Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/10—Coating or impregnating
  • C04B20/1003—Non-compositional aspects of the coating or impregnation
  • C04B20/1014—Coating or impregnating materials characterised by the shape, e.g. fibrous materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
  • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
  • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
  • B05D3/065—After-treatment
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/38—Fibrous materials; Whiskers
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B18/02—Agglomerated materials, e.g. artificial aggregates
  • C04B18/022—Agglomerated materials, e.g. artificial aggregates agglomerated by an organic binder
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/0048—Fibrous materials
  • C04B20/0068—Composite fibres, e.g. fibres with a core and sheath of different material
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
  • C04B20/10—Coating or impregnating
  • C04B20/1018—Coating or impregnating with organic materials
  • C04B20/1029—Macromolecular compounds
  • C04B20/1037—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds

Definitions

• general inventive concepts relate to composite fibers for the reinforcement of concrete, a process of manufacturing and a way of reinforcing concrete and other building materials using such fibers.
• Fibers can introduce toughness (i.e., energy absorption capacity during failure) to concrete, overcoming its intrinsic brittleness and providing post-cracking strength under direct or indirect tensile stresses.
• the vast majority of conventional fibers used for reinforcing concrete reinforcement are made out of low or high carbon content steel, or polymers such as polypropylene, polyvinyl alcohol, polyester, etc. These conventional fibers suffer from limitations. Processability issues can be generated by the relatively high dosages required (such as clustering during mixing, blockings during pumping, reduction of workability, and difficult compaction and finishing).
• Composite reinforcing materials can overcome the shortcomings of conventional fibers; i.e., by achieving a very high performance at relatively low dosages.
• JP2002154853A1 describes composite fibers produced by impregnating a continuous inorganic fiber bundle with a resin, hardening the resulting material and thereafter cutting the hardened material.
• the resin content of this composite fiber is 10 to 80 mass %. Its length is 10 to 80 mm and its cross section is 0.1 to 12 mm.
• WO2006059041 A1 discloses composite fibers or composite tapes based on co-melted glass fibers and polypropylene fibers, such as the composite products sold under the Twintex® brand (available from Owens Corning) and manufactured by thermoplastic pultrusion.
• JP2002154853A1 describes line speeds of only 5 meters/minute.
• U.S. Pat. No. 4,861,621 discloses a pultrusion process which cures materials by ultraviolet radiation for optic cable applications. Specifically, a reinforcing filamentary material, in the form of a glass roving, is impregnated with a curable coating material and then passed underneath a unit for UV radiation. The pultrusion speed is 10 meters/minute (Example 2).
• the general inventive concepts refer to composite fibers used in the reinforcement of concrete.
• the composite fibers comprise a plurality of fibers coated with a polymeric material.
• Required dosages of the composite fibers allow for better processability of concrete and provide high toughness or post-cracking strength up to large crack openings while involving low manufacturing costs.
• the composite fibers are characterized in that the length of the composite fiber is from 10 to 80 mm and the equivalent diameter of the composite fiber is from 0.3 to 2 mm.
• the polymeric coating is a radiation (e.g., UV) cured polymeric coating.
• the polymeric coating is from 5 to 50 wt % of the composite fiber.
• the general inventive concepts further relate to methods of manufacturing a composite fiber.
• the method includes preparing a liquid polymeric coating composition; applying the liquid polymeric coating composition to the surface of a plurality of fibers to form a coated surface; and exposing the coated surface to radiation and curing the liquid coating composition to form a composite fiber.
• the general inventive concepts further relate to methods of forming reinforced concrete.
• the method includes the steps of preparing a concrete and mixing one or more composite fibers of the invention in that concrete, forming reinforced concrete.
• the dosage of composite fibers in the applied concrete is from 2 to 75 kg of fibers per cubic meter of wet concrete.
• the dosage of composite fibers in the applied concrete is from 5 to 25 kg of fibers per cubic meter of wet concrete.
• the dosage of composite fibers in the applied concrete is from 7.5 to 12.5 kg of fibers per cubic meter of wet concrete.
• fiber means a collection of one or more monofilaments.
• polymeric coatings means a mixture of monomers and/or oligomers that are hardened by one of the curing methods described or otherwise suggested herein. herebelow.
• impregnated means partially or fully impregnated.
• radiation cured means that the monomers have been polymerized with the help of radiation preferably in presence of a suitable catalyst.
• UV cured means polymerization of the monomers in presence of UV radiation.
• polymer includes the term “copolymer,” and, unless otherwise indicated, the term “copolymer” refers to polymers made from any two or more different monomers, including, for example, terpolymers, pentapolymers, homopolymers functionalized after polymerization so that two or more different functional groups are present in the product copolymer, block copolymers, segmented copolymers, graft copolymers, and any mixture or combination thereof.
• (co)polymer means homopolymer or copolymer.
• composite fiber means a collection of one or more fibers coated with a polymeric material.
• equivalent diameter means diameter as defined in EN14889 Standard.
• spect ratio means a length-to-diameter ratio as defined in EN14889 Standard.
• crete means any type of building material containing aggregates embedded in matrix (the cement or binder) that fills the space among the aggregate particles and glues them together e.g. Portland Cement based concrete, mineral mortar but also asphalt.
• composite fibers are provided for the reinforcement of concrete.
• the length of the composite fibers may be from about 10 to about 80 mm.
• the equivalent diameter of the composite fibers may be from about 0.3 to about 2 mm.
• the length of the composite fibers is from about 30 to about 50 mm and the equivalent diameter of the composite fibers is from about 0.5 to about 1.0 mm.
• the shape of the composite fiber may vary.
• the composite fibers are generally cylindrical or ellipsoidal.
• the surface of the composite fibers may vary, such as from smooth to rough or embossed.
• the fiber is an inorganic fiber, such as a glass or other mineral fiber.
