Device and method for controlling the surface pressure of flexible molds on concrete parts reinforced with non-metallic fibers

Abstract

The production of hollow concrete elements reinforced with non-metallic materials, particularly basalt fibers, aims to improve assembly efficiency and enhance resistance to tensile forces through various reinforcement methods. This technique for creating hollow concrete formwork, which incorporates non-metallic reinforcement, is suitable for constructing both permanent and temporary structures, or a combination of the two, and is carried out using flexible molds manipulated by an incompressible fluid. The use of prefabricated hollow concrete formwork, reinforced with non-metallic fibers, supports the construction of elements that can be filled with either concrete or non-concrete materials. Furthermore, the method for producing lightweight concrete components reinforced with non-metallic materials enables buoyancy on water surfaces and the possibility of conversion into solid concrete structures. In the process of fabricating concrete components with complex shapes made from non-metallic fibers, especially basalt, a notable challenge is the detachment of the concrete element from the mold, which frequently leads to surface damage and, in some cases, makes removal from the mold entirely impractical. To address this challenge, the claimed invention proposes two distinct methods that involve the utilization of mechanical or mechatronic arms to apply pressure to the inner surface of the flexible mold, along with the application of fluid pressure during the formation of the concrete piece, followed by a reduction in pressure when separating the piece from the mold.

Description

Device and method for controlling the surface pressure of flexible molds on concrete parts reinforced with non-metallic fibers

[0001] The fabrication of hollow concrete components reinforced with non-metallic materials, preferably utilizing basalt fibers, is designed to enhance assembly and improve resistance to tensile forces through various reinforcement types. The technique for creating hollow concrete formwork, which employs non-metallic reinforcement, is applicable in the construction of both fixed and mobile structures, or a combination thereof, and is executed using flexible molds that are manipulated with an incompressible fluid.

[0002] The application of prefabricated hollow concrete formwork, reinforced with non-metallic fibers, facilitates the construction of both concrete and non-concrete-filled elements. Additionally, the method for producing lightweight concrete components reinforced with non-metallic materials allows for buoyancy on water surfaces and the potential transformation into solid concrete structures.

[0003] The technical field of the above invention is in the field of the construction industry and reinforced concrete parts, especially with the ability to be molded by flexible molds with electronic control of the shape of the mold.

[0004] This claimed invention can be searched through international codes (IPC) and international classified codes (Cooperative patent classification with the abbreviation CPC)), B32B13 / 02, B32B13 / 045, B32B21 / 047, B32B3 / 06, B32B3 / 08, B32B3 / 266, B32B3 / 30, B32B5 / 028, B32B5 / 18, B32B5 / 08, B32B5 / 22, B32B5 / 24, B32B5 / 26, B32B2315 / 06, B63B1 / 107, B63B5 / 20, B63B5 / 22, B63B21 / 50, B63B35 / 44, B63B73 / 30, B63B75 / 00, B63B2021 / 505, B63B2035 / 442, C04B20 / 0068, C04B2111 / 40, C04B2201 / 50, C04B30 / 02, E01D21 / 00, E02D2250 / 0007, E02D2250 / 0023, E02D2300 / 002, E02D2600 / 30, E02D27 / 04, E02D27 / 12, E02D3 / 005, E02D31 / 08, E02D5 / 46, E04B1 / 04, E04B1 / 34823, E04B1 / 38 , E04B1 / 942, E04B2001 / 34884, E04B2001 / 3583, E04C2 / 384, E04C5 / 073, E04C5 / 07, E04C5 / 0604, E04C5 / 0609, E04C5 / 163, E04H1 / 02, E04H1 / 12, E04H1 / 1205, E04H3 / 00 and E04H9 / 021, in search engines and international online databases.

[0005] By searching keywords such as "Basalt AND Foundation", "Fiber AND Foundation", "Reinforced Concrete / Cement", "Basalt AND Cement", "Basalt AND Concrete", "Basalt AND (Reinforced Concrete / Cement)", and "Fiber AND (Reinforced Concrete / Cement)", in international patent databases such as Google Patent, Patent Scope, and Lenz, similar patent documents and declarations were obtained as follows.

[0006] In patent No. US20200232205A1, under the title of "system, method, and apparatus for integrated portable building foundation platform with modular components ", which was registered on 2020-01-22, a shelter has been claimed to be designed which contains 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), has been disclosed wherein the foundation, walls, and roof comprise seamless transitions therebetween.

[0007] In patent No. CN113248208A, under the title of "Steam-curing-free high-strength anti-corrosion tubular pile and preparation method thereof ", which was registered on 2021-06-07, steam-curing-free high-strength anti-corrosion tubular pile, has been claimed to be defined by its composition in parts by weight as follows: 320 parts of cement from a 250-grade charge, 1200 parts of fine aggregate from a 1000-grade charge, 1500 parts of coarse aggregate from a 1300-grade charge, 210 parts of water from a 120-grade charge, 40-60 parts of fly ash, 50-70 parts of mineral powder, 6.5-8.5 parts of a water-reducing agent, 20-25 parts of nano calcium carbonate, 0.12-0.2 part of sodium hexametaphosphate, 2-5 parts of chitosan-modified basalt fiber, and 10-18 parts of polydimethylsiloxane.

[0008] In patent No. WO2021017799A1, under the title of "Construction method for improving bearing capacity of pile foundation on basis of large-diameter mixing", which was registered on 2020-07-13, the construction technique that utilizes large-diameter mixing to enhance the load-bearing capacity of pile foundations have been taken into consideration which involves several key steps. In general, the asserted method is centered around the development of a large-diameter deep mixing construction approach, which employs a mixing drill bit equipped with a mixing jet and a high-pressure rotary jet positioned at the rear of the mixing blade, in conjunction with a mixing drill.

[0009] In patent No. CN107938455A, under the title of "The ruggedized construction and reinforcement means of the roadbed ground of Soft Soil Layer folder basaltic layer structure", which was registered on 2017-11-28, a robust construction method for the roadbed foundation of a soft soil layer over a basaltic layer structure has been disclosed which is claimed to be characterized by the following features: It includes a minimum of two primary reinforcing piles, with the top of each pile extending into the roadbed. The lower end of each primary reinforcing pile sequentially penetrates the soft soil layer, the basaltic layer, and the weak soil located beneath the basaltic layer at the top of the roadbed foundation. Additionally, there is at least one secondary reinforcing pile, which is positioned within the soft soil layer above the basaltic layer.

[0010] In patent No. CN110642564B, under the title of "Crude polypropylene-basalt hybrid fiber, prefabricated hard fiber concrete, jacking pipe and manufacturing method", which was registered on 2019-11-11, a distinguishable jacking pipe by its composition has been disclosed, which consists of prefabricated hard fiber concrete made from a crude polypropylene-basalt hybrid fiber. Each cubic meter of this concrete formulation includes 4 kg of crude polypropylene fibers, 2 kg of basalt fibers, 375 kg of cement, 850 kg of sand, 545 kg of coarse aggregate, 545 kg of fine aggregate, and 3.75 kg of a water-reducing agent. Additionally, the diameter of the crude polypropylene fibers measures 0.8 mm.

[0011] In patent No. WO2021164319A1, under the title of "Environment-friendly composite basalt fiber reef base grid suitable for coral reef substrate restoration and restoration method", which was registered on 2020-11-03, an environmentally friendly composite basalt fiber reef-based grid has been taken into consideration suitable for the restoration of coral reef bottoms, which is characterized in that it comprises a square grid woven from glue-free basalt fiber and the glue-free basalt fiber is embedded with pure basalt fiber. The aluminum wire is fixedly connected with a sleeve made of basalt fiber cloth on the four edges of the grid and a sleeve made of basalt fiber cloth is also provided in the middle, and fixed connection holes are provided on the four corners of the grid.

[0012] In patent No. CN109678417A, under the title of "High-durability Reactive Powder Concrete, pile foundation and preparation method thereof ", which was registered on 2018-12-19, a high-durability reactive powder concrete has been claimed to be designed which encompasses the following constituents in parts by weight: 1000 parts of cement, 220-270 parts of silica fume, 100-200 parts of slag powder, 100-200 parts of fly ash, 1100-1400 parts of quartz sand, 0.2-0.3 part of basalt fiber, 50-100 parts of water reducing agent and 15-25 parts of active activator. The high-durability active powder concrete can effectively avoid the occurrence of corrosion, pulverization, and peeling, and effectively prolong the service life of the concrete.

[0013] In patent No. US20240109811A1, under the title of "Reinforcement bar and method for manufacturing same", which was registered on 2023-10-03, several reinforcement bars for concrete structures have been claimed to be designed which comprise continuous, parallel fibers, made of basalt, carbon, and glass fiber, or the like, embedded in a cured matrix, each bar was made of at least one fiber bundle comprising a number of parallel, cylindrical cross section fibers and said bars being provided with a surface shape and / or texture which contributes to good bonding with the concrete. Part of the surface of each bar being deformed prior to or during the curing by: a) strings of an elastic or inelastic, and / or b) at least one deformed section of each reinforcement bar; thereby producing a roughened surface.

