Modular construction blocks and methods

Abstract

A modular nuclear shield wall construction block (1, 40) is disclosed, which includes a framework (30) formed from a basalt fiber reinforced polymer composite material and concrete interspersed within the framework, the block being configured to interlock with corresponding blocks in one or more dimensions. A method (500) for forming the modular construction block (1, 40) and a method (600) for forming a modular structure are also disclosed.

Description

[Technical Field]

[0001] MODULAR CONSTRUCTION BLOCKS AND METHODS FIELD OF THE DISCLOSURE The present disclosure relates particularly, but not necessarily, to modular construction blocks comprising basalt fiber reinforced polymer composites and concrete, the blocks being stackable in three dimensions. [Background technology]

[0002] In construction, it is desirable for a structure to be constructed in a cost-effective and time-efficient manner while still meeting structural requirements. In construction specialties, there may be additional structural requirements.

[0003] In the field of biological shielding ("bioshields") for nuclear reactors, the bioshields may be required during operation to absorb radiation emanating from the reactor while meeting specialized fire and physical impact requirements. After operation, during decommissioning of the nuclear facility, it may be desirable to reduce any dismantling requirements, for example, by reducing (e.g., eliminating) the amount of any radioactive waste generated from bioshield components. Summary of the Invention [Means for solving the problem]

[0004] According to an aspect of the present disclosure, a modular construction block is provided. The modular construction block may include a fiber-reinforced polymer composite (e.g., a basalt fiber-reinforced polymer composite) and / or concrete. The blocks may be stackable (capable of interlocking or joining with other blocks) in the x-direction (e.g., along the wall length), the y-direction (e.g., along the wall depth or thickness dimension), and / or the z-direction (e.g., along the wall height) (e.g., stackable in any one, two, or three of the x-, y-, or z-directions). The blocks may be stackable along three directions. The blocks may include protrusions and recesses (e.g., grooving) on faces perpendicular to the x-, y-, and / or z-directions that are configured to interact with corresponding protrusions and recesses on opposite faces of adjacent blocks to enable interlocking between stacked modules in the x-, y-, and / or z-directions. This aspect may be used in conjunction with and / or form part of any of the following aspects:

[0005] According to another aspect of the present disclosure, a modular construction block for a nuclear shielding wall (e.g., a modular nuclear shielding wall construction block) is provided, the block comprising a fiber-reinforced polymer composite material. The block may comprise a framework formed from the fiber-reinforced polymer composite material. The fiber-reinforced polymer composite material may be a basalt fiber-reinforced polymer composite material. The block may comprise concrete, for example, encased within the framework. The block is configured to interlock with corresponding blocks (e.g., second and / or identical blocks) in one or more dimensions. The block may be stackable (e.g., capable of interlocking or bonding with other blocks to increase the dimensions of the resulting structure). The block may be stackable in the y or depth dimension (e.g., interlocked along a plane substantially perpendicular to the y or depth dimension).

[0006] The block may include a skeleton of fiber-reinforced polymer composite material. The skeleton may define the block (e.g., its outer dimensions and / or geometric shape). The skeleton may be contained (e.g., completely contained) within the block. The skeleton may not extend beyond the block.

[0007] The framework may define an interior volume. The framework may define an array of cells (e.g., cells within the exterior dimensions of the framework). The array may be an array of at least 2x2 cells, such as at least 6x4 cells, such as at least 5x3 cells in the xy plane. Each cell may have an interior volume. Concrete may be dispensed into multiple cells such that the concrete is dispensed in places within the framework (e.g., concrete may be dispensed between various parts of the interior framework). The framework may include a corrugated plate sandwiched between two additional plates (e.g., a sandwich between two non-corrugated plates, such as substantially flat or arcuate plates).

[0008] Each cell may have a uniform cross-section in the xy plane at any position along the z-axis. The or each cell may extend substantially uniformly along the z-direction. Each cell may have (e.g., consist of) a substantially trapezoidal cross-section in the xy plane. The cells may be tessellated (e.g., in the xy plane). The cells may be disposed directly adjacent to each other without interstitial spaces, such that the boundaries of adjacent cells may be continuous. The framework may comprise a trapezoidal prismatic honeycomb-type structure.