• Non-exclusive exemplary glass fibers include A-type glass fibers, C-type glass fibers, G-type glass fibers, E-type glass fibers, S-type glass fibers, E-CR-type glass fibers (e.g., Advantex® glass fibers commercially available from Owens Corning), R-type glass fibers, biosoluble glass fibers, alkali-resistant glass, or combinations thereof, all of which may be suitable for use as the reinforcing fiber.
• an alkali-resistant glass fiber such as Cemfil® available from Owens Corning, is suitable for use as the reinforcing fiber.
• the diameter of the monofilaments forming the fiber may vary from about 10 to about 27 microns, or from about 13 to about 20 microns.
• the tex of the fibers may be from 300 to 2400 tex. In some exemplary embodiments, the tex is in the range of 400 to 1200 tex.
• the polymeric coating may be a radiation cured polymeric coating, such as, for example, a UV cured polymeric coating.
• a radiation cured polymeric coating such as, for example, a UV cured polymeric coating.
• UV curable monomers, oligomers or polymers include acrylates, methacrylates, vinylethers and vinyl derivatives based on polyurethane, epoxy, polyester, polyether structures with or without aliphatic or aromatic backbones, and copolymers based on such structures.
• the polymeric coating includes polyurethanes based on aromatic structure, alone or in a mixture with epoxy or polyether derivative.
• the polymeric coating is a polyurethane resin.
• the polymeric coating may comprise about 5 to about 50 wt %, of the composite fiber. In some exemplary embodiments, the polymeric coating is from about 10 to about 30 wt % of the composite fiber.
• the exemplary composite fibers described herein may be manufactured using any suitable type of fiber, such as, for example, a glass fiber.
• a liquid, or otherwise viscous, monomeric or oligomeric coating composition may be prepared and applied to the surface of the fiber, forming a coated element.
• the polymeric coating comprises a polyester or vinylester.
• the coated element may then be exposed to radiation, such as UV radiation, which cures the coating composition to form a composite fiber.
• the composite fibers described herein may be used to reinforce concrete.
• the reinforced concrete may be formed by preparing a concrete (e.g., using a conventional method of forming concrete) followed by mixing the composite fibers into the concrete, thereby forming a composite fiber reinforced concrete.
• the dosage of composite fibers in the reinforced concrete is from about 2 to about 75 kg of fiber per cubic meter of concrete, or from about 5 to about 25 kg of fiber per cubic meter of concrete.
• the dosage of composite fibers in the reinforced concrete is from about 7.5 to about 12.5 kg of fiber per cubic meter of concrete.
• the general inventive concepts also encompass using the composite fibers for the reinforcement of concrete or other building materials.
• the composite fibers have a combination of particular dimensions that result in a surprisingly good performance in the reinforcement of concrete while showing a surprisingly good workability in the process of manufacturing concrete. This workability performance is evaluated through the Slump test, as defined in EN12350-2 Standard.
• composite fibers described herein include a high speed of dispersion during the mixing process, ease in achieving a uniform distribution of fibers in the concrete mass, reduced wearing of mixing and pumping systems, less risk of clogging pumping pipes and blockings when filling structural elements, and less risk of honeycombs and consequent durability issues when used in combination with conventional reinforcement.
• the composite fibers are also safe for handling by workers. Exemplary reasons for this safety include the low weight of the composite fiber and the nonexistence of any sharp pins.
• the composite fibers do not corrode and, hence, do not develop corrosion stains in case of exposed concrete surfaces. Additionally, the composite fibers make the hardened concrete easier to recycle, as compared to traditional steel fibers.
• the manufacturing process of the composite fibers leads to low or reduced manufacturing costs.
• the process is flexible and adaptable to fit in with other stages in a continuous production line. For instance, the line speed may be easily varied to accommodate overall production variations.
• the coating is immediately functional and able to be handled and requires no post-heating or drying. In that respect, the process allows for line speeds that can reach over 50 m/min, such as, for example, over 100 m/min.
• Composite fibers were prepared with Cemfil® glass fibers available from Owens Corning and polyester resin standard cured using UV radiation. Resin content was 20 wt % of the composite fiber.
• the consistency or workability of the fresh concrete was measured according to the EN 12350-2 Standard. This test is reflected in the tables below as the Slump measurement.
• the flexural performance of hardened concrete was measured according to the EN 14651 after 28 days of standard curing (i.e., 20° C. and 100% relative humidity).
• the concrete compressive strength measured according to the EN 12390-3 standard was 30 MPa.
• LOP refers to the limit of proportionality, which corresponds to the flexural tensile strength at the first crack produced.
• the residual flexural tensile strengths are reflected as f R1 and f R3 .
• Dosage of the fiber was 10 kg fiber per cubic meters of concrete. Length of the composite fiber was 40 mm. The manufacturing speed of the composite fibers was 200 meters/min. Table 1 shows the influence of the equivalent diameter and aspect ratio of the composite fiber on performance.
• Dosage of the fiber was 10 kg of fiber per cubic meters of concrete.
• the equivalent diameter of the composite fiber was 0.70 mm.
• the composite fiber manufacturing speed was 200 meters/min.
• Table 2 shows the influence of the length and aspect ratio of the composite fiber on performance.
• Dosage of the fiber was 10 kg of fibers per cubic meters of concrete.
• the length of the composite fiber was 40 mm and its equivalent diameter was 0.7 mm.
• the manufacturing speed of the composite fiber was 200 m/min.
• Table 3 shows the influence of the resin and aspect ratio of the composite fiber on performance.
• Length of the composite fiber was 40 mm and its equivalent diameter was 0.70 mm and its length was 40 mm. Line speed was 200 m/min. Table 4 shows the influence of different dosages on performance.
• Dosage of the fiber was 10 kg of fiber per cubic meter of concrete. Length of the composite fiber was 40 mm and its equivalent diameter was 0.70 mm. Table 5 shows the influence of different line speeds on performance.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Civil Engineering (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Composite Materials (AREA)
• Physics & Mathematics (AREA)
• Plasma & Fusion (AREA)
• Reinforced Plastic Materials (AREA)
• Health & Medical Sciences (AREA)
• Toxicology (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Electromagnetism (AREA)
• Chemical Or Physical Treatment Of Fibers (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Priority Applications (1)

