WO2023237937A1

WO2023237937A1 - Two-phase floating foundation using basalt fibers

Info

Publication number: WO2023237937A1
Application number: PCT/IB2023/050880
Authority: WO
Inventors: Sara SADEGHI; Masoud ARABAMERY; Mohammadhossein SHARIFNIA
Original assignee: Sadeghi Sara
Priority date: 2023-02-01
Filing date: 2023-02-01
Publication date: 2023-12-14

Abstract

A two-phase floating foundation using basalt fibers, in which lightening and increasing the load capacity is carried out by these natural fibers and deformation and encompasses the following primary parts: The raised section of the foundation with the capability of maintaining air bubbles in visible dimensions and high relative thickness relative to other dimensions. The flat section of the foundation, which is assembled on the raised section with a low thickness, allows air storage in the foundation. Lightened walls and ceiling using basalt fibers and quick connection capability on basalt foundation and Reinforced concrete 3D printing machine equipped with 4-material outlet nozzles.

Description

Two-phase floating foundation using basalt fibers

a two-phase floating foundation using basalt fibers, in which lightening and increasing the load capacity is carried out by these natural fibers and deformation and encompasses the following primary parts: The raised section of the foundation with the capability of maintaining air bubbles in visible dimensions and high relative thickness relative to other dimensions. The flat section of the foundation, which is assembled on the raised section with a low thickness, allows air storage in the foundation. Lightened walls and ceiling using basalt fibers and quick connection capability on basalt foundation and Reinforced concrete 3D printing machine equipped with 4-material outlet nozzles

C04B30/02-C03B37/00-E04B1/38

Foundation bolt make of basalt fiber and preparation method thereof

CN103435324A

The invention discloses a foundation bolt make of basalt fiber. The basalt fiber is used as the raw material of the foundation bolt. The basalt fiber comprises following raw materials, by mass: 60 to 80% of basalt ore, 3 to 20% of limestone, and 15 to 30% of coke. Preferably the basalt fiber comprises, by mass, 70% of basalt ore, 10% of limestone and 20% of coke. The basalt fiber is light in weight and high in strength, and possesses insulating property, high-temperature resistance and corrosion resistance. The basalt fiber is used for preparation of the foundation bolt for the first time, and the foundation bolt possesses high strength, light weight, corrosion resistance and long service life.

Heat-resistant basalt fibre filter material and preparation method thereof

CN101856577A

The invention provides a heat-resistant basalt fiber filter material and a preparation method thereof. The filter materials of the invention can be used in environment of ultra-high temperature, and has excellent folding endurance, corrosion resistance and abrasive resistance. The preparation method of the heat-resistant basalt fiber filter material has the technical scheme as follows: firstly, preparing a basalt fiber foundation and basalt fiber meshes; putting the basalt fiber foundation between the upper basalt fiber mesh and the lower basalt fiber mesh to be manufactured into the filter material; and preparing basalt fiber used for the basalt fiber foundation and then carrying out dipping treatment of teflon mix emulsion.

System, method and apparatus for integrated portable building foundation platform with modular components

US20200232205A1

A shelter, comprising: a foundation system configured to be filled in-place at a construction site with concrete; and a structure mounted to the foundation system, the structure walls and a roof comprising rigid foam insulation plastered with continuous filament winding (CFW), wherein the foundation, walls and roof comprise seamless transitions there between. A method of fabricating a shelter, comprising of a ‘rail system’ for pressing and gluing together foam walls, floor, ceiling, roof and foundation into a full structure. A foundation for a shelter, comprising: a portable tray configured to support the shelter, the portable tray comprising an interior configured to be filled or injected with a mass, and anchor elements configured to be anchored to an underlying formation. A modular tiling system that can be integrated into the foundation, comprising of movable functional components comprising a toilet, sink, speaker, lights, furniture, electronic equipment, cooking surface, lock box, trash bin and HVAC.

