Basalt reinforcement for concrete containment cages

Abstract

Matrix basalt reinforcing member constructed and arrange to provide lateral support for the longitudinal bar steel or FRP tendons that provide tensile strength to cementitious material or plastics to reduce bending moment by reducing the onset of shear. The reinforcement members are formed from basalt fibers treated with a thermoplastic thermoset polymer and formed into structures to provide structural resistance to bending-moment forces, compression forces, and torsional forces acting on the structure.

Claims

1. A method of concrete reinforcement comprising the steps of: selecting a plurality of individual continuous length basalt fiber strands and forming a bundle of basalt fiber strands; wrapping each said bundle of basalt fiber strands around a 90 degree bend radius wherein basalt fiber strands positioned along an inner edge of said radius have a length less than basalt bundle fiber strands positioned along an outer edge of said radius; treating said wrapped bundle of basalt fiber strands with a thermoplastic thermoset polymer selected from the group of: urethane, polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, methacrylate or a combination thereof; allowing said thermoplastic thermoset polymer to cure into a rigid basalt bar; embedding said rigid basalt bar into liquid concrete near a corner wherein said rigid basalt bar improves tensioning the corner of the concrete.

2. The method of concrete reinforcement according to claim 1 wherein said basalt bar embedded in the corner of concrete further is positioned close to the surface of the concrete thereby reducing deflection in the concrete and increasing the leverage of reinforcement on the bending moment in the concrete.

3. The method of concrete reinforcement according to claim 1 wherein said concrete is porous.

4. The method of concrete reinforcement according to claim 1 wherein said basalt bar is constructed and arranged to have an expansion ratio similar to an expansion ratio of the concrete.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a pictorial view of a basalt fiber hook compared to a steel rebar hook;

(2) FIG. 2 is a pictorial view of two basalt fiber hooks;

(3) FIG. 3 is a pictorial view of a basalt fiber hook strained to reveal fibers;

(4) FIG. 4 is a pervious concrete load versus displacement test without use of basalt rebar; and

(5) FIG. 5 is a pervious concrete load versus displacement test with use of basalt rebar.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(6) Disclosed herein is an improved reinforcement matrix member for concrete structures or reinforced pavements. Specifically, the matrix member works with concrete material by forming a structural support use in reinforcing concrete structures, pavements, roads, sidewalks and other infrastructure conventionally reinforced with rebar. Through the use of embodiments of the present invention, the concrete structure can be made stronger by adopting the high tensile, low stretch characteristics of continuous basalt fiber configured into a geometry that acts to tighten to the concrete it reinforces as load increases. The material and method of construction extends the onset of bond slit to beyond the limits of the concrete matrix it reinforces resulting in a somewhat self-healing structure where the lack of memory after a temporary overload will allow the structure to return to its original shape. In particular, the basalt fibers are formed into rectilinear shape with corners form fit to the longitudinal reinforcement by layering filaments atop each other in a manner that subsequently enhances the catenary (balance of load between fibers) within the reinforcement invention resulting in corner strength in excess of currant stirrup reinforcements of steel or FRP allowing for improved stirrup containment.

(7) Basalt is a non toxic naturally occurring volcanic rock that when processed into continuous glassy fibers subsequently bundled into rovings that may be cold formed into shaped reinforcement with a variety of benefits when compared to steel rebar typically used for reinforced concrete. Basalt is a naturally occurring rock which means it can resist rust or develop any type of corrosion and does not absorb any amount of water. Basalt rebar is also about of the weight of steel rebar, which makes basalt rebar much easier to transport and assemble on the job site. Also, basalt rebar can be easily cut using common tools in the field.

(8) Basalt can outperform concrete 10:1 in compression strength and 100:1 in tension strength. The configuration of the instant invention is designed to address expansion and contraction as well as creep and fatigue. When used with pervious concrete, that is, pavement that permits water and air to pass, the use of the basalt for reinforcement eliminates the rusting problem commonly associated with steel rebar.

