Alternative reinforced concrete composite
Alternative Reinforced Concrete Composite [1] The present invention relates to an alternative concrete composite material. [2] Regular concrete uses clean sand and gravel and Portland cement. The clean sand and gravel is transported to site for mixing with concrete using an on-site mixer. Alternatively, ready-mix concrete can be transported to site and used as required. [3] The above, whilst reliable, is too costly for large scale requirements and for developing countries. [4] The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative. [5] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country. [6] According to a first aspect, the present invention provides a reinforcement piece for mixing with a concrete composite, the reinforcement piece comprising at least one hook-shaped or bent shaped formation. [7] Preferably, the reinforcement piece is made from plastics material [8] Preferably, the reinforcement piece is made from recycled waste plastics material. [9] Preferably, the reinforcement piece is 5 mm to 30 mm in length. [10] Preferably, the reinforcement piece is 5 mm to 30 mm in width. [11] Preferably, the reinforcement piece includes at least two hooks. [12] Preferably, the reinforcement piece includes at least two hooks at one end. [13] Preferably, the reinforcement piece includes at least two hooks at each end. [14] Preferably, the reinforcement piece includes a closed formation having an opening at a central portion thereof, [15] Preferably, the reinforcement pieces are shaped as human figures. [16] Preferably, wherein the reinforcement pieces are shaped similar to a number ‘7’, a number ‘2’, ‘C’ shape, ‘S’ shaped, or ‘K’ shaped. [17] There is also disclosed herein a reinforcement piece for mixing with a concrete composite, the reinforcement piece comprising a plastics material. [18] There is also disclosed herein a reinforcement piece for mixing with a concrete composite, the reinforcement piece being 5 mm to 30 mm in length. [19] Preferably, the reinforcement piece is 5 mm to 30 mm in width. [20] Preferably, wherein the reinforcement piece includes at least one hook formation. [21] Preferably, the reinforcement pieces are shaped similar to a number ‘7’, a number ‘2’, ‘C’ shape, ‘S’ shaped, or ‘K’ shaped. [22] There is also disclosed herein a plurality of reinforcement pieces according to any one of the above. [23] Preferably, the reinforcement pieces comprise various shapes and sizes. [24] There is also disclosed herein a concrete composite comprising a plurality of reinforcement pieces according to the above. [25] Preferably, the plurality of reinforcement pieces are added to the soil/cement mixture at a percentage of 10% either by volume or by weight. [26] Preferably, the plurality of reinforcement pieces are added to the soil/cement mixture at a percentage of between 5% and 20% either by volume or by weight. [27] There is also disclosed herein a plastics reinforcement bar for forming a concrete structure. [28] Preferably, the reinforcement bar has a length of 1.7 metre, 2.7 metres, or 3.7 metres and/or a diameters of 10.7 mm, 12.7 mm or 16.7 or 30 mm. [29] Preferably, the reinforcement bar comprise corrugations or spaced ribs along its length. [30] Preferably, the reinforcement bar is made from recycled waste material plastics material. [31] There is also disclosed herein a structure comprising the concrete composite of any one of the above. [32] Preferably, the structure comprises the reinforcement bar of the above. [33] There is also disclosed herein a concrete reinforcement mesh formed from slit and expanded tyre or woven tyre strands. [34] There is also disclosed herein a concrete reinforcement formed from recycled plastics tube. [35] There is also disclosed herein a concrete reinforcement frame formed from joined recycled plastics tubes. [36] Preferably, the ends of the frame are joined by recycled plastics. [37] Other aspects of the invention are also disclosed. [38] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings in which: [39] Fig. 1 shows (a) reinforcement bars and (b) reinforcement pieces in accordance with a preferred embodiment of the present invention; [40] Fig. 2 (a) shows a plurality of reinforcement pieces adjacent an Australian 50 cent coin to indicate the size of the pieces and (b) shows a bag of reinforcement pieces; [41] Fig. 3 illustratively shows excavation of a