U.S. patent application number 10/415762 was filed with the patent office on 2004-03-18 for composite panel for reparing, reinforcing con'c body and method of using the same.
Invention is credited to Ahn, Sang-Ho, Cho, Baik-Soon, Park, Sang Tae.
Application Number | 20040050006 10/415762 |
Document ID | / |
Family ID | 19696170 |
Filed Date | 2004-03-18 |
United States Patent
Application |
20040050006 |
Kind Code |
A1 |
Park, Sang Tae ; et
al. |
March 18, 2004 |
Composite panel for reparing, reinforcing con'c body and method of
using the same
Abstract
Disclosed are a panel for repairing and reinforcing a concrete
body, a multi-purpose anchor, an anchor for level adjustment and
injection a method for repairing and reinforcing the concrete body
using the same, which can connect adhesives and anchors at weak
parts of the concrete body, which is neutralized, aged,
deteriorated, cracked due to water leakage, or segregated, or at
parts requiring the repair and reinforcement due to a change in use
environment. The composite reinforced panel includes lightweight
concrete, high strength concrete or a steel plate and reinforcing
means, thereby being effectively prevented from bad environments
causing a drop of reinforcing capacity, providing good heatproof
and fireproof properties, and maximizing merits of materials used
as the reinforcing means. The multi-purpose anchor has a bolt and
an injection pipe, fixes the panel to the concrete body
effectively, serves as a spacer maintaining a prescribed interval
between the panel and the concrete body, and serves to inject
filler and discharge the inside air to the outside, thereby
improving construction efficiency. The anchor for level adjustment
and injection has a male screw and a female screw at an end and an
injection pipe of a straw type, thereby improving the construction
efficiency when the concrete panel is installed.
Inventors: |
Park, Sang Tae; (Pusan,
KR) ; Ahn, Sang-Ho; (Pusan, KR) ; Cho,
Baik-Soon; (Pusan, KR) |
Correspondence
Address: |
PARK & SUTTON LLP
3255 WILSHIRE BLVD
SUITE 1110
LOS ANGELES
CA
90010
US
|
Family ID: |
19696170 |
Appl. No.: |
10/415762 |
Filed: |
October 3, 2003 |
PCT Filed: |
October 30, 2001 |
PCT NO: |
PCT/KR01/01830 |
Current U.S.
Class: |
52/514 |
Current CPC
Class: |
E04G 23/0211 20130101;
E04G 2023/0251 20130101; E01D 22/00 20130101; E04G 23/0203
20130101; E04G 23/0218 20130101; E01C 7/147 20130101 |
Class at
Publication: |
052/514 |
International
Class: |
E04G 023/00; E02D
037/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 30, 2000 |
KR |
2000/64018 |
Claims
What is claimed is:
1. A composite panel for reinforcing a concrete body, comprising: a
steel plate of a prescribed size; an impregnable adhesion layer
formed on an upper surface of the steel plate; a reinforced fiber
mounted on the upper surface of the steel plate and impregnated and
adhered by the impregnable adhesion layer; and powder sprayed on
the upper surface of the steel plate and impregnated and adhered on
the surface of the impregnable adhesion layer.
2. The composite panel according to claim 1, further comprising: an
adhesion layer formed on a lower surface of the steel plate; and a
precast concrete panel of a prescribed size adhered by the adhesion
layer.
3. The composite panel according to claim 2, wherein the precast
concrete panel is a lightweight precast concrete panel using
lightweight aggregate.
4. The composite panel according to claim 3, wherein when the
lightweight precast concrete panel is cut in the form of a flat
rectangle, the composite panel for reinforcing the concrete body of
claim 1 is cut in the same size as the lightweight precast concrete
panel to be connected with the lightweight precast concrete panel,
or cut larger than the lightweight precast concrete panel and has a
protrusion at one side of four sides, two protrusions at opposite
sides, three protrusions at three sides except one side, or four
protrusions at all sides to be connected with the lightweight
precast concrete panel.
5. The composite panel according to claim 1, wherein the reinforced
fiber is at least one of carbon fiber, glass fiber and aramide
fiber, or is formed by stacking one of carbon fiber, glass fiber
and aramide fiber, by composing at least two or more of carbon
fiber, glass fiber and aramide fiber, or by composing and stacking
at least two or more of carbon fiber, glass fiber and aramide
fiber.
6. A composite panel for reinforcing a concrete body, comprising: a
reinforced fiber of a prescribed size; an impregnable adhesion
layer formed on an upper surface of the reinforced fiber; a steel
plate mounted on the upper surface of the reinforced fiber and
adhered by the impregnable adhesion layer; and powder sprayed,
impregnated and adhered on the upper surface of the steel
plate.
7. The composite panel according to claim 6, further comprising: an
adhesion layer formed on a lower surface of the reinforced fiber;
and a precast concrete panel of a prescribed size mounted on the
lower surface of the reinforced fiber and adhered by the adhesion
layer.
8. The composite panel according to claim 7, wherein the precast
concrete panel is a lightweight precast concrete panel using
lightweight aggregate.
9. The composite panel according to claim 8, wherein when the
lightweight precast concrete panel is cut in the form of a flat
rectangle, the composite panel for reinforcing the concrete body of
claim 6 is cut in the same size as the lightweight precast concrete
panel to be connected with the lightweight precast concrete panel,
or cut larger than the lightweight precast concrete panel and has a
protrusion at one side of four sides, two protrusions at opposite
sides, three protrusions at three sides except one side, or four
protrusions at all sides to be connected with the lightweight
precast concrete panel.
10. A composite panel for reinforcing a concrete body, comprising:
an upper steel plate of a prescribed size; a lower steel plate of a
prescribed size; an impregnable adhesion layer formed on an upper
surface of the upper steel plate; a reinforced fiber mounted on the
upper surface of the upper steel plate and impregnated and adhered
by the impregnable adhesion layer; an adhesion layer formed on an
upper surface of the reinforced fiber; the lower steel plate
adhered by the adhesion layer formed on the upper surface of the
reinforced fiber; an adhesion layer formed on the surfaces of the
upper and lower steel plates; and powder sprayed and adhered on the
adhesion layer formed on the surfaces of the upper and lower steel
plates.
11. The composite panel according to claim 10, further comprising:
an adhesion layer formed on a lower surface of the lower steel
plate; and a precast concrete panel of a prescribed size adhered on
the lower steel plate by the adhesion layer.
12. The composite panel according to claim 11, wherein the precast
concrete panel is a lightweight precast concrete panel using
lightweight aggregate.
13. The composite panel according to claim 12, wherein when the
lightweight precast concrete panel is cut in the form of a flat
rectangle, the composite panel for reinforcing the concrete body of
claim 10 is cut in the same size as the lightweight precast
concrete panel to be connected with the lightweight precast
concrete panel, or cut larger than the lightweight precast concrete
panel and has a protrusion at one side of four sides, two
protrusions at opposite sides, three protrusions at three sides
except one side, or four protrusions at all sides to be connected
with the lightweight precast concrete panel.
14. A composite panel for reinforcing a concrete body, comprising:
a steel plate of a prescribed size; an impregnable adhesion layer
formed on an upper surface of the steel plate; an upper reinforced
fiber mounted on the upper surface of the steel plate and
impregnated and adhered by the impregnable adhesion layer; powder
sprayed, impregnated and adhered on an upper surface of the upper
reinforced fiber; an impregnable adhesion layer formed on a lower
surface of the steel plate; a lower reinforced fiber mounted on the
lower surface of the steel plate and impregnated and adhered by the
impregnable adhesion layer; and powder sprayed, impregnated and
adhered on a lower surface of the lower reinforced fiber.
15. The composite panel according to claim 14, further comprising:
an adhesion layer formed on a lower surface of the lower reinforced
fiber; and a precast concrete panel mounted on the lower portion of
the lower reinforced fiber and adhered by the adhesion layer.
16. The composite panel according to claim 15, wherein the precast
concrete panel is a lightweight precast concrete panel using
lightweight aggregate.
17. The composite panel according to claim 16, wherein when the
lightweight precast concrete panel is cut in the form of a flat
rectangle, the composite panel for reinforcing the concrete body of
claim 14 is cut in the same size as the lightweight precast
concrete panel to be connected with the lightweight precast
concrete panel, or cut larger than the lightweight precast concrete
panel and has a protrusion at one side of four sides, two
protrusions at opposite sides, three protrusions at three sides
except one side, or four protrusions at all sides to be connected
with the lightweight precast concrete panel.
18. A lightweight precast concrete composite reinforced panel used
in a reinforcing construction of a concrete body, the composite
panel comprising: a lightweight precast concrete panel including a
lightweight concrete layer, a reinforced glass fiber mesh of a net
type mounted inside the lightweight concrete layer, and water
soluble cement group, polymer cement group or polymer group resin
layer contained in the lightweight concrete layer, the lightweight
precast concrete panel being formed through a natural cure and a
forced cure in order, the lightweight concrete layer being formed
by mixing one of perlite, filite, celite, ALC aggregate and ALC
crusher run aggregate, water and cement; and concrete body
reinforcing means adhered and connected to a surface of the
lightweight precast concrete panel.
19. The composite panel according to claim 18, wherein the concrete
body reinforcing means includes: thermosetting resin coated on the
lightweight precast concrete panel; and an inorganic group
reinforced fiber sheet impregnated into the thermosetting resin,
cut and jointed in the same size as the lightweight precast
concrete panel, or cut larger than the lightweight precast concrete
panel and protrudingly jointed with the lightweight precast
concrete panel.
