Repair of ballistic concrete panels

1. A ballistic panel formed with a ballistic material, the panel comprising:

a panel with a void, wherein the void is created by hits from projectiles;

wherein the void in the panel is filled with a ballistic replacement material such that the panel includes a filled void including the ballistic replacement material;

wherein the ballistic panel and the ballistic replacement material are formed from a concrete material with uniform density;

wherein the ballistic panel and the ballistic replacement material are formed from wet ballistic concrete prepared without an addition of preformed foam; and

wherein the filled void exhibits ballistic properties equivalent to the ballistic panel formed with the ballistic material.

2. The ballistic panel of claim 1 , wherein the uniform density of the ballistic replacement material and the ballistic material is between about 1121 kg/cubic meter (about 70 pounds per cubic foot) and about 1442 kg/cubic meter (about 90 pounds per cubic foot).

3. The ballistic panel of claim 1 , wherein the ballistic replacement material does not delaminate from adherence to the ballistic panel.

4. The ballistic panel of claim 1 , wherein the ballistic replacement material and the ballistic material are shatter-resistant when struck with a bullet between about 4 mm (.172 caliber) and about 12.7 mm (50 caliber), moving at between about 120 m/sec (390 ft/sec) and about 1,200 m/sec (3,900 ft/sec).

5. The ballistic panel of claim 1 , wherein the ballistic replacement material and the ballistic material comprise: about 1 part by mass Portland cement; about 0.5 to 1.5 part by mass of a fine aggregate; and about 0.0005 to 0.05 part by mass of an air entrainment additive.

6. The ballistic panel of claim 5 , further comprising about 0.005 to 0.05 part by mass aluminum hydroxide and about 0.005 to 0.05 part by mass calcium phosphate.

7. The ballistic panel of claim 5 , further comprising about 0.005 to 0.15 part by mass fiber.

8. The ballistic panel of claim 7 , wherein the fiber is a polyolefin fiber.

9. The ballistic panel of claim 8 , wherein the polyolefin fiber is a fibrillated fiber.

10. The ballistic panel of claim 5 , wherein the air entrainment additive is a mixture of a fatty acid ester and perlite.

11. The ballistic panel of claim 5 , wherein the ballistic replacement material and the ballistic material include air bubbles resulting from the air entrainment additive that are less than about 0.04 inches (1 mm) in diameter or greater than 0.0004 inches (10 microns) in diameter.

12. The ballistic panel of claim 5 , wherein the ballistic replacement material and the ballistic material include air bubbles resulting from the air entrainment additive that are between about 0.0004 inches (10 microns) in diameter and about 0.04 inches (1 mm) in diameter.

13. The ballistic panel of claim 1 , wherein the ballistic replacement material and the ballistic material are made without an addition of a wet foam comprising water, a foaming agent, and a foam stabilizing agent.

14. The ballistic panel of claim 1 , wherein the ballistic replacement material does not delaminate from adherence to the ballistic panel.

15. The ballistic panel of claim 1 , wherein the ballistic replacement material is shatter-resistant when struck with a bullet between about 4 mm (.172 caliber) with muzzle velocity about 120 m/s (390 ft/s) and about 12.7 mm weighing 600-800 grains (40-50 g) (50 caliber) with muzzle velocity of 2800-3100 feet/sec (850-950 m/s) and kinetic energy of 12,000-15,000 foot-pounds (17-21 kJ).

16. A ballistic panel formed with a ballistic material, the panel comprising:

a panel with a void, wherein the void is created by hits from projectiles;

wherein the void in the panel is filled with a ballistic replacement material such that the panel includes a filled void including the ballistic replacement material;

wherein the ballistic panel and the ballistic replacement material are formed from a concrete material with uniform density;

wherein the ballistic panel and the ballistic replacement material are formed from wet ballistic concrete prepared without an addition of preformed foam;

wherein the filled void exhibits ballistic properties equivalent to the ballistic panel formed with the ballistic material;

wherein the ballistic replacement material and the ballistic material comprise between about 1121 kg/cubic meter (about 70 pounds per cubic foot) and about 1442 kg/cubic meter (about 90 pounds per cubic foot); and

wherein the ballistic replacement material and the ballistic material comprise: about 1 part by mass Portland cement; about 0.5 to 1.5 part by mass fine aggregate; and about 0.0005 to 0.05 part by mass air entrainment additive; about 0.005 to 0.15 part by mass fiber; about 0.005 to 0.05 part by mass aluminum hydroxide and about 0.005 to 0.05 part by mass calcium phosphate.

17. The ballistic panel of claim 16 , wherein the fiber is a polyolefin fiber.

18. The ballistic panel of claim 17 , wherein the polyolefin fiber is a fibrillated fiber.

19. The ballistic panel of claim 16 , wherein the air entrainment additive is a mixture of a fatty acid ester and perlite.

20. The ballistic panel of claim 16 , wherein the ballistic replacement material and the ballistic material have air bubbles resulting from an air entrainment additive that are between about 0.0004 inches (10 microns) in diameter and about 0.04 inches (1 mm) in diameter.