WO2006077435A1

WO2006077435A1 - Improvements in and relating to blast protection structures

Info

Publication number: WO2006077435A1
Application number: PCT/GB2006/000227
Authority: WO
Inventors: Peter James
Original assignee: Cintec International Limited
Priority date: 2005-01-20
Filing date: 2006-01-20
Publication date: 2006-07-27
Also published as: GB0501113D0; GB0715507D0; GB2438334B; US20080295445A1; GB2438334A

Abstract

A structure for example a blast protection structure (1) is provided formed by the inflation of one or more containers (2, 3, 4) and (5) which are then filled with a settable cement or other material to provide a rigid free-standing structure. Roof members (8, 9, 10, 11 and 12) (Figures 2 and 3) may be provided also. The roof is formed by inflating roof supports (8, 9) and (10), forming a further roof member (11) from settable cement material above the roof supports (8, 9) and (10), deflating the roof supports (8, 9) and (10) when the further roof member (11) has set to leave the further roof member (11) in place and forming a structural roof member (12) above the roof member (11). The containers and/or inflatable supports may be formed from dropstitch material which provides internal reinforcing. The invention allows free-standing rigid structures to be produced without the need for conventional formwork. Thus, inflating equipment and means for pouring cement etc into the containers and supports is the only equipment required for the erection procedure.

Description

Improvements in and relating to Blast Protection Structures This invention relates to structures, in particular blast protection structures of the type which may be rapidly deployed in battlefield conditions or to counter- terrorist threats by e.g. suicide bombers. In GB 2374625, the disclosure of which is incorporated herein by reference, a blast protection structure is described using inflatable bags having internal reinforcement such as by the use of "drop stitch" material, which effectively prevents or inhibits the side walls of the bags from bulging outwardly to any great degree, thereby maintaining the general overall shape of the bags when filled with a blast suppressant such as water. While such structures are extremely effective in providing speedy initial protection at or around a given location it will be understood that they are necessarily temporary in nature and e.g. a knife or bullets may be used to rupture the bags, to thereafter render them useless. On the other hand, providing a more permanent blast suppression structure usually involves the use of construction workers to erect e.g. a concrete reinforced structure using rigid shuttering to form wall and roof sections and associated lifting apparatus for same.

The present invention is derived from the realisation that there is a need to be able to quickly erect permanent protective structures in e.g. battlefield conditions or at vulnerable locations without specialist personnel or equipment.

According to a first aspect of the invention there is provided a method of erecting a structure including the steps of: filling or partially filling at least one container having internal reinforcement with a settable material which is thereafter allowed to set to form a free-standing rigid structure. Preferably the method further includes the steps of forming at least two spaced apart rigid structures, to form at least two wall members and thereafter providing a fluid-fillable roof member spanning the at least two wall members, the roof member having internal reinforcement, and thereafter forming a second roof member from the settable material and following setting of the second roof member, deflating the first roof member such that the second roof member then becomes a structural roof member spanning the at least two wall members.

Preferably the method further includes the steps of forming a third roof member over the said structural roof member after the first roof member has been deflated, to thereby provide increased structural strength.

The third roof member may be formed by filling at least one further container with a settable material which is thereafter allowed to set. Anchor points may be provided between the second, structural, roof member and/or third roof members and each wall member. At least one of the said wall members may be anchored to an existing structure.

The inside of at least one container may be filled or partially filled with the settable material and includes further reinforcement in the form of one or more rods. The said at least one container may be filled sequentially such that at least one settable material filling is allowed to set before another is introduced.

The or each container may be used as formwork so that the method can be performed employing only inflating equipment and/or means for pouring the settable material and without separate rigid formwork or lifting equipment The invention extends also to a method of producing a structure having one or more inflatable containers each having internal reinforcement, including the steps of inflating the or each container with a fluid, whereafter the lowermost one or portion thereof is filled with a settable or pourable material which is then allowed to set or settle, whereafter the next successive layer is formed, supported by the first such layer and also by the internal reinforcement.

