U.S. patent application number 10/737744 was filed with the patent office on 2004-08-05 for sound barrier.
Invention is credited to Krezel, Zbigniew Adam, McManus, Kerry John.
Application Number | 20040148876 10/737744 |
Document ID | / |
Family ID | 32739136 |
Filed Date | 2004-08-05 |
United States Patent
Application |
20040148876 |
Kind Code |
A1 |
McManus, Kerry John ; et
al. |
August 5, 2004 |
Sound barrier
Abstract
A sound barrier made from recycled concrete aggregate, the sound
barrier being divided into at least two or more sections, each said
section including: an inner layer for supporting the barrier, and
an outer layer, said outer layer having a predetermined number of
voids for absorbing sound energy at a particular frequency, wherein
said respective outer layers of said at least two or more sections
have different predetermined numbers of voids so as to absorb sound
energy at different frequencies. A method of making a sound barrier
is also provided.
Inventors: |
McManus, Kerry John; (Glen
Waverley, AU) ; Krezel, Zbigniew Adam; (Mount
Waverley, AI) |
Correspondence
Address: |
BIRCH STEWART KOLASCH & BIRCH
PO BOX 747
FALLS CHURCH
VA
22040-0747
US
|
Family ID: |
32739136 |
Appl. No.: |
10/737744 |
Filed: |
December 18, 2003 |
Current U.S.
Class: |
52/144 |
Current CPC
Class: |
E04B 2001/848 20130101;
E01F 8/0064 20130101; E01F 8/0029 20130101; E04B 2001/8461
20130101; E01F 8/0017 20130101; E04B 2001/746 20130101 |
Class at
Publication: |
052/144 |
International
Class: |
E04B 001/82 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 13, 2002 |
AU |
47534/02 |
Claims
The claims defining the invention are as follows:
1. A sound barrier made from recycled concrete aggregate, the sound
barrier being divided into at least two or more sections, each said
section including: an inner layer for supporting the barrier, and
an outer layer, said outer layer having a predetermined number of
voids for absorbing sound energy at a particular frequency, wherein
said respective outer layers of said at least two or more sections
have different predetermined numbers of voids so as to absorb sound
energy at different frequencies.
2. A sound barrier according to claim 1, wherein the outer layers
have different thicknesses to determine the number of voids in each
section.
3. A sound barrier according to claim 2, wherein the thickness of
said outer layers is up to 125 mm.
4. A sound barrier according to claim 3, wherein said thickness is
no more than 85 mm.
5. A sound barrier according to claim 4, wherein said thickness is
between 15 mm and 60 mm.
6. A sound barrier according to claim 1, wherein said outer layers
absorb frequencies in the range of between 100 Hz and 2000 Hz.
7. A sound barrier according to claim 6, wherein said outer layers
absorb frequencies between 400 Hz and 800 Hz.
8. A sound barrier according to claim 1, wherein there is a
transition zone between the inner layer and the outer layer to
reflect residual sound energy that travels through the outer
layer.
9. A sound barrier according to claim 8, wherein said inner layer
is denser than said outer layer.
10. A sound barrier according to claim 1, wherein the sound barrier
has three sections arranged sequentially from top to base relative
to the ground in ascending order of each frequency absorbed.
11. A sound barrier according to claim 1, wherein the voids include
one or more of the following types or a combination of the
following types: gel-like pores; capillary-like pores;
interconnected permeable voids; isolated air pockets or channels,
and interconnected air pockets or channels.
12. A sound barrier according to claim 11, wherein the voids range
in size between 100 Angstroms and 5 mm in diameter.
13. A sound barrier according to claim 1, wherein the outer layer
is covered with an additional layer, said additional layer
including perforations or discontinuous portions to facilitate the
absorption of sound energy.
14. A sound barrier according to claim 13, wherein the perforations
or discontinuous portions extend into the additional layer to a
predetermined depth.
15. A sound barrier according to claim 14, wherein the perforations
or discontinuous portions extend into the additional layer to a
depth such that portions of the outer layer are exposed.
16. A sound barrier according to claim 13, wherein the perforations
or discontinuous portions are formed over at least 30% of the outer
surface of the additional layer.
