US20220259876A1

US20220259876A1 - Wall Reinforcement Systems

Info

Publication number: US20220259876A1
Application number: US17/670,950
Authority: US
Inventors: Doug Secrest
Original assignee: Cfs Materials LLC
Current assignee: Cfs Materials LLC
Priority date: 2021-02-15
Filing date: 2022-02-14
Publication date: 2022-08-18

Abstract

Wall reinforcement systems and methods of reinforcing wall structures are provided. The systems and method include at least one carbon fiber strap (CFS) adhered to a wall structure, in which the CFS may be wrapped around a support-lock element (SLE) and clamped to an overhead support member via a top bracket. The systems and methods may also include a support element located within an internal cavity of the wall structure, in which the support element extends from the bottom end of the wall structure upwardly towards the top end of the wall structure and may be surrounded at least partially by a filler material.

Description

CROSS REFERENCE TO PRIORITY CLAIM

This application claims priority to U.S. 63/149,439 filed Feb. 15, 2021, the entire contents of which are hereby incorporated by reference in its entirety.

TECHNICAL FIELD

Embodiments of the presently-disclosed invention relate generally to systems and methods for reinforcing structural elements, such as walls, including a top anchor system, a bottom anchor system, or both for anchoring a carbon fiber strap to a concrete, masonry, timber wall, or other structural member.

BACKGROUND

Walls and other structural elements are generally capable of supporting residential and light commercial structures for a reasonable period of time. However, such walls and structural elements can begin to crack, tilt, bow, or otherwise deform due to a variety of reasons For example, walls and structural elements may begin to deform and/or structurally decay due to inherent weaknesses attributable to particular structural and/or due to exposure to sustained and/or increased hydrostatic pressure from an outside environment. When the soil adjacent an exterior surface of the wall of a building, for example, becomes saturated with water, it forces the soil to expand and press against the wall (e.g., basement wall or foundation). Deformation, such as cracking, tilting, and bowing, if left untreated, can become progressively greater and eventually facilitate collapse of an entire structural element with resultant damage to the structure supported thereon.

