GB1602602A - Fibre reinforced cementitious layers on plastics substrates - Google Patents

Fibre reinforced cementitious layers on plastics substrates Download PDF

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Publication number
GB1602602A
GB1602602A GB22435/77A GB2243577A GB1602602A GB 1602602 A GB1602602 A GB 1602602A GB 22435/77 A GB22435/77 A GB 22435/77A GB 2243577 A GB2243577 A GB 2243577A GB 1602602 A GB1602602 A GB 1602602A
Authority
GB
United Kingdom
Prior art keywords
fibrous mat
cementitious
fibres
mat arrangement
structure according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB22435/77A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Charcon Composites Ltd
Original Assignee
Charcon Composites Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Charcon Composites Ltd filed Critical Charcon Composites Ltd
Priority to GB22435/77A priority Critical patent/GB1602602A/en
Priority to DE19782822601 priority patent/DE2822601A1/en
Priority to FR7816668A priority patent/FR2391848A1/en
Priority to BE188078A priority patent/BE867533A/en
Priority to AU36511/78A priority patent/AU3651178A/en
Priority to JP6240378A priority patent/JPS5433523A/en
Priority to ES470260A priority patent/ES470260A1/en
Priority to IT23927/78A priority patent/IT1094861B/en
Priority to NL7805817A priority patent/NL7805817A/en
Publication of GB1602602A publication Critical patent/GB1602602A/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0023—Lining the inner wall of hollow objects, e.g. pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/14—Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00—Tubular articles, e.g. hoses, pipes

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)