Seismic foundation framer and method of forming a foundation using same

US11286667B2

A plurality of seismic foundation frames are utilized to secure rebar in a fixed location to produce a cementitious supporting form that is embedded in the poured concrete and reinforces the concrete. The frame has an open construction with a plurality of openings to allow the concrete to flow therethrough and to provide increased surface area for reinforcement. The frame has pin openings and rebar openings for receiving and retaining pins or rebar respectively, such as when the frames are stacked. A frame has rebar retainers for retaining rebar that extends perpendicularly to the surface of the frame to a second frame at an offset distance. A flexible containment sleeve is configured around the frames and may be fastened to the frame to create a sleeved form for receiving a cementitious mix. The containment sleeve has apertures for controlled permeation to control the rate of cure of the cementitious mix.

The two-phase floating foundation using basalt fibers is an invention in the field of the construction industry. Using the properties of basalt fibers and simple laws of mechanics, this invention has offered a method for the suspension of low-rise buildings on low-resistance lands or flooded regions or on water. The existing dilemma is the absence of a robust structure for the above-listed areas, which are required in some cases as temporary accommodation or relief, or recreational places. Lacking assurance of the available foundations or the requirement for a long time for the execution contained in the previous approaches has led to proposing this solution. Furthermore, the other problem that the invention attempted to overcome is making high-strength concrete components with complex shapes, where the appropriate reinforced concrete is not deployed in it in the existing methods while printing. By improving the shape of the utilized printer and extruder, the basalt reinforcement employed in this invention is positioned in the desired shape, and resin and hardener are injected into it respectively. After that, the concrete and vibration of the piece with the appropriate density produce the concrete mold.

In flooded areas or flood-prone areas and on the water surface or in lands where the soil has a low bearing capacity, utilizing raft foundations (sometimes referred to as raft footings or mat foundations) is beneficial. Taking into account the high weight of the conventional foundation, the problem of sulfate damage to the foundation is overcome in this invention by changing the spatial shape and using basalt fibers rather than metal reinforcement, while reducing the weight and the capability to keep the structure floating.

Solution of problem

The problem that the claimed invention attempts to overcome is the implementation of a light structure with the capability of floating on water or positioning in environments where the bed between water and soil is changing or has a low load-bearing capacity. In flooded areas and regions in danger of flooding, surfaces covered with wind-blown sand and tidal areas of seawater, or in lakes, creating temporary emergency structures for relief or temporary hospitals or accommodation areas until permanent accommodation be ready is required. In the claimed invention, this is made possible by using Archimedes' law of buoyancy and the simple laws of physics and benefiting from the advancement of technology. Generating a type of mat foundation (raft foundation) with the possibility of floating and bearing the structure weight and the live load on it by employing fibers and meshes made of basalt in low-rise buildings is fulfilled. By placing the mesh (40) made of basalt fibers in matrix mold (5) at a proper spacing from the body wall (4) and depressions (6), a suitable amount of concrete with appropriate grading is poured into the mold and the mandrel mold (1) will be pressed on it.

The protrusions (3) are positioned in the depressions (6) at a suitable distance and the surfaces (4) in the matrix mold will also maintain their distance with the equivalent surface (2) in the mandrel mold. It should be noted that mandrel and matrix molds are exploited as core and cavity. A basalt reinforcement exists in the space between concrete and mesh molds. In the case that vibration or heating is needed, this is done with the vibration of the mold itself. In addition to a noticeable reduction in foundation weight, using basalt also protects it against corrosive agents in water. The foundation is composed of two flat (11) and raised (7) layers, which are assembled on each other. The raised section (7) consists of the connection surface (8) and the air accumulation area depression (9) and the flat tongue conductor depressions (10). In the flat section (11), the foundation of the contact area (16) and the conductor tongues (15) are placed on the raised surface, and the longitudinal joint tongue (14) and the transverse joint tongue (17) as well as the longitudinal joint groove (12) and the transverse joint groove (13), which are so helpful in the assembly and maintaining of the connection until two concrete components are attached to each other. Taking into account the size limitation of trucks carrying these components from the perspective of weight and dimensions, the shape and dimensions of the components are designed in such a way that the assembly is carried out in the fastest possible way while having the capability of transporting and unloading and loading with conventional equipment such as existing cranes at the time of assembly, the assembly process should not be time-consuming due to the small size of the components.