20. The composite panel according to claim 19, wherein the
inorganic group reinforced fiber sheet is selected from at least
one or more kinds of one-way woven aramide fiber sheet, prepreg
type one-way woven carbon fiber sheet, cross type woven carbon
fiber and glass fiber sheet, stacked in at least one or more
layers, wherein if there is direction of woven fiber of the
reinforced fiber sheet, the inorganic group reinforced fiber sheets
are stacked and jointed in the same direction without regard to
stacked number and stacked order thereof, and wherein the inorganic
group reinforced fiber sheets are impregnated and jointed into the
thermosetting resin whenever the reinforced fiber sheet is
stacked.
21. The composite panel according to claim 20, wherein when the
lightweight precast concrete panel is cut in the form of a flat
rectangle, the reinforced fiber sheet is cut in the same size as
the lightweight precast concrete panel to be connected with the
lightweight precast concrete panel, or cut larger than the
lightweight precast concrete panel and has a protrusion at one side
of four sides, two protrusions at opposite sides, three protrusions
at three sides except one side, or four protrusions at all sides to
be connected with the lightweight precast concrete panel.
22. A lightweight precast concrete panel for improving weatherproof
and fireproof properties of a concrete body reinforced by a
reinforcing method using a reinforced fiber sheet, the lightweight
precast concrete panel comprising: a lightweight concrete layer
formed by mixing cement, lightweight aggregate and water; and a
reinforced glass fiber mesh stacked and integrated into the
lightweight concrete layer, the reinforced glass fiber mesh being
formed by impregnating a glass fiber mesh into an impregnable
adhesive and spraying and hardening silica sands or blast furnace
steel slag.
23. A method of installing a lightweight precast panel, the method
for additionally reinforcing a concrete body reinforced by a
reinforcing method using a reinforced fiber sheet to improve
fireproof property or for forming a beautiful finished surface on
the concrete body requiring refinish due to a bad outward
appearance, the method comprising the steps of: removing foreign
matters from a surface of the concrete body; checking error of the
surface of the concrete body and supplementing the surface; coating
an adhesive or mortar on the surface of the concrete body and a
surface of the lightweight precast panel of claim 22 and adhering
the lightweight precast panel to the concrete body; and digging
joints between the lightweight precast panels and performing a
pointed joint work.
24. A lightweight precast concrete composite reinforced panel used
in a reinforcing construction of a concrete body, the composite
panel comprising: a lightweight precast concrete panel of claim 22;
and a reinforced fiber impregnated panel or a prestressed
reinforced fiber composite panel adhered and stacked on an upper
surface of the lightweight precast concrete panel.
25. A multi-purpose anchor comprising: an insert of a cylindrical
shape, the insert including a body part and a head part, the body
part having a plurality of holes (212) formed on an outer
circumference, the body part having an end having a female screw
and the other end split into several sections, the head part formed
at the end on which the female screw is formed protruding from the
body part and having a prescribed thickness; an expanding tool
inserted into the insert and having a hollow part vertically
passing therein, the expanding tool having a size and a shape
capable of expanding the diameter of the insert; a bolt having a
body part, a head part extending from an end of the body part and
having a diameter larger than that of the body part, and a hollow
part vertically passing the center of the body part and the head
part, the body part having a male screw coupled with the female
screw of the insert and a plurality of holes, the hollow part being
connected with the holes of the body part and having a female screw
formed on an inner circumference of the head part; and an injection
pipe having a concave neck part, a head part and a body part, the
head part having a male screw formed on an outer circumference and
coupled with the female screw formed on an inner circumference of
the bolt head part, and a female screw formed on an inner
circumference thereof, the body part having a male screw formed on
an outer circumference of an end thereof and coupled with the
female screw formed on the inner circumference of the head part,
the injection pipe being inserted into the hollow part of the bolt
and the hollow part of the expanding tool when the insert and the
bolt are coupled.
26. A lightweight precast concrete composite reinforced panel for
repairing and reinforcing a concrete body, the composite panel
comprising: a lightweight concrete layer formed by mixing one of
perlite, filite, celite, ALC aggregate and ALC crusher run
aggregate, cement and water; and panel reinforcing means connected
to a surface of the previously poured and hardened lightweight
concrete layer of a panel type.
27. A precast concrete composite reinforced panel for repairing and
reinforcing a concrete body, the composite panel comprising: a
lower concrete layer formed by mixing sand for concrete, aggregate,
cement and water and having a compression strength equal to or
stronger than the concrete body to be reinforced; a precast
concrete panel made in such a manner that one of a reinforced glass
fiber mesh, a wire and a steel bar is installed inside the lower
concrete layer, and instantly, the same concrete as the lower
concrete layer is poured on an upper portion; and concrete body
reinforcing means connected at a surface of the precast concrete
panel.
28. A precast concrete composite reinforced panel for repairing and
reinforcing a concrete body, the composite panel comprising: a
lower concrete layer formed by mixing sand for concrete, aggregate,
cement and water and having a compression strength equal to or
stronger than the concrete body to be reinforced; and a precast
concrete panel made in such a manner that one of a reinforced glass
fiber mesh, a wire and a steel bar is installed inside the lower
concrete layer, and instantly, the same concrete as the lower
concrete layer is poured on an upper portion; wherein one of the
reinforced glass fiber mesh, wire or steel bar is installed on a
surface of the precast concrete panel, synthetic resin for high
strength mortar and hardening agent are mixed, and the mixture is
mixed with silica sand aggregate and poured and adhered.
29. A precast concrete panel for repairing and reinforcing a
concrete body, the precast concrete panel comprising: a lower
concrete layer having compression strength equal to or stronger
than the concrete body and previously poured and hardened to be
formed into a panel type; one of extra thin two-way or one-way
carbon fiber, prepreg one-way carbon fiber, glass fiber and aramide
fiber impregnated on an upper surface of the lower concrete layer
by means of epoxy resin and hardening agent; and an upper concrete
layer formed of the same material and in the same mixing rate as
the lower concrete layer and adhered to the impregnated fiber by
means of the epoxy resin and hardening agent, the upper concrete
layer being previously poured and hardened to be formed into the
panel type.
30. A lightweight precast concrete composite reinforced panel for
repairing and reinforcing a concrete body, the composite panel
comprising: a lower lightweight concrete layer formed by mixing one
of perlite, filite, celite, ALC aggregate and ALC crusher run
aggregate, cement and water; panel reinforcing means adhered on an
upper surface of the lower lightweight concrete layer; and an upper
lightweight concrete layer adhered on an upper surface of the panel
reinforcing means and made of the same material as the lower
lightweight concrete layer.
31. The composite panel according to claim 30, wherein the panel
reinforcing means impregnates and adheres one of prepreg one-way
carbon fiber, extra thin one-way and two-way carbon fiber, aramide
fiber and glass fiber between the previously poured and hardened
upper and lower lightweight concrete layers of the panel type by
means of epoxy resin and hardening agent.
32. The composite panel according to claim 30, wherein the panel
reinforcing means is formed in such a manner that one of a glass
fiber mesh, a wire and a steel bar is covered on the upper surface
of the lower lightweight concrete layer of the panel type, silica
sands, epoxy resin for high strength mortar and hardening agent are
mixed, the mixture is poured on the upper surface of the lower
lightweight concrete layer to adhere the upper lightweight concrete
layer of the panel type to the lower lightweight concrete
layer.
33. A method for repairing and reinforcing a concrete body having
damaged part due to aging, material separation, neutralization and
deterioration, the method comprising the steps of: cutting the
damaged part into a rectangle; digging and removing concrete
contained inside cut lines; forming an anchor hole; installing the
multi-purpose anchor of claim 25 and one of panels of claim 26
through claim 32 into the anchor hole; sealing boundary parts
between the panel and the broken concrete part with inorganic group
sealing material or synthetic resin group sealing material; forming
a plurality of air discharge holes at an upper boundary part of the
boundary parts; injecting high strength synthetic resin by means of
the multi-purpose anchor; and finishing a surface of the panel with
inorganic material.
34. An anchor for adjusting the level of a panel and injecting, the
anchor comprising: a body part of a cylindrical shape and having a
hollow part formed generally, the body part having a male screw
formed on an outer circumference, a through hole formed at an end
thereof and intersecting with the hollow part, and an angular
protrusion formed at the other end having a female screw on an
inner circumference of the hollow part; a nut screwed with the male
screw of the body part; an injection pipe of a generally straw
shape, the injection pipe having a male screw formed at an end
thereof and screwed with the female screw of the body part; and a
clip having a cylindrical part and a ring part connected to the
cylindrical part, the cylindrical part having a female screw formed
on an inner circumference and screwed with the male screw of the
body part.
35. A method for repairing and reinforcing a concrete body in case
that a concrete paved road has a damaged part, the method
comprising the steps of: preparing a precast concrete panel, which
has a plurality of anchor holes for installing the anchor of claim
34 and on which steel bars are arranged or not arranged; cutting
the damaged part into a rectangle; digging and removing concrete
contained inside cut lines; coating epoxy mortar on the dug and
removed concrete surface; fixing the nut of the anchor of claim 34
into the anchor hole of the precast concrete panel; screwing the
nut fixed into the anchor hole and the body part of the anchor of
claim 34 and arranging the precast concrete panels on the dug
concrete road surface; rotating the body part of the anchor to
adjust the level of the panel; sealing boundary parts between the
panel and the concrete road surface with sealing material;
injecting and filling synthetic resin adhesive using a straw; and
removing the straw and sealing and finishing the anchor holes of
the panel with inorganic group resin.
