Patent Application
20240287793
Embodiments of the present disclosure relate to reinforcement or repair of structural elements, such as walls, panels, and slabs.
Structural elements, such as such as wall, retaining wall, sheer wall, panel, slab, column, butress, dike, levy, or any other structure can develop degradation in the structural element, including cracks, fissures, gaps, breaks, tears, spalling, or rifts in the structural elements. Some cracks are covered over, masked, filled, or patched using putty, paint, plaster, cement-based products, petroleum-based products such as tar, or epoxy resins.
Structures that can develop cracks in structural elements include buildings such as homes, offices, retail space, manufacturing spaces, bridges, dams, panels, and other structures. In many cases, soils provide a base or platform on which the building can rest, and that can serve to support the building. Soils can exhibit fluid characteristics, and as a consequence, a solid base such as a foundation, is generally provided as part of building construction. While a foundation may provide a more stable substructure or base than bare soil, the fluid properties of soils can compromise a foundation, or cause the foundation to weaken, degrade, or fail. Many different types of soils are encountered in different geographic locations and in different building situations, which can require adaptations so that the building foundation interacts with the soil in such a way as to provide adequate support and reduces, minimizes, or maintains relative movement of the building and the soil within acceptable tolerances.
Foundation 16 can be disposed in, and supported by, native soil 24. Soil 24 can also provide support for floor slab 26. Slab on grade construction may include a concrete floor slab 26 that can be poured, formed, or built within a perimeter formed by the stem wall 14. Floor slab 26 can be in contact, and often direct contact, with leveled or graded soil. The graded soil can be formed as a prepared pad of soil that has been compacted for stability and built to a particular elevation or grade to account for drainage away from the building and other issues. Advantageously, an intermediate layer of engineered soil or an aggregate base course (ABC) 28 including rock, sand, and dirt can be deposited, graded, wet, and compacted over native soil 24 before placing and finishing concrete floor slab 26 to reduce soil movement and attendant cracking of floor slab 26.
In other instances, foundation 16 may be disposed in, and supported by, native soil 24 while the floor is elevated above, and not in direct contact with, the soil 24. In such instances, an airgap or crawl space may be disposed or formed between the floor and the soil 24.
Movement and settling of structure 10, as well as changes in pH can put stress on structural elements 50, such as concrete or masonry wall 18, and cause crack or cracks 56 to form in the structural element 50 or wall 18. There is a need in the art for improved methods of repairing, limiting, and preventing cracking in structural elements 50, such as walls 18.
In some instances, cracks 56 in structural elements 50, such as concrete structural walls may occur, or be increased or accelerated by, changes in the structural elements 50. Concrete begins with a high alkaline level (normally with a pH of about 13). Over time, the concrete becomes more acidic due to carbonization of CO2 and high sulfate levels. Concrete also includes millions of pores that contain moisture. Over time moisture is absorbed by the concrete of a structural element 50, such as through the footing 12, the stem wall 14, and the walls 18, with the moisture wicking up through the concrete or masonry. Moisture that contacts and passes through the structural element 50 can come from a variety of sources, including storm run-off from the roof, storm water in the yard, plumbing leaks, underground moisture/vapor, irrigation, and from neighbors or adjoining properties. Taken together, the high pH of the concrete, mortar or grout 54, the moisture in the concrete pores, and the iron or rebar develops a micro electrochemical current. The micro electrochemical current deposits chloride ions (Cl−) on the iron or rebar that catalyzes rapid iron oxidation (Fe2O) or rusting. As iron oxidizes the iron or rebar increases in volume and produces tensile pressure within the structural element 50, which leads to increased cracking and breaking,
Fixing degraded sections of structural elements is important in maintaining structural integrity. Repairs such as filling in or covering cracks in the structural elements are often cosmetic, and insufficient for long term health of the structural elements, such as wall, retaining wall, sheer wall, panel, slab, column, butress, dike, levy, or any other structure. A need exists for better methods of repairing structural elements or for preventing or reducing degradation in the structural element, including cracks, fissures, gaps, breaks, tears, spalling, or rifts in the structural elements.