Description

(54) FIBRE REINFORCED CEMENTITIOUS LAYERS ON PLASTICS SUBSTRATES (71) We, CHARCON COMPOSITES LIMITED, a British Company of 83 Friar Gate, Derby, do hereby declare the.
invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to cementitious structures having protective coatings and methods of producing same.
There are many applications in industry where chemical resistance is required, usually allied to other requirements such as weight, fire resistance, installation techniques.
For example, one major problem in the provision and maintenance of sewer lines is the deterioration, sometimes very rapid, of the cementitious materials generally used in their construction.
Currently there are many major problems in sewers caused by the production of Hydrogen Sulphide gas (H2S). Under various conditions which might be caused by inadequate rates of flow, or high temperature or a combination of these with other conditions, the sewage becomes septic after bacteria has consumed the free oxygen and subsequent chemical changes result in very low pH values and condensation on the sewer walls of Sulphuric Acid (H2SO4). The acid is held in contact with the walls by the slime deposits and attacks the cement.
It is well known that Sulphuric Acid {H2SO4) readily attacks all cements, particularly Portland Cement which is generally used in construction, but also cements such as Sulphate resisting and High Alumina.
When H2S exists in a sewer it causes rapid erosion and if adequate steps are not taken, can lead to complete collapse.
It is also well known that many synthetic resins and plastics are resistant to chemical attack, and are sometimes used for sewer pipes. For example pipes of glass reinforced polyester resin, epoxy resin, PVC and high density polyethylene are often used. The use of such pipes is however generally restricted to new installations laid in an open cut trench. In general, pipes cannot be easily or satisfactorily used in an existing sewer where access is normally restricted by manhole chamber size or where the existing sewer is not round, or for lining large dianreter new sewers such as a driven tunnel or concrete pipe.
The in situ applications of resins to the internal surface of existing pipes and tunnels to provide protection against H2S attack has been carried out, but there are many practical difficulties in obtaining an adequate bond between concrete and plastics and a large number of failures have resulted.
It is an object of the present invention to provide a structure which has desired strength, stiffness and structural stability and which also has a coating providing protection against chemical attack.
According to one aspect of the present invention there is provided a method of producing a cementitious structure comprising preforming a plastics material into a sheet of desired shape having a fibrous mat arrangement on one surface thereof, forming a fibre reinforced cementitious material into a pliable dewatered condition, and applying the cementitious material to the fibrous mat arrangement of the preformed sheet.
The present invention also provides a method of forming a sewer lining comprising erecting a plurality of cementitious structures, formed by the method according to any of the two preceding paragraphs in edge-to-edge relation, and sealing joints between adjacent structures by means of cover strips of the plastics material applied across the joints.
According to another aspect of the present invention there is provided a cementitious structure comprising a plastics material preformed into a sheet of a desired shape and having a fibrous mat arrangement on one surface thereof, and a fibre reinforced cementitious material affixed to the fibrous mat arrangement of the preformed sheet.
The cementitious material is advantageously glass reinforced cement.
Preferably also the fibrous mat arrangement incorporates alkali resistant glass fibres. Alternatively the fibrous mat arrangement incorporates E-glass fibres and a resin is applied to' the fibrous mat arrangement of the preformed sheet before the cementitious material.
An embodiment of the present invention will now be described by way of example only.
To produce a cementitious structure having a coating which provides protection against a chemical attack, for example for use as lining structures in sewers wherein the formation of sulphuric acid can cause erosion of the cement, a plastics material such as PVC, high density polyethylene, polyethylene polyester, polypropylene or any other suitable plastics is preformed into a sheet having a fibrous mat arrangement on one surface, as the plastics material cannot be bonded directly to the cementitious material. The mat arrangement may incorporate E-glass fibres or alkali resistant glass fibres. Plastics sheets incorporating Eglass fibre mats are available commercially but have not been found satisfactory when used as coatings on a cementitious material because the E-glass is severely attacked by the free alkali in Portland Cement, leading to a breakdown at the interface between the mat and the cementitious material.
The cementitious material which is preferably of a thickness from 3 to 20mm is advantageously glass reinforced cement (GRC) which, being a fine matrix reinforced with fine glass fibre can penetrate a fibre mat thus providing a homogeneous fibre reinforced matrix at the interface of the mat and the cement.
The GRC may be initially formed in a flat, dewatered state in which the GRC, although in one piece, is pliable and can be laid on the fibrous mat of the preformed sheet to take up the shape thereof.
Alternatively the GRC may be sprayed on to the fibrous mat of the preformed sheet.
To protect an E-glass fibre mat from alkali attack by the cement a resin is applied to the mat before the GRC. The resin is preferably a water tolerant epoxy resin and penetrates into the body of the glass fibre mat. The ability of the resin to bond satisfactorily to the cement mix prevents deterioration of the interfacial bond which would otherwise result from degradation of the glass fibre at the interface and also in fact provides an improved interfacial bond.
In a modification a further glass fibre mat may be provided on the first-mentioned glass fibre mat. The additional mat may incorporate glass fibres which protrude from the surface thereof and provide an additional key for the glass reinforced cement.
In a further modification a further fibre mat may be provided on that face of the cementitious material remote from the face to which is applied the plastics sheet with the first mentioned fibre mat. When the structure so formed is used, the further fibre mat provides protection against chemical attack from the other side of the lining.
The structure may be made to a size and shape to suit its particular use. When used as a new lining for an existing sewer the size and shape is made to suit the internal dimensions and profile of the sewer such that two or more of the structures form a complete ring. However it may be unnecessary to provide a full ring and the structures may then be manufactured and fixed so that they extend over the upper or lower part of the sewer only.
It will be appreciated that when the structures are formed as lining panels it is necessary to seal the joints between adjacent panels so as to prevent the ingress of sewage or chemicals which would then attack the cement behind the plastics coating. Sealing of the joints is preferably carried out by using cover strips of the plastics material to bridge the joints. The cover strips may be either heat welded or bonded to the panels using a compatible adhesive. The choice of joint sealing is determined by the materials used in the lining.
When installed, the panels create in the existing sewer an annulus between themselves and the original wall of the sewer. This annulus is filled with a cement and sand grout thus providing a new smooth pipe securely and rigidly fixed within the original.
It is to be appreciated that the use of the structures in sewers is only one example and the structures may be used for chimney linings, tank and container wall and partition cladding, laboratory fittings, bathroom fittings such as baths and basins, and pipes or any other product desiring a lightweight cementitious structure wherein the glass reinforced cement provides strength, stiffness and structural ability and the plastics coating provides protection against chemical attack.
Various modifications may be made without departing from the invention. For example the mat arrangement may comprise a mat incorporating other fibres of organic or inorganic form, for example, carbon fibres or steel fibres, polypropylene fibres or nylon fibres.
WHAT WE CLAIM IS: 1. A method of producing a cementitious structure comprising preforming a plastics material into a sheet of desired shape having a fibrous mat arrangement on one surface thereof, forming a fibre reinforced cementitious material into a pliable dewatered condition, and applying the cementitious material to the fibrous mat arrangement of the preformed sheet.
2. A method according to claim 1, wherein the cementitious material is glass reinforced cement.
3. A method according to claim 1 or 2 wherein the fibrous mat arrangement incorporates alkali resistant glass fibres.
4. A method according to claim 1 or 2, wherein the fibrous mat arrangement incorporates E-glass fibres and a resin is applied to the fibrous mat arrangement of the preformed sheet before the cementitious material.
5. A method according to claim 4, wherein the resin is a water tolerant epoxy resin.
6. A method according to any of the preceding claims, wherein a further fibrous mat is applied to the fibrous mat arrangement, said further mat having fibres protruding from its free face.
7. A method according to any of the preceding claims, wherein an additional fibrous mat is applied to the surface of the plastics material opposite to said one surface.
8. A method of forming a sewer lining comprising erecting a plurality of cementitious structures, formed by the method according to any of the preceding claims in edge-to-edge relation, and sealing joints between adjacent structures by means of cover strips of the plastics material applied across the joints.
9. A method according to claim 8, wherein the cover strips are applied by heat welding.
10. A method according to claim 8, wherein the cover strips are applied by adhesive.
11. A method according to any of claims 8 to 10, wherein, in an existing sewer, a cavity is created between the lining and the original wall, and a cementitious material is introduced into said cavity.
12. A cementitious structure comprising a plastics material preformed into a sheet of a desired shape and having a fibrous mat arrangement on one surface thereof, and a fibre reinforced cementitious material affixed to the fibrous mat arrangement of the preformed sheet.
13. A structure according to claim 12, wherein the cementitious material is glass reinforced cement.
14. A structure according to claim 12 or 13, wherein the plastics material is PVC, high density polyethylene or polyethylene.
15. A structure according to any of claims 12 to 14, wherein the fibrous mat arrangement incorporates alkali resistant glass fibres.
16. A structure according to any of claims 12 to 14, wherein the fibrous mat arrangement incorporates E-glass fibres with a resin applied thereto.
17. A structure according to claim 16, wherein the resin is a water tolerant epoxy resin.
18. A structure according to any of claims 12 to 17, wherein a further fibrous mat is provided on the fibrous mat arrangement, said further mat having fibres protruding from its free face.
19. A structure according to any of claims 12 to 18, wherein an additional fibrous mat is provided on the surface of the plastics material opposite to said one surface.
20. A cementitious structure formed by the method according to any of claims 1 to 7.
21. A sewer lining formed by the method according to any of claims 8 to 11.
22. A method of forming a cementitious structure according to claim 1 and substantially as hereinbefore described.
23. A method of forming a sewer lining according to claim 8 and substantially as hereinbefore described.
24. A cementitious structure according to claim 12 and substantially as hereinbefore described.
2-5. A sewer lining according to claim 21 and substantially as hereinbefore described.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (24)