The internal reinforcement may be in the form of dropstitch material. The settable or pourable material may be: a settable cement or gypsum based material; a particulate material such as sand or aggregate which may settle to form to a substantially rigid mass; or a settable foam and/or polymeric material .

The invention extends to an inflatable support member adapted to, in use, bridge the gap between adjacent underlying support members and to permit a second support member to be formed and set thereon, such as a concrete lintel, the inflatable support member being adapted to be subsequently deflated to allow the second, set, support member to thereafter bridge the gap between the two adjacent underlying support members.

The member may be made of dropstitch fabric to provide internal reinforcement. Further reinforcement may be provided in the form of reinforcing rods.

The further internal reinforcement may be provided for the or each container or support either integrally with the or each container/support prior to the or each container/support being filled, or by the or each container/support being adapted to be externally accessible for allowing the introduction of the further reinforcement following filling and prior to any material setting in or on the container/support.

The invention extends to inflatable formwork tillable with a settable or pourable material and shaped to form a rigid structural member, when the material of which the rigid structural member is to be formed sets , the formwork having internal reinforcement, and to a set of inflatable formwork for forming individual structural members for subsequent assembly into a structure.

The internal reinforcement may be drop stitch material.

The invention extends to a blast protection structure formed from at least one inflatable support which support or supports have opposite sides which are internally reinforced and are at least partially filled with a settable material to form a rigid structure when the material is set, the internal reinforcement holding together the sides prior to the setting of the material.

The invention extends to a method, an inflatable support, inflatable support member, formwork or a structure wherein, warning notices or signs or other indicia are pre-printed on the outside of the or each container, blast protection structure, inflatable support, inflatable support member or formwork.

The invention extends to a method, an inflatable support, inflatable support member, formwork or structure substantially as described and illustrated herein.

Also envisaged is a method of erecting a rigid blast protection structure including the steps of filling or partially filling at least one container having internal reinforcement, such as drop stitch material, with a settable semi-liquid cement which is thereafter allowed to set to form a free-standing rigid structure. Conveniently, the method also includes the steps of forming at least two spaced apart rigid wall members in accordance with the aforesaid method and thereafter providing a gas-fillable roof member spanning the at least two wall members, the roof member being of drop stitch material, and thereafter forming a second roof member from a settable cement and following setting of the second roof member deflating the first roof member such that the second roof member then becomes a structural roof member between the at least two wall members.

In accordance with a refinement to this concept a third, larger, roof member is then formed over the second, set, roof member after the first roof member has been deflated, to thereby provide increased structural strength.

In a further refinement to the method of the invention the blast protection structure is formed sequentially, particularly where its final height is too high for the formwork to be provided solely by drop stitch material. Thus, a relatively high barrier may be provided having a generally "A" shaped cross-section made up of one or several inflatable containers which are then inflated with air or water, whereafter the lowermost one or portion thereof is filled with liquid cement and/or cement/sand or other particulate which is then allowed to set, whereafter the next successive layer is formed, supported by the first such layer and also by the drop stitch material. In this way, a blast protection structure such as a wall

3m high can be constructed in e.g. three separate stages without the use of construction equipment typically found on a building site but usually not available in e.g. battlefield conditions. Conveniently, anchor points may be provided between the second and/or third roof members and each wall member, and each wall member may itself be anchored to existing structures by e.g. reinforcing rods sealingly inserted through the bags prior to the cement setting. Additionally or alternatively, the insides of the bags may include reinforcement in the form of rods, which may be steel or e.g. composite plastics material, such that when the structure is complete it is effectively a reinforced concrete structure.

Utilising the concept of the invention in which the drop stitch containers are used as formwork, retaining their general shape whilst cement sets, it is therefore possible to erect permanent rigid structures quickly and effectively with only inflatable equipment and/or pourable material and without separate rigid formwork being required or separate equipment for lifting such being necessary.