In some aspects the disclosure addresses this need by providing methods of reinforcing a structural wall comprising identifying a weakened area of wall that comprises cracks; forming at least one channel in the wall with a first portion of the at least one channel disposed adjacent the weakened area; and affixing a plurality of laminate strips to the structural wall by: disposing an adhesive and the laminate strip within the at least one channel, such that the adhesive fills openings formed in the laminate strip, wherein the laminate strips are positioned at differing and irregular angels on the structural wall. It should be noted that either the adhesive or lamiante strip may be first placed in the at least one channel followed by the other element being placed in the at least one channel.
In certain aspects, the disclosure concerns methods of reinforcing a structural wall comprising affixing a plurality of laminate strips to the structural wall, wherein the laminate strips are positioned at differing and irregular angels on the structural wall.
In other aspects, the disclosure concerns reinforced walls comprising a plurality of laminate strips affixed to the reinforced wall; wherein the laminate strips are positioned at differing and irregular angels on the structural wall.
In yet other aspects, the disclosure concerns kits for reinforcing a structural wall comprising: a plurality of plurality of laminate strips comprising a polymer and carbon fiber; and instructions on how to affix the plurality of strips to the concrete wall such that the laminate strips are positioned at differing and irregular angels on the structural wall.
In some embodiments, the disclosure concerns structural walls, wherein the foundation comprises a footing and a stem wall; an upper portion formed on the foundation, wherein the upper portion comprises slabs, blocks, or brick, of concrete, stone, masonry, adobe, or rammed earth; and a high tensile material disposed within, and extending between, the foundation and the upper portion.
In certain embodiments, the laminate strips are not orthogonal to an interface between the upper portion of the structural wall and the foundation. Some laminate strips are at an angle in a range of 30-90° with respect to an inface between the upper portion of the structural wall and the foundation.
Certain laminate strips comprise a plurality of holes extending completely through the laminate strip, and can be any shape. One example of a laminate strip size is 2-4″ wide 1/16th thick (aprox) and 18-24″ long unidirectional. Some laminate strips are available commercially.
Some laminate strips comprise a polymer and carbon fiber.
As used herein, the phrase “structural wall” means vertical units, slabs, blocks, or brick, of concrete, stone, or masonry. In some embodiments, a high tensile material disposed within the material of the structural wall. In certain embodiments, the high tensile material my extend between, the foundation and the upper portion or structural wall.
The foregoing and other aspects, features, applications, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that she can be her own lexicographer if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors' intent and desire that the simple, plain, and ordinary meaning to the terms be applied to the interpretation of the specification and claims.
The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above.
Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.
The foregoing and other aspects, features, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims.
This disclosure, its aspects and implementations, are not limited to the specific material types, or other system component examples, or methods disclosed herein. Many additional components, construction and assembly procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may include any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.
The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.
As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, “a” or “an” means “at least one” or “one or more.”
Throughout this disclosure, various aspects of the claimed subject matter are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the claimed subject matter. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, where a range of values is provided, it is understood that each intervening value, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the claimed subject matter. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the claimed subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the claimed subject matter. This applies regardless of the breadth of the range.
As used herein, “about” or “substantially” means a percent difference less than or equal to a 50% difference or less, a 40% difference or less, a 30% difference or less, a 20% difference or less, a 10% difference or less, or a 5% difference or less.
While this disclosure includes a number of embodiments in different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the embodiments illustrated.
In some aspects, this disclosure relates methods reinforcing a structural wall 50, comprising identifying a weakened area of wall that comprises cracks; forming at least one channel 70 in the wall with a first portion of the at least one channel 70 disposed adjacent the weakened area; and affixing a plurality of laminate strips 80 to the structural wall by: disposing at least one of the plurality of laminate strips 80 within the at least one channel 70, and disposing the adhesive 100 (such as epoxy paste) within the at least one channel 70, around the laminate strip 80, and through opening formed in the laminate strip 90, wherein the laminate strips 80 are positioned at differing and irregular angels on the structural wall 60. It should be noted that either the adhesice or laminate strip 80 may be placed in the channel 70 first. In some embodiments the channel 70 is disposed through or into the weakened area not just adjacent to the weakened area.