[0014] In patent No. US10767369B2, under the title of "Reinforced concrete building structures and methods for making same", which was registered on 2018-08-02, an insulated reinforced concrete wall panel has been alleged to be implemented which encompasses an outer skin coating comprised of at least one of an acrylic resin, ceramic, and titanium; a concrete panel, a mesh mat, at least two fusion bars extending parallel to one another and in a longitudinal direction parallel to the outer skin and interior skin, each comprising a tilt-up connection and a steel member at least 20″in length, wherein each fusion bar is disposed within the insulated reinforced concrete wall panel at about 2′on center intervals, a rebar rod, one or more wall panel weld plates, a foam panel, and an interior skin.

[0015] In patent No. US11286667B2, under the title of "Seismic foundation framer and method of forming a foundation using same", which was registered on 2018-12-01, A series of seismic foundation frames have been claimed to be taken into consideration to be employed to secure rebar in a stable position, thereby establishing a cementitious support structure that is integrated within the poured concrete, enhancing its strength. Also, it has been noted that the referred frame features an open design with multiple openings, facilitating the flow of concrete and increasing the surface area available for reinforcement. It includes pin openings and rebar openings, which are designed to accommodate and hold pins or rebar, particularly when the frames are stacked. Each frame is equipped with rebar retainers that secure rebar extending perpendicularly from the frame's surface to a second frame at a specified offset distance. Additionally, a flexible containment sleeve is arranged around the frames and can be affixed to them, forming a sleeved structure intended to hold a cementitious mixture. This containment sleeve is designed with apertures to regulate permeation, thereby controlling the curing rate of the cementitious mixture.

[0016] In patent No. WO2023237937A1, under the title of "Two-phase floating foundation using basalt fibers", which was registered on 2023-02-01, a two-phase floating foundation utilizing basalt fibers have been proposed, designed to enhance load capacity and reduce weight through the incorporation of these natural fibers. The foundation comprises several key components: the elevated section, which is capable of retaining air bubbles in visible dimensions and possesses a significant relative thickness compared to other dimensions; the flat section, which is constructed atop the elevated portion with a minimal thickness, facilitating air storage within the foundation; and the lightweight walls and ceiling, which are reinforced with basalt fibers. Additionally, it has been noted that the design allows for rapid connections to both the basalt foundation and a reinforced concrete 3D printing machine equipped with four material outlet nozzles.

[0017] In patent No. CN103964697B, under the title of "A kind of high alkali-resistant basalt fiber composition and application method thereof", which was registered on 2014-04-23, a high alkali-resistant basalt fiber composition has been claimed to be prepared, which is formulated based on weight percentages of the following components: SiO2: 48% to 60.5%, Al2O3: 2.5% to 7.5%, MgO: 0.5% to 4.8%, CaO: 9.35% to 15.5%, Fe2O3 + FeO: 8% to 15%, K2O: 1% to 4.5%, Na2O: 3% to 6%, TiO2: 1% to 3%, ZrO2: 3.5% to 9.5%, and CeO2: 0.5% to 1.3%. Moreover, it is mentioned that the inclusion of CeO2 is advantageous as it enhances the alkaline resistance and improves the wire-drawing performance of the basalt fiber. Utilizing this invention, the basalt fiber produced from these raw materials exhibits excellent mechanical properties and alkali resistance, making it suitable for reinforced cement-based composites and serving as a strengthening agent in high alkali-resistant polymer matrix composites.

[0018] In patent No. CN107761963B, under the title of "Concrete structure assembled architecture system and its assembly method", which was registered on 2017-10-31, a type of architectural system has been claimed that utilizes a concrete structure assembly is characterized by the inclusion of a prefabricated foundation, a structural support frame, at least one precast floor slab, and drywall panels. The prefabricated foundation consists of a pedestal and a concrete column positioned on the pedestal. The structural support frame comprises concrete prefabricated reinforcing props and precast beams. The concrete prefabricated reinforcing props are securely connected to the concrete columns using a bonding agent, and the outer walls of the concrete prefabricated reinforcing props are fitted with multiple anchoring steel structures.

[0019] In patent No. EP3312339B1, under the title of "Gypsum boards suitable for wet or humid areas", which was registered on 2015-10-06, a gypsum board has been disclosed that comprises a gypsum core with at least one side covered by a fibrous mat comprising at least one ply of non-woven fabric and a binder composition, wherein the referred binder composition represents from 10 to 40 wt% of the total weight of the mat; and the mentioned binder composition comprises a copolymer comprising a co-monomer unit of a vinyl ester of an alpha branched aliphatic monocarboxylic acid, said copolymer being present in an amount from 25 to 100 wt% of the binder composition weight.

[0020] In patent No. CN206693244U, under the title of "A kind of basalt composite reinforcing material foundation pit supporting pile", which was registered on 2017-04-07, a novel type of basalt composite reinforcing material for foundation pit supporting piles has been introduced, pertaining to the field of foundation pit support structures. This design features vertical stake holes in the ground, with steel bar fixing supports positioned within these holes, which are subsequently filled with concrete. Surrounding these supports are vertical bars made from basalt composite reinforcing materials. Each outer ring of the vertical bars is equipped with stirrups composed of basalt composite reinforcing material. Additionally, it has been noted that the tops of the vertical bars, which extend above the steel bar fixing supports and the basalt composite reinforcing materials, are designed to accommodate connections with the tops of the stakes located outside the stake holes. This utility model represents a high-strength, corrosion-resistant, and environmentally friendly BFRP (basalt composite reinforcing material) foundation pit supporting pile that is also easy to construct and cost-effective.

[0021] In patent No. CN101503881B, under the title of "Method for reinforcing underwater structure by fiber-reinforced composite material grid ribs", which was registered on 2009-03-18, a method for enhancing an underwater structure utilizing fiber-reinforced composite material lattice ribs has been outlined, which includes the following steps: first, the concrete surface of the underwater structure requiring reinforcement is treated; next, at least one layer of fiber reinforced composite material lattice ribs is applied to the surface of the underwater structure; then, an isolator is positioned outside the underwater structure, ensuring that its height is equal to or greater than that of the coated lattice ribs; subsequently, the concrete at the base of the isolator is sealed; finally, the space between the isolator and the structure is filled with underwater epoxy resin, non-dispersed mortar, or non-dispersed concrete. This process is straightforward, as it eliminates the need for water diversion and the construction of a cofferdam around the underwater structure, resulting in minimal disruption to navigation channels. Furthermore, the method is claimed to be cost-effective and will be able to allow for rapid reinforcement, shorten the construction timeline, and significantly enhance the durability of the structure.

[0022] In patent No. US9394035B2, under the title of "Floating wind turbine platform and method of assembling", which was registered on 2011-11-04, a semisubmersible wind turbine platform has been claimed to be designed, capable of floating on a body of water and supporting a wind turbine over a vertical center column includes a vertical center column and three or more vertical outer columns spaced radially from the center column, each of the outer columns being connected to the center column with one or more of bottom beams, top beams, and struts, with the major structural components being made of concrete and having sufficient buoyancy to support a wind turbine tower.

[0023] In patent No. CN109457625B, under the title of "Steel-concrete combined assembled bridge row frame pier system and construction method", which was registered on 2019-01-15, The steel-concrete combined assembled bridge row pier system, has been disclosed which consists of a pile foundation, hollow steel tube concrete double piers resting on the foundation, I-steel transverse tie beams positioned between the double piers, steel cap beams located at the upper ends of the double piers, supports placed on the upper surfaces of the steel cap beams, and main beams supported by these structures. It has also been noted that the claimed hollow steel pipe concrete double-column pier is composed of inner and outer circular coaxial stainless-steel pipes with an interlayer of plain concrete and the short pier is prefabricated as a single unit, while the high pier is constructed in three prefabricated sections: lower, middle, and upper. The steel bent cap is also prefabricated as a single unit using stainless steel pipes with rectangular cross sections, incorporating in-body prestressed reinforcement and plain concrete. Furthermore, it has been claimed that the connections between the prefabricated pier columns and the pile foundation are cast in situ, with all sections nested locally, and the connection points are secured through welding and bolting. This design employs a double-column bridge bent pier anti-seismic system, which is adaptable for use with a multi-column bent pier system. This bent pier system is relevant to the field of bridge engineering and offers advantages in terms of ease of construction, sustainability, and environmental friendliness.

[0024] In patent No. CN103410332B, under the title of "A kind of concrete hollow block reinforcement wall construction technology", which was registered on 2013-08-07, a specific construction technology for fabricating reinforced concrete hollow block walls has been discussed which claimed to be involved in a detailed sequence of operations: setting out lines → placing reinforcing bars → erecting the wall → grouting the wall body → connecting the collar tie beam to adjacent wall panels with lintel construction → completing the blockwork. Additionally, the said wall body structure of this invention is robust, offering superior overall performance while reducing construction costs. The construction process is straightforward, ensuring high-quality results, rapid application, and effective safety management during construction.

