WO2014091047A1

WO2014091047A1 - Ecological reinforcement material for vaults in pre-existing constructions, and associated method

Info

Publication number: WO2014091047A1
Application number: PCT/ES2013/070862
Authority: WO
Inventors: Manuel FORTEA LUNA; José Carlos SALCEDO HERNÁNDEZ; Juan SAUMELL LLADÓ
Original assignee: Universidad De Extremadura
Priority date: 2012-12-10
Filing date: 2013-12-10
Publication date: 2014-06-19
Also published as: ES2485515B1; ES2485515A1

Abstract

The invention relates to an ecological reinforcement material (6) for vaults (5) in pre-existing constructions, and to the associated method, where said material comprises a lime-based mortar that, in turn, comprises: a lime conglomerate in a proportion of between 20% and 40% in relation to the total weight of said lime-based mortar; and a plurality of loads in a proportion of between 60% and 80% in relation to the total weight of said mortar; where said loads comprise natural stony aggregates and light loads; obtaining a material that can structurally consolidate damaged vaults (5), and obtaining an improvement in the resistant behavior of said material in the face of external actions such as earthquakes, or being able to resist new uses with higher loads than the pre-existing ones; and where the associated method describes a series of steps of application of said material in order to obtain reinforcing surfaces for multiple applications.

Description

ECOLOGICAL MATERIAL FOR REINFORCEMENT IN PREEXISTENT CONSTRUCTION DOME, AND PROCEDURE ASSOCIATED WITH THE SAME

Object of the invention

The present invention relates to the description of an ecological material focused on being used in the construction sector, and whose main application is to serve as reinforcement material in the rehabilitation of vaults of architectural constructions such as buildings, churches, and multiple constructions that show in their execution the existence of such architectural vaults.

Said present invention under study aims to obtain a specific material capable of structurally consolidating damaged vaults, as well as obtaining an improvement in its resistant behavior against external actions such as the earthquake (earthquakes) or to be able to resist new uses with loads higher than pre-existing ones; and where the associated procedure describes a series of application stages of said material on the vaults to be restored, which are intended to obtain reinforcing surfaces for multiple applications.

Background of the invention

By way of introduction, the use of the vaulted construction system since antiquity is known. The Romans, for example, developed this concrete-based building system, building such unique works as the Pantheon (Agrippa) over two thousand years ago. Such architectural systems required a prior formwork or formwork to build the vault, so that this formwork served as support and base for the operators in charge of its construction, so that once the vault had sufficient strength, remove the formwork and leave the vaulted space.

This system of realization of such vaults is still used today, since it is an effective and safe system, but, as indicated, requires the formwork or prior formwork for its construction, and all this implies a cost overrun in the formwork, making the construction process more expensive and delaying, in turn, the completion time of the work.

To partially solve this problem, and only applicable in a series of specific vaults, the vault system known as "partition walls" is known, where in its construction the construction is required based on a first brick vault, quickly formed with gypsum, which is subsequently reinforced structurally with two or more successive layers, always of brick, caught or rigged with cement mortar to give more resistance to the whole. In this regard, it is worth mentioning the contribution of the Spanish Guastavino, who developed this system extensively, applied for several invention patents in the United States and carried out unique works.

The procedures described above are focused on the construction of vaults in general, but the material and associated process object of the invention refers to a reinforcement material in vaults of existing constructions, therefore the vault must exist as such.

In order to study direct antecedents of the different materials and procedures used for the reinforcement or consolidation of the structures of buildings and other constructions, it is worth mentioning that the vast majority of these procedures, as well as their materials, are always related to structures adinteladas of rigid knots:

Concrete in any of its forms: reinforced, prestressed, post-tensioned, mass;

- Or profile steel: laminated, shaped, reinforced;

It is extremely difficult to find reinforcement systems of their own and focused on structures of factory vaults (brick, stone) capable of effectively addressing the current needs for increased structural safety required by current building standards (new building requirements). actions) and adaptation to new uses (changes of uses in rehabilitation works). Since the factory vault structures need to be reinforced in many cases for two reasons:

Due to the new regulatory requirements: It is required that the floors (building floors) be able to withstand higher loads (more overloads of use) or new loads (concentrated loads, actions of new facilities, etc.), mandatory by current regulations.

