GB2464316A - Method of reinforcing concrete structures - Google Patents
Method of reinforcing concrete structures Download PDFInfo
- Publication number
- GB2464316A GB2464316A GB0818652A GB0818652A GB2464316A GB 2464316 A GB2464316 A GB 2464316A GB 0818652 A GB0818652 A GB 0818652A GB 0818652 A GB0818652 A GB 0818652A GB 2464316 A GB2464316 A GB 2464316A
- Authority
- GB
- United Kingdom
- Prior art keywords
- concrete
- metal layer
- reinforcing metal
- perimeter
- layer
- 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.)
- Withdrawn
Links
- 238000000034 method Methods 0.000 title claims abstract description 35
- 230000003014 reinforcing effect Effects 0.000 title claims abstract description 31
- 229910052751 metal Inorganic materials 0.000 claims abstract description 49
- 239000002184 metal Substances 0.000 claims abstract description 49
- 239000002987 primer (paints) Substances 0.000 claims abstract description 14
- 239000004033 plastic Substances 0.000 claims abstract description 13
- 229920003023 plastic Polymers 0.000 claims abstract description 13
- 239000007788 liquid Substances 0.000 claims abstract description 4
- 239000002861 polymer material Substances 0.000 claims description 8
- 229920002635 polyurethane Polymers 0.000 claims description 8
- 239000004814 polyurethane Substances 0.000 claims description 8
- 239000007767 bonding agent Substances 0.000 claims description 7
- 150000001875 compounds Chemical class 0.000 claims description 6
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 229920000642 polymer Polymers 0.000 claims description 3
- 239000000428 dust Substances 0.000 claims description 2
- 239000011440 grout Substances 0.000 claims description 2
- 239000004576 sand Substances 0.000 claims description 2
- 239000000565 sealant Substances 0.000 claims description 2
- 229920006334 epoxy coating Polymers 0.000 claims 2
- 239000004593 Epoxy Substances 0.000 claims 1
- 239000002245 particle Substances 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 7
- 230000002787 reinforcement Effects 0.000 description 11
- 238000002347 injection Methods 0.000 description 7
- 239000007924 injection Substances 0.000 description 7
- 239000011162 core material Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 229920005862 polyol Polymers 0.000 description 2
- 150000003077 polyols Chemical class 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000013615 primer Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G23/00—Working measures on existing buildings
- E04G23/02—Repairing, e.g. filling cracks; Restoring; Altering; Enlarging
- E04G23/0218—Increasing or restoring the load-bearing capacity of building construction elements
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Mechanical Engineering (AREA)
- Bridges Or Land Bridges (AREA)
Abstract
The invention relates to a method of reinforcing a concrete structure 1 comprising the steps of; applying a primer coating to the surface of the concrete structure, providing a reinforcing metal layer 8 that is spaced apart from the concrete structure so as to form a cavity, and injecting a liquid plastics material into the cavity where it is allowed to cool to form an intermediate layer (10 figure 5). A plurality of perimeter bars 2 are preferably secured to the structure around the circumference of the area to be reinforced. The reinforcing metal layer is preferably welded to the plurality of bars so as to form a cavity between the surface of the concrete structure and the reinforcing metal layer. The perimeter bars are preferably metallic and secured to the structure by means of anchors 3. A later embodiment relates to a structural sandwich.
Description
METHOD OF REINFORCING CONCRETE STRUCTURES
The present invention relates to a method of reinforcing andlor reinstating andlor rehabilitating an existing concrete structure, particularly large scale existing structures. More particularly, the method relates to reinforcing andlor reinstating concrete structures which have been weakened over time or require additional load bearing capacity.
Over time concrete becomes weaker and may require further reinforcements.
Alternatively, a concrete structure may require reinforcements because it is to be used under greater load. Present methods of reinforcing concrete structures involve reinforcement from below which is cumbersome or the application of a secondary layer of concrete. Although the application of a secondary layer of concrete may reinforce the structure the concrete will ultimately again become weaker over time.
Furthermore applying an additional layer of concrete is very heavy and the additional weight may cause problems.