[0009] The blocks may be linear. They may be arcuate (e.g., perpendicular to the z-direction) or curved. Blocks may be configured to stack with other blocks in the x-direction, or circumferential direction, to form curved or fully circular structures. Blocks may be configured to stack with other blocks in the y- or radial direction, to increase the depth dimension of the structure. Each cell may include a substantially trapezoidal cross-section in the xy-plane, having two concentric arcuate sides and two parallel sides. As the distance from the center increases (e.g., within a block and between blocks), the length of the concentric arcuate sides may increase.

[0010] At least one pair of adjacent cells in the block may include an opening configured to allow communication between the interior volumes of the at least one pair of adjacent cells.

[0011] The blocks may be stackable in the x / length dimension and / or the z / height dimension (e.g., configured to interlock or bond with another block to increase the size of the resulting structure along the x and / or z directions, respectively). The blocks may include protrusions and / or recesses in a plane perpendicular to the x, y, and / or z directions (e.g., in a plane perpendicular to any one, two, or three of the x, y, and z directions). The protrusions may be configured to be received within recesses provided in corresponding faces of adjacent blocks. The recesses may be configured to receive the protrusions provided in corresponding faces of adjacent blocks. When stacked, one block may thereby overlap (e.g., coincide) with an adjacent block along the stacking dimension.

[0012] The blocks may be stackable in the x and / or y dimensions with a riveting arrangement on a surface perpendicular to the x and / or y directions, respectively. The blocks may include corner pieces. The blocks may be configured to mate with blocks extending substantially perpendicular thereto. The blocks may include a 45-degree face configured to mate with a corresponding 45-degree face of an additional block to form a wall corner.

[0013] Some of the cells may be offset along the z-axis so that the cells may protrude from the face of the block perpendicular to the z-direction, and the blocks may include a corresponding array of recesses on the opposite face perpendicular to the z-direction so that the blocks are stackable along the z-direction.

[0014] The fibers may include basalt fibers. The composite may include about 30% by volume basalt fibers. The polymer may include epoxy. The polymer may include a coating on sand or aggregate.

[0015] The block may contain concrete. The concrete may be provided within the interior volume of the cells. The concrete may be graded between the cells. Some of the cells (e.g., at least one cell) may be free of concrete. The polymer may be vulcanized prior to pouring the concrete so that the concrete cannot penetrate the composite and / or basalt fibers are provided around each concrete element. The composite may be self-supporting (e.g., by vulcanizing the polymer prior to pouring the concrete).

[0016] The x-direction may correspond to the length or circumferential dimension of the block and / or resulting structure. The y-direction may correspond to the depth, thickness, or radial dimension of the block and / or resulting structure. For example, the y-direction may be parallel to the shortest dimension of the block. The z-direction may correspond to the height direction of the block and / or resulting structure (e.g., opposite to the direction of gravity).

[0017] Each block may be airtight between opposing faces. Stacked blocks may include an airtight connection or seal between them, which may resist pressure waves. The framework may include a lifting feature, such as a female connector configured to receive a male connector, to allow manipulation of the blocks during assembly of the modular structure.

[0018] According to another aspect of the present disclosure, there is provided a structure including a plurality of modular building blocks (e.g., a plurality of identical or corresponding modular building blocks) according to any of the previous aspects. The structure may include stacked or interlocked blocks (e.g., along the x-, y-, and z-directions). The structure may include a nuclear shielding wall or a bioshield. The modular blocks may include uniform geometric shapes and dimensions (e.g., in each of the x-, y-, and z-directions).

[0019] According to another aspect of the present disclosure, a method of forming a modular block is provided. The method may include forming (e.g., by pultrusion along the z-direction) a fiber framework (e.g., a basalt fiber framework), which may include a trapezoidal prismatic honeycomb-type structure.

[0020] The method may include impregnating the fiber scaffold with a polymer (e.g., an epoxy adhesive) to form a fiber scaffold (e.g., a basalt fiber polymer composite scaffold). The method may include applying aggregate (e.g., sand) to the interior surfaces of the cells (e.g., to adhere to the epoxy).

[0021] The method may include vulcanizing a polymer (e.g., an epoxy resin). The method may then include pouring concrete, for example, into the interior volume of the cell. The concrete may then be allowed to harden.