Applications Claiming Priority (3)

Related Parent Applications (1)

Related Child Applications (1)

Publications (1)

Family

ID=51541351

Family Applications (2)

Family Applications After (1)

Country Status (10)

Cited By (8)

Families Citing this family (6)

Citations (1)

Family Cites Families (13)

• 2014
  • 2014-09-02 MX MX2016002805A patent/MX2016002805A/es unknown
  • 2014-09-02 JP JP2016540305A patent/JP6526009B2/ja active Active
  • 2014-09-02 CA CA2923001A patent/CA2923001A1/en not_active Abandoned
  • 2014-09-02 EP EP14766322.3A patent/EP3041807A1/en not_active Withdrawn
  • 2014-09-02 RU RU2016112169A patent/RU2016112169A/ru not_active Application Discontinuation
  • 2014-09-02 AU AU2014315442A patent/AU2014315442B2/en active Active
  • 2014-09-02 WO PCT/US2014/053655 patent/WO2015034805A1/en active Application Filing
  • 2014-09-02 CN CN201480056079.8A patent/CN105612135A/zh active Pending
  • 2014-09-02 US US14/916,231 patent/US20160194246A1/en not_active Abandoned
• 2016
  • 2016-03-14 ZA ZA2016/01742A patent/ZA201601742B/en unknown
• 2017
  • 2017-05-23 US US15/602,522 patent/US10017419B2/en active Active

Patent Citations (1)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events