A MASONRY REINFORCEMENT STRUCTURE COMPRISING PARALLEL ASSEMBLIES OF GROUPED METAL FILAMENTS AND A POLYMER COATING

Abstract

The invention relates to a masonry reinforcement structure (100) comprising at least two assemblies (102) of grouped metal filaments, at least one positioning element (104) for positioning the assemblies (102) of grouped metal filaments in a predetermined position and a polymer coating (110) for securing the assemblies (102) of grouped metal filaments in this predetermined position. The invention also relates to a method of manufacturing such masonry reinforcement structure (100) and to a roll comprising such a masonry reinforcement structure(100). The invention further relates to masonry reinforced with such masonry reinforcement structure (100) and to a method to apply such masonry reinforcement structure(100).

Claims

1. A masonry reinforcement structure comprising at least two assemblies of grouped metal filaments, at least one positioning element for positioning said at least two assemblies of grouped metal filaments in a predetermined position and a polymer coating for securing said at least two assemblies of grouped metal filaments in said predetermined position, said polymer coating being applied on said at least two assemblies and on said at least one positioning element.

2. A masonry reinforcement structure according to claim 1, wherein said assemblies of grouped metal filaments comprise parallel or substantially parallel metal filaments.

3. A masonry reinforcement structure according to claim 1, wherein said assemblies of grouped metal filaments comprise metal filaments that are twisted together.

4. A masonry reinforcement structure according to claim 1, wherein said positioning element comprises a substrate or elongated element.

5. A masonry reinforcement structure according to claim 1, wherein said polymer coating is selected from the group consisting of acrylic coatings, acrylic based coatings, polyethylene based coatings and polyurethane based coatings.

6. A masonry reinforcement structure according to claim 5, wherein said polymer coating has a thickness ranging between 1 and 100 μm.

7. A masonry reinforcement structure according to claim 1, wherein said at least two assemblies of metal filaments in said predetermined position are oriented parallel or substantially parallel in the length direction of said masonry reinforcement structure.

8. A masonry reinforcement structure according to claim 1, wherein said at least one positioning element comprises a zigzag roving or yarn connected to said at least two assemblies of metal filaments.

9. A masonry reinforcement structure according to claim 8, wherein said at least one positioning element further comprises a textile yarn being knitted or stitched around said at least two assemblies of metal filaments and around said zigzag roving or yarn.

10. A masonry reinforcement structure according to claim 9, wherein part of said polymer coating has penetrated into said textile yarn.

11. A method to manufacture a masonry reinforcement structure as defined in claim 1, said method comprising the steps of providing at least two assemblies of grouped metal filaments; providing at least one positioning element for positioning said at least two assemblies of grouped metal filaments in a predetermined position; manufacturing a structure comprising said at least two assemblies of grouped metal filaments and said at least one positioning element; applying a polymer coating on said structure comprising said at least two assemblies of grouped metal filaments and said at least one positioning element.

12. A method to manufacture a masonry reinforcement structure according to claim 11, wherein said structure is manufactured by welding, weaving, gluing, stitching, knitting, braiding or embroidering or any combination thereof.

13. A roll of a masonry reinforcement structure as defined in claim 1, said masonry reinforcement structure being wound to form said roll.

14. A method to install a masonry reinforcement structure as defined in claim 1, said method comprising the steps of providing masonry comprising at least one layer of units or bricks; uncoiling a masonry reinforcement structure as defined in claim 1; installing said masonry reinforcement structure in a joint on the upper surface of the last layer of units or bricks; providing the next layer of units or brick on said joint.

15. Masonry reinforced with at least one masonry reinforcement structure, said masonry comprising a number of layers of units or bricks and joints between two neighbouring layers of bricks, whereby at least one joint of said masonry is reinforced with a masonry reinforcement structure as defined in claim 1.

Description

BRIEF DESCRIPTION OF FIGURES IN THE DRAWINGS

[0141] The invention will now be described into more detail with reference to the accompanying drawings whereby

[0142] FIG. 1 is an illustration of a masonry reinforcement structure comprising a woven structure;

[0143] FIG. 2 is an illustration of a masonry reinforcement structure comprising a knitted structure;

[0144] FIG. 3 is an illustration of a masonry reinforcement structure comprising parallel assemblies of grouped metal filaments stitched to a substrate;

[0145] FIG. 4 is an illustration of a masonry reinforcement structure comprising a woven structure;

[0146] FIG. 5, FIG. 6 and FIG. 7 are illustrations of masonry reinforcements structures comprising parallel assemblies of grouped metal filaments and at least one connecting element;

[0147] FIG. 8 illustrates the use of a masonry reinforcement structure in a masonry

MODE(S) FOR CARRYING OUT THE INVENTION

[0148] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.

