HIGH-PERFORMANCE FIBER-REINFORCED CONCRETE COMPOSITIONS FOR ENHANCED DURABILITY AND STRUCTURAL INTEGRITY

Abstract

Abstract The present invention provides a high-performance fiber-reinforced concrete (FRC) composition designed to enhance durability, structural integrity, and load-bearing capacity for a variety of construction applications. The composition includes a blend of synthetic fibers, such as polypropylene, polyethylene, or polyvinyl alcohol, and natural fibers (104), such as sisal or coconut coir (101), integrated into a cementitious matrix (102) with pozzolanic materials. This fiber combination optimizes crack resistance, shrinkage control, and resilience under dynamic loads. The invention further includes a unique mixing process that ensures uniform fiber dispersion and bonding, contributing to improved durability under extreme conditions like freeze-thaw cycles, high humidity, and chemical exposure. Suitable for new construction and repair, this FRC composition is ideal for infrastructure, residential, and commercial projects where long-term reliability and maintenance reduction are essential. The composition provides a sustainable, cost-effective solution for enhancing the performance of concrete in demanding environments. The figure associated with the abstract is Fig.1

Specification

Description:DESCRIPTION
Technical Field of the Invention

The present invention relates to the field of construction materials, specifically high-performance fibre-reinforced concrete (108) (FRC) compositions. These compositions are designed to improve the durability, structural integrity, and load-bearing capacity of concrete used in various construction applications.

Background of the Invention

Concrete is one of the most widely used construction materials due to its strength, durability, and versatility. However, traditional concrete suffers from inherent limitations, including a tendency to crack, shrink, and deteriorate over time, especially when exposed to dynamic loads, extreme environmental conditions, or aggressive chemicals. These issues compromise the structural integrity of concrete structures, leading to costly repairs and maintenance. Conventional reinforcing methods, such as the incorporation of steel bars, partially address these challenges but do not mitigate problems like surface cracking, shrinkage, or resistance to freeze-thaw cycles.

Fiber-reinforced concrete (FRC) has emerged as a promising alternative to standard concrete, offering enhanced properties through the integration of fibers within the cementitious matrix (102). However, many existing FRC compositions rely solely on synthetic fibers, which may offer strength but often lack the bonding properties needed to fully integrate with the concrete matrix. Additionally, these synthetic fibers alone may not provide sufficient environmental sustainability or adaptability for applications demanding long-term durability in various conditions.

To address these limitations, the present invention introduces a high-performance FRC composition that combines synthetic fibers with natural fibers. This dual-fiber approach optimizes the distribution and bonding of fibers, resulting in improved resistance to cracking, shrinkage, and structural fatigue. The selected blend of fibers enhances the concrete's performance under severe conditions, including freeze-thaw cycles, high humidity, and chemical exposure. This composition further incorporates unique mixing and processing techniques to maximize fiber dispersion and structural bonding within the matrix. The resulting FRC composition is particularly suitable for both new construction and repair applications, meeting the growing demand for durable, low-maintenance building materials in infrastructure, residential, and commercial sectors where long-term structural reliability is essential.

Brief summary of the Invention

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

The primary objective of this invention is to provide an FRC composition that significantly improves resistance to cracking and shrinkage in concrete applications.

Another key objective is to enhance the structural integrity and load-bearing capacity of concrete through the optimized integration of synthetic and natural fibres.

Another key objective is to introduce an FRC composition capable of withstanding extreme environmental conditions, reducing the need for frequent repairs and maintenance.
Another key objective is to offer a versatile concrete solution suitable for new constructions as well as for repairs of existing structures in infrastructure, residential, and commercial sectors.

According to an aspect of the present invention, a high-performance fibre-reinforced concrete (108) (FRC) composition that addresses common challenges in concrete construction, including susceptibility to cracking, shrinkage, and structural degradation over time. By blending synthetic and natural fibres within the cementitious matrix (102), the FRC composition significantly enhances the material's structural integrity, resistance to dynamic loads, and durability in various environmental conditions. This innovative fibre blend optimally distributes synthetic fibres, which provide tensile strength and resilience, with natural fibres that improve bonding characteristics within the matrix. The result is a composition that delivers superior resistance to cracking and shrinkage, making it especially suitable for long-term, heavy-duty applications.

