Method and apparatus for composite pole repair

Abstract

This invention provides a method for repair for poles which have been damaged by environmental effects, which is easily transportable, simple to install, and easily adaptable to many classes of poles. The method involves excavating around the pole, cleaning the surface of the pole, pumping a fumigant into the pole, applying a bonding agent to the clean surface, and then applying strips of a composite fiberglass mat and resin to the pole in a controlled manner until a desired casement thickness has been achieved. The repair is completed by application of an ultraviolet resistant coating to the pole.

What is claimed is: 
     
       1. A method of repairing a utility pole in situ comprising steps of: (a) excavating around said utility pole to a predetermined depth;   (b) cleaning the surface of said pole;   (c) treating said surface;   (d) selecting and preparing a plurality of .[.longitudinal.]. woven fiber .[.mat strips.]. .Iadd.mats.Iaddend.;   (e) saturating said .[.strips.]. .Iadd.mats .Iaddend.with .[.the.]. .Iadd.a .Iaddend.liquid composite;   (f) positioning each .[.strip with the longitudinal dimension of each strip substantially parallel to the longitudinal axis of said pole.]. .Iadd.mat with the fibers of a first direction of the weave oriented substantially parallel to the longitudinal axis of said pole and the fibers of a second direction of the weave oriented at an angle relative to said first direction.Iaddend.; and,   (g) applying said .[.strips.]. .Iadd.mat .Iaddend.sequentially and circumferentially with each succeeding .[.strip.]. .Iadd.mat .Iaddend.overlapping its preceding .[.strip.]. .Iadd.mat.Iaddend., around the circumference of said pole to form a cylindrical encasement of desired thickness; wherein the manner of applying the saturated woven mat .[.strips.]. comprises: (i) fully saturating each .[.strip by placing the woven mat into a tray filled.]. .Iadd.mat .Iaddend.with .[.the.]. .Iadd.said .Iaddend.liquid .[.composite and rolling the mat strip with a paint roller.].;   (ii) .[.removing said saturated mat strips from the tray and.]. aligning each .Iadd.mat .Iaddend.with the .[.longitudinal axis of the utility pole.]. .Iadd.fibers of a first direction of the weave oriented substantially parallel to the longitudinal axis of said pole and the fibers of a second direction of the weave oriented at an angle relative to said first direction .Iaddend.and then pressing it against the surface of the utility pole at the repair location;   (iii) .[.rolling said saturated woven mat strips with the paint roller to press.]. .Iadd.pressing .Iaddend.the saturated mat against the pole surface and .[.to ensure.]. .Iadd.ensuring .Iaddend.that no air bubbles are entrained;   (iv) repeating the process with the next woven mat .[.strip.]. which is saturated .[.in the tray.].; and then placed against the utility pole so that .[.one half of.]. the second mat .[.strip.]. overlaps .[.half of.]. the first mat .[.strip.]. already in place;   (v) .[.rolling.]. .Iadd.pressing .Iaddend.the second mat .[.strip with a paint roller.]. to ensure that no air bubbles are entrained; and,   (vi) repeating the saturated mat .[.strip.]. application until the .[.composite.]. .Iadd.cylindrical .Iaddend.encasement .[.cylinder shell.]. reaches the desired thickness.     
     
     
       2. A method of applying a bonded structural encasement to wooden poles comprising the steps of: (a) cleaning a portion of the surface of the poles;   (b) selecting a material wherein: lengthwise fibers comprise from 50% to 80% of the total fiber; half of the remaining fibers total from 10% to 25% of the total fibers placed at an angle relative to the lengthwise fibers; and, the remaining 10% to 25% of the fibers placed at an equal angle relative to the lengthwise fibers in the opposite direction relative to the first angled fibers;   (c) saturating woven fiber .[.strips.]. .Iadd.mats .Iaddend.of said material with a composite resin;   (d) selecting and applying a plurality of saturated .[.strips.]. .Iadd.mat .Iaddend.to the clean surface in sequence with each succeeding .[.strip.]. .Iadd.mat .Iaddend.overlapping its preceding .[.strip.]. .Iadd.mat .Iaddend.around the circumference of said pole and .Iadd.having its lengthwise fibers .Iaddend.substantially parallel to the longitudinal axis of said pole to form upon hardening into a cylindrical encasement;   (e) applying an ultraviolet resistant coating to the exterior of the encasement; and,   (f) pumping a fumigant into the pole to arrest biological agents.   
     