[0149] The following terms are provided solely to aid in the understanding of the inventions: [0150] Masonry: all building systems that are constructed by stacking units of for example stone, clay, or concrete, joined by for example mortar or glue into the form of for example walls, columns, arches, beams or domes; [0151] Equivalent diameter of a yarn or filament: the diameter of an imaginary yarn or filament having a circular radial cross-section, which cross-section has a surface identical to the surface area of the particular yarn or filament

[0152] FIG. 1 is an illustration of a first embodiment of a masonry reinforcement structure 100 according to the present invention. The masonry reinforcement structure 100 comprises a woven structure 101. The woven structure 101 comprises assemblies of grouped metal filaments 102 in the warp direction. The assemblies of grouped metal filaments 102 comprise for example steel cords. Preferred steel cords comprise between 2 and 12 filaments, for example a cord having one core filament having a diameter of 0.37 mm and 6 filaments having a diameter of 0.33 m around this core filament (0.37+6×0.33).

[0153] In alternative embodiments the assemblies of grouped metal filaments 102 comprise bundles of parallel or substantially parallel filaments, for example bundles of 12 parallel or substantially parallel filaments.

[0154] The weft direction comprises for example a polymer yarn 104, such as a polyamide, a polyether sulphone, a polyvinyl alcohol or a polypropylene yarn.

[0155] A polymer coating 110 is applied on the woven structure 101. The polymer coating 110 comprises for example an acrylic coating. The thickness of the polymer coating 110 is for example 10 μm or 20 μm. The polymer coating 110 is applied by dipping the woven structure 101 in an acrylic dispersion.

[0156] In alternative embodiments the weft direction comprises a metal yarn, for example a steel yarn. The masonry reinforcement structure 100 is preferably an open structure permeable for the glue or mortar.

[0157] It is clear for a person skilled in the art that different weave patterns can be considered.

[0158] FIG. 2 shows a second embodiment of a masonry reinforcement structure 200 according to the present invention. The masonry reinforcement structure 200 comprises a knitted structure 201. The knitted structure 201 comprises assemblies of grouped metal filaments 202 as pillar threads. The assemblies of grouped metal filaments 202 comprise for example steel cords comprising 3 filaments having a diameter of 0.48 mm twisted together (3×0.48 mm).

[0159] In alternative embodiments the assemblies of grouped metal filaments 202 comprise parallel or substantially parallel filaments, for example a bundle of 12 parallel or substantially parallel filaments.

[0160] The knitted structure 201 further comprises yarn 204 and yarn 206 to keep the assemblies of grouped metal filaments in their mutual parallel or mutual substantially parallel position. The yarn 204 is for example a multifilament yarn, preferably a polyamide, a polyether sulphone, a polyvinyl alcohol or a polypropylene yarn. The yarn 204 may also comprise a metal yarn, for example a steel yarn.

[0161] The yarn 206 is connecting neighbouring assemblies of grouped metal filaments 202. The monofilament yarn 206 is preferably a polyamide, a polyether sulphone, a polyvinyl alcohol or a polypropylene yarn. The yarn 206 may also comprise a metal yarn, for example a steel yarn. A polymer coating 210 is applied on the masonry reinforcement structure 200. The polymer coating comprises for example a styrene acrylic coating. The thickness of the polymer coating is for example 10 μm, 15 μm or 20 μm.

[0162] FIG. 3 is an illustration of a masonry reinforcement structure 300 comprising a structure 301 of parallel assemblies of grouped metal filaments 302 stitched to a substrate 310. The assemblies 302 are stitched to the substrate 310 by means of yarn 304. The assemblies of grouped metal filaments 302 comprise steel cords or bundles of parallel filaments. The yarn 304 forms stitches to couple the steel cords to the substrate 306.

[0163] The substrate 306 comprises for example a woven or non-woven polymer structure.

[0164] A polymer coating 310 is applied on the masonry reinforcement structure 200. The polymer coating 310 comprises for example a styrene acrylic coating. The thickness of the polymer coating is for example 20 μm. In a preferred embodiment the cords comprise steel cords that are stitched to a polymer substrate for example to a non-woven polyether sulphone substrate by means of a polyether sulphone yarn or to an extruded polypropylene grid (35 g/m.sup.2 having a 6×6 mm mesh) by means of a polypropylene yarn.

[0165] In another preferred embodiment the cords are steel cords stitched to a metal substrate, for example a steel mesh or steel grid by a metal yarn, for example a steel yarn. Such structure fully consisting of one material, more particularly metal (steel) is easier to recycle compared to structures comprising a number of different materials.