Description
TECHNICAL FIELD
[0001] The present invention relates to a panel for repairing and
reinforcing a concrete body, a multi-purpose anchor, an anchor for
level adjustment and injection and a method for repairing and
reinforcing the concrete body using the same. More particularly,
the present invention relates to a panel for repairing and
reinforcing a concrete body, a multi-purpose anchor, an anchor for
level adjustment and injection and a method for repairing and
reinforcing the concrete body using the same, which can connect
adhesives and anchors at weak parts of the concrete body, which is
neutralized, aged, deteriorated, cracked due to water leakage, or
segregated, or at parts requiring the repair and reinforcement due
to a change in use environment.
BACKGROUND ART
[0002] People have generally recognized that a reinforced concrete
body is semi-permanent, but the reinforced concrete body is aged
and deteriorated due to various causes, such as neutralization,
corrosion of reinforced steels, exfoliation of an outer layer due
to dryness, contraction and expansion, error in design, false
construction, fatigue load, change in use environment, as time
passes and the use environment is changed, and thereby the concrete
body needs repair and reinforcement. So, new materials and new
construction methods for restraining the progress of the
deterioration in structure and repairing and reinforcing the
concrete body have been studied and developed.
[0003] Recently, as generally used methods for repairing and
reinforcing the concrete body, there are a carbon fiber sheet
reinforcing method, a glass fiber sheet reinforcing method, an
aramide fiber sheet reinforcing method, a steel plate adhering and
reinforcing method, a method for reinforcing synthetic resin panel,
in which reinforce fiber and thermosetting resin are composed, and
so on. Additionally, as the concrete body repairing method, there
are a patching method and a section restoring method.
[0004] The carbon fiber sheet reinforcing method, the glass fiber
sheet reinforcing method and the aramide fiber sheet reinforcing
method are performed in such a manner that a concrete body to be
reinforced is surface-treated, primer is coated on the surface, the
surface is leveled by epoxy putty agent, and the fiber sheet
(carbon fiber sheet, glass fiber sheet or aramide fiber sheet) is
impregnated in the concrete body and adhered to the concrete body
by epoxy resin (for adhesion and impregnation).
[0005] Such reinforcing method using the fiber sheet is
lightweight, and has good operation efficiency, anticorrosion, high
strength, high elasticity coefficient, salt tolerance and chemical
resistance. However, the reinforcing method using the fiber sheet
has several problems that it is very weak in heatproof and
fireproof, and thereby poisonous gas is generated and the
reinforcing effect drops rapidly to cause loss of lives and
properties when there is a fire. Moreover, the main process of the
reinforcing method using the reinforced fiber is the impregnation
of the reinforced fiber, but in fact, it is difficult to perfectly
impregnate the reinforced fiber due to a difficult condition in a
construction site, and the reinforcing effect and realization of
performance depend on the manpower's technical level in the
construction site. Furthermore, it is necessary to perform a
repetitive lamination process to secure a proper reinforcing
strength.
[0006] The steel plate adhering method is a construction method
performed in such a manner that a concrete body to be reinforced is
surface-treated, steel plates are mounted and sealed after an
anchoring work and a welding work, and epoxy resin is injected and
adhered. The steel plate adhering method has several advantages
that materials can be easily bought and properties of the materials
can be surely shown. However, the method has several disadvantages
that it is difficult to carry and handle the materials and to
supervise safety because the steel plates are heavy (generally,
steel plate of 4.5 mm or more is used to secure required strength),
and there is a danger of fire due to the use of fire for welding or
others. Additionally, the method has a load burden of the
reinforced concrete body due to an increase of excessive dead load
after the reinforcement, corrosion of the steel plates, and weak
thermal efficiency in fireproof and heatproof.
[0007] In the synthetic resin panel adhering and reinforcing method
and the steel plate adhering and reinforcing method, panels are
fixed with anchors, and gaps formed between the panels and a
concrete body are filled with filler such as thermosetting resin.
For the filling process, various materials besides the anchors are
mounted, that is, spacers are mounted at regular intervals to form
gap uniformly, injection holes are formed to inject the filler and
air discharge holes are formed to discharge the inside air to the
outside while the filler is inserted. Because the spacers, the
injection holes and the air discharge holes must be mounted at
several portions of the panel, it takes much time to mount them,
and thereby the panel may be damaged and polluted and the filler
does not sealably fill the gaps to cause a drop of the reinforcing
effect because it is very difficult, in installation structure, to
discharge the inside air of the anchor hole. Furthermore, because
most of the existing anchors are made of metal, if the wet concrete
body is reinforced, it becomes rusty as time passes, and thereby
its performance is deteriorated and the outward appearance becomes
bad.
[0008] The patching and section restoring methods are performed in
such a manner that weak parts of the concrete body is dug and
removed, an anticorrosive treatment is performed if reinforced
steels are oxidized, repairing materials are inserted into cracked
portions to prevent the reinforced steels from being contacted with
air or water, the removed portions are plastered with epoxy mortar,
non-contracted concrete and various polymer cement mortar several
times, and the section is restored. For the repairing materials and
methods, various kinds of materials and methods have been
developed, for example, a polyurethane injection method, an epoxy
injection method for moistening, a micro-cement injection method, a
section restoring method using epoxy group mortar, a section
restoring method using various polymer cement mortars such as acryl
group high intensity mortar, and so on. However, though the applied
materials are very good, because the section restoration of the
removed concrete body is finished by the plastering work, the
conventional methods has a limitation in adhesive strength between
the existing concrete body and the surface restored in section.
Additionally, as time passes, the exfoliation and cracks are
generated again and air and water flow into the exfoliated and
cracked surface, and thereby the concrete body is returned into the
previous condition (e.g., the reinforced steels are corroded).
[0009] Therefore, this inventor has developed a panel for repairing
and reinforcing a concrete body, a multi-purpose anchor, an anchor
for level adjustment and injection and a method for repairing and
reinforcing the concrete body using the same to improve the
conventional method for repairing and reinforcing the concrete
body.
DISCLOSURE OF INVENTION
[0010] Accordingly, it is an object of the present invention to
provide a composite reinforced panel, in which a reinforced fiber
sheet is composed to a steel plate, and a method for repairing and
reinforcing using it capable of securing safety of a concrete
body.
[0011] It is another object of the present invention to provide a
composite reinforced panel, in which a reinforced fiber sheet is
composed to a steel plate, and a method for repairing and
reinforcing using it capable of maximizing features of each
material, improving heatproof and fireproof properties of the
composite reinforced panel by supplementing demerits of the
materials, and preventing brittle break by securing softness of the
composite reinforced panel.
[0012] It is a further object of the present invention to provide a
lightweight precast concrete composite reinforced panel, in which
steel plates are connected to a lightweight precast concrete panel,
to reinforce the capacity of the concrete body.
[0013] It is a still further object of the present invention to
provide reinforcing means a lightweight precast concrete panel for
reinforcing the capacity of the concrete body.
[0014] It is a still further object of the present invention to
provide means capable of improving bad construction due to the
conventional site impregnation by manufacturing various composite
reinforced panels in factory, and providing uniform and safe
reinforcing effects by lowering dependence on technical engineers
of a construction site in impregnation and adhesion, which are main
elements of construction quality.
[0015] It is a still further object of the present invention to
provide means capable of injecting filler through an anchor without
any injection hole.
[0016] It is a still further object of the present invention to
provide means capable of forming regular intervals between the
panel and the concrete body without mounting spacers.
[0017] It is a still further object of the present invention to
provide means capable of discharging air, which is between the
panel and the concrete body, by the anchor without any air
discharge hole while the filler is injected.
[0018] It is a still further object of the present invention to
provide a lightweight precast concrete panel 410 for improving
fireproof and heatproof of the surface of the concrete body, which
is reinforced and finished through a reinforcing method using the
existing carbon fiber sheet, glass fiber sheet or aramide fiber
sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Further objects and advantages of the invention can be more
fully understood from the following detailed description taken in
conjunction with the accompanying drawing in which:
[0020] FIG. 1 illustrates a sectional view of a detailed example of
a composite panel for reinforcing a concrete body according to the
present invention;
[0021] FIG. 2 illustrates a flow chart showing a manufacturing
method of the composite panel of FIG. 1;
[0022] FIG. 3 illustrates a sectional view of another detailed
example of a composite panel for reinforcing a concrete body
according to the present invention;
[0023] FIG. 4 illustrates a flow chart showing a manufacturing
method of the composite panel of FIG. 3;
[0024] FIG. 5 illustrates a schematic view of a manufacturing
process and a structure of a lightweight precast concrete panel
according to the present invention;
[0025] FIG. 6 illustrates a flow chart of the manufacturing process
of the lightweight precast concrete panel according to the present
invention;
[0026] FIG. 7 illustrates a schematic view of a manufacturing
process of a lightweight precast concrete composite reinforced
panel according to the present invention;
[0027] FIG. 8 illustrates a brief perspective view of the
lightweight precast concrete composite reinforced panel for
repairing a concrete body according to the present invention;
[0028] FIG. 9 illustrates an elevation view and a sectional view of
an anchor for adjusting level of panel and injecting;
[0029] FIG. 10 illustrates a view showing a state that the anchor
for adjusting level of panel and injecting is connected with an
injection pipe and a clip.