[0025] In patent No. CN110395955B, under the title of "Anti-permeability and anti-freeze-thaw self-compacting concrete and preparation method thereof", which was registered on 2019-08-01, an anti-permeability and freeze-thaw resistant self-compacting concrete and a preparation method thereof has been disclosed which the referred anti-permeability and freeze-thaw-resistant self-compacting concrete, comprises the following components in parts by weight: 370 parts of 350-plus cement, 25-45 parts of fly ash, 25-35 parts of modified metakaolin, 30-50 parts of mineral powder, 800 parts of medium sand 770-plus, 830 parts of gravel 810-plus, 20-40 parts of silica fume, 180 parts of water 170-plus, 1-3 parts of water reducing agent, 20-34 parts of expanding agent, 2-6 parts of air entraining agent and 10-20 parts of fiber composition; the fiber composition is formed by mixing modified polyester fibers, basalt fibers and polyacrylonitrile fibers in a mass ratio of 1:0.6-0.9: 0.3-0.6.

[0026] In patent No. US12024906B2, under the title of "Mobile concrete pump and method for stabilization-relevant control of a mobile concrete pump", which was registered on 2019-03-15, a mobile concrete pump has been disclosed which features a chassis equipped with extendable support legs and a concrete distributor mast, which is capable of rotation and can be adjusted in its inclination through a positioning cylinder connected to a rotating mechanism on the chassis, and the referred concrete distributor mast was claimed to encompass several pivotable mast arms and a processing unit designed to perform a stability calculation that takes into account vertical and / or horizontal forces acting on at least two of the extendable support legs. Additionally, the system is equipped with a control unit that restricts the commencement of a pumping operation based on the results of the stability calculation. Sensors are incorporated to monitor vertical and / or horizontal forces on the extendable support legs, with the stability calculation being based on the load torque and the recorded vertical and / or horizontal forces.

[0027] In patent No. CN112431217A, under the title of "Construction method of large skid-mounted cold box pile-free anti-seismic raft foundation", which was registered on 2020-12-03, a novel construction technique for a large skid-mounted cold box pile-free anti-seismic raft foundation has been introduced, which relies on fabricating upon traditional cold box foundation practices and is specifically designed for rock geological conditions that exhibit strong bearing capacity. By utilizing a pile-free foundation, this approach offers a more convenient and secure construction option. The safety of the cold box foundation construction is enhanced through a comprehensive series of process designs. The construction involves drilling around the foundation, replacing and filling with gravel, pouring a cushion layer, positioning embedded column foot anchor bolts, binding steel bars, installing cooling water pipes, setting up templates, reinforcing template supports, pouring concrete, maintaining the concrete, positioning and retesting foundation bolts, and processing the bolt holes of the cold box bottom plate. These coordinated measures ensure the efficient construction of the large-scale cold box pile-free raft foundation, thereby establishing safe and reliable conditions for the subsequent skid installation.

[0028] In patent No. CN101856577B, under the title of "Heat-resistant basalt fiber filter material and preparation method thereof ", which was registered on 2010-07-06, a heat-resistant basalt fiber filter material and a preparation method thereof has been alleged to be designed which the referred filter materials claimed to be able of being utilized 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.

[0029] In patent No. US10688683B2, under the title of "Method of reinforced cementitious construction by high speed extrusion printing and apparatus for using same", which was registered on 2019-08-07, a comprehensive architectural-scale slip-form molding apparatus has been proposed, which includes a slip-form printing system for reinforced concrete construction and the alleged system has been claimed to be comprised the following components: - A nozzle for a cementitious material pump that dispenses the cementitious material; - An external reinforcing containment sleeve made of a flexible sheet material; - A brick mold attached to the pump nozzle, which moves in conjunction with it, designed to receive the cementitious material from the nozzle to extrude a slip-form printed brick in the desired shape; - The external reinforcing containment sleeve is positioned around the extruded slip-form printed brick; - The external reinforcing containment sleeve advances through the brick mold as the cementitious material is dispensed from the nozzle, resulting in the extrusion of a slip-form printed brick that is reinforced by the external containment sleeve.

[0030] In patent No. CN111056790B, under the title of "High-performance concrete doped with micro-nano-grade fibers and preparation method thereof ", which was registered on 2019-12-13, a high-performance concrete doped with micro-nano-scale fibers and a preparation method thereof has been taken into consideration which belongs to the technical field of concrete, and realizes the synergistic effect of macro-scale fibers and micro-nano-scale fibers at different stages of concrete damage, thereby improving the mechanical property and durability of the concrete. The concrete is doped with polyvinyl alcohol fibers and carbon nanofibers, so that the compressive strength, the rupture strength and the crack resistance are remarkably improved, and the concrete can be applied to structures with requirements on the strength and the crack resistance. The preparation method comprises the steps of weighing cement, fly ash, coarse aggregate and fine aggregate according to the weight, putting the weighed materials into a mixture, uniformly mixing, adding polyvinyl alcohol fiber into the mixture for multiple times, mixing the carbon nanofibers, the water reducing agent and a proper amount of water, and performing ultrasonic dispersion to prepare carbon nanotube slurry; and finally, putting the residual water, the water reducing agent and the carbon nanofiber slurry into the mixture, and uniformly stirring to obtain the hybrid polyvinyl alcohol-carbon nanofiber concrete.

[0031] In patent No. CN111205036B, under the title of "High-strength lightweight concrete and preparation method thereof", which was registered on 2020-01-18, a novel high-strength lightweight concrete and its preparation method have been introduced, pertaining to the field of concrete technology. It has also been noted that the technical formulation of this high-strength lightweight concrete consists of the following components measured in parts by weight: 200 parts of cement and 180 parts of light coarse aggregate, which is reinforced ceramsite. The reinforced ceramsite is produced through a specific process: initially, ceramsite is soaked in water for a duration of 20 to 24 hours, followed by draining for 1 to 2 hours to yield water-absorbing ceramsite. Subsequently, 10 to 20 percent of a reinforcing agent by weight is incorporated into the water-absorbing ceramsite, and the mixture is stirred for 30 to 90 minutes at a temperature range of 70 to 80 degrees Celsius and at a speed of 50 to 400 revolutions per minute to produce the reinforced ceramsite. The concrete developed through this method exhibits notable advantages, including high compressive strength and a low dry apparent density.

[0032] In patent No. US11224990B2, under the title of "Continuous methods of making fiber reinforced concrete panels", which was registered on 2017-07-28, a continuous method for fabricating fiber-reinforced concrete has been disclosed by mixing water and cementitious powder to form a slurry; mixing the slurry and reinforcement fibers in a single pass horizontal continuous mixer to form a fiber-slurry mixture, the mixer including an elongated mixing chamber having a reinforcement fiber inlet port, and upstream of the fiber inlet port is an inlet port to introduce water and cementitious powder together as one stream or at least two inlet ports to introduce water and dry cementitious powder separately as separate streams into the chamber, a rotating horizontal shaft / s within the chamber, part of the chamber for mixing the fibers and slurry and moving the fiber-slurry mixture to a mixture outlet; discharging the fiber-slurry mixture from the mixer outlet; forming and setting the fiber-slurry mixture on a moving surface; cutting the set mixture into fiber reinforced concrete panels and removing the panels from the moving surface.

[0033] In patent No. US10961696B2, under the title of "Fabricated intelligent joint provided with particle damping chambers for energy dissipation and assembly method", which was registered on 2018-07-05, an engineered intelligent joint has been equipped with particle damping chambers designed for energy dissipation. This assembly consists of a core steel frame, an external fully-fabricated steel pipe column, a fully-fabricated annular beam-column connecting assembly, a structural health monitoring system, and the particle damping chambers. It has been noted that the core steel frame is situated within the external fully-fabricated steel pipe column, maintaining concentricity with it, and features a circular hollow steel keel along with multiple protruding steel plate wings. The external fully-fabricated steel pipe column is constructed by joining various arc-shaped steel pipe sheets. Furthermore, the space between the external fully-fabricated steel pipe column and the circular hollow steel keel of the core steel frame houses the particle damping chambers, which are filled with concrete. These chambers contain a significant quantity of spherical rubber particles.

[0034] In patent No. CN109459310B, under the title of "Fiber reinforced concrete uniaxial tensile property test specimen and test method thereof, which was registered on 2018-12-14, a test specimen for evaluating the uniaxial tensile properties of fiber reinforced concrete, along with its corresponding testing method, has been developed. This specimen is designed in a bone shape, featuring clamping sections at both ends, a central testing section, and a force transmission section. The clamping sections are streamlined in design. The testing method involves several steps: molding the test specimen, removing the mold, preparing for the tensile test, and recording experimental data and the specimen is cast within a molding cavity formed by two side plates, clamping molds at each end, and a bottom molding template. During the mold removal process, both the test specimen and the clamping molds are extracted, with the clamping molds being connected to the testing apparatus. The method presented offers several advantages, including the integral formation of the clamping mold and the test specimen, which ensures a high degree of contact between them. The referred design was claimed to minimize the likelihood of stress concentration, promotes uniform force transmission, and allows for the direct installation of the test specimen onto the testing equipment, facilitating rapid and effective testing. Besides that, the bone-shaped test specimen has been alleged to feature smooth transitions between sections, ensuring uniform stress and force distribution, thereby reducing the occurrence of fractures outside the designated test section and enhancing the overall success rate of the testing process.