SUMMARY OF INVENTION

Certain embodiments according to the invention provide a wall reinforcement system including a wall structure having a top end and a bottom end, and at least one carbon fiber strap (CFS) adhered to the wall structure between the top end and a bottom end. The CFS may have a first end, a second end, and an intermediate portion disposed between the first end and the second end. The wall reinforcement system may also include a top bracket fixedly secured to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion. The wall reinforcement system may also include a support-lock element (SLE) located above each of the top bracket and the top end of the wall. In accordance with certain embodiments of the invention, the intermediate portion of the CFS may be wrapped around the SLE, and overlapped upon itself to define a double-ply section of the CFS. In accordance with certain embodiments of the invention, at least a portion of the double-ply section is directly or indirectly clamped between the central body portion of the top bracket and the support member to define a clamped-double-ply portion of the CFS. In this regard, the present invention may also provide a kit including one or more CFSs, one or more top brackets, one or more SLEs, and optionally one or more adhesives and/or instructions for installation.
In another aspect, certain embodiments according to the invention provide a method of reinforcing a wall structure having a top end and a bottom end. The method of reinforcing a wall structure may include adhering a CFS, which may have a first end, a second end, and an intermediate portion disposed between the first end and the second end, to the wall structure between the top end and the bottom end. The method may also comprise securing a top bracket to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion, optionally a first bracket-end portion having a first aperture, and optionally a second bracket-end portion having a second aperture. The method may also include a step of providing a SLE located above each of the top bracket and the top end of the wall, as well as wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. The method may further include a step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to both securing a top bracket to a support member and wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to the step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS.
In another aspect, the certain embodiments of the invention provide a wall reinforcement system including a wall structure comprising a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, and a second row of concrete blocks located above and adjacent the first row of concrete blocks. The wall reinforcement system may also include a CFS adhered to the wall structure between a top end and the bottom end, in which the CFS has a first end, a second end, and an intermediate portion disposed between the first end and the second end. In accordance with certain embodiments of the invention, the wall reinforcement system may also include a support element located at an inside portion of the wall structure and extending through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks. The wall reinforcement system, in accordance with certain embodiments of the invention, may also include a filler material at least partially surrounding the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. In this regard, the present invention may also provide a kit including one or more CFSs, one or more support element, and optionally one or more adhesives and/or instructions for installation.
In another aspect, certain embodiments of the invention provide a method of reinforcing a wall structure having a top end and a bottom end, in which the method includes adhering a CFS, which has a first end, a second end, and an intermediate portion disposed between the first end and the second end, to the wall structure between the top end and the bottom end. In accordance with certain embodiments of the invention, the wall structure comprises a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, and a second row of concrete blocks located above and adjacent the first row of concrete blocks. The method may also include a step of forming a hole through an inside face of the wall structure and inserting a support element through the hole and positioning the support element within an inside portion of the wall structure. In accordance with certain embodiments of the invention, the support element may extend through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks. In accordance with certain embodiments of the invention, the method may also include a step of adding a filler material through the hole and at least partially surround the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material.
In yet another aspect, certain embodiments of the invention provide a wall reinforcement system including a top bracket, SLE, and support element. In accordance with certain embodiments of the invention, the wall reinforcement system may include a wall structure comprising a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, and a second row of concrete blocks located above and adjacent the first row of concrete blocks. The wall reinforcement system may also include a CFS adhered to the wall structure between the top end and a bottom end, in which the CFS may have a first end, a second end, and an intermediate portion disposed between the first end and the second end. The system may further include a top bracket fixedly secured to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion. The system may also include a SLE located above each of the top bracket and the top end of the wall. In accordance with certain embodiments of the invention, the intermediate portion of the CFS may be wrapped around the SLE, and overlapped upon itself to define a double-ply section of the CFS. In accordance with certain embodiments of the invention, at least a portion of the double-ply section is directly or indirectly clamped between the central body portion of the top bracket and the support member to define a clamped-double-ply portion of the CFS. The system may also include a support element located at an inside portion of the wall structure and extending through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks. A filler material, in accordance with certain embodiments of the invention, may also be included in the system. The filler material may at least partially surround the support element and at least partially fill the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. In this regard, the present invention may also provide a kit including one or more CFSs, one or more top brackets, one or more SLEs, one or more support elements, and optionally one or more adhesives and/or instructions for installation.
In yet another aspect, certain embodiments of the invention provide a method for of reinforcing a wall structure having a top end and a bottom end with a CFS, a top bracket and SLE both being located above the top end of the wall structure, and a support element located within an inside portion of the wall at or near the bottom end of the wall structure and extending upwardly towards the top end of the wall structure. In accordance with certain embodiments of the invention, the method may comprise forming a hole through an inside face of the wall structure and inserting a support element through the hole and positioning the support element within an inside portion of the wall structure. In accordance with certain embodiments of the invention, the support element may extend through an internal cavity defined at least in part by a first concrete block of a first row of concrete blocks defining a bottom end of the wall structure and a second concrete block of a second row of concrete blocks. In accordance with certain embodiments of the invention, the method may also include a step of adding a filler material through the hole and at least partially surround the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. The method may also comprise securing a top bracket to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion, a first bracket-end portion having a first aperture, and a second bracket-end portion having a second aperture. The method may also include a step of providing a SLE located above each of the top bracket and the top end of the wall, as well as wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. The method may further include a step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to both securing a top bracket to a support member and wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to the step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments of the invention the step of inserting the support element may be performed prior to the step of adhering the CFS to the wall structure between the top end and bottom end of the wall structure.

BRIEF DESCRIPTION OF THE DRAWING(S)

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout, and wherein:

FIG. 1 illustrates an example wall structure in accordance with certain embodiments of the invention;

FIG. 2 illustrates a top portion of a wall structure including a wall reinforcement system in accordance with certain embodiments of the invention;

FIG. 3A shows a CFS wrapped around a SLE and clamped to a support member via a top bracket in accordance with certain embodiments of the invention;

FIG. 3B shows a CFS wrapped around a SLE and loosely secured to a support member via a top bracket in accordance with certain embodiments of the invention;

FIG. 4A illustrates a schematic of a CFS wrapped around a SLE and back onto itself to form or define a double-ply section of the CFS in accordance with certain embodiments of the invention;

FIG. 4B illustrates a schematic of a CFS wrapped around a SLE and back onto itself to form or define a double-ply section of the CFS, in which a clamped-double-ply portion of the CFS is identified in accordance with certain embodiments of the invention;

FIG. 5 illustrates a bottom portion of a wall structure including a wall reinforcement system in accordance with certain embodiments of the invention;

FIG. 6 illustrates a cross-sectional view of a bottom portion of a wall structure including a wall reinforcement system in accordance with certain embodiments of the invention

FIG. 7 illustrates a wall structure including a wall reinforcement structure including a top bracket and a SLE located above the wall structure, and a support element positioned inside a portion of the bottom end of the wall structure in accordance with certain embodiments of the invention.