17. A sound barrier according to claim 13, wherein the additional
layer is composed of a perforated material.
18. A sound barrier according to claim 17, wherein the perforated
material includes a mortar including RCA fines, cement, water and
an air entraining agent.
19. A sound barrier according to claim 17, wherein the perforated
material includes plasterboard or render.
20. A sound barrier according to claim 13, wherein the thickness of
the additional layer is at least about 10 mm.
21. A sound barrier according to claim 13, wherein the thickness of
the additional layer is at most about 25 mm.
22. A sound barrier according to claim 13, wherein the perforations
or discontinuous portions are formed in a regular pattern.
23. A sound barrier according to claim 13, wherein the perforations
or discontinuous portions are mechanically induced in the
additional layer.
24. A method of making a sound barrier divided into at least two or
more sections from a concrete mix comprising recycled concrete
aggregate, the method comprising the steps of: (a) casting the
concrete mix; (b) compacting the concrete mix to form a plurality
of voids in the concrete mix; (c) curing the concrete mix to form
one said section such that an outer layer of said section has a
predetermined number of said voids for absorbing sound energy at a
predetermined frequency; (d) repeating said steps (a)-(c) for one
or more further sections wherein the number of voids in each
respective outer layer differs so as to vary the frequency of sound
energy absorbed by each respective outer layer, and (e) connecting
said section and said one or more further sections to form said
sound barrier to absorb sound energy at different frequencies.
25. A method according to claim 24, wherein said number of voids in
each respective outer layer is determined by varying the thickness
of each said respective outer layer.
26. A method according to claim 24, wherein the inner layer is
formed with the outer layer of each section in a single pour of
concrete mix.
27. A method according to claim 24, wherein the concrete mix
includes 45 to 60% of recycled concrete aggregate.
28. A method according to claim 24, wherein the recycled concrete
aggregate has a lower density than normal concrete.
29. A method according to claim 24, wherein the concrete mix
includes one or more of the following: general purpose cement; fly
ash; concrete sand and water.
30. A method according to claim 24, wherein said casting step is
performed on a horizontal casting bed.
31. A method according to claim 24, wherein the compacting step
includes vibrating the concrete mix at a predetermined frequency
and time.
32. A method according to claim 31, wherein said predetermined
frequency is about 50 Hz and said predetermined time is between 3
to 6 minutes.
33. A method according to claim 24, wherein said curing step is
performed by steam curing or by introducing a curing compound to
the concrete mix.
34. A method according to claim 24, wherein each respective outer
layer is covered by an additional layer including perforations or
discontinuous portions to facilitate the absorption of sound
energy.
35. A method according to claim 34, wherein the perforations or
discontinuous portions are mechanically induced in the additional
layer.
Description
[0001] This invention relates to sound barriers. In particular, the
invention relates to concrete sound barriers for highways and other
road surfaces carrying large volumes of motorised traffic. Another
application of the invention is the use of the sound barrier for
internal or external cladding in buildings.
[0002] City communities are more aware of significant noise coming
from road and rail traffic. Traffic noise is recognised as serious
environmental problem and consequently relevant traffic and
government authorities have defined residential noise limits for
newly constructed and in (some instances) existing roads. In
Denmark for example, the legal limit is 55 dB(A) day and night, and
in Netherlands the night limit is even lowered to 45 dB(A). In the
state of Victoria in Australia, the road traffic noise limit is set
to 63 dB(A) L10(18 hour). There is often a difference in the sound
pressure level generated on the road surface and what affected
residents are willing to accept.
[0003] To reduce the sound pressure level that reaches nearby
residents, a wide range of options are available to city
authorities to consider, such as earth mounds, wider road reserves,
etc. However, space limitations and financial considerations
dictate in most cases the use of the noise barriers. The maximum
practical reduction that can be achieved with the use of a vertical
barrier is usually 15 dB(A). In general, the lower the noise level
to be achieved, a higher and thicker sound barrier is required.
Because of the limited distance between barriers and/or source and
receiver, the use of reflective barriers is considered to be
satisfactory. Consequently, this approach creates more visual
obstruction as well as causing extensive use of materials and
substantial construction costs. Moreover, these types of barriers,
which reflect or disperse noise, in many cases do not properly
satisfactorily solve traffic noise problems. To lessen the visual
impact of the barriers and to achieve the target noise reduction,
the use of quiet road surfaces and sound absorptive barriers have
been observed as an effective alternative.