In accordance with a yet another aspect of the invention there is provided an inflatable support member adapted to, in use, bridge the gap between adjacent support members and permit a second support member to be formed and set thereon, such as a concrete lintel, whereafter the first support member is adapted to be deflated to allow the second support lintel to thereafter bridge the gap between the two wall members. The inflatable support member may conveniently be made of drop stitch fabric. In a refinement to the concepts of the first and second aspects of the invention, internal reinforcement is provided for the drop stitch containers, either integrally with the containers prior to them being inflated, or by them being adapted to be externally accessible to reinforcement following inflation and prior to any cement setting therewithin. In accordance with yet another aspect of the invention, there is provided inflatable formwork shaped to form a rigid structural member when the material, such as concrete, of which the rigid structural member is to be formed sets. Conveniently, a set of such inflatable formwork may be provided for e.g. forming individual structural members for subsequent assembly into a building, such as wall members, floor members, roof members, lintels and so on.

In a further refinement to the invention, warning notices or signs or other useful information may be pre-printed on the outside of the containers to thereby provide temporary, semi-permanent or permanent information as the case may be.

The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a rigid blast protection structure made in accordance with the method of the invention; Figures 2 &3 show roof members suitable for the structure illustrated in figure 1 ;

Figure 4 illustrates a filling means;

Figure 5 shows internal reinforcement;

Figure 6 shows an anchor suitable for anchoring a structure to a building; and

Figure 7 shows a blast protection structure.

Referring firstly to Figure 1 there is shown a perspective view of a rigid blast protection structure in the form of a rectangular sarcophagus 1 made up of interconnecting walled containers of drop-stitch material filled with set cement to thereby form a blast protection structure which may be used as e.g. a foxhole in combat or it may be used as a water reservoir if provided with a suitable base, or it may be filled with sand to act as a repository for an exploded ordnance, or it may protect a pre-existing installation or even stored ordnance from the effects of bullets and bombs etc.

Although the shape of the structure 1 is relatively simple in shape it would ordinarily require during construction shuttering on the inside and outside with attendant reinforcements for such shuttering whereafter cement would be poured into the void therebetween and allowed to set before the shuttering is removed, therefore being unsuitable for battlefield conditions for a variety of reasons, not least the time involved and the amount of equipment and skill necessary for these structures construction.

In contrast, through the use of drop-stitch material making up the interconnected containers 2, 3, 4 and 5, such a structure can be easily and quickly inflated to the required shape, by air and/or water by the use of a pressure relief valve (not shown) or, if too tall to bear its own weight, despite being made of drop-stitch material, it may be only partially filled with water with cement being added later or a pre-mixture of a settable semi-liquid cement may be used initially and filling of the containers stops when the limit of self-support is reached, whereafter the cement is allowed to set and the process recommenced until the entire structure is complete.

The foregoing concept can be used to construct buildings or similar structures having roofs made of cement materials as such concrete, even reinforced concrete, without the use of specialist equipment, including lifting equipment such as cranes etc. This is shown with reference to Figures 2 and 3, which respectively show initial and final phases of construction of a roofed structure. In Figure 2 sidewalls 6, 7 have been erected, filled with cement either in a single operation or in a sequential operation as described with reference to the structure of Figure 1 , and the cement has been allowed to set. Thereafter, three inflatable ceiling container 8, 9 and 10 are inflated with air under pressure, the central ceiling container being supported in its required position by e.g. a pair of adjustable props although other supports could be used including even an air cushion, and the side containers 8, 9 simply rest for their most part on the tops of the wall structure 6 and 7 such that the containers 8, 9, 10 thereafter provide a generally planar roof capable of supporting a lintel-shaped container 11 which may thereafter be filled with e.g. liquefied cement which is then allowed to set. When the lintel 11 sets then the containers 8, 9 and 10 can simply be deflated, with the centrally disposed container 9 then being removed entirely and containers 8, 10 simply resting in place underneath the lintel 11.

As can be seen by reference to Figure 3, the presence of a concrete lintel 11 above the concrete walls 6,7 thereafter provides a larger container 12, to be placed over the lintel 11 , filled with liquefied cement and then allowed to set. The container 12 may itself be a larger lintel or it may be more planar form extending over several lintels 11 which, along with the tops of the sidewalls 6, 7 collectively support the planar container 12 until it is set, thereafter forming a route protective structure with, effectively, tools which are mostly inflatable.

