Wall reinforcement apparatus and method using composite materials

• US 6,418,684 B1
• Filed: 10/27/2000
• Issued: 07/16/2002
• Est. Priority Date: 02/16/1999
• Status: Expired due to Term

• Current Assignee: Nationwide Reinforcing Ltd
• Original Assignee: Engineered Composite Systems Incorporated
• Inventors: Morton, Steven E.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): KATCHEVES, BASIL S
• Application Number:
  US09/697,966
• Time in Patent Office: 627 Days
• Field of Search: 522/932
• US Class Current: 52/293.2
• CPC Class Codes: E04G 2023/0251 by using fiber reinforced plastic elements
• CPC Class Codes: E04G 2023/0262 Devices specifically adapted for anchoring the fiber reinforced plastic elements, e.g. to avoid peeling off
• CPC Class Codes: E04G 23/0218 Increasing or restoring the load-bearing capacity of building construction elements E04G23/0203 and E04G23/0266 take precedence

Abstract

A wall reinforcing method including reinforcing members adhered to the wall. The reinforcing members are either pre-cured composite plates or composite members formed in situ, that is, a fabric of reinforcing fibers that is saturated with an adhesive to form the matrix of the composite and to adhere the reinforcement to the wall. The in situ members are either strips of fabric or wide sheets that cover most of the wall. The spacing of the reinforcing members is determined, in one embodiment, by an array of spacing distances. The array, which is preferably in table form, is consulted by the installer who first measures some of the wall parameters and environmental characteristics.

Claims

1. A method of reinforcing a wall having an interior wall surface against a force having a component substantially perpendicular to the wall, the method comprising:

(a) forming an array of spacing distances, each of which represents a distance between a first reinforcing member and a second reinforcing member that is sufficient to reinforce the wall, said spacing distances being based upon the characteristics of the wall and its environment, and said reinforcing members being made of a polymer matrix reinforced by embedded fibers;

(b) selecting from the array a spacing distance based upon at least one wall parameter;

(c) disposing a first major surface of the first reinforcing member in a substantially parallel, facing orientation relative to the interior wall surface;

(d) applying adhesive to at least one of said surfaces;

(e) forcing the first major surface of the first reinforcing member against the interior wall surface to mount the reinforcing member in a facing relationship to the interior wall surface with the adhesive interposed between the reinforcing member and the wall;

(f) disposing a first major surface of the second reinforcing member in a substantially parallel orientation relative to the interior wall surface and facing the interior wall surface;

(g) applying adhesive to at least one of said surfaces; and

(h) forcing the first major surface of the second reinforcing member against the interior wall surface to mount the reinforcing member at a distance from the first reinforcing member substantially equal to the selected spacing distance in a facing relationship to the interior wall surface with the adhesive interposed between the reinforcing member and the wall.

2. The method in accordance with claim 1, further comprising:

(a) disposing a major surface of each of a plurality of reinforcing members in a substantially parallel, facing orientation relative to the interior wall surface;

(b) applying adhesive to at least one of said surfaces;

(c) forcing each of the major surfaces of the reinforcing members against the interior wall surface to mount the reinforcing members in a facing relationship to the interior wall surface, wherein each of said reinforcing members is spaced from each adjacent reinforcing member a distance substantially equal to the spacing distance.

3. The method in accordance with claim 1, wherein the reinforcing member is formed by applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to an elongated strip of reinforcing fibers, said resin adhesive absorbing into and adsorbing onto the strip.

4. The method in accordance with claim 1, wherein the reinforcing member is a plate made of a cured polymer matrix reinforced by embedded fibers.

5. The method in accordance with claim 4, further comprising abrading the first major surface of the rigid plate for increasing the surface area of the first major surface to enhance the adhesion of the adhesive to the plate.

6. The method in accordance with claim 4, further comprising mounting at least one fastener to the plate and the wall, said fastener extending into an opening in the wall.

7. The method in accordance with claim 1, wherein the array is in the form of a table.

8. The method in accordance with claim 1, wherein the array is in the form of data stored in retrievable computer memory.

9. The method in accordance with claim 1, further comprising preparing the interior wall surface for attachment of the reinforcing member thereto.

10. The method in accordance with claim 9, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by mechanically cleaning the surface.