DETAILED DESCRIPTION

Embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
When an element or feature is referred to as being “on”, “adjacent”, “clamped”, or “coupled” to another element or feature, it may be directly on, engaged, clamped or coupled to the other element or layer, or indirectly in which intervening elements or features may be present. For example, when an element is referred to as being “directly clamped between” two other elements or features, there may be no intervening elements or features present. To the contrary, for example, when an element is referred to as being “indirectly clamped between” two other elements or features, there may be intervening elements or features present.
Embodiments of the present invention relate generally to wall reinforcement systems and methods of reinforcing wall structures. The systems and methods, in accordance with certain embodiments, may include at least one carbon fiber strap (CFS) adhered to a wall structure, in which the CFS may be wrapped around a support-lock element (SLE) and clamped to an overhead support member via a top bracket and/or a support element positioned within an interior portion of the wall structure at or near a bottom or lower end of the wall structure. For example, the support element may be located within an internal cavity of the wall structure, in which the support element extends from the bottom end of the wall structure upwardly towards the top end of the wall structure and may be surrounded at least partially by a filler material. FIG. 1, for instance, a wall structure 1 including a wall reinforcement system applied thereto. As shown in FIG. 1, the wall reinforcement system may include one or more CFSs 20 adhesively bonded to an inside face or surface of the wall structure. The one or more CFSs 20 may extend from a top end 3 of the wall structure 1 to a bottom end 5 of the wall structure 1. For example, the one or more CFSs may extend and cover at least about 75% to about 100% of the height of the wall as measured by the perpendicular distance from the top end 3 to the bottom end 5 of the wall structure 1. In accordance with certain embodiments of the invention, the wall reinforcement system may comprise a plurality of CFSs 20 adhered to the wall structure 1 in a spaced-apart and generally parallel orientation with respect to each other. For example, the plurality of CFSs 20 may comprise an average spacing between each CFS from about 1 to about 12 feet, such as at least about any of the following: 1, 2, 3, 4, and 5 feet, and/or at most about 12, 10, 8, 6, and 5 feet. The wall structure, by way of example only, may include a block wall (e.g., concrete block wall), brick wall, a poured concrete wall, a timber wall, a concrete pillar, beam, ceiling, floor, or other concrete structure.
Additionally or alternatively, the one or more CFSs may comprise a first end and a second end that define a length of the CFS along an x-y plane, a thickness defined by the shortest dimension of the CFS (e.g., the z-direction being perpendicular to the x-y plane), and a width defined as the shortest dimension in the x-y plance. In accordance with certain embodiments of the invention, the average width of the CFSs may comprise from about 2 inches to about 12 inches, such as at least about any of the following: 2, 4, 6, and 8 inches, and/or at most about any of the following: 12, 10, and 8 inches.
In accordance with certain embodiments of the invention, the one or more CFSs may comprise a unidirectional CFS or a bidirectional CFS. Additionally or alternatively, the one or more CFSs may have a basis weight from about 200 to about 600 grams-per-square meter (gsm), such as at least about any of the following: 200, 250, 300, 350, and 400 gsm, and/or at most about any of the following: 600, 550, 500, 450, and 400 gsm. Additionally or alternatively, the one or more CFSs may comprise a plurality of tows having on average from about 3000 filaments per tow to about 20,000 filaments per tow, such as at least about any of the following: 3,000, 5,000, 6,000, 8,000, 10,000, and 12,000 filaments per tow, and/or at most about any of the following: 20,000, 18,000, 16,000, 15,000, and 12,000 filaments per tow.
In accordance with certain embodiments of the invention, the one or more CFSs may be adhesively bonded to the inside surface of face of the wall structure. The particular adhesive is not necessarily limited in accordance with certain embodiments of the invention. In accordance with certain embodiments of the invention, the adhesive may comprise an epoxy-based adhesive, such as a single of multi-component epoxy. The adhesive may be disposed on portions of the inside face or surface of the wall structure where the one or more CFSs are located or intended to be located. The application pattern of the adhesive in not particularly limited (e.g., continuous or discontinuous segments of applied adhesive, or complete coverage of the location of interest). In accordance with certain embodiments of the invention, the one or more CFSs may be adhesively bonded to the wall structure and additional adhesive may be applied to the outer-facing surface of the one or more CFSs and pushed into and at least partially fill any void volume (e.g., porous cavities formed between the woven components of the CFS) to at least partially saturate the one or more CFSs with the adhesive.
