Erosion control system

Abstract

Improved erosion control systems are provided which, in some embodiments, may comprise large, porous aggregate stabilized with a continuous mesh and a polymeric binding agent. In some embodiments, an erosion control system may include an aggregate layer comprising porous aggregate having a particle size of at least 7.5 mm and containing no more than 5% by weight of smaller particles; a continuous mesh disposed at an upper surface of the aggregate layer; and a polymer adhesive affixing at least some aggregate particles to each other and affixing the mesh to some of the aggregate particles, wherein the polymer adhesive permanently binds the aggregate and mesh such that the system remains porous. The polymer may be applied in-situ after the mesh has been placed on the aggregate.

1 . An erosion control system, comprising:
 an aggregate layer comprising porous aggregate having a particle size of at least 7.5 mm and containing no more than 5% by weight of smaller particles;   a continuous mesh disposed at an upper surface of the aggregate layer; and   a polymer adhesive affixing at least some aggregate particles to each other and affixing the mesh to some of the aggregate particles, wherein the polymer adhesive permanently binds the aggregate and mesh such that the system remains porous.   
     
     
         2 . The system of  claim 1 , wherein the polymer adhesive is applied in-situ after the mesh has been placed on the aggregate. 
     
     
         3 . The system of  claim 1 , wherein the polymer adhesive is disposed substantially uniformly in the upper region of the porous aggregate. 
     
     
         4 . The system of  claim 1 , wherein the polymer adhesive is applied in a pattern with areas of heavier application spaced between areas of lighter or no application. 
     
     
         5 . The system of  claim 4 , wherein the areas of heavier application are impermeable. 
     
     
         6 . The system of  claim 1 , wherein the mesh is anchored at its periphery. 
     
     
         7 . The system of  claim 1 , wherein the mesh is anchored within its periphery. 
     
     
         8 . The system of  claim 7 , wherein the aggregate within an anchorage zone where the mesh is anchored is not treated with a polymer adhesive. 
     
     
         9 . The system of  claim 8 , wherein the aggregate within the anchorage zone is stable due to one or more of size, weight, friction, angularity or combinations thereof. 
     
     
         10 . The system of  claim 1 , further comprising:
 an anchor aggregate layer disposed atop the mesh.   
     
     
         11 . An erosion control system, comprising:
 an aggregate layer comprising porous aggregate having a particle size of at least 7.5 mm and containing no more than 5% by weight of smaller particles;   a continuous mesh disposed within 100 mm of the surface or no lower than two times the particle size of the aggregate when the particle size exceeds 50 mm; and   a polymer adhesive affixing at least some aggregate particles to each other and affixing the mesh to some of the aggregate particles, wherein the polymer adhesive permanently binds the aggregate and mesh such that the system remains porous.   
     
     
         12 . The system of  claim 11 , wherein the polymer adhesive is applied in-situ after the mesh has been placed on the aggregate. 
     
     
         13 . The system of  claim 11 , wherein the polymer adhesive is disposed substantially uniformly in the upper region of the porous aggregate. 
     
     
         14 . The system of  claim 11 , wherein the polymer adhesive is applied in a pattern with areas of heavier application spaced between areas of lighter or no application. 
     
     
         15 . The system of  claim 14 , wherein the areas of heavier application are impermeable. 
     
     
         16 . The system of  claim 11 , wherein the mesh is anchored at its periphery. 
     
     
         17 . The system of  claim 11 , wherein the mesh is anchored within its periphery. 
     
     
         18 . A method of fabricating an erosion control system, comprising:
 depositing an aggregate layer comprising a plurality of aggregate particles having a first diameter of at least 7.5 mm and no more than about 5% or less by weight of smaller particles;   placing a mesh atop an upper surface of the aggregate layer;   applying a polymer adhesive to a first plurality of the aggregate particles to form permanent bonds between the mesh and at least some of the aggregate particles in the upper region.   
     
     
         19 . The method of  claim 18 , further comprising:
 applying a polymer adhesive to a second plurality of the aggregate particles to form bonds between at least some of the aggregate particles in an upper region of the aggregate layer.   
     
     
         20 . The method of  claim 18 , wherein applying the polymer adhesive to the plurality of the aggregate particles to form bonds between at least some of the aggregate particles further comprises:
 mixing the plurality of aggregate particles with the polymer adhesive prior to deposition of the aggregate layer.   
     
     
         21 . The method of  claim 18 , further comprising:
 depositing an anchor aggregate layer atop the mesh.   
     
     
         22 . The method of  claim 21 , wherein anchor aggregate particles of the anchor aggregate layer are mixed with a polymer adhesive prior to deposition of the anchor aggregate layer. 
     
     
         23 . The method of  claim 21 , wherein the anchor aggregate layer is deposited such that one or more regions of the mesh remain exposed.