[0030] FIG. 11 illustrates an elevation view and a partially
sectional view of an insert and an expansion hole according to the
present invention;
[0031] FIG. 12 illustrates an elevation view and a partially
sectional view of a bolt and an injection pipe according to the
present invention;
[0032] FIG. 13 illustrates a schematic view showing a state that a
lower portion of a beam is reinforced using the lightweight precast
concrete composite reinforced panel;
[0033] FIG. 14 illustrates a schematic view showing a state that a
lower portion and a side of a beam is reinforced using the
lightweight precast concrete composite reinforced panel;
[0034] FIG. 15 illustrates a schematic view showing a state that a
damaged part of the concrete road is repaired using the panel for
repairing the concrete body and the anchor for level adjustment and
injection;
[0035] FIG. 16 illustrates a flow chart of an adhesion type
reinforcing method, which is a method for reinforcing the concrete
body using the composite panel for reinforcing the concrete body
according to the present invention; and
[0036] FIG. 17 illustrates a schematic view showing a state that
the damaged part of the concrete road is repaired using the panel
for repairing the concrete body and a multi-purpose anchor.
BEST MODE FOR CARRYING OUT THE INVENTION
[0037] The present invention will now be described in detail in
connection with preferred embodiments with reference to the
accompanying drawings. For reference, like reference characters
designate corresponding parts throughout several views.
[0038] FIG. 1 illustrates a sectional view of a detailed example of
a composite panel for reinforcing a concrete body according to the
present invention, and FIG. 2 illustrates a flow chart showing a
manufacturing method of the composite panel of FIG. 1. In FIGS. 1
and 2, the composite panel for reinforcing the concrete body
includes: a steel plate 510 of a prescribed size; an impregnable
adhesion layer 520' formed on an upper surface of the steel plate
510; a reinforced fiber 530 mounted on the upper surface of the
steel plate 510 and impregnated and adhered by the impregnable
adhesion layer 520'; and powder 540 sprayed on the upper surface of
the steel plate 510 and impregnated and adhered on the surface of
the impregnable adhesion layer 520'. Additionally, the
manufacturing method of the composite panel includes the steps of:
forming the impregnable adhesion layer 520' on a surface of the
steel plate 510 cut in a prescribed size; impregnating and adhering
the reinforced fiber 530 on the surface of the steel plate 510, on
which the impregnable adhesion layer 520' is formed; spraying,
impregnating and adhering the powder 540 on the surface of the
steel plate 510 and the reinforced fiber sheet layer 530; and
hardening the impregnable adhesion layer 520' formed in the second
step.
[0039] In the same way as the manufacturing method, as shown in
FIG. 1b, a sandwich type composite panel is manufactured in such a
manner that reinforced fibers are impregnated and adhered to both
surfaces of a steel plate and then powder is sprayed and
adhered.
[0040] The composite reinforced panel for reinforcing the concrete
body further includes: an adhesion layer formed on a lower surface
of the steel plate of the composite panel (see FIGS. 1a and 1b);
and a lightweight precast concrete panel 550 of a prescribed size
adhered on the lower surface of the steel plate by the adhesion
layer, thereby increasing reinforcing power and fireproof property.
Instead of the lightweight precast concrete panel 550, another
precast concrete panel using a general aggregate may be used (see
FIG. 5).
[0041] When the lightweight precast concrete panel 550 is cut in
the form of a flat rectangle, the composite panel for reinforcing
the concrete body of FIGS. 1a and 1b is cut in the same size as the
lightweight precast concrete panel to be connected with the
lightweight precast concrete panel, or cut larger than the
lightweight precast concrete panel and has a protrusion at one side
of four sides, two protrusions at opposite sides, three protrusions
at three sides except one side, or four protrusions at all sides to
be connected with the lightweight precast concrete panel. It is to
increase reinforcing effect by connecting the adjacent composite
panels through the composite panel of FIGS. 1a and 1b. It will be
appreciated that another precast concrete panel using a general
aggregate may be used instead of the lightweight precast concrete
panel 550.
[0042] The composite panel for reinforcing the concrete body may
include: a reinforced fiber of a prescribed size; an impregnable
adhesion layer formed on an upper surface of the reinforced fiber;
a steel plate mounted on the upper surface of the reinforced fiber
and impregnated and adhered by the impregnable adhesion layer; and
powder sprayed, impregnated and adhered on the upper surface of the
steel plate. Additionally, the composite reinforced panel for
reinforcing the concrete body further includes: an adhesion layer
formed on a lower surface of the reinforced fiber of the composite
panel for reinforcing the concrete body; and a lightweight precast
concrete panel of a prescribed size mounted on the lower surface of
the reinforced fiber and adhered by the adhesion layer, thereby
increasing reinforcing power and fireproof property. Furthermore,
when the lightweight precast concrete panel is cut in the form of a
flat rectangle, the composite panel (including: a reinforced fiber
of a prescribed size; an impregnable adhesion layer formed on an
upper surface of the reinforced fiber; a steel plate mounted on the
upper surface of the reinforced fiber and impregnated and adhered
by the impregnable adhesion layer; and powder sprayed, impregnated
and adhered on the upper surface of the steel plate) is cut in the
same size as the lightweight precast concrete panel to be connected
with the lightweight precast concrete panel, or cut larger than the
lightweight precast concrete panel and has a protrusion at one side
of four sides, two protrusions at opposite sides, three protrusions
at three sides except one side, or four protrusions at all sides to
be connected with the lightweight precast concrete panel. It is to
increase reinforcing effect by connecting the adjacent composite
panels through the composite panel of FIGS. 1a and 1b. It will be
appreciated that another precast concrete panel using a general
aggregate may be used instead of the lightweight precast concrete
panel 550.
[0043] The composite panel for reinforcing the concrete body may
include: an upper steel plate of a prescribed size; a lower steel
plate of a prescribed size; an impregnable adhesion layer formed on
an upper surface of the upper steel plate; a reinforced fiber
mounted on the upper surface of the upper steel plate and
impregnated and adhered by the impregnable adhesion layer; an
adhesion layer formed on an upper surface of the reinforced fiber;
a lower steel plate adhered by the adhesion layer formed on the
upper surface of the reinforced fiber; an adhesion layer formed on
the surfaces of the upper and lower steel plates; and powder
sprayed and adhered on the adhesion layer formed on the surfaces of
the upper and lower steel plates. Additionally, the composite
reinforced panel for reinforcing the concrete body further
includes: an adhesion layer formed on a lower surface of the lower
steel plate; and a lightweight precast concrete panel of a
prescribed size adhered on the lower steel plate by the adhesion
layer, thereby increasing reinforcing power and fireproof property.
Furthermore, when the lightweight precast concrete panel is cut in
the form of a flat rectangle, the composite panel (including: an
upper steel plate; a lower steel plate; an impregnable adhesion
layer formed on an upper surface of the upper steel plate; a
reinforced fiber mounted on the upper surface of the upper steel
plate and impregnated and adhered by the impregnable adhesion
layer; an adhesion layer formed on an upper surface of the
reinforced fiber; a lower steel plate adhered by the adhesion layer
formed on the upper surface of the reinforced fiber; an adhesion
layer formed on the surfaces of the upper and lower steel plates;
and powder sprayed and adhered on the adhesion layer formed on the
surfaces of the upper and lower steel plates) is cut in the same
size as the lightweight precast concrete panel to be connected with
the lightweight precast concrete panel, or cut larger than the
lightweight precast concrete panel and has a protrusion at one side
of four sides, two protrusions at opposite sides, three protrusions
at three sides except one side, or four protrusions at all sides to
be connected with the lightweight precast concrete panel. It is to
increase reinforcing effect by connecting the adjacent composite
panels through the composite panel of FIGS. 1a and 1b. It will be
appreciated that another precast concrete panel using a general
aggregate may be used instead of the lightweight precast concrete
panel 550.
[0044] The composite panel for reinforcing the concrete body may
include: a steel plate of a prescribed size; an impregnable
adhesion layer formed on an upper surface of the steel plate; an
upper reinforced fiber mounted on the upper surface of the steel
plate and impregnated and adhered by the impregnable adhesion
layer; powder sprayed, impregnated and adhered on an upper surface
of the upper reinforced fiber; an impregnable adhesion layer formed
on a lower surface of the steel plate; a lower reinforced fiber
mounted on the lower surface of the steel plate and impregnated and
adhered by the impregnable adhesion layer; and powder sprayed,
impregnated and adhered on a lower surface of the lower reinforced
fiber. Additionally, the composite reinforced panel for reinforcing
the concrete body further includes: an adhesion layer formed on a
lower surface of the lower reinforced fiber; and a lightweight
precast concrete panel mounted on the lower portion of the lower
reinforced fiber and adhered by the adhesion layer, thereby
increasing reinforcing power and fireproof property. Furthermore,
when the lightweight precast concrete panel is cut in the form of a
flat rectangle, the composite panel (including: a steel plate; an
impregnable adhesion layer formed on an upper surface of the steel
plate; an upper reinforced fiber mounted on the upper surface of
the steel plate and impregnated and adhered by the impregnable
adhesion layer; powder sprayed, impregnated and adhered on an upper
surface of the upper reinforced fiber; an impregnable adhesion
layer formed on a lower surface of the steel plate; a lower
reinforced fiber mounted on the lower surface of the steel plate
and impregnated and adhered by the impregnable adhesion layer; and
powder sprayed, impregnated and adhered on a lower surface of the
lower reinforced fiber) is cut in the same size as the lightweight
precast concrete panel to be connected with the lightweight precast
concrete panel, or cut larger than the lightweight precast concrete
panel and has a protrusion at one side of four sides, two
protrusions at opposite sides, three protrusions at three sides
except one side, or four protrusions at all sides to be connected
with the lightweight precast concrete panel. It is to increase
reinforcing effect by connecting the adjacent composite panels
through the composite panel of FIGS. 1a and 1b. It will be
appreciated that another precast concrete panel using a general
aggregate may be used instead of the lightweight precast concrete
panel 550.