In
Angles ϕ1 and ϕ2 in
One method 300 of repairing a structural wall is presented in
An alternate method 400 of repairing a structural wall is presented in
In some embodiments, the at least one channel 70 is formed by saw cut or sawing. In some instances, the channel or opening 70 may be formed in a direction that is orthogonal or substantially orthogonal to the crack 56, or a trend line 58 that approximates a direction of the crack 56. In other instances, the channel or opening 70 may be formed at an angle in a range of 30-90° to the crack 56 or the trend line 58. In yet other instances, the channel 70 or opening may be made along the crack 56 or the trend line 58. In still other instances, if a crack 56 is large enough, a portion of the crack 56 may be filled with the strip 89 and the adhesive 100.
Channels 70 may be of any suitable size and shape. Some channels 70 are rectangular or approximately rectangular.
Support strip 80, such as laminate strip, reinforcements can be used proactively to prevent or limit future damage, not just for remediation of a damaged wall. For example, the methods described herein can be used in construction of a structural wall or for reinforcing structural walls that have not yet cracked or only have minor damage. In such uses, the laminate strips 80 are positioned at differing and irregular angels on the structural walls 60 as described herein. Channels 70 and adhesive 100 may be used in the attachment of the laminate strips 80. The details concerning the laminate strips 80, positioning and affixing the laminate strips 80 are as described herein.
The disclosure also concerns composite reinforcement systems where a structural wall comprises multiple laminate strips or reinforcement material 80, serving as reinforcement strands, at differing and irregular angles. The reinforcement may recur as a repair for remediation.
An alternate method 500 of reinforcing a structural element is presented in
In some methods, the structural wall 60 comprises a foundation 16, wherein the foundation comprises a footing 12 and a stem wall 14; an upper portion formed on the foundation, wherein the upper portion 52 comprises slabs, blocks, or brick, of concrete, stone, masonry, adobe, or rammed earth; and a high tensile material disposed within, and extending between, the foundation and the upper portion. In some embodiments, the high tensile material is rebar 62 or other suitable material.
Some structural walls 60 are connected to a stem wall that connects the structural wall with the foundation 16. Stem walls 14 may be constructed from concrete or reinforced concrete. The stem wall 14 may comprise masonry, block or other suitable material. In some embodiments, the stem walls 14 comprises block elements comprising grout fill that substantially fills all of the voids within the masonry, including vertical cells. In certain embodiments, at least the first 8 inches of the wall may be filled with grout fill. In certain embodiments, rebar is used as the high tensile reinforcement material.
In certain embodiments, the laminate strips 80 are not orthogonal to an interface between the upper portion of the structural wall 60 and the foundation. Angles that the laminate strips 80 are attached to the wall may be non-perpendicular to the crack. In some embodiments that angles of the plurality of laminate strips 80 vary from each other. In certain embodiments, no more than 25%, 20%, 15%, 10%, 5% or 0% of the laminate strips 80 have the same angle.
Some laminate strips 80 are at an angle in a range of 30-90° with respect to an inface between the upper portion of the structural wall 60 and the foundation. Other laminate strips are at an angle of of 30-85°, 35-80° or 40-75° with respect to an inface between the upper portion of the structural wall 60 and the foundation.
In some embodiments, the laminate strips 80 are sized to fit within the channel.
Certain laminate strips 80 comprise a plurality of plurality of openings 90 formed in the laminate strips 90. In some embodiments, the openings and can be any shape. Any suitable shape of the openings 90 may be used. In some embodiments, the openings have a round or oval shape.