**WARNING** start of CLMS field may overlap end of DESC **. Various modifications may be made without departing from the invention. For example the mat arrangement may comprise a mat incorporating other fibres of organic or inorganic form, for example, carbon fibres or steel fibres, polypropylene fibres or nylon fibres. WHAT WE CLAIM IS:
1. A method of producing a cementitious structure comprising preforming a plastics material into a sheet of desired shape having a fibrous mat arrangement on one surface thereof, forming a fibre reinforced cementitious material into a pliable dewatered condition, and applying the cementitious material to the fibrous mat arrangement of the preformed sheet.
2. A method according to claim 1, wherein the cementitious material is glass reinforced cement.
3. A method according to claim 1 or 2 wherein the fibrous mat arrangement incorporates alkali resistant glass fibres.
4. A method according to claim 1 or 2, wherein the fibrous mat arrangement incorporates E-glass fibres and a resin is applied to the fibrous mat arrangement of the preformed sheet before the cementitious material.
5. A method according to claim 4, wherein the resin is a water tolerant epoxy resin.
6. A method according to any of the preceding claims, wherein a further fibrous mat is applied to the fibrous mat arrangement, said further mat having fibres protruding from its free face.
7. A method according to any of the preceding claims, wherein an additional fibrous mat is applied to the surface of the plastics material opposite to said one surface.
8. A method of forming a sewer lining comprising erecting a plurality of cementitious structures, formed by the method according to any of the preceding claims in edge-to-edge relation, and sealing joints between adjacent structures by means of cover strips of the plastics material applied across the joints.
9. A method according to claim 8, wherein the cover strips are applied by heat welding.
10. A method according to claim 8, wherein the cover strips are applied by adhesive.
11. A method according to any of claims 8 to 10, wherein, in an existing sewer, a cavity is created between the lining and the original wall, and a cementitious material is introduced into said cavity.
12. A cementitious structure comprising a plastics material preformed into a sheet of a desired shape and having a fibrous mat arrangement on one surface thereof, and a fibre reinforced cementitious material affixed to the fibrous mat arrangement of the preformed sheet.
13. A structure according to claim 12, wherein the cementitious material is glass reinforced cement.
14. A structure according to claim 12 or 13, wherein the plastics material is PVC, high density polyethylene or polyethylene.
15. A structure according to any of claims 12 to 14, wherein the fibrous mat arrangement incorporates alkali resistant glass fibres.
16. A structure according to any of claims 12 to 14, wherein the fibrous mat arrangement incorporates E-glass fibres with a resin applied thereto.
17. A structure according to claim 16, wherein the resin is a water tolerant epoxy resin.
18. A structure according to any of claims 12 to 17, wherein a further fibrous mat is provided on the fibrous mat arrangement, said further mat having fibres protruding from its free face.
19. A structure according to any of claims 12 to 18, wherein an additional fibrous mat is provided on the surface of the plastics material opposite to said one surface.
20. A cementitious structure formed by the method according to any of claims 1 to 7.
21. A sewer lining formed by the method according to any of claims 8 to 11.
22. A method of forming a cementitious structure according to claim 1 and substantially as hereinbefore described.
23. A method of forming a sewer lining according to claim 8 and substantially as hereinbefore described.
24. A cementitious structure according to claim 12 and substantially as hereinbefore described.
2-5. A sewer lining according to claim 21 and substantially as hereinbefore described.
GB22435/77A 1977-05-27 1977-05-27 Fibre reinforced cementitious layers on plastics substrates Expired GB1602602A (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
GB22435/77A GB1602602A (en) 1977-05-27 1977-05-27 Fibre reinforced cementitious layers on plastics substrates
DE19782822601 DE2822601A1 (en) 1977-05-27 1978-05-24 CEMENT-BASED COMPONENT AND PROCESS FOR ITS MANUFACTURING
FR7816668A FR2391848A1 (en) 1977-05-27 1978-05-25 Cement construction such as a drain pipe - formed from shaped plastics sheet coated with fibre reinforced cement mixt.
BE188078A BE867533A (en) 1977-05-27 1978-05-26 CEMENT COMPOSITIONS WITH PROTECTIVE COATINGS
AU36511/78A AU3651178A (en) 1977-05-27 1978-05-26 Cementitious structures
JP6240378A JPS5433523A (en) 1977-05-27 1978-05-26 Cementtbased structure and method of making same
ES470260A ES470260A1 (en) 1977-05-27 1978-05-27 Cementtbased structure and method of making same
IT23927/78A IT1094861B (en) 1977-05-27 1978-05-29 CEMENTITIOUS STRUCTURES AND METHODS TO PRODUCE THEM
NL7805817A NL7805817A (en) 1977-05-27 1978-05-29 CEMENT PRODUCTS AND PROCESS FOR MANUFACTURE OF SUCH PRODUCT.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB22435/77A GB1602602A (en) 1977-05-27 1977-05-27 Fibre reinforced cementitious layers on plastics substrates