[0004] In addition to the increased nuisance related to the traffic
noise, another environmental problem that needs immediate attention
of the community is the growing amount of waste generated and
requiring disposal at local landfill sites. The construction and
demolition (C&D) industry, with its waste, is the major
contributor to the total waste stream, and accounts for up to 70%
of the total. The major component of C&D waste is concrete,
which amounts for approximately 1.5 million tonnes per year in the
Metropolitan Melbourne area of Victoria, Australia alone.
Approximately 50% of concrete waste can be recycled and reused in
new road infrastructure projects mainly as a substitute for natural
crushed aggregate in bound and unbound pavement sub-base layers.
This recycled concrete waste may be used as an alternative
construction material and is often referred to as recycled concrete
aggregate or RCA. RCA materials may be manufactured in quality
assured processes to set specifications, and subsequently have well
defined basic engineering properties. Concrete products made from
RCA are also referred to as recycled aggregate concrete or RAC.
However, RCA and RAC products are often under utilised.
[0005] According to one aspect of the invention there is provided a
sound barrier made from recycled concrete aggregate, the sound
barrier being divided into at least two or more sections, each said
section including:
[0006] an inner layer for supporting the barrier, and
[0007] an outer layer, said outer layer having a predetermined
number of voids for absorbing sound energy at a particular
frequency,
[0008] wherein said respective outer layers of said at least two or
more sections have different predetermined numbers of voids so as
to absorb sound energy at different frequencies.
[0009] There is also provided according to another aspect of the
invention, a method of making a sound barrier divided into at least
two or more sections from a concrete mix comprising recycled
concrete aggregate, the method comprising the steps of:
[0010] (a) casting the concrete mix;
[0011] (b) compacting the concrete mix to form a plurality of voids
in the concrete mix;
[0012] (c) curing the concrete mix to form one said section such
that an outer layer of said section has a predetermined number of
said voids for absorbing sound energy at a predetermined
frequency;
[0013] (d) repeating said steps (a)-(c) for one or more further
sections wherein the number of voids in each respective outer layer
differs so as to vary the frequency of sound energy absorbed by
each respective outer layer, and
[0014] (e) connecting said section and said one or more further
sections to form said sound barrier to absorb sound energy at
different frequencies.
[0015] As the outer layer of each sound barrier section has a
porous structure due to the voids, sound energy is absorbed by each
section by channelling sound energy through the voids, causing the
sound to dissipate or disperse in the structure of each respective
outer layer. Accordingly, by varying the number of voids in each
sound barrier section, sound at different frequencies is absorbed
by the sections of the sound barrier. Therefore, this improves the
sound absorption capacity and allows the sound barrier and method
according to the invention to have an overall smaller thickness and
be less visible than existing sound barriers. In addition, the
sound barrier and method according to the invention reduces the
consumption of building materials by utilising RCA.
[0016] Preferably, the number of voids is determined by varying the
thickness of the outer layer. The thickness of the outer layers may
be up to 125 mm. Preferably, the thickness of the outer layer is no
more than 85 mm. In a preferred embodiment, the thickness of the
outer layer is between 15 mm and 60 mm.
[0017] The outer layers preferably absorb sound energy of
frequencies in the range of between 100 Hz and 2000 Hz.
[0018] It is preferred that there is a transition zone between the
inner layer and the outer layer. The transition zone preferably
reflects any residual sound energy that travels through the outer
layer.
[0019] The inner layer preferably is denser than the outer
layer.
[0020] The sound barrier preferably has the three sections arranged
sequentially from top to base relative to the ground in ascending
order of each frequency absorbed or reflected. In a preferred
embodiment the sound barrier of the invention has a top section or
panel for absorbing sound at 400 Hz, a middle panel for absorbing
sound at 600 Hz, and a base panel for absorbing sound at 800
Hz.
[0021] It is preferable that the outer layer has a higher thickness
at a top section of the sound barrier than the outer layer at the
base of the sound barrier, relative to the ground. The top section
outer layer preferably has large interconnected air channels. The
thickness of the outer layer may gradually increase from the base
of each sound barrier section to the top portion. Preferably, the
top section of the sound barrier includes up to 15% of the total
volume of the sound barrier.