[0166] FIG. 4 is an illustration of a masonry reinforcement structure 400 comprising assemblies of grouped metal filaments 402 integrated in a woven structure 401. The woven structure 401 comprises in the warp direction a combination of polymer yarns 403 and assemblies of grouped metal filaments 402. The weft direction comprises a polymer yarn 404. A polymer coating 410, more particularly a styrene acrylic coating is applied on the woven structure 401.

[0167] FIG. 5 is an illustration of a masonry reinforcement structure 500 comprising a structure 501 of assemblies of grouped metal filaments 502 interconnected by a connecting structure 504. The connecting structure functions as positioning element, i.e. the connecting structure 504 positions the assemblies of grouped metal filaments 502. The connecting structure 504 comprises for example rovings. In preferred embodiments the masonry reinforcement structure 500 comprises a number of rovings positioned parallel or substantially parallel preferably in the transversal direction of the masonry reinforcement structure 500. The rovings may for example comprise glass rovings, polypropylene rovings or polyester roving.

[0168] The assemblies of grouped metal filaments 502 comprises for example steel cords or bundles of parallel or substantially parallel steel filaments. The assemblies of grouped metal filaments 502 can be connected to the connecting structure for example by means of gluing, stitching, knitting or embroidering.

[0169] A polymer coating 510 is applied on structure 501. The polymer coating 510 comprises for example styrene acrylic having a thickness of 10 μm, 15 μm or 20 μm.

[0170] FIG. 6 is an illustration of a masonry reinforcement structure 600 comprising a structure 601 of assemblies of grouped metal filaments 602 interconnected by a connecting structure 604. The connecting structure 604 positions the assemblies of grouped metal filaments 602 and comprises for example one or a number of zig-zag like glass rovings.

[0171] The assemblies of grouped metal filaments 602 comprises for example steel cords or bundles of parallel or substantially parallel steel filaments. The assemblies of grouped metal filaments 602 can be connected to the connecting structure for example by means of gluing, stitching, knitting or embroidering.

[0172] A polymer coating 610 is applied on structure 601. The polymer coating 610 comprises for example styrene acrylic having a thickness of 10 μm, 15 μm or 20 μm.

[0173] FIG. 7 is an illustration of a particular preferable and advantageous embodiment of a masonry reinforcement structure 700, which is similar to the one of FIG. 6.

[0174] The masonry reinforcement structure 700 comprises a number of parallel assemblies of steel filaments such as steel cords. These steel cords have a simple structure such as 1×3, 1×4, 2+2, 1+6. The density or concentration of the assemblies is greater at the left and right side than in the middle.

[0175] The positioning element that keeps the assemblies of steel filaments parallel comprises a glass roving 704. Starting from the left bottom of FIG. 7, this glass roving 704 runs parallel and in contact with the extreme left steel cord 702′. Going somewhat upwards, the glass roving 704 makes a bend and crosses all steel cords 702 until the glass roving 704 reaches the extreme right steel cord 702″. From there on, the glass roving 704 runs parallel and in contact with the extreme right steel cord 702″. At the right top of FIG. 7, the glass roving 704 makes again a bend and crosses all steel cords 702 until the glass roving 704 reaches the extreme left steel cord 702′ where it restarts to run parallel and in contact with the extreme left steel cord 702′.

[0176] The positioning element also comprises textile yarns 706, preferably one per steel cord 702. These textile yarns 706 are wrapped around the steel cords 702′, 702, 702″ and around the glass roving 704, in case the glass roving is in contact with the particular steel cord 702, 702′, 702″. The glass roving 704 together with the textile yarns 706 form the positioning element to keep the steel cords 702′, 702, 702″ parallel to each other.

[0177] Once the operation of zigzagging of the glass roving 704 and of wrapping of the textile yarns 706 has been done, the thus formed fabric goes in a polymer bath and polymer 710 is adhering to the fabric, more particularly to the glass roving 704 and the textile yarns 706. The polymer 710 thus further secures the parallel relationship between the steel cords 702. This is particularly true in case the polymer can penetrate inside the textile yarns. In addition and next to a coating already present on the steel filaments or steel cords, the polymer adds to the corrosion protection of the steel cords.

[0178] FIG. 8 shows a masonry 800 made of bricks 802. During manufacture of the masonry 800, the top layer of bricks is covered with an bottom layer 804 of mortar or glue. The masonry reinforcement 700 is unrolled upon this bottom layer 804. Thereafter the masonry reinforcement 700 is covered with a top layer 806 of mortar or glue.

[0179] It is not strictly necessary to lay two layers (804, 806) of mortar or glue. One single layer, e.g. the bottom layer, may be sufficient.