[0035] In patent No. CN115162323A, under the title of "High-strength expanded pile of basalt composite rib surrounding hoop reinforced concrete precast pile and construction method thereof ", which was registered on 2022-07-11, a novel construction method has been introduced involving a basalt composite bar that encircles a hoop-reinforced concrete precast pile, specifically designed as a high-strength expanded body pile, which the referred implemented composite comprises an inner core reinforced pile and a surrounding concentric expanded body material. Notably, it was claimed that the entire length of the inner core reinforced pile is enveloped by the expanding body material and the inner core reinforced pile consists of a reinforced concrete precast pile, which is encased by basalt composite bars. The expanding body material is created using cement-based substances, including basalt fiber modified cement mortar or fine aggregate concrete.

[0036] In patent No. CN108101446A, under the title of "Basalt fiber composite rib concrete and preparation method thereof ", which was registered on 2017-12-07, a kind of basalt fiber composite rib concrete has been claimed to be designed, which was characterized in that including Basalt fiber composite rib, passed through by basalt fiber. It has also been noted that after crossing surface treatment, then the fiber bar material for being impregnated and formed by curing by combination resin; the parts by weight that basalt fiber composite rib was alleged to comprise basalt building stones 150-200, nanometer TiCN 0.1-0.3, and magma Rock material 0.1-0.3, which has been noted that the combination resin parts by weight meter is made of vinylite 45-55, epoxy resin 20-32, rosin 2-3.

[0037] In patent No. CN109853727B, under the title of "Recoverable functional reinforced concrete frame anti-seismic energy consumption node", which was registered on 2018-12-29, a recoverable functional reinforced concrete frame earthquake-resistant energy-consuming node has been provided which contains of orthogonal column members and beam members, wherein the column members of the earthquake-resistant energy-consuming node are arranged in the intersecting area of the column members and the beam members, the column members of the earthquake-resistant energy-consuming node are connected with the beam members through the beam members of the earthquake-resistant energy-consuming node, the beam members of the earthquake-resistant energy-consuming node and the column members of the earthquake-resistant energy-consuming node are formed by casting cement-based composite materials and steel reinforcement frameworks, and the column members and the beam members are formed by casting concrete and the steel reinforcement frameworks.

[0038] In patent No. CN102296753A, under the title of "Hollow column member with built-in high tensile steel bars and pipes for the confinement of ultra-high-performance concrete", which was registered on 2011-06-20, a hollow column member with built-in high tensile steel bars and pipes for the confinement of ultra-high-performance concrete has been claimed to be designed which was especially suitable for the field of pier column members of the high rise, heavy load, and long-span structures. The member comprises a reinforcement cage consisting of outer steel pipes, longitudinal high tensile steel bars and stirrups, and hollow ultra-high-performance concrete poured on the internal surface of the outer steel pipes wrapping the reinforcement cage. The invention fully utilizes the advantages of the ultra-high-performance concrete, the high tensile steel bars, and the hoop confinement of the outer steel pipes, effectively reducing the cross-section of the member, improving the bearing capacity and stretchability of the member, so that the member has good earthquake resistant behavior, the materials are saved and the available space is increased at the same time. According to the referred allegations, prestress was unnecessary, the construction technology was simple, and construction speed was improved. Furthermore, the member was claimed to be suitable for precasting production, is good for the application of the two high tensile materials in projects, and meets the design concepts of energy saving, environmental protection, and new style.

[0039] In patent No. CN109779370B, under the title of "Underwater anti-explosion composite protection structure based on hollow glass beads and construction method thereof", which was registered on 2019-02-26, an underwater antiknock composite protection structure, along with its construction method, has been presented which the referred composite protective structure comprises a layer of high-strength concrete reinforced with basalt fiber and a concrete layer infused with hollow glass beads. Both layers are positioned on the surface of a wading structure and are constructed using a cast-in-place technique. The exceptional strength of the basalt fiber-reinforced active powder concrete is claimed to be employed for withstanding close-range underwater explosion impacts. This approach addresses the issue of reduced durability of steel reinforcement within the main structure, which is often compromised due to corrosion from ions present in the water. Additionally, the wave impedance mismatch between the sealing gas within the hollow glass beads and the surrounding medium is leveraged to facilitate the reflection of underwater explosion shock waves, thereby mitigating the propagation of stress waves within the structure.

[0040] In patent No. CN110080438A, under the title of "A kind of incorporation basalt fiber regeneration concrete wall and apply method", which was registered on 2019-04-20, a kind of incorporation basalt fiber regeneration concrete wall and the fabricating method which was applied has been claimed, which the wall is mainly composed of the framework of steel reinforcement with FRP diagonal brace and basalt fiber regeneration concrete. The framework of steel reinforcement of the band FRP diagonal brace is mainly made of high-strength end reinforcing bar, horizontal distribution reinforcing bar, vertical distribution bar, high-performance peg, FRP reinforcing bar diagonal brace； Concrete parts are made of the regeneration concrete of basalt fiber.

[0041] In patent No. CN105350790A, under the title of "Method for reinforcing reinforced concrete slab through prefabricating pre-stress TRC sheet", which was registered on 2015-10-21, a method for the production of precast prestressed TRC plates reinforced with steel concrete has been described which the discussed method is characterized by the inclusion of a Prestressed TRC thin plate, interface processing, and upward-facing construction. The Prestressed TRC thin plate consists of high-performance composite mortar, alkali-resistant fiber mesh, and stainless-steel reinforcing bars, and is produced through the following steps: (1) The alkali-resistant fiber mesh is cut into a groined shape with two bands, where the length L of each band corresponds to the length of the reinforced concrete slab. Each strip has a width ranging from 350mm to 450mm, and the bands intersect at a distance of 1 / 5L to 1 / 4L from their ends. (2) A stainless-steel reinforcing bar is positioned at the center of each band. (3) A layer of high-performance composite mortar, measuring 5mm to 7mm in thickness, is applied to the upper surface of the bottom template. The alkali-resistant fiber mesh, as prepared in step (1), is then placed on the surface of the composite mortar, with its ends secured to a stretching pedestal. This pedestal maintains the fiber mesh in a taut state, controlling the prestressing stress to achieve an ultimate tensile strength of the TRC thin plate between 0.3 and 0.5 times its capacity. (4) Following this, it was claimed that an additional layer of high-performance composite mortar, measuring 7mm to 9mm, is cast on top of the template. The temperature during this process is maintained at 20°C ± 2°C, and humidity levels are kept at a minimum of 95% for a curing period of 28 days, resulting in the formation of a "well" shaped Prestressed TRC thin plate reinforced with alkali-resistant fiber mesh.

[0042] In patent No. CN211113134U, under the title of "FRP pipe sea water sand concrete core reinforced concrete beam", which was registered on 2019-11-08, an FRP pipe filled with seawater sea sand concrete has been incorporated into a reinforced concrete roof beam, which is asserted to be strengthened by conventional concrete. This assembly consists of the FRP pipe, seawater sea sand concrete, vertical tension reinforcing bars, stirrups, and construction reinforcing bars. The claimed seawater sea sand concrete is poured into the cross-section of the FRP pipe, forming a composite component. Multiple such components are arranged within the upper 3 / 5 of the entire cross-section, while the vertical tension reinforcing bars are positioned in the lower 2 / 5. The FRP pipe seawater sea sand concrete components are situated within the framework of the steel reinforcement. Also, it has been noted that the placement and curing of ordinary concrete integrate the vertical reinforcing bars, stirrups, construction reinforcing bars, and FRP pipe seawater sea sand concrete components into a cohesive unit.

[0043] The process of producing hollow non-metallic reinforced concrete components, preferably utilizing basalt fibers, is designed and implemented to enhance assembly and improve resistance to tensile forces through various reinforcement types. In this procedure of fabricating concrete components featuring intricate shapes composed of non-metallic fibers, particularly basalt, a significant challenge arises in the form of detaching the concrete element from the mold, which often results in surface damage to the component, and in certain instances, it may be entirely unfeasible to remove it from the mold.

[0044] To manage and solve the referred challenge in this invention, two various in-lined methods of using mechanical or mechatronic arms and applying pressure to the inner surface of the flexible mold, along with utilizing fluid pressure application during the formation of the concrete piece and reduce the pressure when the piece is separated from the mold, has been provided.