[0022] Preferably, the voids may include one or more of the
following types or a combination of the following types: gel-like
pores; capillary-like pores; interconnected permeable voids;
isolated air pockets or channels, and interconnected air pockets or
channels. The voids may range in size between 100 Angstroms and 5
mm in diameter.
[0023] The outer layer of each section is preferably covered with
an additional layer, the additional layer having perforations or
discontinuous portions to facilitate the absorption of sound
energy. The perforations or discontinuous portions preferably
extend into the additional layer to a predetermined depth. The
perforations or discontinuous portions may extend into the
additional layer to a depth such that portions of the outer layer
are exposed. Preferably, the perforations or discontinuous portions
are formed over at least 30% of the outer surface of the additional
layer. The perforations or discontinuous portions can be
mechanically induced in the additional layer.
[0024] The perforations or discontinuous portions can be formed in
a regular pattern. One embodiment has 9 mm holes spaced at 20-25 mm
centres. Irregular patterns of perforations or discontinuous
portions can be used.
[0025] The additional layer may be composed of a perforated
material. In one embodiment, the additional layer is made from a
mortar including RCA fines, cement, water and an air entraining
agent. Other perforated material may include plasterboard or
render.
[0026] The additional layer is preferably thin relative to the
thickness of the inner layer and the outer layer. It is preferred
that the thickness of the additional layer is at least 10 mm. It is
expected that the maximum thickness is at most 25 mm.
[0027] The concrete mix preferably includes one or more of the
following: general purpose cement; fly ash; concrete sand and
water. Preferably, the concrete mix comprises between 45 and 60% of
RCA.
[0028] Preferably, an inner layer is formed with the outer layer.
The inner and outer layers of each sound barrier section can be
formed in a single pour of concrete mix.
[0029] It is preferable that the recycled concrete aggregate has a
lower density than normal concrete. The recycled concrete aggregate
may have a density that is 10% lower than the density of normal
concrete.
[0030] Preferably, the casting step is performed on a horizontal
casting bed.
[0031] It is preferred that the compacting step includes vibrating
the concrete mix at a predetermined frequency and time. The
concrete mix is preferably vibrated at a frequency of 50 Hz for 3
to 6 minutes, more preferably 3.3 to 5.5 minutes.
[0032] The curing step is preferably performed by steam curing or
by introducing a curing compound to the concrete mix.
[0033] While the perforations or discontinuous portions can be
formed in the additional layer before or after the additional layer
is joined to the outer layer of the second barrier, it is preferred
that the perforations/discontinuous portions are formed after the
additional layer is joined to the outer layer.
[0034] It is preferred that the total thickness of the sound
barrier is 150 mm.
[0035] To assist in the understanding of the invention, preferred
embodiments of the invention will now be described with reference
to the drawings, of which:
[0036] FIG. 1 is front view of a sound barrier made according to
one embodiment of the invention;
[0037] FIG. 2 is a sectional side view of the sound barrier of FIG.
1 along the line A-A;
[0038] FIG. 3 is a side view of a section of the sound barrier of
FIG. 1;
[0039] FIG. 4 is a schematic drawing showing the sound absorbing
mechanisms employed by the sound barrier of FIG. 1.
[0040] FIG. 5 is a schematic side view of a section of a sound
barrier in accordance with another embodiment of the invention.
[0041] FIG. 6 is a chart comparing the sound absorbing
characteristics of embodiments of the invention.
[0042] FIG. 1 illustrates a sound barrier 10 in accordance with a
preferred embodiment of the invention. Sound barrier 10 comprises
three separate sections or panels 13, 14, 15 mounted on rigid
supports 12. The supports 12 are affixed to the ground via footing
members 11 made from RAC. Each of the panels 13, 14, 15
respectively has an outer layer (13a, 14a or 15a) and an inner
layer (13b, 14b or 15b). The outer layers 13a, 14a, 15a each have
voids for absorbing sound energy. The thicknesses of the outer
layers 13a, 14a, 15a increase from the base of the sound barrier 10
to the top, as can be seen more clearly in FIG. 2.
