Composite construct and methods and devices for manufacturing the same

Patent metadata

Field	Value
Publication number	US-10344480-B2
Application number	US-201816202318-A
Country	US
Kind code	B2
Filing date	Nov 28, 2018
Priority date	Dec 4, 2017
Publication date	Jul 9, 2019
Grant date	Jul 9, 2019

Abstract

Methods for manufacturing a composite concrete structure are provided. A method can include utilizing a shell formwork with a displacement piece positioned therein. A first type of concrete can be placed in the shell formwork around the displacement piece. The displacement piece, when removed, leaves a void that is fillable with a second type of concrete for form the composite concrete structure. A reinforcement cage or reinforcement rods can be incorporated into the void prior to placement of the second type of concrete.

First claim

What is claimed is:

1. A composite construct comprising: an outer shell comprising a first type of concrete comprising a moisture-resistant Ultra High performance Concrete (UHPC) and having a void that defines an inner surface, said void formed by a removable replacement piece; and a concrete core formed within the void comprising a second-type of concrete that, while curing, forms an interface with the outer shell where the second type of concrete fuses with the inner surface of the shell.

2. The composite construct, according to claim 1 , further comprising a metal rod or reinforcement cage embedded within the concrete core.

3. The composite construct, according to claim 2 , wherein the second type of concrete comprises Normal Strength Concrete.

4. The composite construct, according to claim 3 , wherein the metal rod or reinforcement cage comprises mild steel.

5. The concrete construct, according to claim 2 , wherein a part of the metal rod or reinforcement cage extends through the outer shell to the outside of the composite construct.

6. The composite construct, according to claim 4 , comprising at least two flat sides.

7. The composite construct, according to claim 4 , comprising a column with a circular circumference.

8. The composite construct, according to claim 4 , comprising at least one arch formed therein.

9. A method for manufacturing a composite construct comprising: obtaining a shell formwork for the composite construct; positioning at least one displacement piece within the shell formwork; depositing a first type of concrete, comprising a moisture resistant High Performance Concrete (UHPC) in the shell formwork to surround the displacement piece, leaving at least a portion of the displacement piece uncovered by the first type of concrete; allowing the first type of concrete to cure around the displacement piece; removing the displacement piece after the first type of concrete has cured to form a void that defines an inner surface within the first type of cured concrete; removing the shell formwork from the cured first type of concrete to provide an outer shell with the void therein; positioning a reinforcement structure within the void: placing a second type of concrete in the void of the outer shell; and allowing the second type of concrete to cure within the void, so as to form an interface with the outer shell where the second type of concrete fuses to the inner surface, thereby forming a core within the outer shell resulting in the composite construct.

10. The method according to claim 9 , further comprising a vault within the at least one displacement piece wherein another at least one displacement piece can be positioned.

11. The method according to claim 10 , wherein the composite construct formed has an arch shape.

12. The method according to claim 11 , further comprising joining two or more outer shells prior to positioning the second type of concrete in the voids of the joined shells.

13. The method according to claim 12 , wherein the shells comprise a lip having a profile that facilitates joining of the two or more shells.

14. The method according to claim 9 , wherein the second type of concrete is Normal Strength Concrete.

15. The method according to claim 9 , wherein the at least one displacement piece is a rigid foam material and the method further comprises securing the displacement piece in position within the shell formwork.

16. The method according to claim 9 , wherein a portion of the metal rod or reinforcement cage extends through the shell and outside the composite construct.

17. The method according to claim 16 , further comprising joining the composite construct to a superstructure.

18. A composite construct comprising: an outer shell comprising a first-type of concrete comprising a moisture-resistant Ultra High Performance Concrete (UHPC) and having a void formed by a foam displacement piece that defines an inner surface, such that, when the foam displacement piece is removed, the void is formed with the outer shell; a concrete core formed within the void comprising a second-type of concrete comprising normal strength concrete that, while curing, forms an interface with the outer shell where the second-type of concrete fuses with the surface; and at least one reinforcement structure comprising at least one of a metal rod and a reinforcement cage that extends through the core to an outside of the outer shell.

19. The composite construct, according to claim 18 , further comprising surface features on the inner surface that increase the interface with the second type of concrete.

20. A composite construct comprising: a first outer shell, comprising a first type of concrete, having a lip on an outer edge and an arched void formed by a removable displacement piece defining an inner surface of the first outer shell; a second outer shell, comprising the first type of concrete, having a lip on an outer edge and an arched void formed by a removable displacement piece defining an inner surface of the second outer shell, and the lip on the first outer shell is joinable to the lip on the second outer shell; a concrete core formed within the arched voids of the joined first outer shell and the second outer shell, the concrete core comprising a second-type of concrete that, while curing, forms an interface with the inner surfaces of the first outer shell and the second outer shell where the second-type of concrete fuses with the inner surface of the first outer shell and with the surface of the second outer shell; and at least one reinforcement structure comprising at least one of a metal rod and a reinforcement cage disposed within the first arched void and the second arched void.

Assignees

• Azizinamini Atorod
• The Florida International Univ Board Of Trustees

Inventors

• Azizinamini Atorod

Classifications

• E04C3/20

  of concrete or other stone-like material, e.g. with reinforcements or tensioning members (reinforcing elements E04C5/00) · CPC title

• E04C3/44

  of concrete or other stone-like material, e.g. with reinforcements or tensioning members (E04C3/46 takes precedence) · CPC title

• E04C3/34 Primary

  of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings (E04C3/36 takes precedence) · CPC title

• E01D19/02

  Piers {(E01D19/005 takes precedence; towers for suspension bridges E01D19/14)}; Abutments (foundations E02D ){; Protecting same against drifting ice (against colliding vehicles E01F15/00)} · CPC title

• E04G13/04

  for lintels, beams, or transoms to be encased separately; Special tying or clamping means therefor ({hat-like or trough-like elements encasing a rib and its adjacent ceiling section E04G11/46; } members, e.g. consoles, for attachment to the wall E04G17/16) · CPC title