With reference to FIG. 2, certain embodiments of the invention provide a wall reinforcement system including a wall structure 1 having a top end 3 and a bottom end 5 (shown in FIG. 1), and at least one CFS 20 adhered to the wall structure between the top end and a bottom end. The CFS 20 may have a first end 22, a second end 24 (shown in FIG. 1), and an intermediate portion 26 disposed between the first end and the second end. The wall reinforcement system may also include a top bracket 40 fixedly secured to a support member 50 located above the top end 3 of the wall structure 1, in which the top bracket includes a central body portion 42. The wall reinforcement system may also include a SLE 60 located above each of the top bracket 40 and the top end 3 of the wall structure 3. In accordance with certain embodiments of the invention, the intermediate portion 26 of the CFS may be wrapped around the SLE 60, and overlapped upon itself to define a double-ply section 70 of the CFS. In accordance with certain embodiments of the invention, at least a portion of the double-ply section 70 is directly or indirectly clamped between the central body portion 42 of the top bracket 40 and the support member 50 to define a clamped-double-ply portion 74 (best illustrated in FIG. 4B) of the CFS. In this regard, the present invention may also provide a kit including one or more CFSs, one or more top brackets, one or more SLEs, and optionally one or more adhesives and/or instructions for installation.
In accordance with certain embodiments of the invention, the top bracket 40 comprises a metal and further comprises a plurality of apertures. FIGS. 3A and 3B, for instance, show top bracket 40 including a central body portion 40, a first bracket-end portion 44 including a first aperture 45 and a second bracket-end portion 46 including a second aperture. 47. The top bracket 40 may be secured to the support member 50 by a first fastener 48 and a second fastener 49 as shown by the example of FIGS. 3A and 3B. In accordance with certain embodiments of the invention, and as shown in FIGS. 3A and 3B, the top bracket 40 may comprise a substantially planar plate. FIG. 3B also illustrates the relative positioning of the top bracket 40 and the SLE 60, in which the top bracket is loosely secured to the support member 50 while the SLE rests upon a top edge of the top bracket and against the support member. As also shown by FIG. 3B the intermediate portion 26 of the CFS 20 is wrapped around the SLE 60. In this regard, the first end 22 of the CFS 20 may be threaded upwardly through a passageway located between the top bracket 40 and the support member, wrapped around the SLE, and threaded downwardly back through the passageway located between the top bracket and the support member. In such embodiments, the first end 22 of the CFS may be pulled downwardly past the top bracket 40 and subsequently adhered to an adjacent portion of the CFS, which may be adhered to the inside facing or surface of the wall structure. In accordance with certain embodiments of the invention, the first end 22 and the second end 24 of the CFS 20 extend away from the SLE 60 in the same direction.
Although FIGS. 3A and 3B illustrate the SLE as a cylindrical rod, the overall cross-sectional shape of the SLE is not particularly limited and may include a circular cross-section, an elliptical cross-section, or polygonal cross-section. The SLE, in accordance with certain embodiments of the invention, may have a diameter from about 0.25 inches to about 1.5 inches, such as about any of the following: 0.25, 0.5, and 0.75 inches, and/or at most about 1.5, 1.25, 1, and 0.75 inches. The material of construction for the SLE may comprise, by way of example one, a metal, a polymer, a fiber-reinforced polymer, or carbon-fiber.
FIG. 4A, for instance, illustrates a schematic of a CFS 20 wrapped around a SLE 60 and back onto itself to form or define a double-ply section 70 of the CFS in accordance with certain embodiments of the invention. In a similar fashion, FIG. 4B illustrates a schematic of a CFS 20 wrapped around a SLE 60 and back onto itself to form or define a double-ply section 70 of the CFS, in which a clamped-double-ply portion 74 of the CFS is identified in accordance with certain embodiments of the invention. In this regard, FIGS. 4A and 4B illustrate the orientation of the CFS 20 in which an intermediate portion 26 is wrapped around the SLE while the CFS has two passes through a passageway between the top bracket 40 and the support member 50 to define a double-ply section 70, in which the portion of the double-ply section that is clamped by and/or between the top bracket 40 and the support member 50 defines a clamped-double-ply portion 74 of the CFS. FIGS. 4A and 4B also illustrate that the double-ply section 70 include a first ply section 76 and a second ply section 78.
In accordance with certain embodiments, the CFS 20 is adhered to the wall structure with an adhesive, such as an epoxy-based adhesive, as noted above. For example, the double-ply section 70 of the CFS 20 includes a first ply section 76 adjacent the wall structure 1 and adhesively bonded to the wall structure and/or adjacent the support member, and a second ply section 78 adjacent the central body portion 42 of the top bracket 40. In accordance with certain embodiments of the invention, the second ply section 78 is located directly or indirectly between the first ply section 76 and the central body portion 42 of the top bracket 40 as illustrated by FIGS. 4A and 4B. In accordance with certain embodiments, the second ply section 78 may be adhesively bonded to the central body portion 42 of the top bracket 40. Additionally or alternatively, the second ply section 78 may be adhesively bonded to the first ply section 76. In accordance with certain embodiments, the clamped-double-ply portion 74 of the CFS 20 may be saturated with an adhesive.