The length of 6 meters and the width of 2 meters will provide appropriate conditions. At the time of on-site assembly, a 12-section air-tight unit with an area of 12 square meters is achieved by positioning a raised foundation section (7) under a flat foundation layer (11) and utilizing a proper mortar or resin between them. In the event of the requirement to enhance merely by existing tongue-and-groove joint next to the flat pieces of the foundation (11), we will have a foundation with larger dimensions. Because of the number of air entrapment spaces, if a section is damaged, only one or two units will lose their resistance to water penetration until repair, and the other sections are still bearing the weight. There are two types of simple (18) and windowed (23) side walls (wing walls). Taking into consideration the ratio of weight to the strength of basalt fibers and reasonable price relative to carbon fibers, it can be evidently employed on the walls in certain cases; however, it can supply the wall's strength in daily, non-industrial or military use with a small number. In the lower part, the walls without windows (18) are placed on the upper depressions of the groove (42) of the integrated foundation (43) using the protrusions of the tongue (22). Next, the side wall will establish a suitable joint with the previous wall in addition to the proper connection with the foundation (43) by using the expanded protrusion (20) at the height of the wall, which is placed in the groove (21) of the previous wall. In the upper part of the simple walls (18), the depressions (19) deliver the likelihood of placing a windowed wall (23). In this wall, there are side grooves (29) and side protrusions (28) for the joint of the side wall and the tongue protrusion (27) at the bottom, and the groove depression (25) at the top of the wall surface (24), which embrace the window (26).

Transverse walls (30) contain two or more different heights on the basis of the roof slope or the structure width. In these walls (30), the window (33) or the door (37) is positioned on the concrete wall surface (38). The protrusion (32) at the bottom and the depression (31) at the top allow the possibility of a safe connection. In the depression (31), the roof tongues can be seen (35). The roof (34) may utilize different materials on the surface (36). Glass fibers or transparent or semi-transparent materials or metal or concrete plates are exploited in this section, relying on the cases of applications. The set of mesh fibers woven from basalt (40) and concrete (39) provides the possibility of maintaining the air bubble (41) and guarantees the structure suspension. More advanced methods relative to molding should be exploited for the construction of complex concrete components using basalt fibers. For example, designing a system of simultaneously placing fibers and resin in different coordinates and then injecting concrete could be helpful. As is specified in conventional methods, after the texture of the basalt fibers, the resin and then the hardener is placed on them until the required thickness. If bending is needed, the strength of the resin will be lowered by heating the required bending section. This action causes the return to the original strength to be necessitated to rework with the resin, which is not conducted in construction workshops because of facilities and time. These problems are overcome by using a 4-purpose printing machine (44). In this device, the extruder (45) performs placing woven basalt and resining on the fibers and spraying hardener and concrete, respectively.

The four-purpose printing machine (44) is composed of the main parts with a fixed body (49), the horizontal actuator (46), the vibrator (47), the movable mold (48), and the extruder (45). The movable mold (48) is made of a flat bottom (51) and sloping edges (50) and metal wheels (54), which are attached to the bottom (51) by wide axles (52) and bases (53). This mold merely creates a surface at the time of printing and making a piece of concrete or basalt mesh. However, in the molding of components that utilize mandrel and matrix molds, the mandrel mold is initially placed on the floor, and a basalt mesh layer is added in different parts after concreting with appropriate distribution by the extruder (45), and then the second layer of concrete is poured and the matrix mold will be located on it. Taking into account the relatively high weight of the concrete pieces and the vibration of the concrete component in the movable mold with the force applied by the bases, the metal wheels (54) are selected. In addition to the ease of movement, this causes the capability of transferring force from the moving body (60) of the main frame to the wheels (54) and then the metal axles (52) and expanded bases (53), which are integrated with the flat bottom (51), to be provided. The movable mold (48) is placed inside the vibration mold (60) by the entry to the conductor groove (59). Then, the latches (58) fix it in place by rotating around the axis (57) up to 90 degrees behind the mold (48). The main frame of the printer (49) is fixed by concrete on the ground using metal bases (63) so that it does not move from its position during vibration and generates maximum efficiency. The vertical columns (55) that hold the horizontal rails (56) are observed in the main frame (49), which have relatively large dimensions so that displacement and deformation do not occur as a result of the weight of the extruder (45).