[0045] In the manufacture of concrete parts with complex shapes made of non-metallic fibers, especially basalt, the problem is the difficulty of separating the concrete part from the mold and damage to the surface of the part, and in some cases, it is impossible to separate it from the mold. In this invention, the above problem has been solved by methods of controlling and reducing pressure during the separation of the mold and part.

[0046] There are two methods to solve the problem mentioned in the previous sections. The first method is based on using mechanical or mechatronic arms and applying pressure to the inner surface of the flexible mold, which leads to the mold being heavier and more expensive, and the second method utilizes fluid pressure during the formation of the concrete piece and reduces the pressure when the piece is separated from the mold. One of the requirements in the construction of a structure with a concrete skeleton reinforced with basalt fibers as reinforcement is the molding of columns at the project site, where environmental factors such as temperature and humidity are very effective on the outer surface of columns and beams.

[0047] Furthermore, maintaining humidity until the concrete is completely set and opening and closing the molds in shapes with special complexity are other problems of concrete skeleton projects. As is known, high temperatures cause rapid evaporation of concrete water from the surface, and the concrete setting reaction requires covering the surface and spraying water in the early hours. Also, at very low temperatures, the phenomenon of freezing of concrete water that starts from the surface will cause an incomplete setting. Despite the limitations in concrete additives and the reduction in strength, the method of making concrete formwork outside the construction site and in a controlled environment is proposed.

[0048] One of the relatively complex shapes of the column is the hexagonal cross-section used for example in this invention. The concrete column (1) reinforced with basalt fibers (2) has an outer surface (3) of concrete and has a series of grooves (4) that may be extended in length or width for technical or purely aesthetic reasons. Technical reasons include the passage of temporary or permanent installations in certain cases such as water pipes or electrical cables. One of the physical methods of controlling the temperature in very cold places is the passage of hot water through the grooves created on the outer shell, which prevents the concrete inside the shell from freezing before it sets.

[0049] Designs and shapes such as company logos or designs related to the culture and civilization of a region may also be visible on the outer surface (3) of the column in a recessed or raised manner. The construction of this hollow shell is carried out in the factory and then by transporting it to the construction site, the concrete will be poured inside it. The empty space (5) significantly reduces the weight of the formwork, which will make its transportation to the site economical and rational.

[0050] For example, the weight of a column with specific dimensions may increase several times when filled, which requires special machinery for transportation. In addition, the connections in the construction site can be implemented with more complex methods. The creation of this empty space (5) is carried out with the help of a rubber balloon in the factory. The construction of this concrete shell (6) requires forms with high flexibility but limited deformation.

[0051] To achieve this purpose, the deformation of the flexible formwork is limited from the outside by a metal formwork (13). The outer metal formwork (13) consists of two pairing parts (14) and conjunction parts (15) that are articulated to each other through hinges (8). Hinges (8) are placed on the reinforcement straps (7) to minimize deformation of the formwork (13) over time and long-term use. The basalt fibers (2) are fixed by metal holders (10) in tension in both directions of the metal formwork (13) until the concrete shell has dried.

[0052] The internal silicone mold (9) is also restrained at the top and bottom of the metal formwork (13) and prevents the release of liquid concrete before it sets. This silicone mold (9) may be filled with compressible or incompressible fluid during concreting and then emptied to allow the mold to exit from the column shell. At the top of the metal formwork (13), a series of slots (11) are provided for the entry of concrete to allow the mold to be filled with concrete after the molds are closed. The metal forms (13) are closed on one side by hinges (8) and on the other side by pins located in the mold lock hole (16).

[0053] The inner silicone mold (9) is filled and emptied with fluid through the inlet (12). As previously stated, the concrete shell of the column (6) is enclosed on the outside and inside by two flexible molds until the concrete sets. The outer flexible mold (17) is simply a reinforced silicone layer with smooth surfaces on the outside and raised or recessed surfaces on the inside, the deformation of which is limited on the outside by the metal mold (13).

[0054] After the concrete sets, when the outer mold (13) is opened, the outer flexible mold (17) is easily separated from the surface of the outer shell of the column, relying on its elasticity and the property of not connecting the surface with the concrete. The outer flexible mold (17) is able to possess protrusions or depressions on the inner surface, which create an inverse shape on the surface of the concrete due to the unevenness of the inner surface (18). During molding and pouring concrete into the mold and if the metal mold of the concrete (13) is placed vertically, the height will also be added as the volume of the flowing concrete increases.

[0055] Considering the mechanical properties of concrete in the pre-setting state as a liquid with high viscosity and bulk density, adding height means increasing the pressure of concrete on the walls at lower levels. In this mold, there are two flexible outer layers (17) and an inner silicone mold (9) that are susceptible to deformation due to this pressure. The outer flexible mold (17) will have a slight deformation due to its small thickness and being restrained by the metal mold (13), which can be ignored.

[0056] However, the situation of the inner silicone mold (9) filled with fluid (20) is different. As previously stated, the fluid inside the silicone mold may be considered liquid or gas, each of which will have different mechanical properties. In addition to the incompressibility of the liquid fluid, the specific gravity and hydraulic pressure acting on the surface at levels lower than the liquid surface (19) are effective in deforming the wall of the inner silicone mold (9). If the entire mold is filled with liquid first, the outward curvature of the wall will cause the mold to sink into the concrete and reduce the thickness of the column's concrete shell wall.

[0057] Moreover, the lower - or flush - level of the liquid fluid level (19) with the concrete as the concrete is poured into the mold will cause the inner silicone mold wall to curve inward, which in addition to creating an inappropriate shape also creates problems in removing the inner silicone mold (9). As shown in, in the lower part, with appropriate magnification, two cases of lower liquid and concrete fluid levels and slightly higher fluid level (19) than concrete are compared.

[0058] As can be seen in the figure on the right, the lower fluid level (19) causes the hydraulic pressure of the concrete to overcome the surface and create an inward curvature. In the case of designing a column with an unusually high height - for example, with a height of 10 meters - it is logical to place the mold horizontally and parallel to the ground instead of vertically and pump the concrete and hydraulic fluid (20) simultaneously.

[0059] Given this principle, in many cases, beyond the construction of a concrete skeleton in a structure, a surface made of concrete and reinforced with metal or non-metal reinforcement may be required for horizontal or vertical surfaces such as floors and walls. One of the expected features in these types of walls, ceilings or floors is high strength while the structure is light. To achieve this purpose, the use of non-metallic reinforcement (22) in each hollow block (21) composed of concrete (23) provides the ability to withstand tension and pressure within the appropriate range.

[0060] As mentioned previously, the concrete body (23) of a block with a relatively high ability to withstand pressure does not have high strength against tension, and this defect is eliminated by adding basalt reinforcement (22). In the design of this type of concrete block (21), a set of holes and holes (24) is considered on the side wall (25), which, if placed next to each other, allows the passage of polyester or basalt reinforcements. These reinforcements may be temporary until the concrete sets between the blocks or permanent and to add strength. Reinforcements (26) will increase strength by filling the inside of the block (21) - if necessary - along the length of the beam or column created.

[0061] The space between the blocks (27) is filled with concrete so that a set of blocks creates a flat volume such as a wall or floor. As shown in, a surface is created using only one row of blocks next to each other. With air bubbles in each block, the above structure will also be able to float on the surface of the water. Using Archimedes' principle in physics, each block (21) exerts an upward force equal to the volume of the air bubble enclosed in it, and part of this force will be used to overcome the weight of the block.

[0062] Obviously, in the mechanical properties of reinforced concrete, the pressure bearing is the responsibility of the concrete and the tensile bearing is the responsibility of the reinforcement, as a result, the maximum tensile force (29) will be created in the two directions of the reinforcement (22). This tensile force (29) will be maximum in the direct direction of the basalt reinforcement (22) and minimum along the cross section, which is divided into horizontal and vertical tensile force components at different angles of force application.

[0063] In a block in this design, non-metallic reinforcements (22) are placed directly near the bottom and near the highest surface to have the highest tensile resistance, but the highest compressive force (28) is on the walls (25). To better show the range of tolerable forces, sections of the concrete block (21) have been used. It can be seen that the maximum tensile force can be tolerated in the direct direction of the basalt reinforcement (22) and the minimum tensile force (29) can be tolerated at an equal distance between the two reinforcements.

[0064] Along the side walls (25), the tensile strength that can be applied will be slightly higher than the areas between the two reinforcements (22). This is due to the partial tensile strength of the concrete. Although the compressive strength of the reinforcements (22) can be neglected in the calculations due to their low cross-section and is very small, the concrete, despite its low tensile strength due to its relatively high cross-section, will be effective in drawing the tensile strength diagram in this design. The cross-section of the block will help in showing the maximum compressive strength.

[0065] It is worth noting that the maximum compressive force (28) that can be tolerated in this section is expected along the side walls (25). In total, these forces are for a block, which in the structure or frame is a set of blocks (21) with concrete between the blocks and additional reinforcements in different directions, which increase the strength and ability to withstand forces. In the design and construction of fixed, temporary, mobile and floating structures, in addition to flat surfaces, there may be a need for surfaces containing a set of curves or multiple sides. One of the most widely used of these volumes is the whole or part of a cylindrical section used at various angles.