trench; [42] Fig. 4 illustratively shows the steps in excavation of the trench of Figure 4 and reinforcing the trench with the alternative concrete composite of the preferred embodiment of the present invention; [43] Fig. 5 illustratively shows reinforcement of a road embankment using the alternative concrete composite of the preferred embodiment of the present invention; [44] Fig. 6 illustratively shows reinforcement of a road embankment and forming a road and footpath using the alternative concrete composite of the preferred embodiment of the present invention; [45] Fig. 7 illustratively shows forming a retaining wall using the alternative concrete composite of the preferred embodiment of the present invention; [46] Fig. 8 illustratively shows forming a wall foundation using the alternative concrete composite of the preferred embodiment of the present invention; and [47] Fig. 9 illustratively shows forming a buttress and embankment retaining wall using the alternative concrete composite of the preferred embodiment of the present invention; [48] Fig. 10 shows examples of different reinforcement frame structures using extruded recycled waste plastics tubes; [49] Fig. 11 shows a threaded end of the recycled waste plastics tube; [50] Fig. 12 shows examples of ends of the recycled waste plastics tubes joined or welded via similar recycled plastic material blocks on site; [51] Fig. 13 shows a typical vehicle tyre cross-section structure; [52] Fig. 14 shows the steps in expanding the recycled tyre into a mesh; [53] Fig. 15 shows a close up of the recycled tyre mesh; [54] Fig. 16 shows examples of concrete reinforcement using (a) the recycled tubes frame and (b) the recycled tubes frame and the recycled tyre mesh; [55] Fig. 17 shows examples of use of the use of cut-out tyre bead of a tyre as concrete reinforcement where (a) shows the tyre beads with horizontal reinforcement bars, (b) with vertical reinforcement bars and (c) with wire rope clips or winding strands [56] Fig. 18 (a) shows slit slide tyre bead portions with the tyre sides slit and the bead intact; [57] Fig. 18 (b) examples of use of the slit side tyre bead portions as concrete reinforcement; [58] Fig. 19 shows a slitting blade for the slit side tyre bead portions; [59] Fig. 20 shows use of the tyre bead as dowels to join tyre mesh of Figure 14 [60] Fig. 21 shows examples of use of cut-out portions of a tyre for concrete reinforcement. Description of Embodiments [61 ] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features. [62] The preferred embodiment in one aspect relates to an alternative concrete composite. Typically, conventional concrete uses clean sand and gravel. This however is expensive. [63] The preferred embodiment uses the soil on site and gravel on site, mixed with cement and reinforcement pieces according to another aspect of the present invention to provide an alternative concrete composite. The use of the reinforcement pieces allows the alternative concrete composite using the available ‘unclean’ soil and gravel on site to be formed into structures as needed at a substantially reduced cost. [64] The alternative concrete composite in the present description is also referred to with its preferred trade mark SoilStone, as it is made from the local soil but provides the properties of a stone when formed. [65] The reinforcement pieces are made from plastics material, and are ideally made from recycled waste plastics material. Figures 1(b), 2 and 3 show reinforcement pieces 10 according to preferred embodiments of the present invention. The reinforcement pieces 10 range from 5 mm to 20 mm in length and 5 mm to 20 mm in width and are generally in the shape of a hook or includes at least one hook shaped formation thereon. [66] As shown in Figure 1, reinforcement piece 10a includes two hooks 12 at each end 14, reinforcement piece 10b includes two hooks 12 at a first end and a closed triangle hook 16 at its opposite end, reinforcement pieces 10c to 10f are generally shaped as human figures and include arm hooks 12. [67] Other reinforcement pieces 10 shown in Figure 2 are shaped similar to a number Τ, a number ‘2’, ‘C’ shape, ‘S’ shaped, ‘K’ shaped and the like. The reinforcement pieces 10 are shown next to an Australian fifty cent coin 40 to indicate their size. As shown in Figure 3, the reinforcement pieces 10 are supplied in bulk for mixing with soil, aggregate and/or gravel, and concrete as