[0022] According to another aspect of the present disclosure, a method of forming a modular structure (e.g., a nuclear shielding wall or a bioshield) is provided, the method including stacking a first modular construction block and a second modular construction block. The first block and the second block may be stacked in an x / length dimension, a y / depth dimension, and / or a z / height dimension (e.g., any one, two, or three of the x / length dimension, the y / depth dimension, and the z / height dimension). The method may include stacking additional blocks in the x dimension, the y dimension, and / or the z dimension. The modular structure may be formed after the concrete has solidified.

[0023] To avoid unnecessary duplication of effort and repetition of text herein, certain features are described in relation to only one or a few aspects or embodiments of the invention, but it will be appreciated that a feature described in relation to any aspect or embodiment of the invention may also be used in any other aspect or embodiment of the invention, where technically possible.

[0024] For a better understanding of the present invention, and to show more clearly how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which: [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 1 is a perspective view of a modular construction block according to the present disclosure; [Figure 2] 1 is a cross-sectional view in the xy plane of a modular construction block according to the present disclosure. FIG. [Figure 3] FIG. 3 is a perspective view of an exemplary composite of the modular construction block of FIGS. 1 and 2. [Figure 4] FIG. 1 is a cross-sectional view in the xy plane of a curved modular construction block according to the present disclosure. [Figure 5] 1 is a flow diagram of an exemplary method for forming a modular construction block. [Figure 6] 1 is a flow diagram of an exemplary method for forming a modular structure. DETAILED DESCRIPTION OF THE INVENTION

[0026] Like reference numbers are used to refer to like features.

[0027] Linear Blocks 1 and 2, a modular building block 1 includes an array of trapezoidal prismatic cells 10 each having a trapezoidal prismatic interior volume 20.

[0028] The trapezoidal cells 10 are tessellated in the xy plane. Along the x direction, the short parallel sides of one cell 10 are adjacent and collinear with the long parallel sides of an adjacent cell 10. Along the y direction, the long parallel sides of one cell 10 are back-to-back with the long parallel sides of an adjacent cell 10, and the short parallel sides of one cell 10 are back-to-back with the short parallel sides of an adjacent cell 10.

[0029] In other words, in the xy plane, adjacent cells 10 along each of the x and y directions are disposed at 180 degrees relative to one another. The cells 10 are thereby tessellated such that one cell is disposed directly adjacent to another cell 10 with no gap space between them. The boundary of one cell 10 may thereby be continuous with the boundary of an adjacent cell 10.

[0030] Each cell 10 extends uniformly along the z direction such that its trapezoidal shape in the xy plane extends along the z direction, forming a trapezoidal prismatic internal volume 20. The block 1 thereby comprises a honeycomb-type structure when viewed along the z direction, as shown in FIG.

[0031] At various locations along the z direction, block 1 may include a substantially uniform cross-section in the xy plane, regardless of the z-direction location of the cross-section. For example, block 1 may include a uniform cross-section in the xy plane throughout a central majority of block 1 in the z dimension. Toward the ends of block 1 in the z dimension, block 1 may include a cross-section in the xy plane that differs from the central majority (e.g., includes protruding cells and recessed cells), as described below.

[0032] The collective structure formed by the cells 10 is referred to as a framework 30 which defines an array of interior volumes 20 separated by boundaries of the cells 10. The structure of the framework 30 is described below.

[0033] Stackable in x and y dimensions A block 1 parallel to and extending along the z direction includes four faces, two faces 3 being substantially perpendicular to the x direction and two faces 5 being substantially perpendicular to the y direction.

[0034] On face 5, every other cell 10 is omitted so that face 5 includes a series of trapezoidal grooves 5a spaced apart by trapezoidal tongues 5b of cells 10. Specifically, trapezoidal tongues 5b include cells 10 with their short parallel sides pointing outward rather than their long parallel sides. Each groove 5a may thereby be defined by two angled sides and one short parallel side of three different cells 10. In this manner, trapezoidal grooves 5a have their long parallel sides outermost such that they are configured to receive corresponding tongues 5b of adjacent blocks 1 during assembly of multiple modular construction blocks 1. In effect, face 5 forms a chamfered surface configured to interact with a corresponding chamfered surface on a corresponding face 5 of an adjacent block 1 to stack the two blocks 1 in the y dimension.