Indeed, the moving body (60) will have a slight movement in the direction of the shaft (62) such that the vibration can excellently be performed. The connection of the moving body (60) to the main frame body (49) is carried out via airbags (64) so that it also has suitable mobility at the time of vibration while maintaining stability during the 3D printing of parts. In the case of the requirement for higher accuracy, these airbags can be empty during printing and filled with air during vibration until a gap between the two bodies is created. These airbags (64) are exploited in the transportation industry for the suspension system and height adjustment of vehicles. The vibrator (47) transmits its force to the moving body (60) by the shaft (62) and is connected to the body through the conductor holes (61). To utilize the conductor holes (61), some protrusions of the conductor's tongue (68) are placed on the body of the vibrator (65), which is in the same direction as the shaft hole (69). The magnetic shaft hole (69) provides the possibility of shaft entry and exit (62). A connector (66) is employed for connecting the electrical module (70) to the communication cables. It is also noteworthy that the induction of electricity by the coils (72), (73), and (74), which are positioned in the co-axial direction is an exothermic phenomenon; hence, the heat exchanger (71) and fans (67) are exploited. The bobbin (72) at the entrance of the shaft is placed, followed by the larger bobbin (73), and the smaller bobbin (74) at the end are located, respectively, so that they do their duty at different frequencies and diverse oscillations amplitudes separately or in combination with minimal depreciation.

The horizontal actuator (46) that is responsible for moving the extruder in the direction of the X-axis is composed of the following different parts. The engine and gearbox (75) of the shaft actuator (76) have the task of rotating this spiral-covered shaft (76). In these rotary motion generators, brushless motors and reduction gearboxes, or speed reducers, are employed for high precision. The spiral shaft (76), which is protected by a moving cover, moves the slide (77) forward and backward along the shaft with rotational movement inside the bead-shaped section (80). The slide (77) that moves on the rail (49) by the idler rollers (78) has a groove (81) in the lower part for the placement of the extruder (45). The rollers are attached to the sliding body (77) by the axles (82). Moreover, a retaining plate (79) is used at the end taking into account the relatively long length of the shaft (76). By restricting the horizontal movement of the shaft (76), this plate (79) merely allows the likelihood of its rotational movement, which may be utilized on the shaft of the bearings or bushings.

The improved extruder (45), nozzle, has rollers (83) for the movement on the sliding groove (81), which provides the possibility of movement in the Y-axis direction. Dissimilar to the idler rollers (78), these rollers (83) have a movement controlled by the gearbox motor positioned in the base (84). The rollers (83) are connected to the body of the extruder via the axes (85). The nozzle outlet consists of a fixed base (86), an intermediate base (87), and an output (88). By gathering the outlet (88) and the intermediary (87) inside the fixed base (86), its length decreases or increases and allows movement in the Z direction. For the insertion of concrete, the inlet (90) is available, which is designed to be at least 30% greater than the biggest grain dimension. Next, the inlet (89) is designed for the cable woven from basalt, the inlet (91) for injecting resin, and the inlet (92) for injecting dryer (hardener).

Advantage effects of invention

Possibility of using this structure in earthquake -prone areas and at risk of flooding

High resistance to sulfate attack and corrosive factors affecting metal reinforcement

Possibility of floating on the surface of the water and the extent of the transmission surface to the lower surface

The weight loss of dead structures

Possibility of quick assembling and creating a niche or building for different purposes

The possibility of expanding by connecting the components to each other

Truck -made parts capability in terms of size and weight

Longevity than similar steel structures and the ability to return to nature

: This map with a scale of 1/100 shows the prominent blind and cavity molds of the foundation

: It shows some 3D views of how to connect the two parts of the foundation formwork

: 100x zoom shows the prominent part of the foundation in several 2D and 3D views

: A few side bars have been seen along the length and width of the prominent foundation

: It shows views of the flat part of the foundation on a scale of 1/100

: It shows how to assemble the flat and raised part of the foundation, as well as how to connect several blocks to each other.