required. The reinforcement pieces 10 are thus shaped to include generally opposed hook or bar portions for embedding into the soil and concrete mix. [68] In the embodiment, the reinforcement pieces 10 are added to a soil/gravel/cement mixture on percentage basis. The percentage of cement added to the mixture will depend on the type of soil on site, its moisture content and the compressive and tensile strength required from the resulting composite. Schedule 1 below lists the different properties of the resulting composition based on the percentage of cement in the mixture. [69] The reinforcement pieces 10 are added to the soil/cement mixture ideally at a percentage of 10%, either by volume or by weight. The percentage of the reinforcement pieces 10 in the alternative concrete composite ranges from 5% to 20% depending on the requirements of the alternative concrete composite structure to be built. [70] The reinforcement pieces 10, typically comprising plastic pieces having hook formations, create ties in the cement/soil mixes in use. The addition of the reinforcement pieces 10 increases the compression strength of the resulting composite by 5% to 10% and the tensile strength of the resulting composite by 10% to 15% compared to a soil/cement composite without the reinforcement pieces 10. [71] Fig. 1 also shows reinforcement bars 20 in accordance with another aspect of the present invention. [72] The reinforcement bars 20 are made from plastics material typically having lengths of 1.7 metre, 2.7 metres, and 3.7 metres (or custom lengths) and diameters of 10.7 mm, 12.7 mm and 16.7 mm (or custom diameters). The tensile strength of the reinforcement bars 20 range from 10 Mpa to 70 Mpa. The reinforcement bars 20 comprise corrugations or spaced ribs along their lengths to assist with the grip or development length binding with the soil/cement mix of the alternative concrete composite. [73] The reinforcement bars 20 are ideally also made from recycled waste material plastics material. The reinforcement bars 20 are used in a similar manner as steel reinforcement bars in concrete structures. Being made from plastics material, the reinforcement bars 20 do not corrode and thus eliminates or reduces the possibility of concrete cancer in the resulting structure. [74] The alternative concrete composite with the reinforcement pieces 10, and preferably used with the reinforcement bars 20 can be used to build support structures and protection structures for conventional concrete structures. [75] The present building system can be used for the following applications: • Protection structure for an existing concrete structure, as a bridge abutment, a road near slope and near river channels • gravity retaining wall, • controlled and engineered fill material • sub grade and base material fill, • dam embankment fill, • contaminated soil containment wall system, • water channel, • soil erosion fill, • meandering river control structures, • deep trench foundation, • deep soil stiffening mix against liquefaction and soft soil, • bridge support embankment, • load bearing wall, • flash flood control and detention • and other structures that can be designed for its own use or support structures to concrete. [76] The alternative concrete composite structure is used for a designed structure that match the stone properties of shear, tensile and compressive strength that can be applied as support structure and protection structure to concrete structures and can be used as embankment, retaining wall and other uses as mentioned above. [77] The preferred embodiment soil stone system Is an engineered soil fill with waste plastic reinforcement prices that provides a range of improved soil compressive, tensile and/or shear strengths. [78] The preferred embodiment is an alternative construction system for developing countries and communities which are short of funds to make infrastructures necessary economic development, natural disaster risk mitigation and others. [79] Fig. 3 and 4 illustratively shows the steps in excavation of a trench 50 which is then filled with the alternative concrete composite 60 for reinforcing the trench 50. The alternative concrete composite structure 60 provides a strength of about 500 kPa, compared to the previous soil strength of 100 kPa. As shown, formwork can also be used to from the alternative concrete composite structure 60 as a channel 60b. [80] Fig. 5 illustratively