Wear-resistant reinforcing coating

Abstract

A method of forming a wear-resistant reinforcing coating on a substrate, such as concrete, wood, metal or particulate. A reinforcing fiber mat is placed on the substrate and a liquid matrix material is mixed with small colored stones. The mixture of matrix material and stones is poured onto the mat, and the liquid wets the mat and contacts the substrate. After curing, a composite coating is formed with stones as the wearing surface. A membrane can be interposed between the substrate and the reinforcing coating to prevent adhesion and “starving” of the mat.

1 . A method of forming a wear-resistant reinforcing coating on a substrate, the method comprising: 
 (a) applying a liquid matrix material to the substrate;    (b) disposing reinforcing fibers in the liquid matrix material;    (c) placing particulate in contact with the liquid matrix material on an opposite side of the fibers from the substrate; and    (d) hardening the liquid matrix material, thereby forming a composite of reinforcing fibers in a matrix of the hardened liquid matrix material with the wearing surface of particulate.    
     
     
         2 . The method in accordance with  claim 1 , wherein the substrate is a solid substrate.  
     
     
         3 . The method in accordance with  claim 2 , wherein the solid substrate is concrete.  
     
     
         4 . The method in accordance with  claim 2 , wherein the solid substrate is asphalt pavement.  
     
     
         5 . The method in accordance with  claim 2 , wherein the solid substrate is wood.  
     
     
         6 . The method in accordance with  claim 2 , wherein the solid substrate is fiberglass composite.  
     
     
         7 . The method in accordance with  claim 2 , wherein the solid substrate is metal.  
     
     
         8 . The method in accordance with  claim 2 , wherein the solid substrate is modular bricks.  
     
     
         9 . The method in accordance with  claim 1 , wherein the substrate is particulate.  
     
     
         10 . The method in accordance with  claim 9 , wherein the particulate is soil.  
     
     
         11 . The method in accordance with  claim 9 , wherein the particulate is sand.  
     
     
         12 . The method in accordance with  claim 9 , wherein the particulate is gravel.  
     
     
         13 . The method in accordance with  claim 9 , wherein the particulate is a combination selected from the group of soil, sand and gravel.  
     
     
         14 . The method in accordance with  claim 1 , further comprising the step of interposing a membrane between the substrate and the liquid matrix material for preventing the liquid matrix material from adhering substantially to the substrate.  
     
     
         15 . The method in accordance with  claim 14 , wherein the membrane is plastic sheeting.  
     
     
         16 . The method in accordance with  claim 14 , wherein the membrane is a release agent.  
     
     
         17 . The method in accordance with  claim 14 , wherein the substrate is a solid substrate.  
     
     
         18 . The method in accordance with  claim 17 , wherein the solid substrate is concrete.  
     
     
         19 . The method in accordance with  claim 17 , wherein the solid substrate is asphalt pavement.  
     
     
         20 . The method in accordance with  claim 17 , wherein the solid substrate is wood.  
     
     
         21 . The method in accordance with  claim 17 , wherein the solid substrate is fiberglass composite.  
     
     
         22 . The method in accordance with  claim 17 , wherein the solid substrate is metal.  
     
     
         23 . The method in accordance with  claim 17 , wherein the solid substrate is modular bricks.  
     
     
         24 . The method in accordance with  claim 14 , wherein the substrate is particulate.  
     
     
         25 . The method in accordance with  claim 24 , wherein the particulate is soil.  
     
     
         26 . The method in accordance with  claim 24 , wherein the particulate is sand.  
     
     
         27 . The method in accordance with  claim 24 , wherein the particulate is gravel.  
     
     
         28 . The method in accordance with  claim 24 , wherein the particulate is a combination selected from the group of soil, sand and gravel.  
     
     
         29 . A wear-resistant reinforcing coating formed on a substrate, the coating comprising: 
 (a) a matrix adjacent the substrate;    (b) reinforcing fibers disposed in the matrix for reinforcing the matrix; and    (c) particulate adhered to the matrix on an opposite side of the fibers from the substrate.    
     