In accordance with the aspect of the present invention, a unique aspect of the invention lies in its specialized mixing and processing methods, which ensure effective fiber dispersion and maximize bonding within the cement matrix. The method begins with pre-wetting natural fibers to enhance their adhesive qualities, followed by a controlled, gradual addition of fibers during mixing. This approach minimizes the risk of fiber clumping and ensures a consistent fiber distribution throughout the matrix. Additionally, precise mixing speeds and durations prevent damage to fiber integrity, further strengthening the material. This process may also include the use of plasticizers or super plasticizers (106), which improve the concrete's workability without compromising the alignment and effectiveness of the fibers. Such processing methods enable the FRC to achieve an optimal blend of flexibility and rigidity, contributing to enhanced load-bearing capacity and reduced risk of premature structural failure.

In accordance with the aspect of the present invention, the FRC composition formulated to perform exceptionally well under severe environmental conditions, including freeze-thaw cycles, high humidity, and aggressive chemical exposure. This durability makes it ideal for infrastructure projects, such as bridges, highways, and tunnels, as well as residential and commercial structures that demand high structural reliability.

In accordance with the aspect of the present invention, the FRC composition is versatile enough to be used for both new construction and repair or rehabilitation of existing structures, making it an effective solution for enhancing and prolonging the service life of diverse construction projects. By reducing the frequency of maintenance and repairs, the invention offers a cost-effective and sustainable approach to concrete reinforcement, addressing the growing need for resilient building materials in the construction industry.

In accordance with the aspect of the present invention, the high-performance FRC composition advances the capabilities of traditional concrete by providing a reliable and durable material that meets the increasing demands of modern construction. The composition's unique fibre blend and innovative processing techniques offer substantial improvements in structural strength, durability, and environmental resistance, positioning it as an invaluable asset for a wide range of applications in infrastructure, residential, and commercial sectors.

Further objects, features, and advantages of the invention will be readily apparent from the following description of the preferred embodiments thereof, taken in conjunction with the accompanying drawings.

Brief Summary of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 illustrates the mixing process for the high-performance fiber-reinforced concrete (FRC) composition, in accordance with an exemplary embodiment of the present invention.

Detailed Description of the Invention

The detailed description of the invention presents a comprehensive view of an automated system designed to revolutionize the production of short news videos, primarily for consumption on digital platforms such as social media. The invention significantly automates the production process, integrating advanced technological components that streamline operations from the capturing of footage to the editing and publishing stages.

According to an exemplary embodiment of the present invention, an advanced fibre-reinforced concrete (108) (FRC) composition designed to improve the structural performance and durability of concrete in various construction applications. This high-performance FRC composition incorporates a blend of synthetic and natural fibres into a cementitious matrix (102), resulting in enhanced crack resistance, load-bearing capacity, and long-term structural integrity. By leveraging the unique properties of each fibre type, the invention achieves a balanced and robust concrete mix that addresses common durability issues encountered in traditional concrete.

In accordance with the exemplary embodiment of the present invention, the cementitious matrix (102) used in this FRC composition consists of Ordinary Portland Cement (OPC) combined with supplementary pozzolanic materials, such as fly ash and silica fume. These additives improve the concrete's strength and durability while reducing its environmental footprint. Fine and coarse aggregates are also included to meet specific grading requirements and enhance the mechanical properties of the concrete. The fiber blend within the matrix includes both synthetic fibers, such as polypropylene, polyethylene, or polyvinyl alcohol (PVA), and natural fibers (104) like sisal or coconut coir (101), or bamboo fibers. The synthetic fibers contribute tensile strength and crack resistance, while the natural fibers offer additional bonding properties and environmental sustainability.
In accordance with the exemplary embodiment of the present invention, the unique combination of synthetic and natural fibers, constituting between 1-5% of the total volume of the mix, optimizes the structural performance of the concrete. The synthetic fibers resist tensile stresses and prevent micro-cracking, while the natural fibers promote superior bonding within the cement matrix, contributing to a more homogenous structure. By improving both tensile and compressive properties, this fiber combination allows the FRC composition to withstand dynamic loads, environmental wear, and mechanical stresses that would typically degrade conventional concrete.