[0045] The steel plate 510 is one of steel plates, which has good
flexural strength and is generally used in steel plate reinforcing
methods, and can be adjusted in thickness according to intensity of
the concrete body to be reinforced. That is, because the steel
plate 510 is reinforced with the reinforced fiber 530, which has
excellent tension strength and elasticity coefficient, laminated
steel plates of 1 mm or less can be used. Furthermore, in case that
an anchor fixing, injecting and adhering type reinforcing method is
applied in consideration of a construction method (adhering type or
anchor fixing, injecting and adhering type) of the composite panel,
the steel plate 510 may have a plurality of anchor holes 511.
[0046] The impregnable adhesion layer 520' is formed by coating
impregnable adhesive on the upper surface of the steel plate. For
the impregnable adhesive, resin for the exclusive use of
impregnation and adhesion, such as epoxy resin for impregnation and
adhesion, which has good adhesive force to the steel plate and good
strength and in which the reinforced fiber is easily impregnated,
is proper.
[0047] The impregnable adhesion layer 520 serves to coat the
surface of the steel plate 510 to prevent corrosion of the steel
plate 510 and improve acid-proof property.
[0048] The reinforced fiber 530 is mounted on the upper surface of
the steel plate 510 and impregnated and adhered by the impregnable
adhesion layer 520' to reinforce the steel plate 510. The
reinforced fiber is made by selecting and composing at least one or
more of carbon fiber, glass fiber and aramide fiber, which have
high tension strength, good elasticity coefficient and durability.
Furthermore, it will be appreciated that the reinforced fiber 530
can be laminated into several layers according to required strength
of the concrete body to be reinforced. When the reinforced fiber
530 is stacked into several layers, the steps of forming the
impregnable adhesion layer 520' and impregnating and adhering the
reinforced fiber 530 are repeated while a worker pays attention to
remove bubbles for perfect impregnation. The steel plate 510 serves
to reinforce against bending or shearing, and the reinforced fiber
530 serves to reinforce tension of the steel plate to correspond to
high tension force, and thereby the concrete body to be reinforced
can be completely reinforced against the bending, shearing and
tension and prevent brittle break of the concrete body due to lack
of softness, which is one of main disadvantages of the conventional
reinforcing method using the reinforced fiber. Therefore, the
composite panel according to the present invention can secure
safety sufficiently.
[0049] The powder 540 is sprayed, impregnated and adhered on the
surface of the impregnable adhesion layer 520' before the
impregnable adhesion layer 520' is hardened. The powder 540
increases the adhesive force with the adhesion resin by making the
surface of the composite panel rough, thereby helping the composite
panel to be integrated with the concrete body.
[0050] FIG. 3 illustrates a sectional view of another detailed
example of a composite panel for reinforcing a concrete body
according to the present invention, and FIG. 4 illustrates a flow
chart showing a manufacturing method of the composite panel of FIG.
3. In FIGS. 3 and 4, a precast concrete panel is applied to
increase a fireproof property of the composite panel 560. The
composite panel includes: a precast concrete panel 550 of a
prescribed size; an adhesion layer 520 formed on an upper surface
of the precast concrete panel 550; a steel plate 510 mounted on the
upper surface of the precast concrete panel 550 and adhered by the
adhesion layer 520; an adhesion layer 520 formed on an upper
surface of the steel plate 510; and powder 540 sprayed on the upper
surface of the steel plate 510 and adhered by the adhesion layer
520.
[0051] The steel plate 510 is the same as the first example, and
the adhesion layer 520 is to adhere the steel plate 510 and the
precast concrete panel 550 to each other. The steel plate 510 is
formed by coating epoxy resin for adhesion. The precast concrete
panel 550 serves to reinforce by being adhered with the steel plate
510 by the adhesion layer 520, and forms a finish surface when
finished composite panel 562 is applied as a panel for reinforcing
the concrete body. Because the precast concrete panel 550 is made
of the same material as the concrete body to be reinforced and
forms a surface cover of the steel plate 510, it is still better in
fireproof than the panel, which consists of the steel plate and the
reinforced fiber, and has a good finishing effect. Because the
lightweight and fireproofing properties are important factors of
the reinforcing panel, it is more effective to use the lightweight
precast concrete panel 550.
[0052] FIG. 5 illustrates a schematic view of a manufacturing
process and a structure of the precast concrete panel 110 formed by
impregnating a lightweight concrete layer 111, an inorganic element
group fiber sheet layer and a water soluble cement group or polymer
group resin layer.
[0053] The lightweight concrete layer 111 is poured after made by
mixing cement, inorganic group porous lightweight aggregate and
water using an electrical hand mixer or a mortar mixer.
[0054] The inorganic porous lightweight aggregate is mixed with
cement to be used as the aggregate and lightweight. According to
conditions applied to the panel, the mixed rate of the cement and
the inorganic porous lightweight aggregate can be changed. In case
that the inorganic porous lightweight aggregate is perlite, the
mixed rate of the cement to the inorganic porous lightweight
aggregate is within the range of 5%.about.80% by weight and the
panel can be adjusted within the range of the mixed rate in
consideration of the required strength and heatproof property of
the panel. The panel generally has proper fireproof property and
strength within the mixed rate of about 20%.
[0055] The inorganic group fiber sheet layer 112 is a reinforced
inorganic group fiber mesh (it is made in such a manner that
inorganic group fiber is impregnated into thermosetting synthetic
resin and silica sands or blast furnace steel slag are scattered
evenly and then hardened), and located within the lightweight
concrete layer 111. The inorganic group fiber sheet layer 112
serves to reinforce tension force of the lightweight concrete panel
110 and can form one layer or several layers. However, in the
inorganic group fiber sheet layer 112, if the inorganic group fiber
sheet alone is contained in the panel 110, an upper layer and a
lower layer of the panel 110 are exfoliated and separated from the
inorganic group fiber sheet layer 112. Therefore, if the reinforce
inorganic group fiber sheet is mounted, the exfoliation and
separation can be prevented. The micro-cement serves to reinforce
the inorganic fiber sheet. However, because the micro-cement drops
adiabatic effect of the panel, fine powder of the inorganic group
porous lightweight aggregate is impregnated to reinforce the
adiabatic effect of the panel. When the micro-cement and the
inorganic group fiber sheet impregnated in the inorganic group
porous lightweight aggregate are impregnated into the concrete
panel, water soluble cement group, polymer cement group or polymer
group resin is a basal plate.
[0056] The panel 110 made through the above process goes through a
natural cure and a forced cure (steam cure) in order, and then the
lightweight precast concrete panel 110 is finished.
[0057] FIG. 6 illustrates a flow chart of a manufacturing process
of another lightweight precast concrete panel 410 having reinforced
glass fiber mesh stacked between the lightweight concrete layers
411.
[0058] The lightweight precast concrete panel 410 is finished in
such a manner that lightweight aggregate, such as bony coal, and
Portland cement are sufficiently mixed according to a proper mixing
rate, predetermined amount of water is added, lightweight concrete
sufficiently mixed by the mortar mixer is first poured to 1/3 of
the thickness of the panel, a reinforced glass fiber mesh is
mounted on the surface of the first poured lightweight concrete
layer 411, and instantly, the lightweight concrete is second poured
and cured (natural cure and steam cure). At this time, the
reinforced glass fiber mesh is manufactured in such a manner that a
glass fiber mesh 412 for reinforcement is impregnated into
synthetic resin and silica sands or blast furnace steel slag are
scattered evenly and hardened. The glass fiber mesh 412 is in the
form of a net having wider intervals between fibers than general
fiber sheet, and reinforces bending and tension force of the
lightweight concrete. The silica sand or blast furnace steel slag
430 serves to improve adhesive force between the reinforced glass
fiber mesh 412 and the lightweight concrete 411. Therefore, the
lightweight precast concrete panel 410 according to the present
invention has completely integrated components, and thereby the
glass fiber mesh 412 is stably fixed inside the lightweight
concrete to maximize tension force and improve durability of the
panel. Moreover, to manufacture a thicker panel, it is preferable
to stack wire meshes or reinforced steel bars inside the
lightweight concrete 411. The lightweight fireproof precast panel
410 can be utilized to make a composite reinforced panel by
composing the lightweight precast panel 410 and other materials
(the existing reinforced fiber (carbon fiber, glass fiber, aramide
fiber, and so on) impregnating panel, prestressed reinforced fiber
composite panel manufactured using a prestress method) like a
reinforced fiber for impregnation, which will be described later,
to show the fireproof property. Furthermore, The lightweight
fireproof precast panel 410 can be utilized when it is needed to
improve fireproof efficiency of the concrete body, which is
reinforced through the reinforcing method using the existing carbon
fiber sheet, glass fiber sheet or aramide fiber sheet or when it is
needed to reinforce due to gradually reduced reinforcing effect.