The present invention provides a method of reinforcing an existing concrete structure comprising the steps of: applying a primer coating to a surface of said concrete structure to be reinforced; providing a reinforcing metal layer spaced apart from said concrete surface to form at least one cavity between the surface of said concrete structure and said reinforcing metal layer; injecting liquid plastics or polymer material into the cavity; arid causing or allowing the plastics or polymer material to cure to form an intermediate layer.
The structure resulting from use of the present invention is similar to those described in US Patent 5,778,813, British Patent GB 2 337 022 and British Patent GB 2 355 957. Similarly, the plastics or polymer core may be any suitable material, * -2-for example an elastomer such as polyurethane, as described in US-5,778,813 and US-6,050,208 and is preferably compact, i.e. not a foam. The core is preferably a thermosetting material rather than thermoplastic. The materials and techniques disclosed in those documents can be made use of in practice of the present invention and structures constructed according to the present invention can enjoy the benefits and advantages described therein.
The invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 a depicts a cross section of a structure undergoing reinforcement according to the invention; Figure lb depicts a plan view of a structure undergoing reinforcement according to the invention; Figure 2 depicts a cross section of the structure at a further stage of reinforcement according to the invention; Figure 3 depicts a cross section of the structure at a further stage of reinforcement according to the invention; Figure 4 depicts a cross section of the structure at a further stage of reinforcement according to the invention; Figure 5 depicts a cross section of the structure at a further stage of reinforcement according to the invention; Figure 6 depicts a cross section according to a further embodiment of the invention; Figure 7 depicts a cross section according to a further embodiment of the invention; and Figure 8 depicts a cross section according to a further embodiment of the invention.
In the Figures, like parts are identified with like numerals.
Figure 1 depicts a cross sectional view of a concrete structure or member 1.
As can be seen, a recess has been drilled into the concrete structure into which an anchor 3 is inserted. For optimal bonding between the anchor and the concrete structure grout 4 may be used to line the walls of the recess. The anchor is preferably made of concrete which ensures that it has similar or identical properties and characteristics to the surrounding concrete. The anchor is inserted through a perimeter bar 2 and into the recess where it serves to firmly attach the perimeter bar to the concrete structure. A metal sheet will later be placed over the perimeter bar so the anchor 3 is preferably countersunk into the perimeter bar such that the metal sheet can lie flat on the surface of the perimeter bar and a smooth seal generated. To avoid moisture entering the arrangement a sealant 5 may be inserted into the countersink recess.
A plurality of perimeter bars are arranged around the area of concrete for reinforcement as shown in Figure lb. The perimeter bars are formed of metal and preferably the same metal as the metal plates used later. The perimeter bars form a closed shape which will form part of the cavity into which the plastics or polymer intermediate layer will be injected. Each perimeter bar is preferably secured with at least two anchors. If the area to be reinforced is large additional metal supporting members may be placed within the cavity to provide additional support. Depending on the area to be reinforced the supporting members may divide the area into a plurality of cavities, each cavity being separated from the neighbouring cavity by a support member. For example if a 1200m2 area is to be reinforced approximately 50 cavities will be needed.
The concrete surface is then cleaned of any unwanted grease or dirt. This may involve blasting the area with, for example, steel shot, sand or grit. A vacuum is then applied to the area to remove any dust to ensure that the intermediate layer is effectively bonded to the concrete. Alternatively any other methods of cleaning may be used.
To further ensure effective bonding between the concrete and the intermediate layer a primer is applied to the concrete surface as shown in Figure 2. The primer is preferably a composition comprising a poiyoi component and a component comprising a compound comprising an isocyanate function group. The polyoi component comprises a mixture of polyols and additives and the component comprising a compound comprising an isocyanate function group preferably comprises a preparation containing diphenylmethane-diicoyanate. Conveniently Elastogran's Elastocoat C6421/l00 may be used. The primer is used to seal the concrete to ensure that any moisture within the concrete does not reach the intermediate layer. Alternatively, if the concrete layer is sufficiently moisture free the primer need not be used. However, to ensure sufficient bond strength the concrete would need to be totally moisture free. A test portion of intermediate layer could be applied directly to the concrete and the bond strength tested to see if it is necessary to apply a primer.