In another aspect, certain embodiments according to the invention provide a method of reinforcing a wall structure having a top end and a bottom end. The method of reinforcing a wall structure may include adhering a CFS, which may have a first end, a second end, and an intermediate portion disposed between the first end and the second end, to the wall structure between the top end and the bottom end. The method may also comprise securing a top bracket to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion, optionally a first bracket-end portion having a first aperture, and optionally a second bracket-end portion having a second aperture. The method may also include a step of providing a SLE located above each of the top bracket and the top end of the wall structure, as well as wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. The method may further include a step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to both securing a top bracket to a support member and wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to the step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS.
In accordance with certain embodiments of the invention, the step of securing the top bracket may comprise inserting a first fastener through the first aperture and into the support member, and inserting a second fastener through the second aperture and into the support member. Additionally or alternatively, the step of clamping comprises tightening the first fastener and the second fastener to eliminate any empty space between the top bracket and the clamped-double-ply portion of the CFS. In this regard, the intermediate portion of the CFS may be wrapped around the SLE and threaded through a passageway between the top bracket and the support member as discussed above, while the top bracket is loosely secured to the support member. After appropriate positioning of the CFS around the SLE and through the passageway between the top bracket and the support member, the top bracket may be clamped onto the double-ply portion of the CFS such that the double-ply portion of the CFS is directly or indirectly sandwiched between the central body portion of the top bracket and the support member. Meanwhile the SLE provides an additional mechanism to prevent the CFS from slipping out from between the top bracket and the support member.
In accordance with certain embodiments of the invention, the step of wrapping the intermediate portion of the CFS around the SLE may further comprise configuring or orienting the CFS with the first end and the second end of the CFS extending away from the SLE in the same direction, such as illustrated in FIGS. 4A and 4B. In accordance with certain embodiments of the invention, the step of adhering the CFS to the wall structure between the top end and the bottom end may comprise adhesively bonding the CFS to the wall structure with, for example, an epoxy-based adhesive. Additionally or alternatively, the method may also comprise adhesively bonding the central body portion of the top bracket to the double-ply section of the CFS. For example, the double-ply section of the CFS may include a first ply section adjacent the wall structure and adhesively bonded to the wall structure and/or adjacent the support member, and a second ply section adjacent the central body portion of the top bracket, wherein the second ply section is located directly or indirectly between the first ply section and the central body portion of the top bracket. Additionally or alternatively, the method may comprise adhesively bonding the second ply section to the central body portion of the top bracket. Additionally or alternatively, the method may comprise adhesively bonding the second ply section to the first ply section. In accordance with certain embodiments of the invention, the clamped-double-ply portion of the CFS may be saturated with an adhesive.
In another aspect, and as illustrated in FIGS. 5 and 6, certain embodiments of the invention provide a wall reinforcement system including a wall structure 1 comprising a concrete block wall including at least a first row of concrete blocks 2 defining a bottom end 5 of the wall structure, and a second row of concrete blocks 6 located above and adjacent the first row of concrete blocks. The bottom end 5 is adjacent a floor 100. The wall reinforcement system may also include a CFS 20 adhered to the wall structure 1 between a top end 3 and the bottom end 5, in which the CFS has a first end 22, a second end 24, and an intermediate portion 26 disposed between the first end and the second end. In accordance with certain embodiments of the invention, the wall reinforcement system may also include a support element 80 located at an inside portion of the wall structure 1 and extending through an internal cavity 9 defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks. The wall reinforcement system, in accordance with certain embodiments of the invention, may also include a filler material 90 at least partially surrounding the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. As shown in FIG. 5, a hole 82 may be formed in the wall structure 1 to enable insertion and positioning of the support element 80 within a portion of the wall structure. In this regard, the present invention may also provide a kit including one or more CFSs, one or more support element, and optionally one or more adhesives and/or instructions for installation.