In Figure 4 there is shown a schematic arrangement suitable for ensuring that liquid cement or other settable material is evenly distributed throughout the entire container 13. This is achieved by the use of an inbuilt inlet tube 14 having a closed end 15 at the opposite end of the container 13 and a closable inlet end 16. Outlet orifices 7 are arranged radially and linearly along the tube 14 within the confines of the container 13 such that when the tube 14 is being filled with liquid cement, the cement can be evenly dispersed throughout the interior of the container 13. As a refinement to this, reinforcement in the form of steel rods or strips of Kevlar may be inserted into the tube before it sets so^' that the finished structure is reinforced.

Figure 5 shows a prearranged reinforcement concept where the container 18 includes a series of spaced reinforcing members 19, which may be steel or where weight is a consideration a flexible material, such that after the container 18 is inflated to the condition as shown the reinforcing members 19 are spaced apart with respect to each other within the container 18, which may thereafter be filled with liquid cement to form a reinforced concrete structure. In Figure 6 there is shown a tie rod concept where the container 13 of

Figure 4 is shown tied to e.g. the side of a building 20 by the expedience of extending the inner tube 14 into an aperture 21 , which may be a pre-existing aperture or purpose formed, and thereafter driving a pin 22 through the inlet tube 14 before the cement is allowed to set, thereafter tying the container 13 to the building 20.

In Figure 7 the concept is taken further to the stage whereby the container 23 has built in openings in the form of a door aperture 24 and pill box style window slits 25 which collectively remain open when the container 22 has been filled with liquid cement and the cement has then set. In Figure 8 is shown a further concept whereby a container 26 is intended to act as reinforced building block with built in reinforcement rods 27 extending through, in this case, two of the outer walls of the container 26 intended to be received within correspondingly shaped recesses 28 within another container 27 adjacent thereto. With this arrangement, one container 26 may be inflated and formed into a rigid block, whereafter another container 26 may be placed adjacent thereto, inflated such that the reinforcement rods 27 may be inserted into correspondingly shaped recesses 28 as appropriate, whereafter the second such container 26 is filled with cement which is thereafter allowed to set. The realisation that drop stitch material can be used to replace rigid formwork therefore allows for a variety of structures to be easily erected which, when set, can therefore be regarded as permanent structures which can provide valuable protection to personnel and property at locations where heavy construction equipment is unavailable. In particular the invention is suited for use in battlefield conditions where there is a general need to ensure that such structures can be erected quickly and effectively, especially if the settable semi liquid cement includes an accelerating agent allowing for such rigid structures to be formed quickly. In addition, such structures may be formed under water to protect e.g. pipelines, which can be easily and quickly protected on a permanent or semi permanent basis.

In accordance a third aspect of the invention as shown with reference to Figure 9 the container 29 may include on one side thereof a ground sheet 30 intended to cover the whole of the container on that side and a separately inflatable inner container 31 , the containers 29 and 31 defining the shape of a structural member, in this case a rectangular frame, which may then be formed therebetween by the use of settable concrete, which is thereafter allowed to set, whereafter the containers 29, 31 are deflated and the concrete frame thereafter removed, for another such frame to be then made by the same method. In this way, a set of such containers may be provided for making e.g. lintels, panels for forming walls and roofs, and so on. It will be appreciated that in this embodiment of the invention it may be utilised in other circumstances, such as where conventional formwork is not readily available but where rigid structures are required, such as in arid climates or mountainous regions above the tree line.

Whilst planar surfaced structures have been illustrated it will be understood that it is possible to produce non-planar, eg simple, compound, concave or convex curves using the equipment and techniques described. Whilst cement based materials have been described above it will be apparent that other materials may be used instead e.g particulates like sand or aggregate, which may be pumped in liquid suspension and allowed to settle when the transporting liquid is drained. Alternatively a foam material may be used which could contain particulates. A polymeric material could be used also which could be foamed and/or have particulates mixed with it. Blast protection structures have been described and illustrated above however, the construction of other structures may be carried out with according to this invention.

Claims

1. A method of erecting a structure including the steps of: filling or partially filling at least one container having internal reinforcement with a settable material which is thereafter allowed to set to form a free-standing rigid structure.