For seismic safety issues: it has been shown that in cases of seismic events (earthquakes), the most affected buildings are the old factory buildings; circumstance found in the last three major earthquakes in Spain, Lisbon (1755), Albolote (1956) and, more recently, Lorca (201 1). In case of earthquakes, the buildings of factory vault structures, due to their high rigidity, need to be duly reinforced, without effective procedures for earthquake-resistant reinforcement for these structural-structural elements have been developed to date. Moreover, in recent seismic episodes it has been found that vaulted buildings reinforced with concrete have had a lousy structural behavior.

In this sense, every day it is more necessary to intervene in the heritage built with rehabilitation works (restoration, expansion, reform, etc.), both for structural safety and for image and representation of emblematic buildings. Since it is mainly the idea that it is the field in which construction will take place in the coming years, taking advantage of existing heritage buildings, rather than building new buildings.

In relation to the background related to the material used, it is known that over the years, the use of materials that have been often inadequate, such as mortar or concrete fillings that have been heavy and in many cases have been used produced counterproductive effects. There is also an incompatibility between the cement (which is part of the composition of the concrete and mortars) and the reinforced factory structure itself (stone or brick), among other reasons for producing the structure pre-existing efflorescence (or salt stains) that seriously deteriorate the original material of the vaults. Being also a material obtained 100% from quarry sands and, therefore, a material that does not allow recycling by direct routes.

That is why, in view of the aforementioned background, and of the inconveniences presented by both the reinforcement materials and the procedures described above, it is necessary the appearance of a new reinforcement material that allows it to be applied without the use of a formwork or previous formwork, as the traditional vault had; that is structurally compatible with the pre-existing factory vault in terms of density (weight) and strength; and that additionally it is considered ecological in the sense of being able to be manufactured through recycling components, helping to the sustainability of the environment.

Description of the invention

The present invention relates to an ecological reinforcement material in vaults of pre-existing constructions, wherein said reinforcement material comprises a lime-based mortar, which in turn comprises:

- A lime binder whose proportion is defined according to the range between 20% and 40% lime binder with respect to the total weight of said lime-based mortar.

- A plurality of charges whose proportion is defined according to the range between 60% to 80% of said plurality of charges with respect to the total weight of said lime-based mortar; where said charges include:

- Natural stone aggregates comprising between 1/3 and 1/2 of the total amount of said charges, and

- Light loads comprising between 2/3 and 1/2 of the total amount of said loads. In this way the proportions of components comprising the lime-based mortar are illustrated, with two preferred embodiments depending on the type of lime:

1) The lime binder is an air lime binder whose proportion is defined according to the interval between 20 and 45% of air lime binder with respect to the total weight of said lime-based mortar, to take into account that the proportion of lime increases slightly by 5% with respect to the scale described above, this increase being a preferred embodiment; and where the proportion of the plurality of charges is defined according to the range between 55% and 80% of said plurality of charges with respect to the total weight of said lime-based mortar.

And in relation to said air lime binder, the possibility that the air lime binder comprises a cement material with a maximum proportion of 1/3 of the total weight of said binder is contemplated.

2) The lime binder is a hydraulic lime binder, and in this case the proportion of hydraulic lime is defined according to the range described above: between 60% and 80% of said plurality of loads with respect to the total weight of said lime-based mortar

In view of the components that form the lime-based mortar, the existence of the ecological reinforcement material object of the invention further comprises water intended to be mixed with said lime-based mortar is described, where the weight ratio between the water and the lime binder is defined in the range between 0.6 and 1.2 of water with respect to the lime binder weight. It is therefore observed that the ecological reinforcement material has well-defined materials with weight ranges limits in order to achieve the best properties of resistance, density, manageability and ease of handling, obtaining important advantages over concrete reinforcement materials such how: Ecological reinforcement material has a lower weight than cement mortars or concrete; therefore it produces a smaller increase in the overweight of the reinforcement material on the architectural vault.

The ecological reinforcement material does not produce efflorescence: salt stains.

The ecological material of reinforcement is compatible with the mampuestos of the reinforced factory, both at the level of construction technique and at the historical level, since lime is a construction material used since antiquity that visually and structurally fits better with old vaults.

The ecological reinforcement material produces less shrinkage than concrete, improving as it has been put into service on the architectural vaults.

In relation to the ecological term, it should be noted that among the main components of the ecological reinforcement material object of invention, lime is a component known since ancient times, which comes from natural rock without additions and obtained by a natural chemical process. On the contrary, cement is much more polluting in its production, since it usually needs additives to make the combination of concrete and water ideally performed.