In accordance with certain embodiments of the invention, the filler material may comprise any material that initially flowable but hardens over a period of time. By way of example only, the filler material may comprise grout or concrete. In accordance with certain embodiments of the invention, the filler material encases at least a portion of the support element and at least partially fills the inner cavity (e.g., the contiguous hollow cores of the stacked blocks) housing the support element. For example, the support element may have a downward facing end located proximate to or adjacent a top surface of an existing footing or slab 110 as shown in FIGS. 5 and 6 and an upward facing end pointing generally toward the top end 3 of the wall structure, in which the distance between the downward facing and upward facing ends define a length of the support element. In this regard, from about 10% to about 100% of the length of the support element may be surrounded or encased with in the filler material, such as at least about any of the following: 10, 20, 30, 40, 50, 60, 70, and 80% of the length of the support element, and/or at most about any of the following: 100, 98, 95, 90, 85, and 80% of the length of the support element.
As shown in FIGS. 5 and 6, in accordance with certain embodiments of the invention, the support element 80 and the filler material 90 may extend into a third concrete block of a third row of concrete blocks 8, in which the third row of concrete blocks may be located above and adjacent the second row of concrete blocks 6.
In accordance with certain embodiments of the invention, the support element may comprise, by way of example only, one or more bars of steel, carbon-fiber rods, or a fiber-reinforced polymeric rods. Additionally or alternatively, the length of the support element (as defined above) may comprise from about 12 inches to about 36 inches, such as at least about any of the following: 12, 14, 16, 18, 20, 24, and 26 inches, and/or at most about any of the following: 36, 34, 32, 30, 28, and 26 inches. Additionally or alternatively, the support element may comprise an average diameter from about 0.25 inches to about 2 inches, such as at least about any of the following: 0.25, 0.5, 0.75, and 1 inch, and/or at most about any of the following: 2, 1.75, 1.5, 1.25, and 1 inch.
In another aspect, certain embodiments of the invention provide a method of reinforcing a wall structure having a top end and a bottom end, in which the method includes adhering a CFS, which has a first end, a second end, and an intermediate portion disposed between the first end and the second end, to the wall structure between the top end and the bottom end. In accordance with certain embodiments of the invention, the wall structure comprises a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, and a second row of concrete blocks located above and adjacent the first row of concrete blocks. The method may also include a step of forming a hole through an inside face of the wall structure and inserting a support element through the hole and positioning the support element within an inside portion of the wall structure. In accordance with certain embodiments of the invention, the support element may extend through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks. In accordance with certain embodiments of the invention, the method may also include a step of adding a filler material through the hole and at least partially surround the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. In accordance with certain embodiments of the invention, the support element and the filler material may extend into a third concrete block of a third row of concrete blocks, in which the third row of concrete blocks are located above and adjacent the second row of concrete blocks.
In accordance with certain embodiments of the invention, the steps of inserting the support element and adding the filler material may be performed prior to adhering the CFS to the wall structure. Alternatively, the step of adhering the CFS to the wall structure between the top end and the bottom end comprises adhesively bonding a lower portion of the CFS subsequent to inserting the support element and adding the filler material. In accordance with certain embodiments of the invention, the lower portion of the CFS comprises a section of the CFS proximate to the hole and extending below the hole. By way of example only, the section of the CFS proximate to the hole may have (i) a starting location from about 1 inch to about 3 feet above the hole along the inside face of the wall structure, and (ii) a finishing location below the hole along the inside face of the wall.
In accordance with certain embodiments of the invention, the support element includes a downward facing end that is positioned adjacent in contact with a top surface of an existing footing or existing slab as illustrated in FIGS. 5 and 6. In this regard, the support element in combination with the filler material interlocks the bottom rows of concrete blocks to mitigate shearing at the bottom end of the wall structure without damaging the existing flooring 100, as illustrated in FIGS. 5 and 6.