11. The method in accordance with claim 9, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by chemically cleaning the surface.

12. A method of reinforcing a wall having an interior surface against a force having a component substantially perpendicular to the wall, the method comprising:

(a) applying a paste adhesive having viscosity greater than about 20,000 cps to a selected area of the interior wall surface;

(b) applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to an elongated strip of reinforcing fibers, said resin adhesive absorbing into and adsorbing onto the strip;

(c) disposing a first major surface of the strip in a substantially parallel, facing orientation relative to the interior wall surface at the selected area; and

(d) forcing the first major surface of the strip against the selected area of the interior wall surface to mount the strip in a facing relationship to the interior wall surface.

13. The method in accordance with claim 12, further comprising:

(a) applying a paste adhesive having viscosity greater than about 20,000 cps to a plurality of selected areas of the interior wall surface;

(b) applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to a plurality of elongated strips of reinforcing fibers, said resin adhesive absorbing into and adsorbing onto the strips;

(c) disposing a major surface of each of the strips in a substantially parallel, facing orientation relative to the interior wall surface at the selected areas onto which the paste adhesive is applied; and

(d) forcing the major surfaces of the strips against the selected areas of the interior wall surface to mount the strips in a facing relationship to the interior wall surfaces.

14. The method in accordance with claim 12, further comprising preparing the interior wall surface for attachment of the strip thereto.

15. The method in accordance with claim 14, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by mechanically cleaning the surface.

16. The method in accordance with claim 14, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by chemically cleaning the surface.

17. A method of reinforcing a wall having an interior surface against a force having a component substantially perpendicular to the wall, the method comprising:

(a) forming an array of spacing distances, each of which represents a distance between a first elongated strip of reinforcing fibers and a second elongated strip of reinforcing fibers that is sufficient to reinforce the wall, said spacing distances being based upon the characteristics of the wall and its environment;

(b) selecting from the array a spacing distance based upon at least one wall parameter;

(c) applying a paste adhesive having viscosity greater than about 20,000 cps to a first selected area on the interior wall surface;

(d) applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to the first strip, said resin adhesive absorbing into and adsorbing onto the first strip;

(e) disposing a first major surface of the first strip in a substantially parallel, facing orientation relative to the interior wall surface;

(f) forcing the first major surface of the first strip against the interior wall surface at the first selected area to mount the first strip in a facing relationship to the interior wall surface with at least one of the adhesives interposed between the first strip and the wall;

(g) applying a paste adhesive having viscosity greater than about 20,000 cps to a second selected area of the interior wall surface spaced from the first selected area a distance substantially equal to the selected spacing distance;

(h) applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to the second strip, said resin adhesive absorbing into and adsorbing onto the second strip;

(i) disposing a first major surface of the second strip in a substantially parallel, facing orientation relative to the interior wall surface; and

(j) forcing the first major surface of the second strip against the interior wall surface at the second selected area to mount the second strip in a facing relationship to the interior wall surface with at least one of the adhesives interposed between the second strip and the wall.

18. The method in accordance with claim 17, further comprising:

(a) applying a paste adhesive having viscosity greater than about 20,000 cps to a plurality of areas of the interior wall surface, said plurality of areas spaced from each other a distance substantially equal to the selected spacing distance;

(b) applying a saturating resin adhesive having a viscosity substantially equal to or less than about 20,000 cps to a plurality of strips, said resin adhesive absorbing into and adsorbing onto the plurality of strips;

(c) disposing a major surface of each of the plurality of strips in a substantially parallel, facing orientation relative to the interior wall surface; and

(d) forcing each major surface of the plurality of strips against the interior wall surface at one of the selected areas, one strip per selected area, to mount the plurality of strips in a facing relationship to the interior wall surface with at least one of the adhesives interposed between the strips and the wall.

19. The method in accordance with claim 17, wherein said array is in the form of a table.

20. The method in accordance with claim 17, wherein the array is in the form of data stored in retrievable computer memory.

21. The method in accordance with claim 17, further comprising preparing the interior wall surface for attachment of the reinforcing strips thereto.

22. The method in accordance with claim 21, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by mechanically cleaning the surface.

23. The method in accordance with claim 21, wherein the step of preparing the interior wall surface comprises removing matter from the interior wall surface by chemically cleaning the surface.