Additionally, conventional concrete has to use 100% aggregate quarry, on the contrary, the ecological reinforcement material can use recycling material in the loads (light aggregates), which facilitate and reduce its manufacturing cost.

The components described above can be included in the set of main components of the ecological reinforcement material object of the invention, but in addition different possibilities of components are contemplated Side effects that can be used to improve certain mechanical properties of the whole assembly, see for example:

The ecological reinforcement material comprises a plurality of synthetic fibers, wherein said synthetic fibers can be made of polypropylene or glass fiber. So that they manage to provide the necessary ductility (which improves their seismic behavior) and reduce the retraction cracks that occur in the material during its setting and hardening process.

The ecological reinforcement material comprises a plurality of natural fibers; which can be used to also improve mechanical properties of resistance and / or ductility.

It should be noted that, to date, concretes with fibers (natural, steel, synthetic, etc.) have been widely developed to provide this stone material (concrete or mortar) with a certain tensile strength, improving even other properties, but lime-based conglomerate stone materials, on which the material object of the invention is based, have not been developed.

Once the reinforcement material, as well as its main and secondary components, have been described, a procedure for reinforcing a vault with the ecological reinforcement material described above is described; where from the existence of a vault to be reinforced, the procedure comprises the following steps: a) Elaborate the lime-based mortar described in the ecological reinforcement material, where said preparation gives rise to said mortar defined as dry lime-based mortar Being free of water.

b) Pack said dry lime-based mortar to be transported; so that being without water, its packaging is simple by weight and volume, and therefore transport is favored by this method of packaging. c) Introduce the dry lime-based mortar in at least one hopper; where once the dry lime-based mortar has reached the area to be reinforced, the mixture of water and mortar is carried out. d) Introduce water into said at least one hopper comprising in its interior the dry mortar introduced in step c). e) Mix the dry mortar and water until the ecological reinforcement material is obtained in building vaults; where said mixing requires a minimum regulated time depending on the amount of mixture of dry mortar and water. f) Pour the ecological reinforcement material over the back of the construction vault to be reinforced. Where the application or pouring can be constructed by direct pouring, by projection or by application with tools, of successive layers, until it is provided with the appropriate thickness.

The possibility is contemplated that prior to stage f), the vault to be reinforced is cleaned to improve the adhesion between the ecological reinforcement material and said construction vault to be reinforced.

In the event that the system carries anchors, reinforcements or woven or directional fibers, all these elements will be placed on the vault in the calculated arrangement, and before placing the mass, so that they are embedded in it, and work as a tendons, so that they "arm" the reinforcement of the factory, being able to be additionally attached to the factory by different procedures. So that prior to stage f), at least one reinforcement is available on the back of said construction vault to be reinforced.

And similarly, the possibility is contemplated that prior to step f), at least a plurality of directional fibers are available on the back of said construction vault to be reinforced. As a consequence of the reinforcement made, the weight and the thrust of the vault on its supports (walls, pilasters or pillars) are increased, so that the possibility of a stage is contemplated: g) Rebalancing the structure, it may be necessary to increase the vertical load on the walls that may require its structural consolidation (braced, cable-stayed, recessed, buckled, stamped, etc.) by the usual procedures of the construction technique.

Finally, it is contemplated that there may be aerators of the mass of the ecological reinforcement material, to reduce the density of said material object of the invention.

Thus, according to the described invention, the ecological reinforcement material object of the invention, as well as the process associated therewith, constitute an important novelty in reinforcement materials belonging to the state of the art, obtaining a series of advantages unknown to date. , such as:

The resistance of the reinforced vaults (compression and local stability-buckling) is significantly increased, with a relative weight increase. This improvement makes the vaults suitable for receiving new loads (new weight of the reinforcement, more permanent load of new construction elements or an increase in overloads of use or installations).

It is given a certain monolithism, which allows more uniform distribution of loads and the work of stone segments or brick masonry, improving their behavior.

In the solutions that additionally have fibers, it is possible to significantly increase the ductility of the factory structure, improving the seismic behavior, carrying out the reinforcement of two functions (of distribution of actions between pieces and, being equipped with fibers, absorption of the energy produced by the earthquake). Description of the figures

To complement the description that is being made, and in order to help a better understanding of the features of the invention, according to a preferred example of practical implementation thereof, a series of drawings are attached as an integral part of said description. where for illustrative and non-limiting purposes, the following has been represented:

Figure 1.- Shows a schematic view of a concrete or mortar vault belonging to the state of the art, and built by the Roman procedure.