[0066] For example, if a decision is made to create a concrete foundation for a wind turbine, a cylinder with a relatively high cross-section with an empty interior that gradually decreases in diameter as the height increases would be desirable. In this case, with increasing height, due to the reduction in static load of the higher materials and the lower weight required, the reduced diameter tolerance will be provided, providing an antenna-like volume with different cross-sections. This structure is an example of the vertical use of cylindrical sections.

[0067] In cases such as creating a tunnel at or below the surface for transporting materials or vehicles, etc., the cylindrical structure is used horizontally, but in cases such as shipbuilding, a part of the horizontal section of the cylinder is used parallel to the central axis. For technical reasons, some sections are considered a regular polygon close to a part of a circle or a whole circle. In the cylindrical section (30), the polygonal shape is maintained on the inner surface (32) and the outer surface (33).

[0068] These surfaces can be used to create patterns or materials such as glass or glass deflectors as needed. However, in cases where friction with fluids is considered or increased strength based on geometric shape is prioritized, the section will be converted into a part of a circular cylinder (31) by reducing and adding concrete on the inner and outer surfaces. The arrangement of the blocks (21) next to each other and in the direction of the height of the cylinder (31) will be one in between, and in the direction of the circular cross-section, the set of holes, designed with the aim to provide the passage of the basalt fibers (24), will be in the same direction.

[0069] This claimed set of holes (24) may be used to increase the strength of the concrete piece, and all or some of the blocks may also be reinforced in this direction to withstand the applied loads. In some cases, due to the lack of need for this level of strength and with the prioritization of economic approaches and goals, it will be suggested not to use basalt reinforcement.

[0070] The non-metallic reinforcements (22) placed in the concrete block (21) require a suitable method for production and fabrication to make their use fast and economical. In the basalt rebars available on the market, the straight shape of the rebar is maintained by using resin and hardener to maintain the straight state of the reinforcement after the basalt fibers are woven together. To create a bend at a point, heat is required to weaken the resin at that point and make it possible to create a bend. For limited cases, this method is suitable, but for a workshop production line or a larger scale factory producing concrete blocks reinforced with basalt fibers, this method is slow, time-consuming and uneconomical.

[0071] In order to solve and manage the above problem, the woven fibers are delivered wrapped on large spools and the desired shape is cut to the size of the intended area. Then a flexible rubber or silicone mold is used. The woven fibers are inserted into the location of the fibers (33) using the groove (32) and, after hardening, are removed from the groove (32) by adding resin and hardener.

[0072] After the basalt frame (22) is removed, this mold returns to its previous shape and can be used again. After preparing the basalt frame (22), two concrete blocks are molded in each block (21). Despite the complexity of their shape, it requires a mold consisting of a flexible part (35) and a solid non-flexible part with a flexible compartment (34). The non-flexible part is made of stainless-steel alloy and will only cover the outer surfaces in the mold. Considering the angles of the mold and the concrete block (21), this part will be easily separated.

[0073] Regarding the lower part of the mold, which includes the flexible part (35), the parts of the block that are created as cavities by the mold after the concrete sets, such as the set of holes for the reinforcement (24), are created by the extensions (37) of this part of the mold so that after setting, the block and the mold can be separated from each other by relying on the elasticity of the lower mold (35).

[0074] Also, the process of embedding and placing the non-metallic reinforcement (22) in the block is the factor that changes the shape of the lower mold (35) for the passage of the reinforcement (22) during the drying of the concrete, meaning that for this non-metallic reinforcement (22) to come out of the block mold, it will be necessary to create a hollow cylinder (39) along the length of the mold and a wide gap (40) to the top of the mold. When the flexible mold (35) is filled, the gap (40) is completely closed, and after the concrete of the block dries, this gap is opened by removing part of the incompressible fluid from the tube (36) and the non-metallic reinforcements (22) come out of the groove.

[0075] In multi-section molds, a groove or a guide tongue and a guide tongue are used to correctly position the mold sections on top of each other. In this mold, the surface of the tongue (38) is also recessed into the tongue-shaped section and will allow the concrete to enter through the hole (42). So far, the construction of various components such as the concrete shell of the column (6) and the reinforced concrete block (21) has been investigated, which may be produced at the construction site or in another location such as a production line for prefabricated concrete components and used after being transported to the site.

[0076] These components may be used in completely dry lands or lands requiring drainage or on the seashore or in the sea. Besides that, at sea, the structure may be mobile or temporarily mobile or completely fixed, which will be examined in the following several cases of creating the structure using the above components. For the simplest case, a skeleton and roof and floor surfaces are considered, which are constructed in very hot and dry weather conditions on land with a static level above the water and close to the ground surface.

[0077] In such cases, the bed is created using vertical pile driving, but in our implementation method, with a slight change in the concrete shell of the column (6), the pile driving costs can be saved. If the water level is higher than the lowest level of the column in operation, after filling the concrete shell mold (6) with concrete, water will penetrate the concrete and by changing the mixing plan, the compressive strength will be greatly reduced and in the long term it will cause cracks in the shell or settlement of the structure. To solve this problem, two solutions are considered in the claimed invention.

[0078] The first way is to close the top of the concrete shell (6) with a temporary holder and create air pressure, followed by pouring concrete from the upper area, which requires carrying an air compressor and making a completely watertight holder with a wall inside the concrete shell (45). Although this method can be implemented with high efficiency, it requires simultaneous injection technology of air and concrete, and the air pressure must be maintained for a while until the concrete sets inside the mold.

[0079] The second solution is to create a temporary concrete surface (43) in the inner space of the mold, which after the column is placed in the created hole (48) on the ground surface (49), following the impact and pressure from the barrier (44) placed on the solid surface (47) of the ground, the temporary concrete surface (43) is broken and contact between the fresh concrete inside the mold (6) and the barrier (44) placed on the surface will be established.

[0080] This barrier may be made of different metals, ionic compounds originating from stone textures, concrete pieces, or in special cases, made of metal and combinations of these three materials. The solid ground surface (47) has sufficient density to withstand the pressure of the column and the structure on which it is placed and, after the concrete inside the column has set, will transfer the vertical forces to the ground in the best possible way.

[0081] The creation of a hole (48) on the visible surface of the ground (49) will generally be done by human labor, but in special cases, hydraulic or electric machinery may take over this task. The concrete is poured into the concrete shell (6) up to the upper surface of the column, but if it is necessary to place the next shell on the executed column, the level of the poured concrete at this level is reduced to create the necessary space for the placement of the concrete inside the next form.

[0082] This claimed empty space in the upper surface of the concrete (46) may be provided by a metal or concrete spacer with basalt, providing a secure connection between the lower column (54) and the upper column (55). The spacer (50), which is made of reinforced arms (52) and a hole (53) along its height, is connected to the inner wall of the column shell by edges (51) and is preferably selected from the concrete itself to maintain its integrity.

[0083] After the columns are installed, it is time to install surfaces parallel to the ground surface. These surfaces may be from a few centimeters to tens of meters above the ground or water surface in offshore or marine structures. For residential structures in wet areas or at risk of flooding and tides, a distance of less than one meter from the ground surface is sufficient, but on a pier or oil platform or wind turbine base installed at sea, this height increases significantly.

[0084] For placing concrete blocks (21) next to each other, two methods have been studied: planar and cross-sectional, cylindrical or spherical, but in each case, depending on the required strength and lightness of the structure and the economic justification of the type of connections between the blocks and the amount of reinforcement by non-metallic reinforcement and the creation of hollow or solid spaces, the amount of concrete and reinforcement used will vary.

[0085] Placing two concrete blocks (21) next to each other and reinforcing them with non-metallic reinforcement (26) is done by placing the walls of the block (23) next to each other and then covered with a layer of concrete. This concrete layer may only include the surface of the block or may have higher strength and consequently more weight by filling the inside of the block. The example shown in the image is of the hollow type, which can be seen from the fracture (56) of the parts inside it.

[0086] If there is a need to create structures in which the inside of the block needs to remain permanently empty, it is better to use nylon bags filled with air with sufficient strength until the concrete sets. Considering the required strength of surfaces made of concrete blocks, by placing several layers on top of each other, a multilayer surface with higher strength (57) will be produced, which increases the uses of this type of block. In this type of increase in strength, the space (27) between each dual units of the hollow concrete blocks (21) are filled with concrete as in the case of a single layer.

[0087] Another example of structures that can be built using this technology is offshore structures such as wind turbine bases (59). In the implementation of this type of structure, the first issue is transporting materials and equipment to the project site. Considering the relatively high weight of the concrete parts, first the flat layers (57) fabricated by concrete blocks in the form of hollows will be transported to the site, which will act as temporary land craft for carrying other reinforcements such as the concrete shell of the column and circular sections.