A bonding agent is then applied to the surface, as shown in Figure 3. The bonding agent is preferably a composition comprising a polyoi component and a component comprising a compound comprising an isocyanate function group. The polyol component comprises a mixture of polyois, fillers, catalysts and surfactants and the component comprising a compound comprising an isocyanate function group preferably comprises a preparation containing diphenylmethane-diicoyanate.
Conveniently Elastogran's Elastocoat C6610.-CN may be used as a bonding agent.
For the primer, bonding agent and plastics and (polyurethane) intermediate layer to bond to the concrete the concrete should have a moisture level of below 4%.
The metal plates 8 are then placed over the perimeter bars and supporting members to form one or more closed cavities as shown in Figure 4. Conveniently the metal plates may be steel, stainless steel, an aluminium alloy or any other typical metal associated with standard construction practice. The metal plates are then welded to both the perimeter bars and the supporting members. The perimeter bars and the metal plates are preferably made of the same material such that when they are welded at their perimeter a strong bond is formed.
Figure 5 depicts the formation of an intermediate layer 10. The intermediate layer comprises a plastics or polymer material (preferably a thermoset, compact elastomer such as polyurethane as discussed above) which is bonded to the reinforcing metal sheet 8 and the primed and bonded concrete with sufficient strength and has sufficient mechanical properties to transfer shear forces expected in use. The bond strength between the intermediate layer and concrete surface and reinforcing metal layer is usually 2MPa and the modulus of elasticity of the core material should be greater than 200MIPa, preferably greater than 25OMIPa. For low load applications, where the typical use and occupancy loads are of the order of 1.4kPa to 7.2kPa, the bond strength may be lower, e.g. approximately 1.OMPa, but sufficient to provide the required resistance, based on safety indices associated with construction for all anticipated loads, including use and occupancy loads, construction loads and wind, earthquake (if appropriate) and temperature loads. By virtue of the intermediate layer 10, the structure has a strength and load bearing capacity of a stiffened steel plate having a substantially greater plate thickness and significant additional stiffening.
The unfoamed intermediate layer 10 acts to transfer shear forces between the outer reinforcing metal plate and the concrete.
The uncured plastics or polymer material is injected through and injection port and then allowed or caused to set. If there is more than one cavity each cavity has its own injection port and each is injected with sufficient polyurethane to completely fill the cavity. The injection ports may be located in the metal plate and located to minimize or eliminate splash. The injection ports may include one way valves that can be ground off after use. After use the injection ports may be sealed with plugs. The polyurethane or intermediate layer may include additives e.g. to alter the mechanical properties or other characteristics (e.g. adhesion) and fire retardants may also be included.
Figures 6 to 8 depict further embodiments of the invention although not all * -6-the features previously discussed are explicitly depicted.
To improve the bonding strength of the intermediate layer to the concrete various measures, shown in Figures 6 to 8 may be taken. Figure 6 depicts a shaped perimeter bar 21. The bond strength between the intermediate layer and metal (such as the perimeter bar) is stronger than the bond strength between the intermediate layer and concrete and the contraction stresses in the intermediate layer are greatest at the edge near the perimeter bar. Thus, by providing a shaped perimeter bar which allows the intermediate layer to bond to metal rather than concrete the strength of the bond at the weakest point can be increased. Although Figures 6 to 8 depict a perimeter bar having a U-shaped cross-section with the arms of the U arranged along the concrete and reinforcing metal plate it is not limited to this configuration and may take any form which increases the area over which the intermediate layer is bonded to metal rather than concrete.
In Figure 7 the metal reinforcing layer 81 additionally comprises metal studs 82. These operate to increase the bonding area between the metal layer and the intermediate layer. Metal studs 83 have also been attached to the concrete layer. As discussed above, the bond strength between metal and the intermediate layer is greater than the bond strength between concrete and the intermediate layer and thus the use of these metal studs serves to increase the bond strength between the concrete and the intermediate layer. The shape of the studs 82, 83 is not limited to the rectangular cross section shown but may be any shape which increase the total area of the bond between the intermediate layer and either the reinforcing layer or the concrete. By using these studs the total strength of the joints between the different materials is strengthened.