Figure 2.- Shows a schematic view of another vault belonging to the state of the art, this being a partitioned or "Catalan" vault, made by successive layers of brick.

Figure 3.- Shows a schematic view of an architectural vault to be rehabilitated, after applying the ecological reinforcement material.

Figure 4.- Shows a schematic continuation view of that shown in Figure 3, where the ecological reinforcement material has been poured.

Figure 5.- Shows a schematic continuation view of that shown in Figure 4, where a top filling has been made on the layer of ecological reinforcement material, to leave the floor flat, suitable for receiving new overweight actions.

Preferred Embodiment of the Invention

With respect to the state of the art known about construction procedures for architectural vaults, a concrete or mortar vault (1) constructed by the Roman procedure described in the background section of the present specification is observed in Figure 1; where said concrete or mortar vault (1) is constructed based on a formwork or formwork (2) on which the concrete or mortar, where once set and with adequate strength, it is removed, leaving the space of the diaphanous vault.

Figure 2 shows another procedure for the construction of architectural vaults, where in this case a partitioned or "Catalan" vault is shown, made by a series of brick layers superimposed on each other. The first layer (3) is built with plaster paste without formwork and the second layer (4) is built on the first, with cement mortar, to provide the resistance system, the total thickness will increase as the successive layers of brick.

Once the state of the art linked to the construction of architectural vaults (5) is illustrated, the ecological reinforcement material (6) for the rehabilitation of said vaults (5) is described, with two preferred embodiments:

1) The ecological reinforcement material (6) in vaults (5) of constructions, comprises a lime-based mortar which in turn comprises:

An air lime binder whose proportion is defined according to the range between 20% and 45% lime binder with respect to the total weight of said air lime based mortar; wherein the air lime binder comprises a cement material with a maximum proportion of 1/3 of the total weight of said binder.

A plurality of charges whose proportion is defined according to the range between 55% and 80% of said plurality of charges with respect to the total weight of said lime-based mortar; where said charges comprise: o Natural stone aggregates comprising between 1/3 and 1/2 of the total amount of said charges, or Light loads comprising between 2/3 and 1/2 of the total amount of said charges loads 2) The ecological material of reinforcement (6) in vaults (5) of constructions, comprises a mortar of base lime that includes as well:

A hydraulic lime binder whose proportion is defined according to the range between 20% and 40% of hydraulic lime binder with respect to the total weight of said lime-based mortar.

A plurality of charges whose proportion is defined according to the range between 60% and 80% of said plurality of charges with respect to the total weight of said hydraulic lime-based mortar; where said charges comprise: o Natural stone aggregates comprising between 1/3 and 1/2 of the total amount of said charges, or Light loads comprising between 2/3 and 1/2 of the total amount of said charges loads

Both preferred embodiments of ecological reinforcing material (6) additionally comprise water to be mixed with said lime-based mortar (either aerial or hydraulic), where the weight ratio between the water and the lime binder is defined in the range between 0 , 6 and 1, 2 of water with respect to the weight of the lime binder; and its dosage is dependent on calculations, depending on the strength and density benefits needed, to make the reinforcement compatible with the vault (5) to be reinforced, which must comply with:

Characteristic resistance to compression between 1, 25 and 20 N / mm ² .

Apparent specific weight between 8 and 18 KN / m ³

Additionally, and again in both preferred embodiments, the ecological reinforcing material (6) comprises a series of natural additives such as a plurality of natural fibers. Once the ecological reinforcement material (6) has been described in its two preferred embodiments, the procedure for reinforcing said vault (5) with the ecological reinforcement material (6) described above is described.

For this we take as reference the figure 3 where a vault (5) to be reinforced is illustrated, and it is to said vault (5) to which the ecological reinforcement material (6) is to be applied, following the following steps: a) Prepare the lime-based mortar described in the ecological reinforcement material (6) in any of its two preferred embodiments (air lime or hydraulic lime), where said preparation gives rise to the mortar defined as dry lime-based mortar when it is free of water . b) Pack said dry lime-based mortar in sacks to be transported by land vehicles such as trucks or similar. c) Once the dry mortar has arrived at the site where the vault (5) to be reinforced is located, introduce the dry lime-based mortar into a hopper. d) Introduce water into said hopper which comprises in its interior the dry mortar introduced in step c). e) Mix the dry mortar and water until the ecological reinforcement material (6) is obtained in vaults (5) of constructions. f) Clean the back of the vault (5) to improve the adhesion between the ecological reinforcement material (6) and said construction vault (5) to be reinforced. g) Having a reinforcement on the back of said construction vault (5) to be reinforced and / or providing a plurality of directional fibers on the back of said construction vault (5) to be reinforced. h) Pour the ecological reinforcement material (6) over the back of the construction vault (5) to be reinforced; so that when applying the ecological reinforcement material (6) a homogeneous layer is obtained, with a suitable thickness determined in the calculation in each zone.