shows reinforcement of a road embankment 70 using the alternative concrete composite 60 of the preferred embodiment of the present invention. The alternative concrete composite is poured into a cavity 72 formed along the embankment and when formed, functions as both the retaining wall and fill material for the embankment 70. [81 ] Fig. 6 illustratively shows reinforcement of a road embankment 70 similar to the above and also forming a road and footpath 80 using the alternative concrete composite of the preferred embodiment of the present invention. Deep anchors 62 can be formed as part of the retaining wall structure 60 and the road surface 80 in one pour of the alternative concrete composite. [82] Fig. 7 illustratively shows forming a retaining wall using the alternative concrete composite of the preferred embodiment of the present invention. As shown, formwork 92 can be used as needed to shape the resulting retaining wall 60 using the alternative concrete composite. The retaining wall 60 shown includes a foundation section 64 formed to be deeply embedded in the ground. [83] Fig. 8 illustratively shows forming a wall foundation 60 using the alternative concrete composite of the preferred embodiment of the present invention. Similar to the retaining wall 60, the wall foundation 60 is formed to be deeply embedded in the ground and can then be used to support the wall 100 of a building. [84] Fig. 9 illustratively shows forming a buttress and embankment retaining wall 110 using the alternative concrete composite of the preferred embodiment of the present invention. Similar to the application of Figure 6, deep anchors 62 are formed as part of the retaining wall structure 110 in one pour of the alternative concrete composite. The retaining wall 110 is used for enforcing and raising the bank level of a waterway to avoid erosion and flash flooding. [85] Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described. For example, the following additives can be added to the concrete composite: a. 2-5% plastic or glass fibre strands, 50-100mm long b. 2-5% strip wire strands with rubber from old tires 50-100mm long c. 5-7% oxide pigment; and/or d. 5-10% calcium carbonate. [86] Figures 10 to 12 show the use of recycled waste plastics tube to form different reinforcement frame structures. The recycled waste plastics tube are made from any suitable recycled plastics material extruded into a tube 200 and formed with flanged internal threaded ends 202. [87] The ends 202 can be joined by disposing the ends adjacent each other within a form casting block and pouring melted recycled plastics material into the casting block, forming joining blocks 204. Alternatively, the joining blocks 204 can be formed separately with matching threaded structures to which the threaded ends 202 can be attached. [88] The recycled plastics tube are extruded to form enlarged dumb bell ends with internal threads for use in connections and joining. [89] Fig. 13 shows a typical vehicle tyre cross-section structure which as is known comprises steel belt sandwiched by rubber. A vehicle tyre 600 comprises inner and outer circular beads 302, inner and outer sidewalls 308, and a tread portion 606. [90] Fig. 14 shows the steps in expanding the recycled tyre into a mesh for use as a reinforcement structure. The tyre is slit in a pattern, expanded and stabilised to form a mesh 220. The recycled tyres are slit to create an expandable material mesh without removal of it steel strands. [91] Recycled waste tyre is cleaned and slit from its original form to slit sections of 8 to 12 mm width along the steel belt and expanded, or slit in 8 to 12mm widths and weaved to form an interlocking mesh or array of matrix strands. Typically, the beads 302 are removed. The sidewalls 308 can also be removed. The mesh can then be formed with the tread portion 606. [92] The processed tyre rubber matrix strands are then used as is for the concrete composite (Soilstone) or further processed by liquid rubber and vulcanization on a heated steel plate to form a permanent cross link shape of matrix strands before its application in the Soilstone concrete composite. [93] Further treatment of the matrix strands against fire is the application of vulcanizing cement liquid or other form of rubber adhesive with fire retarding materials (like vermiculite power or micro perlite material, micro sands) prior to application. [94] Fig. 16 shows examples