In yet another aspect, certain embodiments of the invention provide a wall reinforcement system including a top bracket, SLE, and support element as illustrated in FIG. 7. In accordance with certain embodiments of the invention, the wall reinforcement system may comprise any foregoing combination of features disclosed herein to provide a wall reinforcement system providing top (e.g., top bracket and SLE) and bottom anchoring (e.g., support element) features.
In accordance with certain embodiments of the invention, the wall reinforcement system as illustrated by FIG. 7 may include a wall structure 1 comprising a concrete block wall including at least a first row of concrete blocks 2 defining a bottom end 5 of the wall structure, and a second row of concrete blocks 6 located above and adjacent the first row of concrete blocks. The wall reinforcement system may also include a CFS 20 adhered to the wall structure 1 between the top end 3 and a bottom end 5 of the wall structure, in which the CFS may have a first end 22, a second end 24, and an intermediate portion 26 disposed between the first end and the second end. The system may further include a top bracket 40 fixedly secured to a support member 50 located above the top end 3 of the wall structure, in which the top bracket includes a central body portion 42 as previously described. The system may also include a SLE 60 located above each of the top bracket 40 and the top end 3 of the wall. In accordance with certain embodiments of the invention, the intermediate portion 26 of the CFS 20 may be wrapped around the SLE 60, and overlapped upon itself to define a double-ply section 70 of the CFS. In accordance with certain embodiments of the invention, at least a portion of the double-ply section 70 is directly or indirectly clamped between the central body portion 42 of the top bracket 40 and the support member 50 to define a clamped-double-ply portion 74 of the CFS. The system may also include a support element 80 located at an inside portion of the wall structure 1 and extending through an internal cavity 9 defined at least in part by a first concrete block of the first row of concrete blocks 2 and a second concrete block of the second row of concrete blocks 6. A filler material 90, in accordance with certain embodiments of the invention, may also be included in the system. The filler material 90 may at least partially surround the support element 80 and at least partially fill the internal cavity 9, wherein the first concrete block of the first row of concrete blocks 2 and a second concrete block of the second row of concrete blocks 6 are internally coupled via the support member 80 and filler material 90. In this regard, the present invention may also provide a kit including one or more CFSs, one or more top brackets, one or more SLEs, one or more support elements, and optionally one or more adhesives and/or instructions for installation.
In yet another aspect, certain embodiments of the invention provide a method of reinforcing a wall structure having a top end and a bottom end with a CFS, a top bracket and SLE both being located above the top end of the wall structure, and a support element located within an inside portion of the wall at or near the bottom end of the wall structure and extending upwardly towards the top end of the wall structure. In accordance with certain embodiments of the invention, the method may comprise any foregoing combination of features disclosed herein to provide a method of reinforcing a wall structure including top (e.g., top bracket and SLE) and bottom anchoring (e.g., support element) features.
In accordance with certain embodiments of the invention, the method may comprise forming a hole through an inside face of the wall structure and inserting a support element through the hole and positioning the support element within an inside portion of the wall structure. In accordance with certain embodiments of the invention, the support element may extend through an internal cavity defined at least in part by a first concrete block of a first row of concrete blocks defining a bottom end of the wall structure and a second concrete block of a second row of concrete blocks. In accordance with certain embodiments of the invention, the method may also include a step of adding a filler material through the hole and at least partially surround the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material. The method may also comprise securing a top bracket to a support member located above the top end of the wall structure, in which the top bracket includes a central body portion, a first bracket-end portion having a first aperture, and a second bracket-end portion having a second aperture. The method may also include a step of providing a SLE located above each of the top bracket and the top end of the wall structure, as well as wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. The method may further include a step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to both securing a top bracket to a support member and wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS. In accordance with certain embodiments, the step of adhering the CFS may be performed subsequent to the step of clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS. In accordance with certain embodiments of the invention the step of inserting the support element may be performed prior to the step of adhering the CFS to the wall structure between the top end and bottom end of the wall structure.
These and other modifications and variations to embodiments of the invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and it is not intended to limit the invention as further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.

