Porous Ceramic Paving Material

Abstract

The disclosure is directed to a method of constructing a porous, ceramic pavement that is permeable to aqueous fluids and more resistant to acidic rainwater than concrete. The method includes selecting a porous, ceramic paving material having a compressive strength sufficient for a particular use of a surface to be paved. A base material can be selected to serve as a support for the paving material, wherein the base material is permeable to aqueous fluids. The base material is applied to the surface to be paved, and the paving material is positioned on top of the base material to provide a porous, ceramic pavement.

1 . A method of creating the porous, ceramic paving material comprising
 preparing a composition comprising a metal oxide and a filler material, wherein the preparing comprises selecting the filler material to provide a desired porosity to the paving material and mixing the filler material with the metal oxide;   forming the composition into a desired shape by applying pressure to the composition in a mold;   heat-treating the desired form to create the porous, ceramic paving material, wherein the paving material is permeable to aqueous fluids and more resistant to acidic rainwater than concrete.   
   
   
       2 . The method of  claim 1 , wherein the preparing comprises selecting a soil having a desired metal oxide composition and the mixing comprises mixing the soil with the filler material. 
   
   
       3 . The method of  claim 1 , wherein the soil comprises flint clay. 
   
   
       4 . The method of  claim 1 , wherein the preparing further comprises adding a bonding agent to the composition. 
   
   
       5 . The method of  claim 1 , wherein the bonding agent comprises flint clay. 
   
   
       6 . The method of  claim 1 , wherein the metal oxide comprises a component selected from a group consisting of Al 2 O 3 , SiO 2 , Fe 2 O 3 , TiO 2 , CoO, MgO, Na 2 O, K 2 O, hydrated forms thereof, or combinations thereof. 
   
   
       7 . The method of  claim 1 , wherein the metal oxide comprises a combination of Al 2 O 3  and SiO 2 . 
   
   
       8 . The method of  claim 1 , wherein the filler material comprises sand, gravel, ceramic particles, glass particles, or a combination thereof. 
   
   
       9 . The method of  claim 1 , wherein the filler material comprises particles having average diameters that range from about 1/16 of an inch to about ¼ of an inch. 
   
   
       10 . The method of  claim 1 , wherein the forming comprises applying a pressure of about 500 psi to about 3000 psi to form the desired shape from the composition. 
   
   
       11 . The method of  claim 1 , wherein the heat-treating occurs at a temperature ranging from about 1100° C. to about 1300° C. 
   
   
       12 . The method of  claim 1 , wherein the paving material has a rate of permeation ranging from about 1.0 to about 2.5 inches per minute. 
   
   
       13 . The method of  claim 1 , wherein the paving material has a compressive strength ranging from about 4000 psi to about 12,000 psi. 
   
   
       14 . The method of  claim 1 , wherein the preparing further comprises mixing an additive with the filler material and metal oxide, such that the additive provides a desired color to the paving material. 
   
   
       15 . The method of  claim 1 , wherein the preparing further comprises mixing an additive with the filler material and metal oxide, such that the additive provides a non-slip surface, wherein the additive has a melting point that is higher than the temperature at which the heat-treating occurs. 
   
   
       16 . The method of  claim 1 , wherein the desired shape is a unit form having features that provide structural integrity to a network of the unit forms, a non-slip surface, a support for the addition of other components unrelated to paving, or a combination thereof.