[0043] FIG. 3 shows a side view of section 13 of sound barrier 10
of FIGS. 1 and 2 in more detail. Sections 14, 15 have the same
structure as section 13 except in relation to the thicknesses of
their respective inner and outer layers. Section 13 has an inner
dense layer 13b (also indicated as "RL"--reflective layer) and
outer porous layer 13a (also indicated as "SA"--sound absorbent
layer). The inner dense layer 13b provides structural support for
13 as well as for reflecting sound energy at the transition zone 20
between the inner layer 13b and the outer layer 13a. The outer
layer 13a has a number of voids in the form of interconnected air
channels 40. The outer porous layer 13a is an absorptive layer for
channelling sound energy through voids or air channels 40 to
disperse or dissipate sound energy generated by traffic noise.
[0044] It has been found that the greater the porosity of the outer
layer of the sound barrier, the lower the frequency of the sound
absorbed by the sound barrier. This means that the number of voids
in the outer layer determines the frequencies at which sound is
absorbed. Accordingly, particular sound frequencies may be absorbed
according to the thickness of the outer porous layer of the sound
barrier as this determines the number of voids.
[0045] Thus, each panel or section 13, 14, 15 will absorb and
reflect different frequencies of sound. For example, panel 13 has
an outer layer 13a of approximately 60 mm thickness and absorbs
sound frequencies of 400 Hz. Panel 14 has an outer layer 14a of
approximately 40 mm thickness and absorbs frequencies of 600 Hz.
Panel 15 has an outer layer 15a of approximately 30 mm thickness
and absorbs frequencies of 800 Hz.
[0046] It has been found that sound barriers made in accordance
with the invention may absorb sound having frequencies in the range
of between 100 Hz and 2000 Hz. In particular, the most effective
range of frequencies absorbed is between 400 Hz and 800 Hz. The
thickness of the outer layer is preferably no more than 85 mm,
although thicknesses of up to 125 mm may be used.
[0047] By dividing the sound barrier into sections or panels, each
panel having an outer layer of a different thickness, the sound
barrier according to this preferred embodiment of the invention may
absorb a broader range of frequencies than a sound barrier having
an outer porous layer of uniform thickness.
[0048] The sound absorbing mechanisms used by each section 13, 14,
15 are illustrated in FIG. 4. Incident sound generated from passing
traffic is absorbed or reflected by the sound barrier in two
ways--flow resistivity and resonance. Firstly, an incident sound
wave may be simply reflected from the outer porous layer 13a.
Secondly, an incident sound wave may penetrate and be absorbed by
the outer layer 13a. In this case, the incident sound wave travels
through the outer porous layer 13a via voids or air channels 40,
dissipating most, if not all, of its energy. Any residual sound
energy that reaches transition zone 20 is reflected back through
the outer porous layer 13a due to the denser nature of the inner
layer 13b. The reflected residual sound energy will dissipate as it
travels back through the outer layer 13a. Therefore, each sound
barrier section 13, 14, 15 both absorbs and reflects sound energy
generated by traffic noises.
[0049] It has been discovered that the sound absorption properties
of the RAC sound barrier are proportional to the porosity of the
RCA that is used to make up the RAC. This means that the overall
porosity of the sound barrier (that is, the concrete density and
the number of voids per volume (also known as void volume))
determines the effectiveness of the sound barrier. Table 1
indicates examples of this relationship between porosity of the RCA
and noise reduction, the Noise Reduction Coefficient being an
arithmetic mean of Sound Absorption Coefficient measured at 250 Hz,
500 Hz, 1000 Hz and 2000 Hz.
1TABLE 1 Acoustic characteristics of sound barrier panels Concrete
Noise Density % Reduction Panel [kg/m.sup.3] Porosity Coefficient
Alpha-400 1,650 22.0 0.42 Alpha-600 1,745 18.0 0.27 Alpha-800 1,865
13 0.21
[0050] FIG. 5 schematically shows one section 50 of a sound barrier
according to another embodiment of the invention. The sound barrier
section 50 of this embodiment has an inner structural layer 51, a
porous outer layer 52 and an additional or second outer layer 54
covering outer layer 52. The inner layer 51 and outer layer 52 are
respectively the same as the inner layer 13a, 14a, 15b and outer
layer 13b, 14b, 15b of the sound barrier 10 of FIG. 1. The only
difference between the two embodiments is the provision of
additional layer 54.