[0088] After the columns are established and placed in the previously mentioned method, the weight of this structure is placed on the column and the strength is increased by concreting between the blocks. Then the circular sections are added and blocked from above. In one view, this concrete tower (58) may be used to store chemical substances or compounds in the form of gas or liquid.

[0089] For example, by transporting fuel to these sites by smaller ships and storing it at a higher cost to ships that are unable to approach the coast due to their large size, or, considering the expansion of storage and use of hydrogen, the electricity generated by the turbine is directly used to separate hydrogen from water and provide the ability to refuel hydrogen at the base of the platform.

[0090] The lightness of the structure compared to metal-reinforced samples and much higher resistance to corrosion and atmospheric factors are the biggest advantages of this invention. The lack of need for iron ore resources and easier production are the advantages of using non-metallic fibers. Furthermore, the higher resistance of the reinforced structures claimed in this invention compared to metals against acids and bases greatly reduces the possibility of decay and makes it possible to use this method claimed in the claimed invention in mobile and fixed structures.

[0091] : Representing a three-dimensional view of a concrete column and all its constituents.

[0092] : Illustrating a section of a hexagonal column prior to concreting in the workshop and below after concreting.

[0093] : Depicting a top view and a bottom view of a hexagonal concrete shell mold with basalt fibers in place on the right and left.

[0094] : Demonstrating several three vertical and horizontal sections of the hexagonal column mold.

[0095] : Showing an exploded figure of the concrete shell of the column when it is removed from the mold, in isometrical shapes.

[0096] : Illustrating a section of a cement column reinforced with basalt fibers at the top and two enlarged views of a portion of the section at the bottom to compare the effect of the fluid level on the shape of the mold.

[0097] : Representing two different forms of hidden lines visible and hidden lines removed schematics of a cement block with the ability to represent various parts and sections of the block from two points of view, determining the location of the basalt fibers.

[0098] : Depicting three different perspectives of a concrete block and all its constituents.

[0099] : Illustrating a set of concrete blocks in a three-dimensional view at the top and a side view of the blocks next to each other at the bottom.

[0100] : Demonstrating a diagram representing the range of load-bearing capacity of claimed concrete blocks.

[0101] : Representing the range of load-bearing capacity in various sections in two different cuts and perspectives.

[0102] : Showing a section of a regular polygon close to a cylindrical cross-section at the top and the same section with a circular shape at the bottom.

[0103] : Demonstrating a section of the outer wall showing how the blocks are placed next to each other.

[0104] : Illustrating two various views of the flexible mold used to make the basalt frame in block production in two elevation and wireframe drawings at the top and bottom of the figure.

[0105] : Depicting two sections of the rubber mold used for the basalt frame of the referred concrete block.

[0106] : Representing two 3D schematics, one schematic representation in the form of hidden lines removed at the top, and another schematic with more technical details of the same form, in the similar point of view and in the hidden lines visible form, at the bottom.

[0107] : Showing two 3D views of the exploded representation of the concrete block mold.

[0108] : Demonstrating the process of enclosing the bottom of the concrete mold of the column, to be placed and embedded in various areas below the water level.

[0109] : Illustrating a specific unit of concrete formwork of the column, on the left side, before being placed below the water level and on the right, after being placed and filled with concrete.

[0110] : Depicting multiple two-dimensional and three-dimensional views of the spacer connecting the two concrete shells of the same section of the column.

[0111] : Showing a section of the spacer placement between the two columns.

[0112] : Illustrating the placement of two concrete blocks on the top, and the reinforcement by non-metallic reinforcement in the middle of the figure, and at the bottom, in addition to depicting the concrete surface executed on the blocks, a fracture in the surface of the components below have been shown.

[0113] : Showing a surface executed by concrete blocks on the top and the bottom of the map shows how to execute three layers of concrete blocks.

[0114] : Representing a cross-section of one-layer execution on the top and a view of three layers of concrete blocks on the bottom, which is used to estimate the amount of concrete consumed between the layers.

[0115] : Depicting a concrete offshore structure constructed with a compilation of concrete blocks and columns, with the approach of removing shells to attain a better representation of the procedure of placement of the pieces.

[0116] : It shows a concrete column and all its components and constituents, from a vertical visual angle, in the upper direction, along with 3 coordinate axes and in the form of hidden lines removed. The scale of the drawn figures is 1 to 6 real scale and the dimensions shown are in centimeters. Referred components include the concrete column (1), the basalt fibers (2), an outer surface of concrete (3), a series of grooves situated in the outer concrete’s surface (4), the empty space (5), and the concrete shell of the column (6).

[0117] : It depicts several 2D schematic representations of a section of a hexagonal column prior to applying the process of concreting in the workshop and below after concreting, from lateral viewing angles, along with 2 coordinate axes of coordinate system and in the form of hidden lines removed. The scale of the drawn figures is 1 to 20 real scale and the dimensions shown are in centimeters.

[0118] : It demonstrates two different views of a hexagonal concrete shell mold with basalt fibers in place on the right and left, from upper and lower directions, along the 3 coordinate axes of the coordinate system, in isometrical shapes, and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 10 real scale and the dimensions shown are in centimeters. Referred components include the reinforcement straps (7), the hinges (8), the internal silicone mold (9), the metallic holders (10), a series of slots (11), the inlet (12), the metallic formwork (13), the pairing part (14), the conjunction part (15), the mold lock hole (16)

[0119] : It demonstrates several three vertical and horizontal sections of the hexagonal column mold, from various upper, lower and lateral viewing angles and along the 3 axes of the coordinate system, in the form of wireframed. The scale of the drawn shapes is 1 to 21 real scale and the dimensions shown are in centimeters. Referred component includes the outer flexible mold (17)

[0120] : It represents an exploded figure of the concrete shell of the column when it is removed from the mold, from various vertical and horizontal angles, along the 3 coordinate axes, in isometrical shapes and in the hidden lines removed form. The scale of the drawn shapes is 1 to 25 real scale and the dimensions shown are in centimeters. Referred component includes the concrete’s inner surface (18)

[0121] : It shows a section of a cement column reinforced with basalt fibers as well as two enlarged presentations of a portion of the section at the bottom to compare the effect of the fluid level on the shape of the mold, from lateral directions, in line with the x and z axes of the coordinate system, and in the forms of wireframed. The scale of the drawn shapes is 1 to 18 real scale and the dimensions shown are in centimeters. Referred components include the liquid fluid level (19), and the hydraulic fluid (20)

[0122] : It depicts two different schematics of a cement block with the ability to represent various parts and sections of the block from two points of view, determining the location of the basalt fibers, from lateral and asymptotic perspectives, in line with the 3 axes of the coordinate system, in both isometric and dimetric shapes and in both forms of hidden lines visible and hidden lines removed. The scale of the drawn shapes is 1 to 1.5 real scale and the dimensions shown are in centimeters. Referred components include the hollow concrete block (21), and the hydraulic fluid (22), the concrete-based wall (23), and the set of holes, designed with the aim to provide the passage of the basalt fibers (24)

[0123] : It demonstrates several schematic representations of the concrete block and all its constituents, from various upper, lower and lateral viewing angles, in line with the x and z axes of the coordinate system, and in the hidden lines removed form. The scale of the drawn shapes is 1 to 3.5 real scale and the dimensions shown are in centimeters. Referred component includes the side / lateral wall (25)

[0124] : It illustrates a three-dimensional schematic representation of a set of concrete blocks as well as the blocks next to each other at the bottom, from lateral and asymptotic viewing angles, in line with the 3 axes of the coordinate system, and both represented schematics are in the forms of hidden lines removed. The scale of the drawn shapes is 1 to 25 real scale and the dimensions shown are in centimeters. Referred components include the non-metallic reinforcement (26), and the space between each dual concrete-based block set (27)

[0125] : It represents a diagram representing the range of load-bearing capacity of the claimed concrete blocks, from lateral and asymptotic viewing angles, in line with the 3 axes of the coordinate system, in an isometrical shape and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 2.5 real scale and the dimensions shown are in centimeters. Referred components include the trajectories representing maximum compressive force (28) and the minimum tensile force (29).

[0126] : It shows the range of load-bearing capacity in various sections, in two different cuts and perspectives, from a lateral and an asymptotic angle, in line with the x and z axes of the coordinate system, and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 7 real scale and the dimensions shown are in centimeters.

[0127] : It depicts a section of a regular polygon close to a cylindrical cross-section at the upper position and the same section with a circular shape at the lower position, from a lateral visual angle, alongside the 3 coordinate axes, in isometric shapes, and in both forms of wireframed and hidden lines removed. The scale of the drawn shapes is 1 to 21 real scale and the dimensions shown are in centimeters. Referred components include the cylindrical section (30), the cylinder (31), the inner surface (32), and the outer surface (33)

[0128] : It demonstrates a section of the outer concrete wall, with the aim of illustrating how the blocks are placed next to each other, from an asymptotic point of view, alongside the 3 coordinate axes, in isometric shapes, and in form of hidden lines removed. The scale of the drawn shapes is 1 to 12 real scale and the dimensions shown are in centimeters.