Claims

That which is claimed:

1. A wall reinforcement system, comprising:

(i) a wall structure having a top end and a bottom end;

(ii) a carbon fiber strap (CFS) adhered to the wall structure between the top end and a bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end;

(iii) a top bracket fixedly secured to a support member located above the top end of the wall structure, the top bracket includes a central body portion; and

(iv) a support-lock element (SLE) located above each of the top bracket and the top end of the wall;

wherein the intermediate portion of the CFS being wrapped around the SLE, and overlapped upon itself defining a double-ply section of the CFS, and wherein at least a portion of the double-ply section is directly or indirectly clamped between the central body portion of the top bracket and the support member to define a clamped-double-ply portion of the CFS.

2. The wall reinforcement system of claim 1, wherein the wall structure comprises a concrete block wall.

3. The wall reinforcement system of claim 1, wherein the CFS comprises a unidirectional CFS or a bidirectional CFS.

4. The wall reinforcement system of claim 1, wherein the first end and the second end of the CFS extend away from the SLE in the same direction.

5. The wall reinforcement system of claim 1, wherein the CFS adhered to the wall structure with an epoxy-based adhesive.

6. The wall reinforcement system of claim 1, wherein the intermediate portion of the CFS is adhesively bonded to the central body portion of the top bracket.

7. The wall reinforcement system of claim 1, wherein the double-ply section of the CFS includes a first ply section adjacent the wall structure and adhesively bonded to the wall structure and/or adjacent the support member, and a second ply section adjacent the central body portion of the top bracket; wherein the second ply section is located directly or indirectly between the first ply section and the central body portion of the top bracket.

8. The wall reinforcement system of claim 7, wherein the second ply section is adhesively bonded to the central body portion of the top bracket.

9. The wall reinforcement system of claim 8, wherein the second ply section is adhesively bonded to the first ply section.

10. The wall reinforcement system of claim 1, wherein the top bracket comprises a substantially planar plate.

11. The wall reinforcement system of claim 1, wherein the wall structure comprises a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, a second row of concrete blocks located above and adjacent the first row of concrete blocks; and wherein the wall reinforcement system further comprises (a) a support element located at an inside portion of the wall structure and extending through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks; and (b) a filler material at least partially surrounding the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material.

12. A method of reinforcing a wall structure having a top end and a bottom end, comprising:

(i) adhering a carbon fiber strap (CFS) to the wall structure between the top end and the bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end;

(ii) securing a top bracket to a support member located above the top end of the wall structure, the top bracket includes a central body portion, a first bracket-end portion having a first aperture, and a second bracket-end portion having a second aperture;

(iv) providing a support-lock element (SLE) located above each of the top bracket and the top end of the wall; and

(vi) wrapping the intermediate portion of the CFS around the SLE and overlapping the CFS upon itself to provide a double-ply section of the CFS;

(v) clamping at least a portion of the double-ply section directly or indirectly between the central body portion of the top bracket and the support member to provide a clamped-double-ply portion of the CFS.

13. The method of claim 12, wherein wrapping the intermediate portion of the CFS around the SLE further comprises configuring the CFS with the first end and the second end of the CFS extending away from the SLE in the same direction.

14. The method of claim 12, wherein adhering the CFS to the wall structure between the top end and the bottom end comprises adhesively bonding the CFS to the wall structure with an epoxy-based adhesive, and further comprising adhesively bonding the central body portion of the top bracket to the intermediate portion of the CFS.

15. A wall reinforcement system, comprising:

(i) a wall structure comprising a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, and a second row of concrete blocks located above and adjacent the first row of concrete blocks;

(ii) a carbon fiber strap (CFS) adhered to the wall structure between a top end and the bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end;

(iii) a support element located at an inside portion of the wall structure and extending through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks;

(iv) a filler material at least partially surrounding the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material.

16. The wall reinforcement system of claim 15, wherein the filler material comprises concrete.

17. The wall reinforcement system of claim 15, wherein support element comprises one or more bars of steel.

18. A method of reinforcing a wall structure having a top end and a bottom end, comprising:

(i) adhering a carbon fiber strap (CFS) to the wall structure between the top end and the bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end, and wherein the wall structure comprises a concrete block wall including at least a first row of concrete blocks defining a bottom end of the wall structure, a second row of concrete blocks located above and adjacent the first row of concrete blocks;

(ii) forming a hole through an inside face of the wall structure;

(iii) inserting a support element through the hole and positioning the support element within an inside portion of the wall structure, wherein the support element extends through an internal cavity defined at least in part by a first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks;

(iv) adding a filler material through the hole and at least partially surround the support element and at least partially filling the internal cavity, wherein the first concrete block of the first row of concrete blocks and a second concrete block of the second row of concrete blocks are internally coupled via the support member and filler material.

19. The method of claim 18, wherein adhering a carbon fiber strap (CFS) to the wall structure between the top end and the bottom end comprises adhesively bonding a lower portion of the CFS subsequent to inserting the support element and adding the filler material; wherein the lower portion of the CFS comprises a section of the CFS proximate to the hole and extending below the hole.

20. The method of claim 18, wherein the support element includes a downward facing end that is positioned adjacent in contact with a top surface of an existing footing or existing slab.