Additionally, the lightweight precast panel 410 can be utilized as
a method for protecting and repairing surface of the concrete body
by providing beautiful appearance to the concrete body, which has
bad outward appearance due to material difference between the
concrete body and the fiber sheet or due to aging of the concrete
body.
[0059] There is a method for repairing and reinforcing the concrete
body using the lightweight fireproof precast panel 410. The method
is to cut the lightweight fireproof precast panel in a proper size
(in the same size as or larger than the conventional tile) and
compress and adhere it to the surface of the concrete body, which
is reinforced through the reinforcing method using the existing
carbon fiber sheet, glass fiber sheet or aramide fiber sheet, or to
the surface of the severely aged concrete body with synthetic resin
group adhesive or polymer cement for adhesion.
[0060] The method will be described in more detail hereinafter.
[0061] Dust and foreign matters attached on the existing basal
plane are completely removed through a high pressure washer or a
dust collector while the worker pays attention not to damage the
reinforced fiber attached on the basal plane, and then, the worker
checks flaws of portions where the existing reinforced fiber is
adhered, such as bubble, poor adhesion and exfoliation, and
performs the reinforcing work. If the portions where the existing
reinforced fiber is adhered are finish-coated with epoxy group or
aqueous and oil group, very low viscosity epoxy group adhesive is
coated, and at the same time, powder such as silica sand is sprayed
on the coated surface to make the surface rough. If the portions
where the existing reinforced fiber is adhered are finish-coated
with urethane group, urethane group adhesive is coated.
[0062] After that, the panel is adhered, and from this step, the
adhering method using synthetic resin group adhesive and the
adhering method using polymer cement group adhesive are performed
differently from each other. The adhering method using synthetic
resin group adhesive is finished by adhering the panel and filling
up joints. The epoxy or urethane group adhesive of high viscosity
being in the form of grease is coated and adhered on the surface of
the surface of the concrete body, on which the coated adhesive is
completely hardened, and the surface of the lightweight precast
panel in thickness of about 3.about.5 mm evenly. After that, the
worker makes joints within 30 minutes after adhering the panel and
sprays aggregate such as silica sands into the joints to make the
surface rough, and then performs pointed joint work. At this time,
the epoxy resin for adhesion can be used by mixing fine aggregate
or fine lightweight aggregate. Material for filling up the joints
is synthetic resin or the existing compound cement mortar, and a
width of the joint is about 5 mm. If the width of the joint is over
5 mm, the worker fills up the joint twice while pressing
sufficiently to prevent cracks.
[0063] The adhering method using the polymer cement group adhesive
is finished by plastering mortar on the basal plane, adhering the
panel and filling up the joints. When the worker plasters the
mortar on the surface of the concrete body, on which the coated
adhesive is completely hardened to make the surface rough, the
worker performs the plastering work while paying attention not to
exceed 10 mm at once when the plastered thickness exceeds 10 mm.
After the mortar plastering work is finished, the plastered surface
is cured for a week. The worker checks and repairs excitation and
cracks of the mortar plastered surface before adhering the panel.
In case of an exterior construction, the worker sprays water on the
surface of the panel and completely contacts the panel to the
surface of the concrete body to prevent permeation of rain or
water, to increase adhesive force and prevent exfoliation, freeze
and fusion. A once plastered area of the basal mortar plastered
surface is less than 1.0 m.sup.2. The panel is adhered after
adhesive mortar is plastered in thickness of about 3.about.6 mm
evenly. After the adhesive mortar is plastered again in thickness
of about 3.about.4 mm evenly, instantly tiles are adhered, and at
this time, the worker strikes the tiles with a wood hammer to make
the mortar protrude over 1/2 of the thickness of the panel at the
joint portions. After the lapse of 3 hours after the adhesion of
the panel, the worker digs the joints and performs the plaster
joint work. Before the plaster joint work, the worker sprays water
on the basal plane of the joints to maintain moisture. Preferably,
the width of the joint is about 5 mm, but, if the width of the
joint is over 5 mm, the worker fills up the joint twice while
pressing sufficiently to prevent cracks.
[0064] FIG. 7 illustrates a state that the reinforced fiber sheet
120 as reinforcing means for the concrete body is connected to the
lightweight precast concrete panel 110. In other words, the
reinforcing means includes: the reinforced fiber sheet 120 and
powder layer. The reinforced fiber sheet is impregnated based on
thermosetting resin coated on the surface of the lightweight
precast concrete panel 110 and thermosetting resin 123, and cut in
the same size as the lightweight recast concrete panel 110 and
jointed to the lightweight precast concrete panel 110, or cut
larger than the lightweight precast concrete panel 110 and jointed
to the lightweight precast concrete panel 110 to protrude. The
powder layer is sprayed on an upper portion of the reinforced fiber
sheet layer impregnated to increase the adhesion force to the
concrete body to be reinforced. The thermosetting resin 123 may be
one of epoxy resin or converted epoxy resin. The reinforced fiber
sheet layer is formed on the upper surface of the lightweight
precast concrete panel while stacked in at least one or more
layers. That is, after the impregnable adhesive is coated on the
upper surface of the panel, the reinforced fiber sheet layer is
finished by impregnating and adhering the reinforced fiber sheet on
an upper surface of the impregnable adhesive in one layer or
several layers. The reinforced fiber sheet is made by selecting and
composing at least one or more of carbon fiber, glass fiber and
aramide fiber, which have high tension strength, good elasticity
coefficient and durability. Furthermore, to stack the reinforced
fiber sheet in at least one or more layers, the steps of coating
the impregnable adhesive and impregnating and adhering the
reinforced fiber sheet are repeated while the worker pays attention
to remove bubbles for perfect impregnation.
[0065] The composite reinforced panel consisting of the lightweight
precast concrete panel, the reinforced fiber sheet layer and the
powder is adhered on the concrete body by an adhering method using
anchors. For this, the composite reinforced panel has a plurality
of anchor holes. In case that the reinforced fiber sheet layers are
stacked in several layers, the reinforced fiber sheets are cut to
have different extension lengths from each other. Preferably, the
extension lengths of the stacked reinforced fiber sheets are
gradually shortened upward. The powder is sprayed and adhered on
the surface of the reinforced fiber sheet layer before the
reinforced fiber sheet layer is completely hardened. The powder
makes the surface of the composite reinforced panel rough, thereby
increasing adhesive force with adhesive resin during construction
to help the composite reinforced panel to be integrated with the
concrete body. The powder may be silica sand or blast furnace steel
slag. In case that the reinforced fiber sheet layers are stacked
into several layers, the reinforced fiber sheets 120 must be
stacked in the same weaving direction to maximize the tension
force. For means for reinforcing capacity of the concrete body,
thermosetting resin mortar may be coated instead of primer,
thermosetting resin and the reinforced fiber sheet. The composite
reinforced panel consisting of the lightweight precast concrete
panel, the reinforced fiber sheet layer and the powder is adhered
on the concrete body by an adhering method using anchors. For this,
the composite reinforced panel has a plurality of anchor holes.
[0066] FIG. 8 illustrates a schematic and perspective view of a
lightweight precast concrete composite reinforced panel 310 for
repairing the concrete body, the panel including a lightweight
concrete layer 311 and reinforcing means 312 for reinforcing the
lightweight concrete layer 311. The lightweight precast concrete
composite reinforced panel 310 differs from the lightweight precast
concrete composite reinforced panel 110 of FIG. 5 in the
reinforcing means 120.
[0067] First, the lightweight precast concrete composite reinforced
panel 310 including the reinforcing means 312 connected at a side
of the lightweight concrete layer 311 is made in such a manner that
epoxy resin for high strength mortar and hardening agent are mixed
with each other, the mixture is mixed with silica sand aggregate in
a prescribed rate, and the mixture is poured on the lightweight
concrete layer 311 cured by forced steam.
[0068] The lightweight precast concrete composite reinforced panel
310 having the lightweight concrete layer 311 containing the
reinforcing means 312 therein can divide the lightweight concrete
layer into an upper lightweight concrete layer and a lower
lightweight concrete layer, and the reinforcing means 312 forms
boundary parts between the upper lightweight concrete layer and the
lower lightweight concrete layer. Moreover, the lightweight precast
concrete composite reinforced panel 310 can be formed in two types:
one being that the lightweight concrete layer 311 is formed in a
previously poured and cured panel type and connected with the
reinforcing means 312; and the other being that the reinforcing
means 312 is impregnated before the lightweight concrete layer 311
is hardened after being poured, and then, concrete is poured again
to connect the reinforcing means 312 with the lightweight concrete
layer 311. The lightweight concrete layer 311 may be replaced with
the generally used high strength concrete layer if necessary.
[0069] As described above, the lightweight precast concrete
composite reinforced panel 310 according to the present invention
can be sorted by the reinforcing means 312. The reinforcing means
312 is selected from one of prepreg one-way carbon fiber, extra
thin two-way woven carbon fiber, aramide fiber, glass fiber, a wire
net, a wire mesh and a steel bar, and connected between the upper
and lower lightweight concrete layers 311 by impregnated by means
of epoxy resin and hardening agent. The manufacturing process will
be described in more detail.