[0051] The additional layer 54 has a number of perforations 56
formed over at least 30% of its outer surface 58 to assist in the
absorption of sound energy. The perforations 56 extend from outer
surface 58 right through additional layer 54 to expose portions of
outer layer 52. It has been found that this additional layer 54
assists in improving the sound absorbing characteristics of the
sound barrier section 50, particularly at lower frequencies of
sound energy.
[0052] In the preferred embodiment, the perforations 56 are
mechanically induced in the additional layer 54 after the
additional layer is joined to the outer layer 52. The perforations
56 are formed in a regular pattern of 9 mm holes spaced at 20-25 mm
centres. The perforations may be substituted with discrete
discontinuous portions. Furthermore, an irregular pattern can be
used with either perforations or discontinuous portions. For
example, discrete discontinuous portions can be formed in an
irregular pattern to the same effect as a regular pattern of
perforations, so long as the discontinuous portions are in at least
30% of the outer surface.
[0053] Generally, as the additional layer 54 increases in
thickness, the sound barrier has more improved sound absorbing
characteristics. The minimum thickness of the additional layer 54
in this embodiment is 10 mm. The maximum thickness of the
additional layer 54 will depend on the sound frequencies being
targeted by the sound barrier, although it is expected that a
maximum thickness is at about 25 mm.
[0054] The sound barrier of this embodiment has a density of about
1650-1865 kg/m.sup.3. The outer layer 52 of the sound barrier has a
density of 1200-1700 kg/m.sup.3 whereas the additional layer 54 has
a density of about 840-1200 kg/m.sup.3.
[0055] Reverberation chamber tests were conducted using three
examples of embodiments of the invention to compare their sound
absorption characteristics. Two of the examples (labelled S1 and
S2) were structurally the same as the sound barrier of FIG. 1; ie.
having an inner and outer layer. The third example (labelled S3)
was a sound barrier made according to FIG. 5, having an inner
layer, an outer layer and an additional layer, the additional layer
being made from perforated plasterboard material.
[0056] FIG. 6 is a chart showing the results of the tests for each
of the above sound barriers. As can be seen in FIG. 6, example S3
generally has a higher sound absorption coefficient than examples
S1 and S2 over the frequency range, especially between about 400 Hz
to 1400 Hz, due to the presence of the perforations in the
additional layer.
[0057] A method of making the sound barrier 10 in accordance to
another aspect of the invention is also provided. A concrete mix is
formed primarily of RCA, the proportion of RCA varying between 45
and 60% of the concrete mix. Other materials can be included, such
as general purpose (GP) cement, fly ash, concrete sand or water.
The GP cement and fly ash is generally used as a binder for the
section or panel. It has been determined that the best results use
a combination of the above materials. Various proportions of RCA
and other materials in different concrete mixes are shown in Table
2 below for a panel with a compressive strength of 25 MPa.
[0058] The concrete mix design is classified as a combination of
no-fines and gap-graded concrete and is described as "less-fines
concrete".
2TABLE 2 Concret mix design Coarse RC Aggregate Fine RC Water
Binder Bulk Aggregate Concrete Vibration V Mass V Mass V Mass Air
Mass V Density time Panel Binder [m.sup.3] [kg] [m.sup.3] [kg]
[m.sup.3] [kg] V [m.sup.3] [kg] [m.sup.3] [kg/m.sup.3] [min] Alpha-
GP+ 0.150 150 0.08 240.0 0.452 950 0.22 250 0.10 1,650 5.5 400 Fly
0.02 60.0 Ash Alpha- GP+ 0.150 150 0.08 240.0 0.474 995 0.18 300
0.11 1,745 5.5 600 Fly 0.02 60.0 Ash Alpha- GP+ 0.150 150 0.08
240.0 0.507 1065 0.13 350 0.13 1,865 5.5 800 Fly 0.02 60.0 Ash
[0059] The concrete mix designs in Table 2 are based on the
following characteristics:
[0060] GP cement having a specific gravity of 3.15;
[0061] fly ash having a specific gravity of 2.4;
[0062] coarse aggregate concrete with a specific gravity of 2.1 and
a bulk density of 1600 kg/m.sup.3;
[0063] fine aggregate concrete with a specific gravity of 2.58;
[0064] a slump of concrete of 50 mm (ie. the workability of fresh
concrete into moulds to create the final shape of the set
concrete);
[0065] a water/cement ratio of 0.55 (used in the mix and relates to
the final compressive strength of the mix), and
[0066] fineness modulus (FM) of fine aggregate of 3.
