregate, and plastic fines and optionally cenosphere. In embodiments of the present disclosure, a rigid structure may comprise a resin and plastic aggregate but not plastic fines and optionally cenosphere. In embodiments of the present disclosure, a rigid structure may comprise a resin and plastic fines but not plastic aggregate and optionally cenosphere. The structures may include, but are not limited to, flat work, walls, supports, beams, surface repairs, roadways, sidewalks, buildings, houses, pipes, beams, surface repairs, conduits, manholes, risers, pre-formed structures, and sewer structures. As used herein, the term “about” means within one of 5%, 10%, 15%, 20% and 30% of the stated value, both above and below.

As can be observed in Tables 1-12, below, various formulations of a composition according to the present invention are disclosed. The compositions may be utilized to repair damaged surfaces or to create pre-formed structures.

TABLE 5IngredientComprising:Part AResin5-96fluid ozRecycled Plastic Aggregate or5-100lbs.Recycled Plastic FinesPart BHardening Agent1-20fluid oz.Mix instructions: Combine all in forced induction mixer for mixing time of 3-5 minutes.

TABLE 8IngredientComprising:Part AResin5-96fluid ozPlastic Aggregate between No. 45-100lbs.(4.76 mm) and No. 40 (.420mm) or any size or size range inbetweenPart BHardening Agent1-20fluid oz.Mix instructions: Combine all in forced induction mixer for mixing time of 3-5 minutes.

TABLE 9IngredientComprising:Part AResin5-96fluid ozPlastic Fines between No. 405-100lbs.(.420 mm) and No. 400 (.037mm) or any size or size range inbetweenPlastic Aggregate between No. 45-100lbs.(4.76 mm) and No. 40 (.420mm) or any size or size range inbetweenPart BHardening Agent2.5-20fluid oz.Mix instructions: Combine all in forced induction mixer for mixing time of 3-5 minutes.

TABLE 10IngredientComprising:Part AResin5-96fluid ozPlastic Aggregate between No. 45-100lbs.(4.76 mm) and No. 40 (.420mm) or any size or size range inbetweenPlastic Powder5-100lbs.Part BHardening Agent2.5-20fluid oz.Mix instructions: Combine all in forced induction mixer for mixing time of 3-5 minutes.

TABLE 11IngredientComprising:Part AResin22 to 40 fluid oz, or about 36fluid oz, or an effectiveamountHigh Density Polyethylene70 to 110 fluid oz, or about(HDPE) Pellets or Plastic88 fluid ozAggregatePVC Pulverized or50 to 70 fluid oz, or about 64Plastic Finesfluid ozFly Ash5 to 25 fluid oz, or about 12fluid ozPart BHardening Agent10 fluid oz., or an effectiveamountMix instructions: Combine all in forced induction mixer for mixing time of 3-5 minutes.

In an embodiment, any of the above formulations may be utilized to create pre-formed structures. These structures may include, without limitation, panels, sewage structures, pathways, countertops, roadways, runways, bridges and upright structures, including without limitation, walls, shelters, buildings, and the like. The structures may have a thickness of between one-half inch to five inches. In an embodiment, the structures may have a width and a height from one foot to ten feet. The structures may be planar, such as a panel, or include a curvature. The structures may be utilized to build storage or living accommodations, including walls and roofs. In an embodiment, the structures may be attached to the exterior of structures. The structures may be formed in molds of various shapes.

In an embodiment, the present invention is directed to a pre-formed structure having a composition comprising any of the above formulations in Tables 1-12. According to the present invention, a pre-formed structure is comprised of plastic aggregates, plastic fines, fly ash, a resin, and a hardener. According to another aspect of the present invention, a pre-formed structure is comprised of HDPE pellets, pulverized PVC, fly ash, a resin, and a hardener.

In an embodiment, the recycled plastic may be formed by the following steps:

Step 1: Collection

The first step in the recycling process is always collecting the plastic material that is to be recycled. This step may be reliant upon businesses, restaurants, and the public to dispose of their plastic waste in the correct place. If plastic waste is disposed of in normal trash bins, it will not be recycled, so it is extremely important to separate common waste and plastic waste. Additionally, it is ideal for governments to have a recycling collection system that goes to people's houses or businesses to collect the plastic waste. If this is not possible, local collection points for plastic should be easy for the public to access. Making it easy and convenient for people to correctly dispose of plastic waste is paramount in promoting recycling.

Step 2: Washing

Plastics must be washed before they are further processed. The goal of this step is to remove impurities and everything that is not made from plastic. Most containers and packages have labels, adhesive, or even food residue that must be removed. This non-plastic waste cannot be recycled and can cause the final product to have poor structural integrity.

Resizing consists of shredding or granulating the plastic waste into small particles. This increases the surface area of the plastic, making it easier to process, reshape, and transport if needed. Additionally, it gives recycling facilities one last opportunity to remove any non-plastic waste that has made it through the first steps of processing. This is often done with metal detectors or magnets that will help remove any leftover metal in the mixture.

Compounding is when the small particles are smashed and melted together into plastic shapes. In an embodiment, the small particles are smashed and melted together and then extruded through an opening. The extrusion is then sliced to form the pellets. The pellets may be disc shaped.

The two-part compositions of the present disclosure may include a part A and a part B. Parts A and B are typically mixed on-site just prior to installation. Mixing parts A and B causes a reaction which starts the curing process. Part A is referred to herein as the resin and part B is referred to as the hardening agent. The two-part composition is applied to a damaged surface while it is still a liquid. Once applied over a surface, the composite material cures until hard. In an embodiment, the resin utilized herein may be a polymer resin.

It will be appreciated that embodiments of the present invention provide an improved concrete repair technology that is able to repair foundations, road, curbs, speed bumps, parking lots, concrete pads, driveways, sidewalks, and other concrete structures. It will be further appreciated that repairs using the formulations disclosed herein may be up to four times stronger than traditional concrete. It will be further appreciated that embodiments of the present disclosure may reduce repair time to 30 minutes and significantly reduce repair costs as compared to traditional repair methods. Moreover, embodiments of the present disclosure allow repairs to be performed year-round—in both hot and cold weather.