[0035] Similarly, on face 3, every other cell 10 is omitted such that face 3 includes a series of trapezoidal grooves 3a spaced apart by trapezoidal tongues 3b of cells 10. Specifically, trapezoidal tongues 3b include cells 10 having angled sides facing outward. Each groove 3a may thereby be defined by one angled side, one short parallel side, and one long parallel side of three different cells 10. In this manner, grooves 3a are configured to receive corresponding tongues 3b of adjacent blocks 1 during assembly of the plurality of modular construction blocks 1. Face 3 thereby forms a chamfered surface configured to interact with a corresponding chamfered surface on a corresponding face 3 of an adjacent block 1 in the assembled modular building.

[0036] The faces 3, 5 are configured to thereby form tongue and groove joints with adjacent blocks 1 along the x and y directions. The modular blocks 1 can thereby be stacked along each of the x dimension (wall length) and y direction (wall depth) so that structures of desired dimensions can be modularly constructed.

[0037] In an embodiment not shown, the block 1 may include a corner piece in which the faces 3, 5 may be configured to mate with corresponding faces of a further block 1 extending substantially perpendicular thereto. For example, the bevel arrangement of one of the faces 3, 5 may be provided with a bevel configured to interlock with a bevel on the other face 3, 5 of the perpendicular block 1. Alternatively, the block 1 may itself include a right angle such that the block 1 itself forms a corner piece separate from the further block 1.

[0038] In a further embodiment not shown, a block 1 may include a corner piece having a face extending at 45 degrees to the x and y directions, which may be configured to mate (e.g., by a clevis arrangement) with a corresponding block 1 having a 45 degree face, such that two blocks 1 having 45 degree faces together define a corner of a wall.

[0039] Stackable in the z dimension Block 1 includes two faces 7 that are substantially perpendicular to the z-direction, with only one face 7 being visible in Figure 1. As shown in Figure 1, the majority of cells 10 terminate at the same location along the z-direction. A minority of cells 10 terminate at different locations along the z-direction, such that a minority of cells 10 protrude from the majority of cells 10. In this manner, face 7 includes several protruding cells 7b that protrude substantially beyond the majority of cells 10 in the z-direction.

[0040] 1, the protruding cells 7b are spaced apart from one another along the x-direction by three intervening cells 10. Similarly, the protruding cells 7b are spaced apart from one another along the y-direction by one intervening cell 10. In this way, the protruding cells 7b have the same orientation, with their long parallel sides pointing in the increasing y-direction.

[0041] Of course, the exact number of intervening cells 10 along the x and y directions between the protruding cells 7b may vary according to particular requirements, but it may be desirable to maintain an odd number of intervening cells 10 so that the protruding cells 7b maintain the same orientation.

[0042] On the face 7, which is not visible in FIG. 1 , the block 1 includes an array of trapezoidal prismatic recesses that correspond in protruding dimension along the z-direction to the spacing of the protruding cells 7 b on the visible face 7. For example, each cell 10, whether protruding or not, may include the same dimension along the z-direction. Thus, the protruding dimension of a protruding cell 7 b may be equal to the depth of the corresponding recess on the opposite face 7.

[0043] Of course, due to the uniform cross-section and orientation of each cell 10, the protruding cells 7b and corresponding recessed portions will have the same orientation. The lower surface 7, not visible in FIG. 7, thereby includes an array of corresponding recessed portions, each recessed portion configured to receive a protruding cell 7b of a corresponding surface 7 of an adjacent block 1 in the assembled modular building. The blocks 1 may thereby be stacked in the z-dimension (wall height) so that structures of desired height dimensions may be modularly constructed.

[0044] The cells 10 may not include an end face perpendicular to the z-direction so that a fluid, suspension, or mixture (eg, wet concrete) is poured into each cell 10 along the z-direction.

[0045] Although shown aligned along the x-direction in Figure 1, the protruding cells 7b that are spaced apart along the y-direction do not necessarily need to be aligned along the x-direction, for example, two protruding cells 7b may not occupy the same location along the x-direction.

[0046] In this method, the blocks 1 include protrusions 7b and recesses on opposite faces, which are configured to engage with corresponding recesses in adjacent blocks 1 along the z-direction in the assembled modular building, so that the adjacent blocks 1 are in fact interlocked along the z-direction.

[0047] The modular blocks 1 include structures configured to cooperate with adjacent blocks 1 along each of the x-, y-, and z-directions, such that adjacent blocks can interlock and / or connect. The modular blocks 1 can be stacked along one or more of the x-, y-, and z-directions, such that modular structures of any dimensions can be constructed from multiple modular blocks 1 (e.g., multiple identical modular blocks 1).