of concrete reinforcement using (a) the recycled tubes frame 230 and (b) the recycled tubes frame and the recycled tyre mesh 220. These additional reinforcement can be use with the alternative concrete composite described above. [95] The matrix tyre strands/mesh can also be joined with the recycled plastic bar or frame for stability of the reinforcement prior to the Soilstone mix casting. [96] Fig. 17 shows examples of use of the use of cut-out tyre beads 300 of a tyre as concrete reinforcement. The bead portions are cut such that the circular wire bead 302 remains intact as single unit. The cut-out tyre bead portions 300 are thus strong rings that are flexible. [97] Figure 17(a) shows the tyre beads portions 300 with horizontal reinforcement bars 400, (b) with vertical reinforcement bars 400 and (c) with wire rope clips or winding strands 410. The cut-out tyre bead portions 300 can thus be arranged along reinforcement bars 400 prior to concrete pour as independent units or can be tied to each other at adjacent ends for additional reinforcement. [98] Fig. 18 (a) shows slit side tyre bead portions 310 with the tyre side walls 308 slit and the bead 302 intact. Fig. 19 shows a slitting blade 500 for the slit side tyre bead 310. In this embodiment, most of the tyre side walls 308 are retained and the tyre contact sections with the tread 606 can be removed. The side walls 308 are then slit using the slitting blade 500 to form strands extending from the intact wire bead 302. [99] Fig. 18 (b) examples of use of the use of slit side tyre bead portions 310 as concrete reinforcement. The slit side walls provide additional grip into the poured concrete. [100] Fig.20 shows use of the tyre bead 302 as dowels to join tyre mesh of Figure 14. The tyre beads 302 are joined to the tyre mesh 220 and can then be used to join to other tyre mesh 220. [101] Fig. 21 shows examples of use of cut-out portions of a tyre for concrete reinforcement. A single tyre 600 can be recycled to form slit side tyre bead portions 310, cut-out tyre beads 300, and recycled tyre mesh 220. Alternatively, the tread portion 606 and/or the sidewalls 308 can be slit to form strands 612, being 25 mm χ 10 mm flexible bars of 6 to 8 meters in length. These reinforcement pieces can then be combined 700 for concrete reinforcement. Schedule 1 Shear Strength for Soil Stone Mean value of unconfined compressive strength of different soils modified from Kasama et al. (2007). Other 0.63 Waste 3.49 Masado 10.74 Unusual soil Peat 0.43 Diatom soil 3.24 Variations of Weight, Density, and Compressive Strength of Concrete Mixes with Water-Cement Ratio. 1 part cement 2 parts soil material, and 4 part sand and stone or gravel on site The invention in one aspect relates to an alternative concrete composite using the soil on site and gravel on site, mixed with cement and reinforcement pieces according to another aspect of the present invention. The use of the reinforcement pieces allows the alternative concrete composite using the available 'unclean' soil and gravel on site to be formed into structures as needed at a substantially reduced cost. The reinforcement pieces (10, 20) in one embodiment are made from plastics material, and are ideally made from recycled waste plastics material, shaped to include generally opposed hook or bar portions for embedding into the soil and concrete mix. In another embodiment, a single used tyre (600) can be recycled to form slit side tyre bead portions (310), cut-out tyre beads (300), recycled tyre mesh (220), or strands (612) as reinforcement pieces. 1. A reinforcement piece for mixing with a concrete composite, the reinforcement piece comprising at least one hook-shaped or bent shaped formation. 2. The reinforcement piece of claim 1 wherein the reinforcement piece is made from plastics material 3. The reinforcement piece of claim 1 wherein the reinforcement piece is made from recycled waste plastics material. 4. The reinforcement piece of claim 1 wherein the reinforcement piece is 5 mm to 30 mm in length. 5. The reinforcement piece of claim 1 wherein the reinforcement piece is 5 mm to 30 mm in width. 6. The reinforcement piece of claim 1 wherein the reinforcement piece includes at least two hooks. 7. The reinforcement piece of claim 1 wherein the reinforcement piece includes at least two hooks at one end. 8. The reinforcement piece of claim 1 wherein the reinforcement piece includes at least two hooks at each end. 9. The reinforcement piece of claim 1 wherein the reinforcement piece includes a closed formation having an opening at a central portion thereof. 10. The reinforcement piece of claim 1 wherein the reinforcement pieces are shaped as human figures. 11. The reinforcement piece of claim 1 wherein the reinforcement pieces are shaped similar to a number Τ, a number ‘2’, ‘C’ shape, ‘S’ shaped, or ‘K’ shaped. 12. A reinforcement piece for mixing with a concrete composite, the reinforcement piece comprising a plastics material. 13. A reinforcement piece for mixing with a concrete composite, the reinforcement piece being 5 mm to 30 mm in length. 14. The reinforcement piece of claim 13 wherein the reinforcement piece is 5 mm to 30 mm in width. 15. The reinforcement piece of claim 12 or 13 wherein the reinforcement piece includes include generally opposed hook or bar portions for embedding into the concrete composite. 16. The reinforcement piece of claim 12 or 13 wherein the reinforcement pieces are shaped similar to a number ‘7’, a number ‘2’, ‘C’ shape, ‘S’ shaped, or ‘K’ shaped. 17. A plurality of reinforcement pieces according to any one of claims 1 to 16 . 18. The plurality of reinforcement pieces of claim 17 , wherein the reinforcement pieces comprise various shapes and sizes. 19. A concrete composite comprising the plurality of reinforcement pieces according to claim 17 or 18 . 20. The concrete composite of claim 19 wherein the plurality of reinforcement pieces are added to the soil/cement mixture at a percentage of 10% either by volume or by weight. 21. The concrete composite of claim 19 wherein the plurality of reinforcement pieces are added to the soil/cement mixture at a percentage of between 5% and 20% either by volume or by weight. 22. A plastics reinforcement bar for forming a concrete structure. 23. The reinforcement bar of claim 23 having a length of 1.7 metre, 2.7 metres, or 3.7 metres and/or diameters of 10.7 mm, 12.7 mm or 16.7 mm. 24. The reinforcement bar of claim 23 comprise corrugations or spaced ribs along its length. 25. The reinforcement bar of claim 23 made from recycled waste material plastics material. 26. A structure comprising the concrete composite of any one of claims 19 to 21 . 27. The structure of claim 26 comprising the reinforcement bar of any one of claims 22 to 25 . 28. A concrete reinforcement mesh formed from slit and expanded tyre or woven tyre stands. 29. A concrete reinforcement formed from recycled plastics tube. 30. A concrete reinforcement frame formed from joined recycled plastics tubes. 31. The frame of claim 30 wherein the ends of the frame are joined by recycled plastics. 32. A reinforcement piece for mixing with a concrete composite, the reinforcement piece comprising a tyre bead. 33. The reinforcement piece of claim 32 wherein the piece comprises side wall of the tyre extending from the wire bead, the side walls being slit to form strands. 34. A method of reinforcing concrete, the method comprising using a plurality of tyre beads embedded into the concrete.Field of the Invention
Background of the Invention
Summary of the Invention
Brief Description of the Drawings
Cement content 28 days unconfined Cement Deformation (%) compressive strength Addition modulus (kPa) (%) (kPa) 5 300 0.80 35200 7 462 1.11 62300 10 802 1.05 92100 12 1080 0.95 133100 15 1287 0.93 161000 20 1505 0.90 180100 Cement content (%) Unconfined compressive strength (kPa) Tensile strength (kPa) Cement content (%) Unconfined compressive strength (kPa) Tensile strength (kPa) 5 308 32 12 1083 106 7 450 41 15 1290 110 10 805 56 20 1510 125 Unconfined compressive strength of natural soil samples (kPa) Shear strength parameters of natural soil Cement content (%) Unconfined compressive strength of soil-cement (kPa) Cohesio η (kPa) Angle of internal friction (degrees) Cohesio η (kPa) Angle of internal friction 7 460 118 2 29.1 25.2 10 10 800 211 2 15 1290 283 3 Soil type Mean (Mpa) Gravel 1.58 Sandysoil 4.77 Cohesive soil Silt 1.92 Clay 4.72 Unknown 2.92 Organic soil 1.15 Volcanic soil Kanto laom 1.86 Kuroboku 0.26 Tensile Strengths
S/N Mix Proporti Water-Cement Compressiv ℮ 1 1:2:4 035“ 5789 2 17514- W 5.58 3 1727Τ 533“ 4 17274" error 4.6 5 1:2:4 0.80 4.2 6 1:2:4 0.55 11.00 7 1:2:4 0.60 9.36 8 1:2:4 0.65 8.56 9 1:2:4 0.70 7.89 10 1:2:4 0.80 7.49 11 172:4 0.55“ 15.O0 12 № 12.33 13 1:2:4 0.65 Τ27Τΐ 14 T72^~ OTD- TT3T~ Τ5 1:2:4 ϋ8(Τ 11.00