Publications (1)

Publication Number Publication Date
GB1602602A true GB1602602A (en) 1981-11-11

Family

ID=10179327

Family Applications (1)

Application Number Title Priority Date Filing Date
GB22435/77A Expired GB1602602A (en) 1977-05-27 1977-05-27 Fibre reinforced cementitious layers on plastics substrates

Country Status (2)

Country Link
BE (1) BE867533A (en)
GB (1) GB1602602A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0659114A1 (en) * 1992-08-25 1995-06-28 BARISH, Benjamin J. Flexible protective membrane particularly useful for waterproofing and protecting reinforced concrete bodies and metal pipes
US5543188A (en) * 1992-08-25 1996-08-06 Te'eni; Moshe Flexible protective membrane particularly useful for waterproofing and protecting reinforced concrete bodies and metal pipes
GB2302153A (en) * 1995-06-12 1997-01-08 Wrc Plc Lining a pipeline and liner therefor

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0659114A1 (en) * 1992-08-25 1995-06-28 BARISH, Benjamin J. Flexible protective membrane particularly useful for waterproofing and protecting reinforced concrete bodies and metal pipes
EP0659114A4 (en) * 1992-08-25 1995-09-27 Barish Benjamin J Flexible protective membrane particularly useful for waterproofing and protecting reinforced concrete bodies and metal pipes.
US5543188A (en) * 1992-08-25 1996-08-06 Te'eni; Moshe Flexible protective membrane particularly useful for waterproofing and protecting reinforced concrete bodies and metal pipes
GB2302153A (en) * 1995-06-12 1997-01-08 Wrc Plc Lining a pipeline and liner therefor
GB2302153B (en) * 1995-06-12 1999-10-20 Wrc Plc Pipeline renovation
US5993114A (en) * 1995-06-12 1999-11-30 Wrc Plc Apparatus and method for pipeline renovation

Also Published As

Publication number Publication date
BE867533A (en) 1978-11-27

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PCNP Patent ceased through non-payment of renewal fee