In accordance with the exemplary embodiment of the present invention, the fiber distribution and bonding, the composition includes a specific mixing and processing methodology. The process begins by pre-wetting the natural fibers, which enhances their bonding capability within the cementitious matrix (102). This step is crucial in ensuring that natural fibers do not absorb excessive water from the mix, which could otherwise lead to reduced durability. Following this, fibers are gradually added to the concrete mix to ensure even dispersion and prevent fiber clumping. Controlled mixing speeds (105) and durations are applied to maintain fiber integrity, thereby enhancing the FRC's structural properties. Plasticizers or super plasticizers (106) may be incorporated to improve the workability of the mix without affecting fiber alignment or distribution. This controlled process results in a uniform matrix with consistent fiber distribution, which is essential for achieving optimal strength and durability in the final product.

In accordance with the exemplary embodiment of the present invention, the high-performance FRC composition has been rigorously tested for its ability to withstand challenging environmental conditions. Specifically, it demonstrates remarkable durability under freeze-thaw cycles, high humidity, and chemical exposure. These characteristics make it ideally suited for infrastructure projects where environmental stresses can lead to rapid material degradation. The FRC composition is also effective for residential and commercial applications, where reduced maintenance and long-term reliability are essential. Additionally, the composition's versatility allows it to be used both in new construction projects and in the repair or rehabilitation of existing structures, thereby enhancing the lifespan of buildings, bridges, highways, and other structures.

In accordance with the exemplary embodiment of the present invention, the high-performance FRC composition offers a substantial advancement over traditional concrete, providing improved structural integrity, enhanced crack resistance, and superior environmental resilience. The optimized fiber blend and innovative processing techniques enable the FRC to meet the rigorous demands of modern construction, offering a sustainable, cost-effective solution for a wide range of applications in infrastructure, residential, and commercial sectors. This invention represents a valuable contribution to the field of construction materials, addressing the growing need for durable, reliable, and low-maintenance concrete solutions in an increasingly demanding construction environment.
, Claims:5. CLAIMS
I/We Claim
1. A high-performance fiber-reinforced concrete composition comprising:
a. a cementitious matrix (102) including Ordinary Portland Cement (OPC) and pozzolanic materials selected from the group consisting of fly ash and silica fume;
b. fine and coarse aggregates meeting specific grading requirements;
c. a blend of synthetic fibers and natural fibers, wherein the synthetic fibers are selected from polypropylene, polyethylene, or polyvinyl alcohol (PVA) fibers, and the natural fibers (104) are selected from sisal or coconut coir (101), or bamboo fibers, said fiber blend comprising between 1-5% by volume of the total concrete composition;
d. wherein the synthetic fibers provide tensile strength and crack resistance, and the natural fibers enhance bonding within the matrix, resulting in a concrete composition with improved crack resistance, load-bearing capacity, and environmental durability.

2. The fiber-reinforced concrete composition as claimed in claim 1, wherein the water-to-cement ratio of the composition is in the range of 0.3 to 0.5, optimized to facilitate fiber dispersion and reduce shrinkage.

3. The fiber-reinforced concrete composition as claimed in claim 1, further comprising plasticizers or super plasticizers (106) in an effective amount to improve the workability of the composition without compromising fiber alignment and distribution.

4. The fiber-reinforced concrete composition as claimed in claim 1, wherein the synthetic and natural fibers are pre-wetted prior to mixing to enhance bonding within the cementitious matrix (102) and prevent water absorption from the mix.
5. The fiber-reinforced concrete composition as claimed in claim 1, wherein the blend of synthetic and natural fibers is gradually added to the mix during the controlled mixing process, allowing for even fiber dispersion and minimizing fiber clumping.

6. The fiber-reinforced concrete composition as claimed in claim 1, wherein the mixing process involves controlled mixing speeds (105) and durations to maintain fiber integrity and prevent degradation of the natural fibers.

7. The fiber-reinforced concrete composition as claimed in claim 1, wherein the synthetic fibers contribute to tensile strength and load-bearing capacity, resulting in a compressive strength increase of 15-20% over conventional concrete.

8. The fiber-reinforced concrete composition as claimed in claim 1, wherein the concrete composition demonstrates enhanced performance under freeze-thaw cycles, high humidity, and exposure to chemicals, thereby extending the service life of the concrete in demanding environmental conditions.

9. The fiber-reinforced concrete composition as claimed in claim 1, wherein the composition is suitable for infrastructure applications, including bridges, highways, and tunnels, where enhanced durability and reduced maintenance are critical.

10. The fiber-reinforced concrete composition as claimed in claim 1, wherein the composition is applicable in both new construction and the repair or rehabilitation of existing structures, providing enhanced durability and structural integrity in a wide range of residential and commercial construction applications.

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