Composite Concrete Repair Material Resists Tensile Loading
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Solution Overview
Problem
Existing methods for repairing and strengthening concrete structures, particularly pre-cast and pre-stressed double tee systems, are labor-intensive, costly, and prone to cracking and corrosion, leading to potential structural failures.
Innovation Solution
A method and apparatus utilizing an improved composite material with a first fiber system, partially or fully coated with a resin material, to connect, strengthen, and repair concrete connections, specifically designed to resist tensile loading and simple shear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional drilling and reinforcing bar methods are used to repair concrete connections, then mechanical connection between new and existing concrete can be achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The invention extracts the function of mechanical reinforcement from traditional drilling and bar insertion methods, replacing it with a pre-fabricated composite material that provides equivalent or superior mechanical connection without requiring hole drilling and bar installation
Solution Approach 2:
The invention uses a composite material comprising a rigid foam core with embedded reinforcement elements (such as steel bars or fibers) and outer protective layers. This composite structure integrates multiple functions (structural reinforcement, corrosion protection, ease of installation) into a single component that can be directly placed into a routed channel in the concrete
2Reliability
If multiple holes are drilled into existing concrete for reinforcing bar installation, then mechanical connection is achieved, but the process becomes slow and labor-intensive
Solution Approach 1:
The invention merges multiple separate operations (drilling holes, cleaning holes, inserting bars, applying adhesive, installing protective coatings) into a single pre-fabricated composite component that is installed as one unit, dramatically reducing repair time and labor requirements while maintaining connection strength
3Reliability
If reinforcing bars are installed in drilled holes, then mechanical connection is achieved, but vibrations from drilling can cause concrete section failure
Solution Approach 1:
The invention removes the drilling operation entirely from the installation process. Instead of drilling holes and inserting bars, a pre-fabricated composite material is placed into a routed channel, eliminating the harmful vibrations and potential concrete damage associated with impact drilling while maintaining connection integrity
4Reliability
If drilled holes are used for reinforcing bar installation, then mechanical connection is achieved, but holes require subsequent cleaning of dust and particles for proper adhesive bonding
Solution Approach 1:
The invention performs preliminary preparation of the bonding surfaces and protective coatings during the factory manufacturing of the composite material. The reinforcement elements are pre-coated with corrosion-resistant materials and the outer surfaces are prepared for optimal adhesive bonding, eliminating the need for on-site cleaning and preparation operations
5Reliability
If metallic reinforcing bars are used in concrete repairs, then mechanical connection is achieved, but cracks can form over time allowing moisture to cause rust and corrosion leading to failure
Solution Approach 1:
The invention uses a composite structure with a rigid foam core containing embedded reinforcement elements, surrounded by outer protective layers (such as polymer coatings or concrete-like materials). This composite construction protects the metallic reinforcement from moisture and corrosion while maintaining structural connection strength, significantly extending service life
Solution Approach 2:
The invention employs flexible protective coatings and outer layers that envelop the reinforcement elements, creating a barrier against moisture penetration and corrosion. These protective films maintain their integrity over time, preventing the rust and corrosion that would otherwise compromise the metallic reinforcement
6Reliability
If traditional concrete repair methods are used, then structural repair can be achieved, but the process is costly and labor-intensive
Solution Approach 1:
The invention extracts the complex, multi-step traditional repair process and replaces it with a pre-fabricated composite material that can be installed by simple routing of a channel and placement of the composite component, dramatically reducing labor requirements and overall cost while maintaining structural repair reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved composite material effectively enhances the strength and durability of repaired concrete connections, reduces cracking, and minimizes the risk of corrosion, while being less labor-intensive and cost-effective compared to traditional methods.
Implementation Method 1
an improved composite material with a first fiber system, partially or fully coated with a resin material
Data Source
AI summary
An improved composite material used to connect, strengthen and/or repair concrete. The improved composite material includes a first fiber system including at least one fiber layer. Each fiber layer includes a plurality of fibers. The binding material can be used to optionally secure together the plurality of fibers. The improved composite material is positioned and secured in a slot cut in a concrete structure. The top edge of the improved composite material includes a recess portion.