[0067] FM is an aggregate property, which is the sum of cumulative
ratios retained on 4.75 to 0.075 mm sieves. FM does not describe a
particle size distribution of the aggregate.
[0068] One manner in which the method according to the invention
may be performed is described below.
[0069] Once the appropriate concrete mix is selected, the mix is
placed on a horizontal casting bed. The cast concrete mix is then
compacted, preferably by using a vibrating table to promote the
creation of voids in the outer layer. The vibrating table is
usually run at 50 Hz for 3.3 to 5.5 minutes with amplitude of
approximately 2 mm. An immersed vibrator may also be used to
promote the creation of voids in the outer layer.
[0070] After compaction, the concrete mix is then cured to set the
concrete mix as the sound barrier section. Curing may be performed
using either steam curing or introducing a curing compound to the
concrete mix. Typical curing compounds include Duro-Seel, made by
Ability Building Chemicals.
[0071] Once the desired number of sections or panels have been
produced, the sections are then joined or connected to each other
to form sound barrier 10. This can be done by sliding the sections
into H-shape posts or attached to posts with bolts. Other methods
can be used to connect the sound barrier sections using standard
structural engineering design and construction methods.
[0072] Table 3 shows several sound barriers made using according to
the above method using different concrete mixes, the manner of
performing the method only varying in the use of steam curing or a
curing compound.
3TABLE 3 Concrete mix design and manufacturing method Concrete mix
design Recycled Concrete Aggregate General 14/10 or Manufacturing
method Panel Purpose 10 mm Curing/ type (GP) Pulverised Concrete
Class 2 Placing/ Compaction/ (SC) steam frequency [Hz]/ Cement Fuel
Ash Sand Industry Horizontal Vibrating curing/ compressive AS 1315
AS3582.1 AS 2758 Standard Water casting table - 50 Hz (CC) curing
strength [MPa] [kg] [kg] [kg] [kg] [l] bed (3.3-5.5 min) compound
.alpha. -400/25 MPa 240 60 250 950 150 Yes Yes SC .alpha. -600/25
MPa 240 60 300 995 150 Yes Yes SC .alpha. -800/25 MPa 240 60 350
1065 150 Yes Yes SC .alpha. -400/32 MPa 330 80 250 950 200 Yes Yes
CC .alpha. -600/32 MPa 330 80 300 995 200 Yes Yes CC .alpha.
-800/32 MPa 330 80 350 1065 200 Yes Yes CC
[0073] In another example, about 57% RCA was used in the concrete
mix to create a sound barrier having a compressive strength of 15
MPa, which can absorb frequencies of 400 Hz. Other sound barriers
of compressive strengths in the range of 25 MPa to 40 MPa were also
be made.
[0074] For the embodiment described at FIG. 5, after the concrete
mix is set to form the inner and outer layers, the additional layer
is joined to the outer layer. While the perforations or
discontinuous portions can be mechanically induced into the
additional layer prior to joining, it is preferred that the
perforations or discontinuous portions are mechanically induced in
the additional layer after joining the additional layer to the
outer layer.
[0075] While the above example describes one particular manner of
performing the method according to the invention, it is readily
apparent to the person skilled in the art that other means may be
employed to perform the casting, compacting and curing steps of the
method according to the invention.
[0076] The above preferred embodiments and examples relate to a
concrete sound barrier for absorbing traffic noise generated along
road surfaces. However, the sound barrier of the invention may also
be applied to other sound reducing applications, such as for
internal or external cladding in buildings.
[0077] It is understood that various modifications, alterations,
variations and additions to the construction and arrangement of the
embodiment described herein are considered as falling within the
ambit and scope of the present invention.
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