(9) FIG. 1 is a pictorial view of a basalt fiber roving into a hook shape as depicted by a first extension 10 leading to a substantially 90 degree angle along corner 12. The second extension 14 continuing outwardly from the corner 12. It should be obvious to one skilled in the art that the formation of the basalt into a substantially right angle allows the placement of the basalt rebar into a position much closer to the corner of a concrete structure providing an improvement reinforcement to the corner. By way of comparison, a steel rebar 16 used in forming a right corner is bent to form a corner 18 before continuing to the length 20. The bending of the steel eliminates the ability to form a proper 90 degree or right angle corner resulting in a rounded corner. The rounded corner does not allow for concrete reinforcement near the corner of the overlying concrete resulting in an area of concrete that does not have tension reinforcement. The continuous basalt fibers are woven within a thermoplastic of a thermoset polymer selected from the group of as urethane, polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, methacrylate, or a combination thereof. A principal advantage is in the non-rusting nature of the hoops composite structure allowing the tensile elements of the reinforcement cage to be place close the outside of the bend radius of the concrete member being reinforced without fear of rust degradation from insufficient concrete coverage.

(10) Stirrups for beam cages are produced by filament winding continuous basalt layer by layer resulting in fully 360 degrees enclosing hoops composed of more evenly loaded fiber tendons. The use of basalt reduces the considerations over inadequate coverage to resist concrete spalling due to rusting steel, the basalt offers weight reduction and dimensional consistency of adopting filament wound hoops. The strength of a basalt hoop may be controlled during the winding process simply by filament count. It should be noticed that compared to a conventionally formed stirrup, the basalt member fits more concisely around the corner.

(11) FIG. 2 is a pictorial view illustrating the ability to nest multiple bundles to further enhance corner edge concrete structures. In this embodiment, a first basalt rebar includes a first extension leg 10 leading to a second extension leg 14 once formed along a ninety degree angle 12. Similarly, a second basalt rebar includes a second extension leg 30 leading to a second extension leg 34 once formed along a ninety degree angle 32. It is noticed that the foliation of the basalt rebar allows for the angle without the need to bend the material, as required with the rebar. It should also be understood that the cold bending of any steel affects the structure and can quickly degrade any coating that may be been placed over the steel.

(12) FIG. 3 depicts a basalt rebar in a straightened format where the first extension 40 is placed substantially parallel to the second extension 42 causing the corner fibers 44 to propagate outward. This illustrates that the corner was specifically made in the 90 degree angle and the fibers are rejecting the straightening of the rebar. The rebar is placed into the straightened position by wrenches 50, 52. Placing longitudinal tinsel tendons of low elongation to break out further on the bend radius tends to reduce deflection of the element being reinforced. With steel reinforcement, the limiting factor has been to provide sufficient cover over the steel to protect it from moisture penetration of the cementus material and subsequent rusting resulting in spalling of the concrete and reduced life cycle of the structure.

(13) FIG. 4 is a chart indicating pervious concrete beam failures without the instant invention, the load on the beam indicates a failure of 3042 lbs, 3167 lbs and 3667 lbs. FIG. 5 is a chart indicating pervious concrete beam failures that were reinforced by twin legs of continuous basalt fiber/epoxy matrix measuring 610 mm with the fibers braded into a long bar with the basalt tex interlaced to provide positive lock against pullout. The failure now improved to 7905 lbs, 8771 lbs, and 8958 lbs. The beams were made from a standard mix with polymer without sand.

(14) The shear behavior of concrete beams reinforced with the basalt hoops, as opposed to steel stirrups, will show reduced handling fatigue and better consistency during cage construction. The design tensile strength for a FRP (fiber reinforced polymer) reinforced concrete element cannot be greater than the strength of the bend in the stirrup which is typically 40 to 50% less than that of a straight bar.

(15) The method of concrete reinforcement comprising the steps of selecting a plurality of individual continuous length basalt fiber strands and forming a bundle of basalt fiber strands; wrapping said bundle of basalt fiber strands around at least one peg to form a 90 degree bend radius; treating said wrapped bundle of basalt fiber strands with a thermoplastic thermoset polymer selected from the group of urethane, polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, methacrylate or a combination thereof and allowing said thermoplastic thermoset polymer to cure into a basalt bar; and embedding said basalt bar into concrete to improve tensioning in the corners of the concrete. The individual fiber strands within the bundle are positioned closer to the peg and have a length less than individual fiber strands that are positioned further from the peg.

(16) The deflection of beam or panels can be controlled by increasing the area of basalt bar tension reinforcement. To reduce deflection by adding basalt bar installed out closer to the surface of the bend radius thereby increasing the leverage of the reinforcement on the bending moment would take advantage of the basalts higher tensile and lower stretch as compared to that fiberglass reinforcement.

(17) Detailed embodiments of the instant invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

(18) It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

(19) One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.