In this way the ecological reinforcement material (6) is arranged on the vault (5) as shown in figure 4 of the present specification, so that once placed it can be seen in figure 5 how the Vault (5) can be subsequently reinforced to receive new actions, such as the weight of new construction elements (7) and new overloads of use (8), which make it possible to integrate the pre-existing vault (5) into a rehabilitated building or extended.

Additionally, the entire system formed by the ecological reinforcement material (6) and the vault (5) can be completed with other systems, such as:

Top filling of the vault (up to the key) to horizontalize the floor, with the use of light materials, with the creation of a solera layer that evenly distributes the loads and braces the factory structural assembly formed by vaults and walls.

Reinforcement of the factory vertical structure (bearing walls) to balance the thrust produced by the weight gain.

Reinforcement of the foundation (overhang) to make new actions compatible with the terrain.

In view of this description and set of figures, the person skilled in the art will be able to understand that the embodiments of the invention that have been described can be combined in multiple ways within the scope of the invention. The invention has been described according to some preferred embodiments thereof, but it will be apparent to the person skilled in the art that multiple variations can be introduced into said preferred embodiments without exceeding the object of the claimed invention.

Claims

1. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, characterized in that it comprises a lime-based mortar comprising:

- a lime binder whose proportion is defined according to the range between 20% and 40% lime binder with respect to the total weight of said lime-based mortar;

- a plurality of charges whose proportion is defined according to the range between 60% and 80% of said plurality of charges with respect to the total weight of said lime-based mortar; where said charges include:

- light loads comprising between 2/3 and 1/2 of the total amount of said loads.

2. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to claim 1, characterized in that the lime binder is an air lime binder whose proportion is defined according to the range between 20 and 45% of air lime binder with respect to the total weight of said lime-based mortar; and where the proportion of the plurality of charges is defined according to the range between 55% and 80% of said plurality of charges with respect to the total weight of said lime-based mortar.

3. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to claim 2, characterized in that the air lime binder comprises a cement material with a maximum proportion of 1/3 of the total weight of said binder .

4. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to claim 1, characterized in that the lime binder is a hydraulic lime binder.

5. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to any of the preceding claims, characterized in that it comprises water to be mixed with said lime-based mortar, where the weight ratio between the water and the lime binder is defined in the range between 0.6 and 1.2 of water with respect to the lime binder weight.

6. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to any of the preceding claims, characterized in that it comprises a plurality of synthetic fibers.

7. - Ecological reinforcement material (6) in vaults (5) of pre-existing constructions, according to any of the preceding claims, characterized in that it comprises a plurality of natural fibers.

8. Procedure for reinforcing a vault (5) with the ecological reinforcement material (6) defined in any of the preceding claims, characterized in that, from the existence of a vault (5) to be reinforced, it comprises the following steps: a) elaborate the lime-based mortar defined in the ecological reinforcement material (6), where said preparation gives rise to said mortar defined as dry lime-based mortar when it is free of water; b) packaging said dry lime-based mortar to be transported; c) introduce the dry lime-based mortar into at least one hopper; d) introducing water into said at least one hopper comprising in its interior the dry mortar introduced in step c); e) mixing the dry mortar and water until the ecological reinforcement material (6) is obtained in vaults (5) of constructions; and f) pour the ecological reinforcement material (6) over the back of the construction vault (5) to be reinforced.

Method for reinforcing a vault (5) with the ecological reinforcement material (6), according to the preceding claim, characterized in that prior to step f), the vault (5) to be reinforced is cleaned to improve the adhesion between the ecological reinforcement material (6) and said construction vault (5) to be reinforced.

10. Procedure for reinforcing a vault (5) with the ecological reinforcement material (6), according to any of claims 8 and 9, characterized in that prior to step f), at least one reinforcement is provided on the back of said construction vault (5) to be reinforced.

1 1. Procedure for reinforcing a vault (5) with the ecological reinforcing material (6), according to any of claims 8 to 10, characterized in that prior to step f), at least a plurality of directional fibers are available on the back of said vault (5) of construction to be reinforced.