AU2021104691A4 - FRP reinforcement bar with improved recycled glass coating - Google Patents

FRP reinforcement bar with improved recycled glass coating Download PDF

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Publication number
AU2021104691A4
AU2021104691A4 AU2021104691A AU2021104691A AU2021104691A4 AU 2021104691 A4 AU2021104691 A4 AU 2021104691A4 AU 2021104691 A AU2021104691 A AU 2021104691A AU 2021104691 A AU2021104691 A AU 2021104691A AU 2021104691 A4 AU2021104691 A4 AU 2021104691A4
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Australia
Prior art keywords
reinforcing member
fibres
composite reinforcing
bars
parallel
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AU2021104691A
Inventor
Dmitry Yatsenko
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Beyond Materials Group Pty Ltd
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Beyond Mat Group Pty Ltd
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Priority to AU2021104691A priority Critical patent/AU2021104691A4/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
    • E04C5/07—Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2031/00—Use of polyvinylesters or derivatives thereof as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/26—Scrap or recycled material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2509/00—Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
    • B29K2509/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/06—Rods, e.g. connecting rods, rails, stakes

Abstract

The invention relates to reinforcement bars for concrete structures, comprising of continuous, parallel fibres, preferably made of basalt, carbon, glass fibre, or the like, embedded in a cured matrix, the bars preferably having an average diameter of 2 mm to 40mm, each bar being made of at least one fibre bundles comprising a number of parallel, preferably straight fibres having a cylindrical cross section and said bars being provided with a surface texture with recycled glass powder which contributes to good bonding with the concrete. At least a part of the surface ofeach bar being deformed prior to or during the curing stage ofthe matrix by means of: a) one or more strings of an elastic or inelastic, but tensioned material being helically wound around said at least one bundle of parallel, straight fibres prior to curing of the matrix in which the fibres are embedded, maintaining the fibres in an parallel state during curing and providing an uneven external surface in a longitudinal direction of the reinforcement bars, and/or b) at least one deformed section and/orat least one end of each reinforcement bar; thereby producing a roughened surface. The innovation also relates to application ofrecycled glass powder as a coating for reinforcement bars.