Figure 8 depicts an embodiment of the invention which incorporates a metal mesh 15. This is included within the structure before the injection of the intermediate layer. This reinforces the structure, especially in low temperatures when the intermediate layer may be susceptible to contraction.
In an embodiment of the invention, parts of the material of the intermediate layer may be replaced by relatively lightweight forms, that is having a lower density than the plastics or polymer material of the rest of the core, in order to reduce the overall weight. The forms may be hollow or solid, e.g. of foam, and any of various types as disclosed in WO 2001.32414, WO 2002/078948, WO 2003/101728, WO 2004/082928 and WO 2005/05 1645, which documents are hereby incorporated by reference.
It should be noted that after the intermediate layer has cured, the reinforcing metal layer and perimeter bars are bound together by the intermediate layer so that in some cases the fixing of the perimeter bars to the reinforcing metal plates need only be sufficient to withstand loads encountered during the injection and curing steps, and not necessarily loads encountered during use of the structure.
Once the concrete has been fully reinforced it may have a load bearing capacity of in excess of 70 kg/rn. Thus this method of reinforcement may be used to strengthen concrete car parks, bridges or any other concrete structure.
It will be appreciated that the above description is not intended to be limiting and that other modifications and variations fall within the scope of the present invention, which is defined by the appended claims.
Claims (15)
- CLAIMS1. A method of reinforcing an existing concrete structure comprising the steps of: applying primer coating to a surface of said concrete structure to be reinforced; providing a reinforcing metal layer spaced apart from said concrete surface to form at least one cavity between the surface of said concrete structure and said reinforcing metal layer; injecting liquid plastics or polymer material into the cavity; and causing or allowing the plastics or polymer material to cure to form an intermediate layer.
- 2. A method according to claim 1 wherein said primer comprises a polyurethane or epoxy based primer.
- 3. A method according to claim 1 further comprising securing a plurality of perimeter bars to said structure, said perimeter bars being arranged around the circumference of the area to be reinforced, said reinforcing metal layer being attached to said perimeter bars.
- 4. A method according to any one of the preceding claims wherein, prior to said step of applying an epoxy coating said concrete surface is blasted.
- 5. A method according to claim 4 wherein said concrete surface is blasted with steel shot or sand.
- 6. A method according to any one of the preceding claims wherein, prior to said step of applying an epoxy coating, dust particles are removed from said concrete surface by suction. *
- 7. A method according to any one of the preceding claims wherein after said step of applying a primer and before said step of attaching a reinforcing metal layer a bonding agent is applied to said concrete surface.
- 8. A method according to any one of the preceding claims wherein said perimeter bars are made of metal.
- 9. A method according to any one of the claims 3 to 8 wherein at least one perimeter bar has a U shaped cross section, the arms of the U being arranged along the concrete structure and said reinforcing metal layer.
- 10. A method according to any one of claims 3 to 9 wherein said step of securing said perimeter bars comprises inserting an anchor bolt through said perimeter bar and into a recess in said concrete structure.
- ii. A method according to claim 10 wherein grout is arranged between the walls of said recess and said anchor bolt.
- 12. A method according to either claim 10 or claim 11 wherein said anchor bolt is countersunk into said perimeter bar.
- 13. A method according to any one of claims 10 to 12 wherein sealant is applied to the joint between said anchor bolt and said perimeter bar.
- 14. A method according to any one of the preceding claims wherein said reinforcing metal layer comprises a plurality of metal studs arranged to protrude towards said concrete structure.