     
       3. A method of applying a bonded structural encasement to wooden poles comprising the steps of: (a) cleaning a portion of the surface of the poles;   (b) selecting a material wherein; lengthwise fibers comprise from 50% to 80% of the total fibers, half of the remaining fibers total from 10% to 25% of the total fibers placed at an angle relative to the lengthwise fibers; and, the remaining 10% to 25% of the fibers placed at an equal angle relative to the lengthwise fibers in the opposite direction relative to the first angled fibers.Iadd.; .Iaddend.   (c) applying a bonding agent to the cleaned surface prior to applying .[.the.]. .Iadd.a plurality of .Iaddend.saturated .[.strips,.]. .Iadd.mats of said material.Iaddend.;   (d) saturating .Iadd.said .Iaddend.woven fiber .[.strips.]. .Iadd.mats .Iaddend.of said material with a composite resin;   (e) selecting and applying .[.a.]. .Iadd.said .Iaddend.plurality of saturated .[.strips.]. .Iadd.mat .Iaddend.to the cleaned surface in sequence, with each succeeding .[.strip.]. .Iadd.mat .Iaddend.overlapping its preceding .[.strip.]. .Iadd.mat .Iaddend.around the circumference of said pole and .Iadd.having its lengthwise fibers .Iaddend.substantially parallel to the longitudinal axis of said pole to form upon hardening into a cylindrical encasement;   (f) applying an ultraviolet resistant coating to the exterior of the encasement; and,   (g) pumping a fumigant into the pole to arrest biological agents.   
     
     
       4. A method of repairing a utility pole in situ comprising the steps of: (a) excavating around said utility pole to a predetermined depth;   (b) cleaning and treating the surface of said pole;   (c) pumping a fumigant into .[.the.]. .Iadd.said .Iaddend.pole to arrest biological agents;   (d) applying an ultraviolet resistant coating; and   (e) applying a bonding agent to .[.the.]. .Iadd.said .Iaddend.cleaned surface prior to applying the saturated .[.strips.]. .Iadd.mats.Iaddend.;   (f) saturating woven fiber .[.strips.]. .Iadd.mats .Iaddend.with a .Iadd.liquid .Iaddend.composite .[.resin.].;   (g) fully saturating each .[.strip by placing the woven mat into a tray filled.]. .Iadd.mat .Iaddend.with .[.the.]. .Iadd.said .Iaddend.liquid composite .[.and rolling the mat strip with a paint roller.].;   (h) .[.removing said saturated mat strips from the tray and.]. aligning each .[.with the longitudinal axis of the utility pole.]. .Iadd.mat with the fibers of a first direction of the weave oriented substantially parallel to the longitudinal axis of said pole and the fibers of a second direction of the weave oriented at an angle relative to said first direction .Iaddend.and then pressing it against the surface of the utility pole at the repair location;   (i) .[.rolling.]. .Iadd.pressing .Iaddend.said saturated woven mats .[.strips with a paint roller to press the saturated mat.]. against the pole surface .[.and.]. to ensure that no air bubbles are entrained;   (j) repeating the process with the next woven mat .[.strip.]. which is saturated .[.in the tray.].; and then placed against the utility pole so that the second mat .[.strip.]. overlaps the first mat .[.strip.]. already in place;   (k) the step of preparing said .[.strips.]. .Iadd.mats .Iaddend.comprises selecting a woven fiber mat wherein lengthwise fibers comprise from 50% to 80% of the total fibers within a mat and half the remaining 10% 25% of the fibers are placed at an angle relative to the lengthwise fibers; and, wherein the remaining 10% to 25% of the fibers are placed at an equal angle relative to the lengthwise fibers in the opposite direction relative to the first angled fibers,   (l) selecting and applying a plurality of saturated .[.strips.]. .Iadd.mats .Iaddend.to the cleaned surface in sequence, with each succeeding .[.strip.]. .Iadd.mat .Iaddend.overlapping its preceding .[.strip.]. .Iadd.mat .Iaddend.around the circumference of said pole and .Iadd.having its lengthwise fibers .Iaddend.substantially parallel to the longitudinal axis of said pole to form upon hardening into a cylindrical encasement.