: It shows some views of a simple longitudinal wall with 100 times zoom

: It is used to show the details of the windowed side wall with a scale of 1/100

: It shows how to connect the longitudinal walls on the foundation

: It shows a detail of the transverse wall equipped with a window

: It shows how to connect the transverse walls and the roof

: It shows the stages of connecting the roof and completing the structure

: On the left side, we have some views and on the right side, we have details of the same view with cross-section lines drawn for further comparison. Two maps are drawn next to each other for ease of mental understanding of the completed structure

: We have sections of the completed structure

: 20 times smaller than the original size of a portion of the foundation section is shown enlarged.

: It shows two views of the 3D printer of reinforced concrete parts

: It has shown the same two views with more details of the internal parts

: It shows some 2D and 3D views of the printer

: It shows sections of the printer with all the parts installed on it.

: An exploded view of the printer is shown so that the location of the parts is clear

: It shows some views above and some cuts below from the moving mold

: It shows a few views of the fixed main frame

: By enlarging the images compared to map number 22, more details of the fixed frame have been displayed

: It shows horizontal and vertical sections of the fixed frame

: It shows some 2D and 3D views of the electric vibrator.

: Shows vibrating cuts

: It is used for the dimensions and placement of internal parts

: It shows views of the horizontal drive

: It shows several views of the extruder

: By zooming in more than the previous map, it shows more details of the entrances

: 1. Mandrel mold 2. Equivalent surface of mandrel mold 3. Protrusion of matrix mold 5. Matrix template levels 4. Matrix format 6. Depression

: 1. Mandrel mold 5. Matrix template levels

: 7. Prominent part 8. Connecting surface 9. Indentation of the air accumulation area 10. Indentations of flat tongue conductor

: 11. The flat part of the foundation 12. Longitudinal connection palate of the foundation 13. Foundation transverse connection palate 14. Embossed surface and longitudinal connection tab of the foundation 15. Foundation conductor tabs 16. Foundation contact surface 17. Transverse connection tab

: 7. Prominent part 11. The flat part of the foundation

: 18. Simple side walls (without windows) 19. Built-in recess on the wall 20. Expanded protrusion of the side wall 21. Wall groove 22. Existing protrusions on plain walls (without windows)

: 23. A wall with a window 24. Above the surface of the wall 25. Depression of the palate 26. Window 27. Protrusion of the tongue 28. Lateral protrusion of the wall 29. Lateral groove of the wall

: 19. Built-in recess on the wall 22. Existing protrusions on plain walls (without windows) 27. Protrusion of the tongue

: 30. Transverse walls 31. Depression of the transverse walls 32. Protrusion of transverse walls

: It shows how to connect the transverse walls and the roof

: It shows the stages of connecting the roof and completing the structure

: We have sections of the completed structure

: 12. Longitudinal connection palate of the foundation 14. Embossed surface and longitudinal connection tab of the foundation 39. Concrete 40. Basalt 41. Air bubbles

: 44. 4-purpose printer 45. Extruder device 46. Horizontal drive 47. Vibrator 48. Moving format 49. Fixed body

: 45. Extruder device 46. Horizontal drive 47. Vibrator 48. Moving format

: It shows some 2D and 3D views of the printer

: It shows sections of the printer with all the parts installed on it.