- 15. A method according to any one of the preceding claims further comprising the step of providing metal studs protruding from the concrete layer. *16. A method according to any one of the preceding claims further comprising the step of providing a metal mesh arranged between said metal layer and said concrete surface, said liquid plastics or polymer material being injected into the mesh.17. A method according to any one of the preceding claims, wherein supporting members are arranged in said at least one cavity in contact with the inner surface of said reinforcing metal layer.18. A method according to any one of the preceding claims, wherein said reinforcing metal layer is between 4mm and 8mm thick.19. A method according to any one of the preceding claims, wherein said intermediate layer is between 15mm and 25mm thick.20. A method according to any one of the preceding claims wherein said primer comprises a composition comprising a poiyol component and a component comprising a compound having an isocyanate function group.21. A method according to claim 20 wherein said primer is Elastogram Elastocoat C6421/100.22. A method according to any one of claims 6 to 20 wherein said bonding agent comprises a composition comprising a poiyol component and a component comprising a compound having an isocyanate function group.23. A method according to claim 22 wherein said bonding agent is Elastogran Elastocoat C66 1 0-CN.24. A method according to any one of the preceding claims wherein said reinforcing metal layer is welded to said perimeter bars. *25. A method according to any one of the preceding claims wherein the cured intermediate plastics or polymer layer is unfoamed polyurethane.26. A structural sandwich panel comprising a concrete layer, a reinforcing metal plate spaced apart from said concrete layer and a core bonded to the outer metal plates and arranged to transfer shear forces therebetween, wherein the edge member comprises wherein said core comprises unfoamed polyurethane.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0818652A GB2464316A (en) | 2008-10-10 | 2008-10-10 | Method of reinforcing concrete structures |
PCT/GB2009/002066 WO2010040975A1 (en) | 2008-10-10 | 2009-08-24 | Method of reinforcing concrete structures |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0818652A GB2464316A (en) | 2008-10-10 | 2008-10-10 | Method of reinforcing concrete structures |
Publications (2)
Publication Number | Publication Date |
---|---|
GB0818652D0 GB0818652D0 (en) | 2008-11-19 |
GB2464316A true GB2464316A (en) | 2010-04-14 |
Family
ID=40083872
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB0818652A Withdrawn GB2464316A (en) | 2008-10-10 | 2008-10-10 | Method of reinforcing concrete structures |
Country Status (2)
Country | Link |
---|---|
GB (1) | GB2464316A (en) |
WO (1) | WO2010040975A1 (en) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2000204769A (en) * | 1999-01-07 | 2000-07-25 | Sekisui Chem Co Ltd | Reinforcing method for concrete |
WO2002036902A1 (en) * | 2000-10-30 | 2002-05-10 | Maintenance Professional Co., Ltd. | Composite panel for repairing, reinforcing con'c body and method of using the same |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1905405A (en) * | 1931-07-03 | 1933-04-25 | Edward J Winslow | Repair device for closing ruptures in concrete structures |
US1971331A (en) * | 1933-09-06 | 1934-08-28 | Grace F Marquis | Building reconstruction |
FR1501792A (en) * | 1966-08-22 | 1967-11-18 | Const Metalliques De La Correz | Device for reinforcing reinforced concrete slabs |
GB8719143D0 (en) * | 1987-08-13 | 1987-09-23 | Scott Bader Co | Pole repair system |
FR2718771B1 (en) * | 1994-04-14 | 1996-06-07 | Claude Gosselin | Method of consolidating concrete structures. |
FR2788568B1 (en) * | 1999-01-20 | 2001-03-02 | Somain | DEVICE AND METHOD FOR FIXING A PLANAR METAL ELEMENT ON A CONCRETE SUPPORT |
-
2008
- 2008-10-10 GB GB0818652A patent/GB2464316A/en not_active Withdrawn
-
2009
- 2009-08-24 WO PCT/GB2009/002066 patent/WO2010040975A1/en active Application Filing
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2000204769A (en) * | 1999-01-07 | 2000-07-25 | Sekisui Chem Co Ltd | Reinforcing method for concrete |
WO2002036902A1 (en) * | 2000-10-30 | 2002-05-10 | Maintenance Professional Co., Ltd. | Composite panel for repairing, reinforcing con'c body and method of using the same |
Also Published As
Publication number | Publication date |
---|---|
WO2010040975A1 (en) | 2010-04-15 |
GB0818652D0 (en) | 2008-11-19 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |