Building blocks for reinforced structures

Abstract

A method of making a reinforced structure of the type including a body of solidified matrix material, for example a cement based material, and reinforcing elements embedded therein, said method comprising shaping and solidifying matrix material so as to form a plurality of matrix body members ( 10 ) which when arranged adjacent to each other form a matrix body with a plurality of elongated cavities ( 11/12 ) therein, at least one of the matrix body members having matrix reinforcement components incorporated therein, at least one of the elongated cavities being formed on an interface between matrix body members when arranged adjacent to each other and/or at least two of the elongated cavities being formed transversely to each other and each intersects an interface between matrix body members arranged adjacent to each other, arranging the matrix body members adjacent to each other with reinforcing elements ( 13, 14, 15 ) within the said cavities, and interconnecting the matrix body members and the reinforcing elements so as to form said reinforced structure. Reinforced structures made by that method, and a kit of parts for use in that method are also claimed.

1 . A method of making a reinforced structure of the type including a body of solidified matrix material and a plurality of reinforcing elements embedded therein, said method comprising 
 shaping and solidifying matrix material so as to form a plurality of matrix body members which when arranged adjacent to each other form a matrix body with a plurality of elongated cavities therein, 
 at least one of the matrix body members having matrix reinforcement components incorporated therein,  
 at least one of the elongated cavities being formed on an interface between matrix body members when arranged adjacent to each other and/or  
 at least two of the elongated cavities being formed transversely to each other and each intersects an interface between matrix body members arranged adjacent to each other  
   arranging the matrix body members adjacent to each other with reinforcing elements within the said cavities, and    interconnecting the matrix body members and the reinforcing elements so as to form said reinforced structure.    
     
     
         2 . A method according to  claim 1 , wherein at least one of the elongated cavities is formed on an interface between matrix body members arranged adjacent to each other.  
     
     
         3 . A method according to  claim 2 , wherein at least one additional elongated cavity is formed which intersects the said interface.  
     
     
         4 . A method according to any of the preceding claims, wherein the elongated cavities are in the form of essentially linear bores.  
     
     
         5 . A method according to any of the preceding claims, wherein at least one of the reinforcing elements is a lined reinforcing element.  
     
     
         6 . A method according to any of the preceding claims, wherein substantially all of the plurality of matrix body members have matrix reinforcement components incorporated therein.  
     
     
         7 . A method according to any of the preceding claims, wherein at least one of the matrix body members is in a fluid/plastic condition and is arranged adjacent to one or more other matrix body members and one or more reinforcing elements and is brought in intimate contact with the said other matrix body member(s) and one or more pre-arranged reinforcing elements by mechanical influence, the one more reinforcing elements thereby forming an elongated cavity on an interface between the fluid/plastic matrix body member and the said other matrix body member(s), and then the fluid/plastic matrix body member(s) is/are solidified and interconnected with the other matrix body member(s) and the reinforcing element(s) so as to form the reinforced structure.  
     
     
         8 . A method according to  claim 7 , wherein the matrix body member or members which is/are in a fluid/plastic condition contain(s) matrix reinforcement components which substantially retain their configuration and orientation under the mechanical influence.  
     
     
         9 . A method according to any of the preceding claims, wherein the modulus of elasticity of the solidified matrix body members, or of the reinforced structure, is at least 30 GPa.  
     
     
         10 . A method according to  claim 9 , wherein the modulus of elasticity of the solidified matrix body members, or of the reinforced structure, is in the interval 60-150 GPa.  
     
     
         11 . A method according to  claim 9 , wherein the modulus of elasticity of the solidified matrix body members, or of the reinforced structure, is in the interval 150-300 GPa, or above 300 GPa.  
     
     
         12 . A method according to any of the preceding claims, wherein the compressive strength of the solidified matrix body members, or of the reinforced structure, is at least 30 MPa.  
     
     
         13 . A method according to  claim 12 , wherein the compressive strength of the solidified matrix body members, or of the reinforced structure, is in the interval 60-120 MPa.  
     
     
         14 . A method according to  claim 12 , wherein the compressive strength of the solidified matrix body members, or of the reinforced structure, is in the interval 120-250 MPa.  
     
     
         15 . A method according to  claim 12 , wherein the compressive strength of the solidified matrix body members, or of the reinforced structure, is in the interval 250-600 MPa.  
     
     
         16 . A method according to  claim 12 , wherein the compressive strength of the solidified matrix body members, or of the reinforced structure, is in the interval 600-1500 MPa.  
     
     
         17 . A method according to  claim 12 , wherein the compressive strength of the solidified matrix body members is in the interval 1500-4000 MPa, or above 4000 MPa.  
     
     
         18 . A method according to any of the preceding claims, wherein the tensile strength of the reinforcing elements is at least 300 MPa.  
     
     
         19 . A method according to  claim 18 , wherein the tensile strength of the reinforcing elements is in the interval 300-1000 MPa.  
     
     
         20 . A method according to  claim 18 , wherein the tensile strength of the reinforcing elements is in the interval 1000-3000 MPa, or larger than 3000 MPa.  
     
     
         21 . A method according to any of the preceding claims, wherein the volume of reinforcement elements arranged in the cavities is such that the volume of reinforcement elements, excluding any lining thereof, in the reinforced structure, defined as the sum of the percentage ratio between reinforcement area and total area in three mutually perpendicular sections of the reinforced structure is at least 2%.  
     
     
         22 . A method according to  claim 21 , wherein the volume of the reinforcement is in the interval 3-15%.  
     
     
         23 . A method according to  claim 22 , wherein the volume of the reinforcement is in the interval 3-5%.  
     
     
         24 . A method according to  claim 22 , wherein the volume of the reinforcement is in the interval 5-10%.  
     
     
         25 . A method according to  claim 22 , wherein the volume of the reinforcement is in the interval 10-15%.  
     
     
         26 . A method according to  claim 21 , wherein the volume of the reinforcement is at least 15%.  
     
     
         27 . A method according to any of the preceding claims, wherein the number of reinforcing elements arranged in cavities extending in one direction is at least 3.  
     
     
         28 . A method according to  claim 27 , wherein the number of reinforcing elements arranged in cavities extending in one direction is at least 6.  
     
     
         29 . A method according to  claim 27 , wherein the number of reinforcing elements arranged in cavities extending in one direction is at least 12.  
     
     
         30 . A method according to claim any of claims  27 - 29 , wherein the number of reinforcing elements arranged in cavities extending in a direction perpendicular to the said one direction is at least 4.  
     
     
         31 . A method according to  claim 30 , wherein the number of reinforcing elements arranged in cavities extending in the third possible perpendicular direction is at least 2.  
     
     
         32 . A method according to any of the preceding claims, wherein the reinforcing elements are rod-shaped and have a diameter of at least 60 mm.  
     
     
         33 . A method according to  claim 32 , wherein the reinforcing elements have diameters in the interval between 60 mm and 100 mm, and/or between 100 mm and 250 mm, and/or between 250 mm and 600 mm and/or between 600 mm and 1200 mm and/or between 1200 mm and 3000 mm.  
     
     
         34 . A method according to any of the preceding claims, wherein the fracture energy of the solidified matrix body members, expressed in kN/m, is in one of the following intervals: 
 2-5    5-20,    20-50    50-200    200-1000    or larger than 1000.    
     
     
         35 . A method according to any of the preceding claims, wherein the matrix material is compacted or compressed when shaped into a matrix body or matrix body members.  
     
     
         36 . A method according to any of the preceding claims, wherein the matrix body members are machined or subjected to another mechanical treatment subsequent to shaping and solidification thereof.  
     
     
         37 . A method according to any of the preceding claims, wherein the reinforcing elements are interconnected with the matrix body or body members by mechanical means and/or by means of one or more binders.  
     
     
         38 . A method according to  claim 37 , wherein binder is introduced or injected into the cavities of the matrix body in a liquid form, when the reinforcing elements have been arranged therein, and subsequently allowed to solidify within the cavities.  
     
     
         39 . A method according to any of claims  1 - 37 , wherein a binder or binder component is applied to the outer surface of the reinforcing elements prior to arranging the reinforcing elements in the cavities.  
     
     
         40 . A method according to any of the claims  1 - 37 , wherein a binder or binder component is applied to the inner surfaces of the matrix body members defining the cavities prior to arranging the reinforcing elements within these cavities, or subsequently to arranging the reinforcing elements within these cavities.  
     
     
         41 . A method according to any of claims  1 - 38 , wherein at least one further gaseous or liquid binder component is subsequently introduced into the spaces or cavities of the matrix body so as to activate the binder composed by said components.  
     
     
         42 . A method according to any of the preceding claims, wherein the matrix body members are shaped so as to mechanically interlock with adjacent matrix body members.  
     
     
         43 . A method according to any of the preceding claims, wherein surface parts of the reinforcing elements on one hand and adjacent surface parts of the matrix body members on the other hand are shaped so as to mechanically interlock the reinforcing elements and the matrix body or body members.  
     
     
         44 . A method according to any of the preceding claims, wherein the matrix body reinforcement components are ore include fibres.  
     
     
         45 . A method according to any of the preceding claims, wherein the matrix body members are composite material body members.  
     
     
         46 . A method according to any of the preceding claims, wherein the solidified matrix material is a porous material, a binder being injected into said porous material so as to mutually interconnect the matrix body members and/or to connect the matrix body members with the reinforcing elements.  
     
     
         47 . A method according to any of the preceding claims, wherein the matrix material comprises at least first and second different materials having different characteristics, matrix body members being made from such different materials.  
     
     
         48 . A method according to any of the preceding claims, wherein said reinforced structure is a building structure or an element of a building structure.  
     
     
         49 . A method according to any of the preceding claims, wherein the matrix material comprises a material selected from the group consisting of cement based materials, ceramics based materials, plastics materials, metal or metal alloy materials, including DSP materials, and glass.  
     
     
         50 . A kit of parts for constructing a reinforced structure, comprising preformed solidified matrix body members as defined in any of the preceding claims, reinforcement elements shaped for insertion into the cavities formed by the arranged matrix body members, and interconnecting means for interconnecting the matrix body members and the reinforcing element or elements so as to form a reinforced structure.  
     
     
         51 . A reinforced structure comprising 
 a plurality of shaped solid matrix body members arranged adjacent to each other form a matrix body with a plurality of elongated cavities therein,    at least one of the matrix body members having matrix reinforcement components incorporated therein,    at least one of the elongated cavities being formed on an interface between matrix body members and/or    at least two of the elongated cavities being formed transversely to each other and are formed so that each intersects an interface between matrix body members    reinforcing elements being arranged within the said cavities, and    the matrix body members and the reinforcing elements being interconnected by binder material having a composition different from that of the matrix body members to which they are interconnected.    
     
     
         52 . A kit of parts as claimed in  claim 50  or a reinforced structure as claimed in  claim 51  which has any of the characteristics defined in any of  claims 2  to  49 .