[0048] When compared to prior blocks that do not include a cooperating or interlocking arrangement or to the same extent, the interlocking arrangement between adjacent blocks 1 can eliminate shine paths (e.g., straight lines through the structure along which radiation may leak) between adjacent blocks 1 (e.g., in each of three directions).

[0049] Although shown with eight cells 10 in the y dimension and four cells 10 in the x dimension, those skilled in the art will understand that if an arrangement of tongues 3b, 5b and grooves 3a, 5a is present on the outer surfaces 3, 5, the block 1 may include a greater number of cells 10 in one or more of the x and y dimensions.

[0050] By providing modular construction blocks, it is possible that during the decommissioning phase, only those blocks that have received the greatest amount of radiation (e.g., only those cells that may have activated components) need to be removed.

[0051] framework Referring to Figure 3, an exemplary structure of a framework 30 is depicted. The framework 30 includes a corrugated sheet 32 having a repeating trapezoidal shape in the xy plane and a uniform cross-section with distance along the z direction. The framework 30 further includes a pair of sandwich panels 34, 36 that sandwich the corrugated sheet 32 between them. Specifically, the sandwich panels 34, 36 substantially abut the short, parallel sides of the repeating trapezoidal shape of the corrugated sheet 32.

[0052] Each trapezoidal cell 10 is formed by cooperation between a corrugated sheet 32 and a sandwich panel 34, 36. In particular, one of the sandwich panels 34, 36 forms the long parallel sides of each cell 10 in a plane perpendicular to the y direction. Adjacent cells along the x direction can be formed by cooperation between the corrugated sheet 32 and the other of the sandwich panels 34, 36.

[0053] Of course, each sandwich panel 32, 34 can form long parallel sides to the cell 10 on both sides, such that each panel 32, 34 can form a continuous long parallel side to the cell, being adjacent to each other along the y direction at 180 degrees to each other.

[0054] In addition to or as an alternative to the example of Figure 3, cells 10 may be formed by individual trapezoidal prismatic cells that are separate from and distinct from other frame cells, such that each individual cell 10 is displaceable along the z-direction relative to the other cells 10. For example, some rows of cells (extending along the x-direction) may be formed by the arrangement of corrugated sheets 32 and sandwich panels 34, 36 of Figure 3, while other rows (e.g., intervening rows) may be formed by individual trapezoidal cells. Alternatively, protruding cells 7b may be provided between the ends of adjacent corrugated sheets 32 as individual trapezoidal prismatic cells. The protruding cells 7b and the corresponding recesses may be formed by displacing portions of the individual trapezoidal cells along the z-direction.

[0055] Whether formed by individual trapezoidal cells and / or the arrangement of corrugated sheets 32 and sandwich panels 34, 36 of FIG. 3, the framework 30 comprises a basalt fiber reinforced composite material. The composite preferably contains 30% basalt fiber by volume. The polymer may include epoxy. The fibers may be unidirectional with a uniform distribution along the z-direction. The composite may be formed by pultrusion along the z-direction.

[0056] The inventors have determined that the fire-resistant properties of basalt fiber make it desirable as a construction material, particularly for nuclear reactor bioshields. Basalt fiber-reinforced polymer composites may thereby replace rebar bars as a construction material. Those skilled in the art will appreciate the advantages of construction materials including basalt fiber rather than steel when exposed to high temperatures.

[0057] Additionally, the basalt fiber reinforced composite has the advantage that it does not become activated when exposed to radiation (eg, neutrons and / or gamma rays) over the course of the bioshield's approximately 40 year lifespan.

[0058] In terms of scale, each block 1 may have a height of about 3m.

[0059] Concrete filling The trapezoidal prismatic interior volume 20 of each cell 10 of the framework 30 is filled with concrete and allowed to solidify. Thus, the framework 30 serves as a reinforcing structure for the concrete. However, the nature of the reinforcing may differ from existing concrete reinforcing devices in that the cells 10 of the framework 30 may fully contain the reinforced concrete and divide it into individual volumes 20, rather than being an open mesh through which the concrete extends continuously.