The adhesive 100 or paste can be any material that securely attaches the laminate strips 80 within the channels 70 to the structural wall 60. In some embodiments, the adhesive 100 is an epoxy paste. Some epoxy pastes have a viscosity of 1-3 million centerpoise.
In certain embodiments, the epoxy paste can be inserted into the channel 70 prior to inserting the laminate strip 80. In other embodiments, the epoxy paste can be inserted into the channel after the lamiante strip is inserted.
In certain aspects, the disclosure concerns methods of reinforcing a structural wall 60, comprising affixing a plurality of laminate strips 80 to the structural wall 60; wherein the laminate strips 80 are positioned at differing and irregular angels on the structural wall 60. In some embodiments, the laminate strips 80 are affixed to the structural wall 60 by inserting the laminate strips 80 and epoxy into channels 70 cut into the structural wall 60.
Other aspects of the disclosure concern reinforced structural walls 50 comprising a plurality of laminate strips 80 affixed to the structural wall 60 (such as within a channel 70 cut into the structural wall 60); wherein the laminate strips 80 are positioned at differing and irregular angels on the structural wall 60. The number of laminate strips are based on the needed load. Some strip position and density are designed to deal with uplift wind loads. Some laminate strips are placed in corners of the walls. Other laminate strips are placed elsewhere.
While the laminate strips 80 can be placed on either the inner or outer side of the structural wall 60, typically the inner side of the structural wall 60 is more accessible for the reinforcing process. As such, in some embodiments, the laminate strip 80 is placed in a channel 70 cut into the inside portion of the structural wall 60.
When multiple possible ranges are presented, embodiments include all combinations of numbers within the given range. For example, 35-80° includes 36°, 37°, 38° and all other numbers with 35-80°. Also contemplated are all ranges within 35-80° such as 40-70°.
“Stem walls” are structures that are used to connect a buildings foundation to its walls. In some embodiments, the stem wall is reinforced concrete, masonry, or block. In certain embodiments, the stem wall is connected to a wall constructed from masonry, block, or other suitable material.
In some embodiments, the wall comprises grout fill. This allows for open cells, voids, or columns of the wall to be filled with grout fill such that the structural wall avoid voids between or withing masonry or blocks. Block can be used for stem walls, vertical cells, or the first few inches or feet of the structural wall. While any suitable wall may be utilized, in certain embodiments, rebar may be utilized in the wall as high tensile reinforcement material.
Channels 70 may be formed by any suitable means including by cutting, sawing, or other suitable process. In certain embodiments, at least a portion of the channel may be disposed through a weakened area—not just adjacent to it. In some embodiments, the channel 70 may extend from the stem wall to the structural wall 60.
In some aspects, the disclosure concerns kits for reinforcing a concrete wall comprising (a) a plurality of plurality of laminate strips comprising a polymer and carbon fiber; and (b) instructions on how to affix the plurality of strips to the concrete wall such that the laminate. The laminate strips, polymer, and carbon fiber are as described herein.
The present disclosure includes one or more aspects or embodiments in the following description with reference to the figures, in which like numerals represent the same or similar elements. Those skilled in the art will appreciate that the description is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the disclosure as defined by the appended claims and their equivalents as supported by the following disclosure and drawings. In the description, numerous specific details are set forth, such as specific configurations, compositions, and processes, etc., in order to provide a thorough understanding of the disclosure. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the disclosure. Furthermore, the various embodiments shown in the FIGS. are illustrative representations and are not necessarily drawn to scale.
Where the above examples, embodiments, and implementations reference examples, it should be understood by those of ordinary skill in the art that other systems, devices, and examples could be intermixed or substituted with those provided. In places where the description above refers to particular embodiments of stabilization and construction methods, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these embodiments and implementations may be applied to other technologies as well. Accordingly, although particular component examples may be disclosed, such components may be comprised of any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended purpose, method and/or system of implementation. Thus, the presently disclosed aspects and embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. The disclosed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the disclosure and the knowledge of one of ordinary skill in the art, as set forth in the claims.