Description

The invention relates to reinforcement bars for concrete structures, comprising of continuous, parallel fibres, preferably made of basalt, carbon, glass fibre, or the like, embedded in a cured matrix, the bars preferably having an average diameter of 2 mm to 40mm, each bar being made of at least one fibre bundles comprising a number of parallel, preferably straight fibres having a cylindrical cross section and said bars being provided with a surface texture with recycled glass powder which contributes to good bonding with the concrete. At least a part of the surface ofeach bar being deformed prior to or during the curing stage ofthe matrix by means of: a) one or more strings of an elastic or inelastic, but tensioned material being helically wound around said at least one bundle of parallel, straight fibres prior to curing of the matrix in which the fibres are embedded, maintaining the fibres in an parallel state during curing and providing an uneven external surface in a longitudinal direction of the reinforcement bars, and/or b) at least one deformed section and/orat least one end of each reinforcement bar; thereby producing a roughened surface. The innovation also relates to application ofrecycled glass powder as a coating for reinforcement bars.
EDITORIAL NOTE
2021104691
THERE ARE FIVE PAGES OF DESCRIPTION ONLY
[0001] The term "FRP rod" as used herein is intended to include bars and rods. Some of the rods and bars can be hollow. The outside surface is preferably but not necessarily of circular cross section. The rods can be of any length including elements which are relatively short.
[0002] BACKGROUND OF THE INVENTION The use of fibre reinforced plastics (FRP) rods in construction, marine, mining and others has been increasing for years. This is because FRP has many benefits, such as non- corroding, non metallic (or non-magnetic) and non-conductive, about twice to three times tensile strength and 1/4 weight of steel reinforcing rod, a coefficient of thermal expansion more compatible with concrete or rock than steel rebar. Most of the bars are often produced by pultrusion process and have a linear or uniform profile.
[0003] Conventional pultrusion process involves drawing a bundle of reinforcing material fibres or fibre filaments from a source thereof, wetting the fibres and impregnating them (preferably with a thermosettable polymer resin) by passing the reinforcing material through a resin bath in an open tank, pulling the resin-wetted and impregnated bundle through a shaping die to align the fibre bundle and to manipulate it into the proper cross-sectional configuration, winding a yarn around cross- sectional configuration and curing the resin in a mould while maintaining tension on the filaments. The resulting products generally have exceptionally high tensile strength in the longitudinal direction in the direction the fibre filaments are pulled.
[0004] FRP uniform profile or linear rods offer several advantages in many industrial applications. The rods are corrosion resistant, and have high tensile strength and weight reduction. In the past, steel rods or bolts had been widely used in engineering practice.
Due to seawater corrosion resistance, the FRP rods, bolts and anchors are also proven as good solutions in waterfront on shore or off-shore seawalls to reinforce the concrete structures. In general, the fibreglass, basalt or carbon fibre rod/bolt is already an important niche, and will be a more important product to the mining and construction industries. The critical needs of these industries are for structural reinforcements that provide long-term reliability that is of cost-effective. The savings in repair and maintenance to these industries will be significant, as the composite rebar will last almost indefinitely.
[0005] In construction industries, such as bridges, roads, pavements, seawall and building structures, reinforcements of the steel rebar have been widely used and the most of steel rebars have been corroded after a few years of service life. Typically, the structures with the steel rebars are often torn down after a period of time. Therefore, the use of the corrosion resistant composite FRP rods have been increased for construction industries in recent years.
[0006] SUMMARY OF THE INNOVATION It is proposed herein to provide an improved composite FRP rod coated with recycled glass powder, as well as methods of making the improved composite FRP rod.
[0007] A method of forming the improved FRP rod involves a pultrusion process that includes pre-forming, pre-heating, and pre-wetting continuous collimated glass, basalt or carbon fibre roving for consolidation to a uniform higher fibre content, a higher modulus fibre composition, or higher modulus hybrids in the pultruded rod. The pultruded rods are cured in a thermosetting resin without significant residual stresses causing voids, crazing, or splitting leading to premature failure from the load environment or durability issues. The cured rods provide internal reinforcement that uniformly shares load across the rod matrix and the area of work (strain energy absorption) with high shear modulus, high fracture toughness, and low damage accumulation rate.
[0008] A subsequent surface treatment applied to the wet rods. Recycled glass powder of 0.005-2mm particle size contained in special form reservoir, simultaneously fed onto wet FRP rod. Excess of recycled glass falls into container with sieve screen where lumps of epoxy and debris get separated and clean powder supplied back into main reservoir. Recycled glass coating can further enable appropriate strain for slippage and mechanical shear adhesion to place concrete in shear compression for best cohesion under tension, compression, bending, or local shear loads when designing to the crushing threshold of concrete.
[0009] In one exemplary embodiment, a composite reinforcing member comprises a plurality of fibres held together by a cured epoxy or vinylester resin, wherein the fibres are substantially parallel to one another, and wherein the epoxy or vinylester resin is formulated to increase corrosion resistance of the reinforcing member.
[0010] In some exemplary embodiments, the epoxy or vinylester resin has an elongation to break greater than 4%.
[0011] In some exemplary embodiments, the epoxy or vinylester resin has a glass transition temperature in the range of 1000 C. to 1400 C.
[0012] In some exemplary embodiments, the composite reinforcing member is a cylindrical rod. In some exemplary embodiments, the rod has a diameter in the range of 4mm to mm. In some exemplary embodiments, the rod has a length in the range of 0.2 meters to 20 meters.
[0013] In some exemplary embodiments, the rod is straight. In some exemplary embodiments, the rod has bent shape.
[0014] In some exemplary embodiments, the yarn is one of a glass roving, a polyester veil, and an acrylic veil.
[0015] In some exemplary embodiments, a diameter of the raw fibre is within the range of 13 pm to 35 pm. In some exemplary embodiments, a diameter of the raw fibre is within the range of 17 pm to 32 pm.
[0016] In some exemplary embodiments, a linear mass density of the raw fibre is within the range of 1,200 tex to 19,200 tex. In some exemplary embodiments, a linear mass density of the raw fibre is within the range of 2,400 tex to 8,800 tex.
[0017] The input material (e.g., glass fibres, basalt fibres, carbon fibres) will typically have a sizing applied thereto that is compatible with the resin matrix being used to form the composite FRP rod.
[0018] In some exemplary embodiments, the input material is a hybrid fiber content including a combination of E-CR glass fibre and high modulus glass fibre. In some exemplary embodiments, the input material is a hybrid fiber content including E-CR glass fibre and carbon fiber or basalt fibre. In some exemplary embodiments, the input material is a hybrid fiber content including E-CR glass fibre and metal strand. In various exemplary embodiments having a sheath-core arrangement, the sheathing material can be E-CR glass fibre with the core containing E-CR glass fibre and/or some other fibre.
[0019] The input fibres are held together by a resin binder that when cured (as described below) fixes the fibers relative to one another and forms the composite FRP rod.
[0020] Polyester (PE) resins, vinylester (VE) resins, and epoxy (EP) resins are commonly used matrix resins or binders for forming composite FRP rod.
[0021] In general, the inventive composite FRP rebar enables higher modulus, good strength and / or improved durability performance and improved bond with concrete.

Claims (9)

EDITORIAL NOTE 2021104691 THERE IS ONE PAGE OF CLAIMS ONLY
1. A composite reinforcing member comprising a plurality of fibres held together by a cured vinylester or epoxy resin, wherein the fibres are substantially parallel to one another, and wherein the vinylester or epoxy resin is formulated to increase corrosion resistance of the reinforcing member.
2. The composite reinforcing member of claim 1 wherein Glass, Basalt or Carbon fibre used.
3.. The composite reinforcing member wherein of claim 1 a yarn is wrapped around the rod.
4. The composite reinforcing member of claim 3 wherein the yarn is one of a glass veil, a polyester veil, and an acrylic veil.
5. The composite reinforcing member of claim 1, wherein recycled glass coating applied
6. The composite reinforcing member of claim 5, wherein recycled glass powder is 0.05-2mm particle size.
7. The composite reinforcing member of claim 1, wherein the resin has a glass transition temperature in the range of 1000 C. to 140° C.
8. The composite reinforcing member of claim 1, wherein the fibers constitute between 65% and 88% by weight of the composite reinforcing member.
9. The composite reinforcing member of claim 1, wherein the composite reinforcing member has a cylindrical, hexagonal, polygonal, square or hollow cross section.
AU2021104691A 2021-07-29 2021-07-29 FRP reinforcement bar with improved recycled glass coating Active AU2021104691A4 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2021104691A AU2021104691A4 (en) 2021-07-29 2021-07-29 FRP reinforcement bar with improved recycled glass coating

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
AU2021104691A AU2021104691A4 (en) 2021-07-29 2021-07-29 FRP reinforcement bar with improved recycled glass coating

Publications (1)

Publication Number Publication Date
AU2021104691A4 true AU2021104691A4 (en) 2021-09-30

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Country Status (1)

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AU (1) AU2021104691A4 (en)

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