[0060] The individual properties of each volume 20 may allow the concrete within block 1 to be graded. Specifically, the properties of the concrete poured into each volume 20 may vary depending on the location of block 1 within the final structure. For example, within the bioshield, concrete having a higher density with a higher radiation absorption capacity (e.g., boron-containing concrete including boron frit and / or barite sand) may be provided closer to the radiation source within the final structure, and / or concrete having a lower density (e.g., boron-containing concrete including elemental boron, boron oxide, and / or boron carbide) may be provided further from the radiation source within the final structure.

[0061] Additionally or alternatively, the individual nature of each volume 20 may allow some cells 10 to not be filled with concrete. In this manner, scientific equipment (e.g., detectors such as radiation detectors or other monitoring devices) may be placed in the otherwise empty cells 10 so that real-time data can be collected during operation.

[0062] A percentage (e.g., none, some, or all) of the cells 10 may include communication openings so that the internal volume of one cell 20 may communicate with the internal volume of an adjacent cell. The presence of such communication openings may improve filling of the block 1 during the concrete pouring procedure. Additionally or alternatively, data cables may pass through the openings between the cells 10. This may facilitate the transmission of data from chemical equipment located in the otherwise empty cells 10.

[0063] The pouring of concrete into blocks 1 can be performed off-site, so that blocks 1 are delivered to the construction site already containing solidified concrete. This can have the advantage of reducing construction time, as separate blocks 1 cool faster than an aggregate structure. Furthermore, the application of vibration to the concrete facilitates the concrete being poured in a smaller volume, so that the presence of air pockets is reduced (e.g., eliminated), thus improving the mechanical strength of the final structure.

[0064] The use of concrete combined with basalt fiber reinforced composites, rather than steel, as the reinforcing material may offer the advantage of closer coefficients of thermal expansion.

[0065] curved block Referring to Figure 4, a curved embodiment of a modular construction block is depicted. The modular construction blocks 41, 42 (collectively 40) are identical to modular construction block 1 of the previous figure with the following exceptions.

[0066] The blocks 40 include a curvature with a large radius relative to the scale of the blocks 40. The blocks 40 are configured to be stacked circumferentially with other blocks to form a curved or fully circular structure, such as a bioshield wall intended to enclose a nuclear facility. The blocks 40 are configured to be stacked radially to increase the depth dimension of the structure. In the example shown in FIG. 4, each block 40 includes a 12° arc relative to the final structure, and has a height of approximately 3 m.

[0067] Each of the short "parallel" sides and the long "parallel" sides of each substantially trapezoidal cell 49 includes a circular arc. Thus, the "parallel" sides of each trapezoidal cell 49 are concentric arcs, with the center defined as the center of the modular structure of which the blocks are intended to form a module. More precisely, each substantially trapezoidal cell 49 includes a sector minus a concentric sector having the same arc angle but a smaller radius. The arcuate concentric sides of the cell 49 increase in length with radial distance from the center of each block 40. Each substantially trapezoidal cell 49 further includes two angled sides.

[0068] The two modular blocks 41, 42 shown in FIG. 4 represent the innermost and outermost blocks 42, 41 of such a curved structure. Thus, the innermost block 42 includes a continuous inner surface 42a, while the outermost block 41 includes a continuous outer surface 41a. These continuous surfaces 41a, 42a can be achieved by providing the final sandwich panels 34, 36 on the innermost or outermost surfaces. Additionally or alternatively, to form the continuous surfaces 41a, 42a, the plane can be formed by providing a complete row of individual substantially trapezoidal cells 49 such that the short arcuate sides of the cells 49 alternate with the long arcuate sides of the cells 49. In other words, the riveting arrangement can be omitted on the innermost and outermost surfaces 42a, 41a. Those skilled in the art will appreciate that the riveting arrangement of the blocks 1 can also be omitted in linear embodiments to provide a continuous outer surface on the innermost and outermost blocks.

[0069] Those skilled in the art will appreciate from the above that curved modular construction blocks 40 having inlay features on each face extending in the z direction (e.g., oriented substantially in the x / circumferential and y / radial directions) in the same manner as faces 3, 5 of block 1 may be provided between the innermost and outermost blocks 40 and stacked in three dimensions to increase the overall size of the structure. Additionally, faces 7 perpendicular to the z direction may also be provided on blocks 40 such that blocks 40 are stackable in the z dimension.