     
         30 . The wear-resistant reinforcing coating in accordance with  claim 29 , wherein the substrate is a solid substrate.  
     
     
         31 . The wear-resistant reinforcing coating in accordance with  claim 29 , wherein the substrate is particulate.  
     
     
         32 . The wear-resistant reinforcing coating in accordance with  claim 29 , further comprising a membrane interposed between the substrate and the matrix, thereby preventing adhesion of the matrix to the substrate.  
     
     
         33 . The wear-resistant reinforcing coating in accordance with  claim 32 , wherein the substrate is a solid substrate.  
     
     
         34 . The wear-resistant reinforcing coating in accordance with  claim 32 , wherein the substrate is particulate.  
     
     
         35 . A method of forming a wear-resistant reinforcing coating on a solid substrate, the method comprising: 
 (a) applying a liquid matrix material to the substrate;    (b) interposing a membrane between the substrate and the liquid matrix material for preventing the liquid matrix material from adhering substantially to the solid substrate;    (c) disposing reinforcing fibers in the liquid matrix material;    (d) placing particulate in contact with the liquid matrix material on an opposite side of the fibers from the substrate; and    (e) hardening the liquid matrix material, thereby forming a composite of reinforcing fibers in a matrix of the hardened liquid matrix material with the wearing surface of particulate.    
     
     
         36 . A wear-resistant reinforcing coating formed on a solid substrate, the coating comprising: 
 (a) a matrix adjacent the substrate;    (b) a membrane interposed between the substrate and the matrix, thereby preventing adhesion of the matrix to the substrate;    (c) reinforcing fibers disposed in the matrix for reinforcing the matrix; and    (d) particulate adhered to the matrix on an opposite side of the fibers from the substrate.    
     
     
         37 . A method of forming a reinforced floor having a substrate, the method comprising: 
 (a) applying a liquid matrix material to the substrate;    (b) disposing reinforcing fibers in the liquid matrix material;    (c) hardening the liquid matrix material, thereby forming a composite of reinforcing fibers in a matrix of hardened liquid matrix material, wherein an exposed surface of the reinforcement is unsuitable for foot traffic; and    (d) mounting a layer of rigid flooring material to said substrate above said composite of reinforcing fibers, said layer of flooring material having a wearing surface that is suitable for traffic.    
     
     
         38 . A reinforced floor having a planar substrate, the reinforced floor comprising: 
 (a) a hardened, planar matrix mounted to the substrate;    (b) reinforcing fibers disposed in the matrix;    (c) a planar layer of rigid flooring material mounted to the substrate above the reinforcing fibers, said layer of flooring material having a planar wearing surface that is suitable for traffic.    
     
     
         39 . A modular flooring unit of a discrete size and weight that can be lifted by a human, the flooring unit comprising: 
 (a) a planar matrix;    (b) reinforcing fibers embedded in the matrix for reinforcing the matrix;    (c) particulate mounted to a major surface of the matrix.    
     
     
         40 . The flooring unit in accordance with  claim 39 , wherein the particulate mounted to the matrix forms the traffic-bearing surface of the flooring unit.  
     
     
         41 . A method of forming a modular flooring unit of a size and weight that can be lifted by a human, the method comprising: 
 (a) placing a liquid matrix material in a receptacle;    (b) disposing reinforcing fibers in the liquid matrix material;    (c) placing particulate in contact with the liquid matrix material on an opposite side of the fibers from the substrate; and    (d) hardening the liquid matrix material, thereby forming a composite of reinforcing fibers in a matrix of the hardened liquid matrix material with a traffic-bearing surface of particulate.    
     
     
         42 . A method of forming a wear-resistant reinforcing coating on a substrate, the method comprising: 
 (a) aligning a composite with the substrate, the composite comprising a hardened matrix embedded with reinforcing fibers;    (b) applying an adhesive between the composite and the substrate;    (c) forcing the composite against the substrate with the adhesive in a layer interposed between the composite and the substrate;    (d) applying adhesive to the composite on a side of the composite opposite the substrate;    (e) placing particulate in contact with the adhesive; and    (f) hardening the adhesive, thereby forming a wearing surface of particulate.