: 45. Extruder device 46. Horizontal drive 47. Vibrator 48. Moving format 49. Fixed body

: 48. Moving format 49. Fixed body 50. Sloping edges 51. Flat sole 52. Broad axes 53. Base 54. Metal wheels

: 63. Air bags 64. Vibrator body

: 49. Fixed body 50. Sloping edges 51. Flat sole 52. Broad axes 53. Base 54. Metal wheels 55. Vertical columns 56. Horizontal rails 57. The axis embedded in the form of vibration 58. Guarantor 59. Conductor groove inside the vibration mold 60. The moving body of the main frame 61. Conductor holes 62. Shaft 63. Air bags

: It shows horizontal and vertical sections of the fixed frame

: 65. Vibrator body 66. Connector 67. Fan

: Shows vibrating cuts

: 70. Electric module 71. Heat transfer 72. Solenoid 73. Larger solenoid 74. Smaller solenoid

: 75. Gearbox 76. Spiral shaft 77. Sliding door 78. Round weed rollers 79. Holder plate 80. Nut-like part 81. The groove in the lower part

: 82. The axes of the roller interface and sliding body 83. Roller 84. Gearbox motor placement base 85. The axis connecting the roller and the extruder body 86. Fixed base 87. Intermediate base 88. Fixed base output

: 86. Fixed base 89. Cable entry 90. Incoming concrete 91. Resin injection input 92. Input of dryer injection (hardener)

Examples

To execute this invention, it is first produced in a foundation workshop and walls and ceilings and after loading and shipping by the truck or ship to the deployment site. Cement sand mortar or resins can be used to maintain connections with each other, which requires assembly of a conventional dimensions of a residential apartment in less than a day.

The use of this invention is limited in temporary structures with limited altitude that can bear the loads if the underlying substrate is changed from water to soil or vice versa without damage. It is also used in structures with specific architecture and complex reinforced concrete shapes.

Claims

This invention is a two-phase floating foundation using basalt fibers, in which lightening and increasing the load capacity is carried out by these natural fibers and deformation and encompasses the following primary parts:
The raised section of the foundation with the capability of maintaining air bubbles in visible dimensions and high relative thickness relative to other dimensions

The flat section of the foundation, which is assembled on the raised section with a low thickness, allows air storage in the foundation.

Lightened walls and ceiling using basalt fibers and quick connection capability on basalt foundation

Reinforced concrete 3D printing machine equipped with 4-material outlet nozzles
Lightening method and air entrapment in changing the unit mass of the foundation volume is carried out for the structure floating and two-phase application.
According to claim 1, building the concrete raised component is conducted in the mandrel/matrix molds under pressure.
According to claim 1, the reinforcement utilized to enhance the concrete strength is the mesh woven from basalt fibers without the need for resin in a thickness of less than one millimeter.
According to claim 2, the reduction of the foundation volume mass is carried out by entrapping air in the concrete foundation.
According to main claim 1, building walls and ceilings is done using a mesh made of basalt fibers.
According to claim 1 and main claim 2, the deformation of the foundation and the reduction of the contact surface with the ground surface from top to bottom is performed for enhancing the resistance against sinking into the soil.
According to claim 1, the description and construction plan of concrete components with complex shapes are made in limited numbers without requiring molds and by using a 3D printer.
According to claims 1 and 8, a nozzle-extruder with the capability to exit 4 non-identical materials at a non-synchronous point is revealed.
According to claims 1 and 8, 3D printing of reinforced concrete is fulfilled without the need for deformation of reinforcements before implementation.
According to claims 1 and 10, there is the possibility of fixing the shape of the reinforcement at the time of printing concrete blocks without the requirement for heat.
According to claims 1 and 8, the vibration and the exit of unwanted air bubbles from the concrete happen on the surface below the concrete printer.
According to claims 1, 8, and 12, the likelihood to control the frequency and amplitude of oscillation by a magnetic vibrator is achievable.
According to claim 1 and the presented drawings, changing from a static state to a flexible state in printing concrete mold is conducted by airbags.
According to claims 1 and 14, changing the height of the conductor rails of the movable mold wheel at the time of entry and exit at the ground level is made possible by the expanded airbags.
According to claims 1 and 8, the extruder is designed with the capability of injecting 4 heterogeneous materials with time intervals.
According to claims 1, 8, and 16, placing deforming basalt fibers as reinforcement in printed concrete is carried out by an on-site printer