[0070] According to the width and the depth of a damaged portion
383 of the concrete body, a frame is manufactured and a special
film is attached on the surface of the frame. One of Portland
cement, back cement and color cement, lightweight aggregate, such
as perlite, filite, celite, ALC aggregate and ALC crusher run
aggregate, and water are mixed, and the mixture is poured and
hardened on the frame to make a panel form, and thereby the upper
and lower lightweight concrete layers 311 are formed. Epoxy resin
for impregnation and hardening agent are mixed in a prescribed
mixing rate and the mixture is coated on a side of the lower
lightweight concrete layer thin. After the epoxy resin is coated,
one of the prepreg one-way carbon fiber, extra thin two-way woven
carbon fiber, aramide fiber and glass fiber is impregnated into the
epoxy resin. Bubbles generated during the impregnation are removed,
and epoxy resin for upper impregnation is coated again. After the
epoxy resin for the upper impregnation is coated, the upper
lightweight concrete layer is connected, and thereby the
lightweight precast concrete composite reinforced panel 310 is
formed. Alternatively, the lightweight precast concrete composite
reinforced panel 310 can be formed by impregnating one of the glass
fiber mesh, wire mesh and steel bar in a condition that the
lightweight concrete layer 311 is not hardened, and instantly
pouring the upper lightweight concrete layer. Furthermore, a
general concrete panel may be formed and used by using a general
stone aggregate instead of lightweight aggregate of the lightweight
concrete layer. Moreover, it is possible that the lightweight
precast composite panel or the precast concrete composite panel is
manufactured larger than a portion of the concrete body to be
repaired and the lightweight precast composite panel or the precast
concrete composite panel is cut corresponding to the portion to be
repaired with a hand cutter.
[0071] Because the lightweight precast concrete composite
reinforced panel 310 is light and easy in construction but uses
lightweight aggregate, it has a limit in its strength. If the
portion of the concrete body 380 to be repaired requires prescribed
compression strength, a precast concrete composite reinforced panel
314 can be applied. The precast concrete composite reinforced panel
314 includes the reinforcing means 312 formed and connected between
the upper and lower concrete layers 315 and the upper and lower
concrete layers 315. As described above, the concrete layer 315 is
formed by mixing generally used aggregate, cement and water, and
the cement is selected from one of Portland cement, back cement and
color cement. The upper and lower concrete layers 315 can be
connected with the reinforcing means 312 in a previously poured and
hardened panel type. Alternatively, the upper and lower concrete
layers 315 can be formed in such a manner that the reinforcing
means 312 is impregnated before the lower concrete layer is
hardened after it is poured, and the upper concrete layer is poured
again. The reinforcing means 312 of the precast concrete panel, to
which the previously poured and hardened upper and lower concrete
layers of the panel type are connected, is formed in such a manner
that one of extra thin two-way or one-way woven carbon fiber,
prepreg one-way carbon fiber, glass fiber and aramide fiber is
selected, epoxy resin and hardening agent, which is lower
impregnating means, are coated on a side of the lower concrete
layer of the panel type, the epoxy resin and hardening agent are
coated again as upper impregnating means, and the upper concrete
layer of the panel type is connected before the impregnating means
is hardened. If the panel reinforcing means is glass fiber mesh,
wire or steel bar, the glass fiber mesh, wire or steel bar is
impregnated in the lower concrete layer before the poured lower
concrete layer is hardened, and then the upper concrete layer is
poured. The panel reinforcing means can be formed in such a manner
that one of the wire or steel bar is mounted, synthetic resin for
high strength mortar and hardening agent are mixed with each other,
silica sand aggregate is mixed, and the mixture is poured and
connected to the concrete body. To provide stronger connection
force to the glass fiber mesh, wire and steel bar, micro-cement
paste is plastered and impregnated on the surface of the glass
fiber mesh, wire or steel bar. To increase the strength of the
precast concrete panel, the panel is forcedly cured after the lapse
of prescribed time after the hardening.
[0072] FIGS. 9 and 10 illustrate an elevation view and a sectional
view of an anchor for adjusting and injecting the level of the
panel according to the present invention. The anchor includes a
body part 320, a nut 323, a clip 330 for carrying, and a pipe 340
for injection. The body part 320 has a hollow part 325 and is in
the form of a cylinder. The body part 320 includes a male screw 321
formed on an outer circumference, a through hole 324 intersecting
with the hollow part 325 at an end thereof, a female screw 333
formed on an inner circumference of the hollow part 325 at the
other end thereof, and an angular protrusion 322. The protrusion
322 may be in the form of a hexagon or an octagon. The male screw
321 formed on the outer circumference of the body part 320 is to
engage with the nut 323. The nut 323 is a rotatable tool connected
with the protrusion 322, and when the body part 320 is rotated, the
nut 323 fixed to the panel 310 is moved in a vertical direction of
the body part 320, thereby adjusting the level of the panel 310.
The clip 330 for carrying has a cylindrical part 331 having a
female screw 333 formed on an inner circumference thereof, and the
female screw 333 is engaged with the male screw 321 of the body
part 320, to which the nut 323 is engaged, thereby serving as a
link (to help the carrying of the panel. The pipe 340 for injection
is generally in the form of a straw and has a male screw 341 formed
at an end thereof. The male screw 341 of the pipe 340 is screwed
with the female screw formed on the inner circumference of the
protrusion 322 of the body part 320. Filler is injected into an
empty space of a rear surface of the panel through the pipe 340,
the hollow part 325 and the through hole 324 of the body part. When
the injection of the filler is finished, the pipe 340 is
removed.
[0073] FIG. 11 illustrates an elevation view and a partially
sectional view of an insert 210 and an expanding tool 220 of a
multi-purpose anchor for connecting the panel to the concrete body.
The insert 210 has a body part 210 being generally in the form of a
cylinder and a plurality of holes 212 formed in the body part 211.
The holes 212 formed in the body part 211 of the insert 210 serves
as injection paths of the filler injected through an injection pipe
240 and as air discharge paths for discharging air between the
panel and the concrete body. The body part 211 has a female screw
213 coupled with a bolt 230 inserted into a prescribed depth from
an end. At the end where the female screw 213 is started, formed is
a head part 214 protruding from the body part 211 and serving as a
spacer. The head part 214 allows the panel connected with the
anchor of the present invention to be maintained at a prescribed
interval from the concrete body. Because the interval between the
panel and the concrete body is determined according to the
thickness of the head part 214, the thickness of the head part 214
is changed according to the interval between the panel and the
concrete body. It will be appreciated that the head part 214 may
have various shapes besides the shape of FIG. 11. The other end of
the insert 210 is split into several sections to be spread when the
expanding tool 220 is struck with a striker.
[0074] The expanding tool 220 is inserted into the insert 210 after
the insert 210 is inserted into the hole formed in the concrete
body, and thereby the diameter of the insert is enlarged and the
concrete body and the insert 210 are jointed. To make the above
operation smooth, a hollow part 221, which has a vertical section
of a trapezoidal cylinder shape and in which the injection pipe 240
is inserted, is formed.
[0075] FIG. 12 illustrates an elevation view and a sectional view
of the bolt 230 and the injection pipe 240 of the present invention
(multi-purpose anchor). The bolt 230 includes a body part 231 and a
head part 232. The bolt 230 has a hollow part 235 vertically
passing the body part 231 and the head part 232 to allow insertion
of the injection pipe 240. The body part 231 has a male screw 233,
which is formed on the surface thereof and engaged with the female
screw 213 of the insert 210, and a plurality of holes 236 serving
as injection paths of the filler and as inside air discharge paths.
The hollow part 235 vertically passing the center of the head part
232 has a female screw 234, which is formed on an inner
circumference and engaged with the injection pipe 240. The screwing
engagement between the head part 232 and the injection pipe 240 may
be substituted with other coupling means having the same capacity.
The hollow part 221 of the expanding tool 220 and the hollow part
235 of the bolt 230 have the same diameter, and thereby they are
extended by coupling the bolt 230 and the insert 210.
[0076] The injection pipe 240, which is generally in the form of
the straw, includes a head part 241 and a body part 243. The body
part 243 has a diameter to the extent that the body part 243 can be
inserted into the hollow part 221 of the bolt 230 and the expanding
tool 220, and has a male screw 244, which is formed on an outer
circumference of an end thereof, coupled with or separated from the
head part 241. The injection pipe 240 receives the filler from the
head part 241. A neck part of the head part 241 is formed concavely
to remove the head part 241 by striking the head part 241 with a
hammer after the injection of the filler. The head part 241 has a
male screw 242 formed on an outer circumference of a lower end to
be coupled with the female screw 234 of the bolt 230, and a female
screw formed on an inner circumference to be coupled with the male
screw 244 of the body part 243 of the injection pipe.
[0077] The multi-purpose anchor can be made of metal material or
thermosetting resin. If the anchor is made of thermosetting resin,
the anchor is prevented from corrosion, so that the anchor has good
outward appearance.
[0078] The panel 560, 562 for reinforcing the concrete body in
bending, shearing and tension by composing the steel plate and
reinforced fiber, or the steel pate, the reinforced fiber and the
precast concrete maximizes merits of each material and supplements
demerits of the materials, thereby securing softness of the panel
to prevent the brittle break and stably reinforce the concrete
body.
[0079] The lightweight concrete composite reinforced panel, in
which the reinforcing means is connected to the lightweight
concrete panel to reinforce the concrete body and improve the
capacity of the concrete body, improves the fireproof property of
the reinforcing means impregnated, adhered and composed at the
surface of the lightweight concrete panel and provides stable
reinforcing effect by effectively protecting the reinforcing means
from various bad environments such as sudden weather change.