[0129] : It illustrates two various schematics of the flexible mold used to construct the basalt frame in block production in two elevation and wireframe drawings at the top and bottom of the figure, alongside the x and z axes of the coordinate axes. The scale of the drawn shapes is 1 to 10 real scale and the dimensions shown are in centimeters.

[0130] : It depicts two sections of the rubber mold utilized for the purpose of fabricating basalt frame of the referred concrete block, from lateral and asymptotic viewing angles, alongside the x and z axes of the coordinate axes and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 12 real scale and the dimensions shown are in centimeters.

[0131] : It represents two different 3D schematic representations, from the asymptotic and lateral direction, alongside the 3 coordinate axes, both in an isometric shape, and which one of the two is in the form of hidden lines removed and the other one with more technical details of the same form and in the similar point of view, is configurated in the hidden lines visible form. The scale of the drawn shapes is 1 to 1.5 real scale and the dimensions shown are in centimeters. Referred components include the solid part with the flexible compartment (34) and the flexible part (35)

[0132] : It shows two 3D views of the exploded representation of the concrete block mold, from the asymptotic and lateral direction, in line with the 3 axes of the coordinate system, in both isometric and dimetric shapes, and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 3.5 real scale and the dimensions shown are in centimeters. Referred components include the tube (36), the extensions of the flexible part (37), the surface of the tongue-shaped section (38), the hollow cylinder (39), the gap related to the mold surface (40), the conjunction and fixating area for the referred tube (41), the hole (42), and the temporary concrete surface (43)

[0133] : It depicts the installation process of embedding the bottom of the concrete mold of the column, to be placed and situated in various areas below the water level. The scale of the drawn shapes is 1 to 12 real scale and the dimensions shown are in centimeters. Referred component includes the barrier (44)

[0134] : It demonstrates a specific unit of concrete formwork of the column, before and after being embedded and situated below the water level and placed and be filled with concrete, on the left side and on the right side respectively. The scale of the drawn shapes is 1 to 12 real scale and the dimensions shown are in centimeters. Referred components include the concrete shell (45), the empty space existed on the upper surface of the concrete (46), the solid ground surface (47), the hole (48), and the visible surface of the ground (49)

[0135] : It illustrates several 2D and 3D schematic representations of the spacer connecting the two concrete shells of the same section of the column, from various upper, lower, lateral and asymptotic directions, along the 3 coordinate axes, in both isometric and 2D shapes, and in hidden lines removed form. The scale of the drawn shapes is 1 to 3 real scale and the dimensions shown are in centimeters. Referred components include the spacer section (50), the series of edges (51), a reinforced arm unit (52), and a hole situated along the spacer’s height (53)

[0136] : It represents a 2D schematic representation of the placement area of the spacer between the two columns, in frontal perspective, along the 2 axes of the coordinate system, in hidden lines removed form. The scale of the drawn shapes is 1 to 12 real scale and the dimensions shown are in centimeters. Referred components include the secure connection between the lower column (54), and the upper column (55).

[0137] : It shows the placement of two concrete blocks on the top, the reinforcement by non-metallic reinforcement in the middle of the figure, and at the bottom, and the fracture in the surface of the components below, in addition to depicting the concrete surface executed on the blocks, from diverse lateral and asymptotic angles, in line with 3 axes of the coordinate system, in both isometric and dimetric shapes and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 6 real scale and the dimensions shown are in centimeters. Referred components include the schematic fracture for better clarification (56), the upper column the multilayer surface with higher strength (57), the concrete tower (58), the designed wind turbine bases (59), and the external surface of each concrete block (60).

[0138] : It illustrates a surface executed by concrete blocks on the top and the bottom of the represented figure to show how to execute three layers of concrete blocks, from two different lateral and asymptotic points of view, alongside the 3 axes of the coordinate system, in both isometric and dimetric shapes and in the form of hidden lines removed. The scale of the drawn shapes is 1 to 25 real scale and the dimensions shown are in centimeters.

[0139] : It demonstrates a cross-section of one-layer execution process and a view of three layers of concrete blocks, from a frontal direction, alongside the x and z axes and the coordinate system, and in the form of hidden lines removed, which the represented process is aimed to be used to evaluate the amount of concrete consumed between the layers. The scale of the drawn shapes is 1 to 25 real scale and the dimensions shown are in centimeters.

[0140] : It represents a fully assembled concrete offshore structure and all its comprising constituents, which have been constructed with a series of concrete blocks and columns, with the approach of removing shells to attain a better representation of the procedure of placement of the pieces. The scale of the drawn shapes is 1 to 100 real scale and the dimensions shown are in centimeters.Examples

[0141] To implement a fixed structure reinforced with non-metallic reinforcement, first the concrete parts or shells are manufactured in the part production workshop in an environment with effective condition control and transported to the construction site. Then, depending on the required strength, fibers are placed in the parts and distances, and concrete is poured between them.

[0142] The application of this invention is in the construction industry and concrete structures reinforced with non-metallic fibers. The above structures may be used in dry lands or on beaches requiring drainage or offshore. It is also possible to construct wind turbine bases or solar towers with this method. Considering the low weight of the structures built in this method and their floating capability, its use in the shipbuilding and land craft industries is justified.

[0143] The presence of empty spaces in the structure with high resistance to chemicals allows the construction of tanks from this material. The use of these structures will also be useful in the construction of lightweight military fortifications such as temporary or permanent trenches. Moreover, by floating surfaces of concrete blocks, it is possible to quickly build bridges and pass equipment. This method can also be used in radar bases, where less metal around the base will be an advantage.

Claims

The construction of hollow concrete parts reinforced with non-metallic reinforcement preferably by utilizing basalt fibers and with the ability to assemble and increase the stability against tensile force by various types of reinforcement.The method of constructing a hollow concrete formwork reinforced with non-metallic reinforcement used in the construction of fixed or mobile buildings or a combination of the two is carried out by flexible forms controlled with the help of an incompressible fluid.The use of a prefabricated hollow concrete formwork reinforced with non-metallic fibers is carried out to construct concrete or non-concrete filled parts.The method of constructing lightweight concrete parts reinforced with non-metallic reinforcement with the ability to float on the water surface and the ability to be converted into a solid concrete structure is feasible.According to claims 1 and 2, the stability of lightweight concrete parts is increased by placing non-metallic reinforcement in the part. It can also be claimed that the construction of flexible molds with the ability to be reused for molding inside or outside a reinforced concrete piece by reinforcement with the ability to change partial deformation and the degree of flexibility in the elastic range, has been carried out by changing the pressure of an incompressible fluid, and the reduction of the number of molds required with the ability to be used multiple times has been achieved by the method of changing the mold shape by fluids.According to claim 5, lightweight concrete pieces reinforced with non-metallic reinforcements have the possibility of increasing the tensile strength in different directions by adding non-metallic or metallic reinforcement.According to claim 3, prefabricated concrete molds reinforced with non-metallic fibers will have the possibility of being maintained and integrated by concrete inside the mold or other non-concrete materials and creating filled volumes after the materials set and turned into a solid state.According to claim 3, the removal of temporary molds to create concrete and non-concrete column and beam volumes has been carried out using prefabricated concrete molds reinforced with non-metallic reinforcements.According to claim 4, prefabricated concrete parts reinforced with non-metallic reinforcement that is lightened for buoyancy and bearing the weight of other components will have the ability to increase compressive strength by adding concrete in empty spaces.According to claims 4 and 6, the construction of marine transportation equipment such as ships and land craft is carried out by lightening reinforced concrete parts with sufficient tensile and compressive strength.According to claim 5, the construction of non-metallic bodies of lightweight mobile or fixed structures from a combination of reinforced concrete parts by non-metallic reinforcements can be carried out without the use of additional reinforcement or by using additional reinforcement in land or coastal or offshore and marine structures.According to claims 1 and 4, the construction of reinforced concrete tanks for storing chemicals with metal corrosive properties is provided by reinforced concrete parts with the help of non-metallic reinforcements and preferably based on the use of basalt fibers.According to claims 2 and 4, it has become possible to reduce the size of the base columns of the structure by reducing the weight of the lightweight structure by using non-metallic fiber reinforced concrete parts.According to claim 1, the lifespan of aquatic and marine structures has been increased by replacing non-metallic reinforcements with metal reinforcements that are subject to oxidation.According to claim 1, it has become possible to reduce hairline cracks by creating a rigid structure without relying on metal reinforcement with a close expansion coefficient between the non-metallic reinforcement and the concrete composition.According to claim 2, it has become possible to allow non-metallic reinforcements to pass through the empty spaces of the concrete part by a flexible mold filled with an incompressible fluid.According to claims 1 and 3, by lightning and creating sufficient strength, it has become possible to construct multi-purpose structures such as wind turbine bases with the ability to store materials.

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