Insulated composite reinforcement material
View Patent ↗An insulated composite material for structural reinforcement applications is provided. The insulated composite material includes a fiber reinforced composite material and a cementitious insulating layer applied over the composite material. Also provided is a structural member reinforced with the insulated composite material and a method of reinforcing a structural member with the insulated composite material.
1. An insulated composite reinforcement material comprising:
a fiber reinforced polymer composite material; and
an insulating layer comprising a hydraulic cementitious material applied over at least a portion of the fiber reinforced polymer composite reinforcement material, wherein said insulated composite material achieves a 4 hour fire rating as tested in accordance with ASTM E119.
2. The insulated composite reinforcement material of claim 1 , wherein said polymer is selected from the group consisting of epoxy, acrylic, vinyl ester, polyester, furan, polyurethane, and mixtures thereof.
3. The insulated composite reinforcement material of claim 1 , wherein said fiber is selected from the group consisting of aramid fibers, carbon fibers, metal fibers, glass fibers, and mixtures thereof.
4. The insulated composite reinforcement material of claim 3 , wherein said fibers are provided in the form of an open woven fiber fabric.
5. The insulated composite reinforcement material of claim 4 , wherein said open woven fiber fabric comprises an open woven carbon fiber fabric.
6. The insulated composite reinforcement material of claim 5 , wherein said composite material comprises a carbon fiber fabric reinforced epoxy composite material.
7. The insulated composite reinforcement material of claim 1 , wherein said cementitious material comprises a hydraulic mortar.
8. The insulated composite reinforcement material of claim 7 , wherein said mortar comprises treated shell sand and a hydraulic binder.
9. The insulated composite reinforcement material of claim 8 , wherein said hydraulic binder comprises Portland cement.
10. The insulated composite reinforcement material of claim 6 , wherein said cementitious material comprises a hydraulic mortar.
11. The insulated composite reinforcement material of claim 10 , wherein said mortar comprises treated shell sand and a hydraulic binder.
12. The insulated composite reinforcement material of claim 1 , further comprising an intermediate bonding agent applied over the fiber reinforced polymer composite material and over which is bonded the insulation material.
13. The insulated composite reinforcement material of claim 1 , further comprising an intumescent layer applied over the insulating layer.
14. The insulated composite reinforcement material of claim 12 , wherein said intermediate bonding material is selected from the group consisting of silica sand and fiber.
15. A reinforced structural member comprising:
a structural member;
a fiber reinforced polymer composite material applied over at least a portion of said structural member; and
an insulating layer comprising a hydraulic cementitious material applied over at least a portion of the a fiber reinforced polymer composite material, wherein the reinforced structural member achieves a 4 hour fire rating as tested by ASTM E119.
16. The reinforced structural member of claim 15 , wherein said structural member is selected from the group consisting of columns, beams, slabs and walls.
17. The reinforced structural member of claim 16 , wherein said structural member is a column.
18. The reinforced structural member of claim 15 , wherein said polymer is selected from the group consisting of epoxy, acrylic, vinyl ester, polyester, furan, polyurethane, and mixtures thereof.
19. The reinforced structural member of claim 15 , wherein said fiber is selected from the group consisting of aramid fibers, carbon fibers, metal fibers, glass fibers, and mixtures thereof.
20. The reinforced structural member of claim 19 , wherein said fibers are provided in the form of an open woven fiber fabric.
21. The reinforced structural member of claim 20 , wherein said open woven fiber fabric comprises an open woven carbon fiber fabric.
22. The reinforced structural member of claim 15 , wherein said composite material comprises a carbon fiber fabric reinforced epoxy composite material.
23. The reinforced structural member of claim 15 , wherein said hydraulic cementitious material comprises a hydraulic mortar.
24. The reinforced structural member of claim 22 , wherein said cementitious material comprises a hydraulic mortar.
25. The reinforced structural member of claim 24 , wherein said hydraulic mortar comprises treated shell sand and a hydraulic binder.
26. The reinforced structural member of claim 25 , wherein said hydraulic binder comprises Portland cement.
27. The reinforced structural member of claim 15 , further comprising an intumescent layer applied over the insulating layer.
28. A method for reinforcing and insulating a structural member comprising:
applying a fiber reinforced polymer composite material over at least a portion of said structural member; and
applying an insulating layer comprising a hydraulic cementitious material over at least a portion of the fiber reinforced polymer composite material to provide a 4 hour fire rating as tested by ASTM E119.
29. The method for reinforcing and insulating a structural member of claim 28 , wherein said hydraulic cementitious material comprises a hydraulic mortar.
30. The method for reinforcing and insulating a structural member of claim 28 , further comprising application of an intumescent layer over the insulating layer.