[0080] The panel according to the present invention can be
effectively fixed on the concrete body. The panel allows the filler
to be injected through the anchor without injection hole, has the
prescribed interval formed between the panel and the concrete body,
and allows the air to be discharged through the anchor without any
air discharge hole while the filler between the panel and the
concrete body is injected. The anchor is made of thermosetting
resin, so that the anchor is prevented from corrosion.
[0081] The lightweight concrete composite reinforced panel can
secure uniform impregnation by manufactured through a nonstop
manufacturing system in factory. Because the composite panel
manufactured in the factory is simply assembled when being
constructed in a construction site, causes dropping construction
quality can be removed previously and dependence on technique of
the workers in the site can be reduced, so that stable and
estimated reinforcing effects can be obtained.
[0082] The lightweight precast concrete panel 410 can have improved
durability to the bending and tension force of the panel by stably
fixing and integrating the reinforced glass fiber mesh into the
lightweight concrete. Furthermore, The present invention can have
good adhesion property to the concrete body by coupling the
reinforced fiber sheet for reinforcing the capacity of the concrete
body to the lightweight precast concrete panel 410 and the powder
is sprayed on the reinforced fiber sheet to treat the surface
rough.
[0083] The lightweight concrete composite reinforced panel, in
which the reinforcing means is connected to the lightweight
concrete panel to reinforce the concrete body and improve the
capacity of the concrete body, improves the fireproof property of
the reinforcing means impregnated, adhered and composed at the
surface of the lightweight concrete panel and provides stable
reinforcing effect by effectively protecting the reinforcing means
from various bad environments such as sudden weather change.
[0084] FIGS. 13 and 14 illustrate schematic views showing a state
that a lower portion of a beam is reinforced by the lightweight
precast concrete composite reinforced panel 100 and a state that a
lower portion and a side of the beam are reinforced by the
lightweight precast concrete composite reinforced panel 100. The
reinforced fiber sheet is used as the reinforcing means for
reinforcing the capacity of the concrete body. As shown in the
drawings, the lightweight precast concrete composite reinforced
panel 100 is changed in an arranged condition between units of the
panel 100 according to the shape and area of the concrete body to
be reinforced. To overlap the adjacent panel units and the
reinforced fiber sheets 120 and continuously construct, the
reinforced fiber sheet 120 is cut and adhered larger than the
lightweight precast concrete panel 110, and thereby the reinforced
fiber sheet 120 protrudes in a prescribed length. The protruded
length is adjusted in proportion to weight by unit area of the
reinforced fiber sheet 120. For example, if the weight of the
reinforced fiber sheet 120 is 200 g, 300 g and 400 g per 1 m.sup.2,
the reinforced fiber sheet 120 is protruded to 20 cm, 25 cm and 30
cm. The units of the lightweight precast concrete composite
reinforced panel 100 are connected in such a manner that a side of
the panel 100 from which the reinforced fiber sheet 120 protrudes
and a side from which the reinforced fiber sheet 120 does not
protrude are faced and connected with each other. Therefore, when
the lightweight precast concrete panel 110 is cut in the form of
the rectangle, the reinforced fiber sheet 120 protrudes from one of
the four sides of the lightweight precast concrete panel 110, from
opposite sides, from three sides except one side, or all four sides
of the lightweight precast concrete panel 110.
[0085] FIG. 15 illustrates a method for installing the panel to a
concrete paved road 380 containing a damaged part 383 using the
anchor for adjusting the level of the panel and injecting. In more
detail, the worker performs a joint indication work on the damaged
road surface and cuts the indicated part with a road surface
cutter. The damaged part 383 of the concrete paved road surface is
inside a cutting line 381, and the cutting line, which is a
straight line, is at right angles with another cutting line 381.
The cut part is broken by hydraulic pressure or an electric hammer.
The epoxy mortar 361 in which synthetic resin of high adhesion
force and silica sands are mixed in a prescribed rate is poured
into the broken basal surface 388. At this time, the worker
performs a leveling work of the basal surface while forming fine
holes of about 10 mm between the epoxy mortar coated surface and
the panel. The nut 123 of the anchor is fixed into the anchor hole
313 formed in the panel 310 with synthetic resin adhesive, the body
part 320 is screwed with the nut 323, and the clip 330 is screwed
with the body part 320, and then, the panel 310 is carried and
seated on the broken part. After the clip 330 is removed, as
described above, the body part 320 is rotated and the level of the
panel is adjusted to be consistent with the concrete road surface.
Because the nut 323 is fixed, when the body part 320 is rotated,
the level of the panel can be adjusted. When the level adjusting
work of the panel is finished, gap between the panel and the
concrete paved road is sealed, a cylinder 352 for injecting low
pressure is mounted at a prescribed location of the sealed part,
and the pipe 340 is mounted on the anchor. First, the fine hole of
the rear surface of the panel is filled with synthetic resin group
filler such as epoxy resin through the injection pipe 340. To
prevent occurrence of non-filled part, the filler is second
injected into the fine hole of the rear surface of the panel
through a low pressure injection cylinder 352. When the injection
work is finished, depressed parts such as the anchor hole 313 are
finished with epoxy mortar.
[0086] FIG. 16 illustrates a flow chart of a method for reinforcing
the concrete body using a composite panel 560. At this time, an
adhesion type reinforcing method is applied. That is, the
reinforcing method includes the steps of: preparing a basal surface
500 of the concrete body to be reinforced; forming an adhesion
layers 520 on the basal surface 500 of the concrete body and a
surface of the composite panel 560; and adhering the composite
panel 560 on the basal surface 500 of the concrete body.
[0087] If the preparing of the basal surface 500 of the concrete
body is finished, anchor holes are formed at ends of the composite
panel 560 or in the composite panel 560 at regular intervals. When
the anchor holes are formed, dust inside the anchor holes is
removed clean and permeable adhesion layer is formed on the surface
(epoxy permeable adhesive is coated). The permeable adhesion layer
serves to remove fine dust of the basal surface 500, reinforce weak
parts to improve the adhesive force of the composite panel 560.
After the permeable adhesion layer coated on the basal surface 500
is completely hardened, epoxy adhesive for adhering the composite
panel 560 is coated thick to about 3 mm or more to form the
adhesion layer. The adhesion layer is formed also on a surface of
the composite panel 560 and contacted and fixed on the basal
surface. When the composite panel 560 is fixed on the basal
surface, the worker tights it with an anchor bolt, and thereby the
anchor can prevent breakdown of the composite panel.
[0088] In case that the composite panels of a prescribed size are
continuously installed, for perfect adhesion of connected parts,
the steel plates are extended longer than the precast concrete
panel, and thereby connection parts 515 are formed. At this time,
powder 540 is sprayed on a lower surface of the connection parts
515 to improve adhesive force of the connection parts. If
necessary, the anchor can be installed on the connection parts.
[0089] If the thickness of the composite panel in which the steel
plate and the reinforced fiber are composed is more than 3 mm or
the lightweight precast concrete panels are combined, the panels
are constructed by a method of injecting and adhering synthetic
resin.
[0090] FIG. 17 illustrates a method for repairing the concrete body
having the damaged part using the lightweight precast concrete
composite reinforced panel 310. The damaged part 383 of the
concrete body may be various.
[0091] First, if the cause of aging, material separation,
neutralization, deterioration, lock pocket and exfoliation is water
leakage, the worker set damaged part, forms cutting lines 381
meeting at right angles to each other and performs a cutting work.
If an exposed steel bar 384 is corroded, the worker removes rust
from the corroded part using a sand grinder for removing rust, and
then, coats with anticorrosive using a brush. When the removal of
rust and the anticorrosion work is finished, the worker perforates
the damaged part using the hammer to form a packer hole for
injection. After the perforation work, dust inside the hole is
removed, a packer 363 for injection is tightened and fixed, and the
worker performs an injection and filling work using a high pressure
injector. When coffering levee is injected through the packer 363,
the packer 363 is removed by striking it with hammer, dust on the
surface is removed, and wet adhesion type high strength coffering
levee 371 is plastered manually or by using a steel trowel. After
the lapse of 24 hours after the plastering work, the worker checks
whether or not there is water leakage, forms a multi-purpose anchor
hole 385 using a hammer drill and removes dust and foreign matters
inside the anchor hole 385 using an air pump. The multi-purpose
anchor and one of the composite panels 310 for reinforcing the
concrete body are installed and the level of the panel is adjusted
to remove a surface deviation between the panel and the existing
concrete body. The gap between the panel and the concrete body is
sealed with inorganic group sealing material. Because the
multi-purpose anchor serves as the air discharge hole, the air
discharge hole 342 is formed only in the gap of the upper portion
of the panel. After the sealing material is hardened, wet adhesion
type grout material 372 is injected from the lower multi-purpose
anchor upwardly. After the lapse of about 24 hours after the first
injection is finished, the second low pressure injection is
performed to achieve a perfect filling up. After the lapse of about
24 hours after the second injection, the depressed part around the
multi-purpose anchor hole, the portion where the air discharge hole
342 is formed, and polluted surfaces are finished.
INDUSTRIAL APPLICABILITY
[0092] While the present invention has been described with
reference to the particular illustrative embodiments, it is not to
be restricted by the embodiments but only by the appended claims.
It is to be appreciated that those skilled in the art can change or
modify the embodiments without departing from the scope and spirit
of the present invention.
* * * * *