2. A method of erecting a structure as claimed in claim 1 further including the steps of forming at least two spaced apart rigid structures, to form at least two wall members and thereafter providing a fluid-fillable roof member spanning the at least two wall members, the roof member having internal reinforcement, and thereafter forming a second roof member from the settable material and following setting of the second roof member, deflating the first roof member such that the second roof member then becomes a structural roof member spanning the at least two wall members.

3. A method of erecting a structure as claimed in claim 2 further including the steps of forming a third roof member over the said structural roof member after the first roof member has been deflated, to thereby provide increased structural strength.

4. A method of erecting a structure as claimed in claim 3 wherein the the third roof member is formed by filling at least one further container with a settable material which is thereafter allowed to set.

5. A method of erecting a structure as claimed in claim 3 or 4 wherein anchor points are provided between the second, structural, roof member and/or third roof members and each wall member.

6. A method of erecting a structure as claimed in claims 2 to 5 wherein at least one of the said wall members is anchored to an existing structure.

7. A method of erecting a structure as claimed in any preceding claim wherein the inside of at least one container is filled or partially filled with the settable material and includes further reinforcement in the form of one or more rods.

8. A method of erecting a structure as claimed in any preceding claim wherein the said at least one container is filled sequentially such that at least one settable material filling is allowed to set before another is introduced.

9. A method of erecting a structure as claimed in any preceding claim wherein the or each container is used as formwork so that the method can be performed employing only inflating equipment and/or means for pouring the settable material and without separate rigid formwork or lifting equipment

10. A method of producing a structure having one or more inflatable containers each having internal reinforcement, including the steps of inflating the or each container with a fluid, whereafter the lowermost one or portion thereof is filled with a settable or pourable material which is then allowed to set or settle, whereafter the next successive layer is formed, supported by the first such layer and also by the internal reinforcement.

11. A method of erecting or producing a structure as claimed in any preceding claim wherein the internal reinforcement is in the form of dropstitch material.

12. A method of erecting or producing a structure as claimed in any preceding claim wherein the settable or pourable material is: a settable cement or gypsum based material; a particulate material such as sand or aggregate which may settle to form to a substantially rigid mass; or a settable foam and/or polymeric material.

13. An inflatable support member adapted to, in use, bridge the gap between adjacent underlying support members and to permit a second support member to be formed and set thereon, such as a concrete lintel, the inflatable support member being adapted to be subsequently deflated to allow the second, set, support member to thereafter bridge the gap between the two adjacent underlying support members.

14. An inflatable support member as claimed in claim 13 wherein the member is made of dropstitch fabric to provide internal reinforcement.

15. An inflatable support member as claimed in claim 13or 14 wherein further reinforcement is provided in the form of reinforcing rods.

16. A method as claimed in claim 6 or an inflatable support member as claimed in claim 15 wherein the further internal reinforcement is provided for the or each container or support either integrally with the or each container/support prior to the or each container/support being filled, or by the or each container/support being adapted to be externally accessible for allowing the introduction of the further reinforcement following filling and prior to any material setting in or on the container/support.

17. Inflatable formwork tillable with a settable or pourable material and shaped to form a rigid structural member, when the material of which the rigid structural member is to be formed sets , the formwork having internal reinforcement.

18. A set of inflatable formwork as claimed in claim 17 for forming individual structural members for subsequent assembly into a structure.

19. Inflatable formwork or a set of inflatable formwork as claimed in claims

17 or 18 wherein the internal reinforcement is drop stitch material.

20. A blast protection structure formed from at least one inflatable support which support or supports have opposite sides which are internally reinforced and are at least partially filled with a settable material to form a rigid structure when the material is set, the internal reinforcement holding together the sides prior to the setting of the material.

21 A method, an inflatable support, inflatable support member, formwork or a structure as claimed in any one preceding claim wherein, warning notices or signs or other indicia are pre-printed on the outside of the or each container, blast protection structure, inflatable support, inflatable support member or formwork.

22 A method, an inflatable support, inflatable support member, formwork or structure substantially as described and illustrated herein.