[0070] Due to the above discussion, one skilled in the art will further appreciate that modular blocks 1 may need to be pre-ordered (e.g., have their location and therefore dimensions in the final modular structure pre-determined) to achieve a structure of a particular inner diameter and thickness. This may differ from linear block 1 embodiments in which the same blocks may be used throughout the structure (e.g., with the exception of innermost blocks, outermost blocks, and possibly end blocks).

[0071] How to Form Blocks Referring to Figure 5, a method 500 of forming modular construction blocks 1, 40 is depicted. The method 500 includes the step 502 of forming a fiber framework (e.g., with protrusions along the z-direction). The fiber framework may include a trapezoidal prismatic honeycomb-type structure as described above in connection with Figures 1-4. The fibers may also include basalt fibers.

[0072] The method 500 includes step 504 of impregnating a fiber skeleton with an epoxy adhesive to form a fiber skeleton 30. The method 500 includes step 506 of applying aggregate (e.g., sand) to the interior surfaces of the cells 10 (e.g., to adhere to the epoxy).

[0073] The method 500 includes the step 508 of curing the epoxy resin, followed by the step 510 of pouring concrete into the interior volume 20. The concrete may then be allowed to harden.

[0074] Thus, in the installed structure, the modular blocks 1, 40 may include basalt fiber and epoxy forming a basalt fiber reinforced polymer composite, concrete, and sand, which may form a mechanical interlock between the composite and the concrete to improve the overall mechanical properties of the blocks 1, 40. It will be understood by those skilled in the art from the method described above that the concrete does not impregnate the composite.

[0075] Method for forming a structure 6, a method 600 of forming a modular structure is described. The method 600 includes a step 602 of stacking a first block 1, 40 and a second block 1, 40 in the y / depth dimension. The method 600 further includes a step 604 of stacking additional blocks 1, 40 in the x, y, and / or z dimensions.

[0076] While the present invention has been described by way of example with reference to one or more examples, it will be understood by those skilled in the art that it is not limited to the disclosed examples, and that alternative examples may be considered without departing from the scope of the invention as defined by the appended claims.

Claims

1. a framework formed from a fiber-reinforced polymer composite material; Concrete placed in places within the framework Including, 1. A modular nuclear shield wall construction block, wherein the blocks are configured to interlock with corresponding blocks in at least two of the x or length dimension, the y or depth dimension, and the z or height dimension.

2. 2. The block of claim 1, wherein the framework defines an array of cells, each having an interior volume, and optionally the cells are tessellated.

3. 3. The block of claim 2, wherein each cell comprises a uniform cross-section in the xy plane at any location along the z-axis.

4. A block according to claim 2 or 3, wherein the cells comprise substantially trapezoidal cross sections in the xy plane.

5. 5. The block of claim 2, wherein at least one pair of adjacent cells includes an opening configured to allow communication between the interior volumes of the at least one pair of adjacent cells.

6. The block of any one of claims 1 to 5, wherein the block is configured to interlock with corresponding blocks in the x or length dimension, the y or depth dimension, and the z or height dimension.

7. 7. A block according to any one of claims 1 to 6, wherein the blocks are stackable in the x or length direction and / or y or depth direction by a flickering arrangement on a face of the block perpendicular to the x or length dimension and / or y or depth dimension, respectively.

8. 8. A block according to any one of claims 2 to 7, wherein some of the cells are offset along the z axis such that some of the cells protrude from a face of the block perpendicular to the z or height direction, and optionally the block includes a corresponding array of recesses on an opposite face such that the blocks are stackable along the z or height direction.

9. The block of any preceding claim, wherein the fiber reinforced polymer composite material comprises a basalt fiber reinforced polymer composite material.

10. The block according to any one of claims 1 to 9, wherein the block is linear or arcuate.

11. A block according to any one of claims 2 to 10, wherein concrete is provided within the internal volume of the cells.

12. 12. The block of claim 11, wherein the concrete is graded between cells and / or some of the cells are free of concrete.

13. A method for forming a block according to any one of claims 1 to 12, comprising the steps of: forming a fiber reinforced polymer composite scaffold; pouring concrete into the framework; A method comprising:

14. A structure comprising a plurality of modular construction blocks according to any one of claims 1 to 12.

15. 13. A method of forming a modular structure, the method comprising stacking a first modular construction block according to any one of claims 1 to 12 and a second modular construction block according to any one of claims 1 to 12.

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