Polymer concrete pipe

1 . A polymer concrete pipe, comprising:

a unitary tubular member formed of polymer concrete and having a primary wall portion with a plurality of outer ribs projecting therefrom and extending therearound, the ribs formed of the polymer concrete and spaced apart along a length of the tubular member; and

a reinforcing member forming a discrete reinforcing region encased by the polymer concrete and localized in one of said ribs.

2 . The polymer concrete pipe of claim 1 further comprising a second reinforcing member forming a second discrete reinforcing region encased by polymer material and localized in the primary wall portion.

3 . The polymer concrete pipe of claim 1 wherein the ribs are spaced equidistant from each other.

4 . The polymer concrete pipe of claim 1 wherein the primary wall portion is substantially cylindrical.

5 . The polymer concrete pipe of claim 4 wherein the ribs extend circumferentially around the primary wall portion.

6 . The polymer concrete pipe of claim 5 wherein the reinforcing member extends circumferentially with the rib.

7 . The polymer concrete pipe of claim 6 wherein the reinforcing member has an inner diameter greater than an outer diameter of the wall portion.

8 . The polymer concrete pipe of claim 1 wherein the reinforcing member comprises steel.

9 . The polymer concrete pipe of claim 1 wherein the primary wall portion is non-cylindrical.

10 . The polymer concrete pipe of claim 1 wherein each rib includes a respective reinforcing member forming a discrete reinforcing region encased by polymer concrete and localized within said rib.

11 . A polymer concrete pipe, comprising:

a unitary tubular member formed of polymer concrete and having a primary wall portion with a plurality of ribs projecting therefrom and extending therearound, the ribs spaced apart along a length of the tubular member;

at least one layer of reinforcing steel within the primary wall portion; and

each projecting rib including at least one piece of reinforcing material arranged therein to carry tension and compression forces.

12 . The polymer concrete pipe of claim 11 wherein the ribs extend circumferentially around the primary wall portion.

13 . The polymer concrete pipe of claim 12 wherein the reinforcing material in each rib extends circumferentially with the rib.

14 . A method for manufacturing a polymer concrete pipe, comprising:

placing a reinforcing member and polymer concrete into a pipe form to produce, when cured, a polymer concrete pipe having a primary wall portion with a plurality of ribs projecting outwardly therefrom and extending therearound, the ribs spaced apart along a length of the pipe, the reinforcing member forming a discrete reinforcing region encased within polymer concrete and localized in one of said ribs to carry compression and tension forces.

15 . A method for manufacturing a polymer concrete pipe having strength comparable to a reference polymer concrete pipe having smooth walls, a thickness of X inches, and a length the same as the reference polymer concrete pipe utilizing polymer concrete having the same properties as polymer concrete of the reference polymer concrete pipe, the method comprising:

producing the polymer concrete pipe with a primary wall portion of a thickness of no more than ¾ X inches;

providing the polymer concrete pipe with a series of reinforcing ribs formed of the polymer concrete and extending from the outer side of the primary wall portion, each of ribs extending about the primary wall portion and including a reinforcing member forming a discrete reinforcing region encased by the polymer concrete and localized in an associated rib, the reinforcing member arranged to carry tension and compression forces;

wherein an amount of polymer concrete in the polymer concrete pipe is no more than eighty percent (80%) of an amount of polymer concrete in the reference polymer concrete pipe.

16 . The method of claim 15 wherein the primary wall portion is produced to include a second reinforcing member forming a second discrete reinforcing region encased by the polymer concrete and localized in the primary wall portion.

17 . A method for manufacturing a polymer concrete pipe having strength comparable to a reference polymer concrete pipe having smooth walls, a thickness of X inches and a layer of reinforcing steel near an inner side of the pipe, the polymer concrete pipe having a length the same as the reference polymer concrete pipe utilizing polymer concrete having the same properties as polymer concrete of the reference polymer concrete pipe, the method comprising:

producing the polymer concrete pipe with a primary wall portion of a thickness of no more than ¾ X inches, the primary wall portion including at least one layer of reinforcing material;

providing the polymer concrete pipe with a series of reinforcing ribs extending from the outer side of the primary wall portion, each of ribs extending about the primary wall portion and including one piece of reinforcing material arranged therein to carry tension and compression forces;

wherein an amount of polymer concrete in the polymer concrete pipe is no more than eighty percent (80%) of an amount of polymer concrete in the reference polymer concrete pipe.

18 . A polymer concrete pipe, comprising:

a unitary pipe member formed of polymer concrete and having a wall;

a reinforcing void form located in the pipe member to displace polymer concrete and to provide reinforcement to carry compressive and tensile stresses.

19 . The polymer concrete pipe of claim 18 wherein the reinforcing void form is helically wound within the wall.

20 . The polymer concrete pipe of claim 18 wherein the reinforcing void form comprising tubular steel has a cross-section that is round, triangular or rectangular.

21 . The polymer concrete pipe of claim 18 wherein the reinforcing void form comprises tubular metal or tubular fiberglass.

22 . The polymer concrete pipe of claim 20 wherein the wall includes a primary wall portion and a helical rib portion, the reinforcing void form is located at least partially in the helical rib portion.

23 . The polymer concrete pipe of claim 20 wherein the reinforcing void form comprises a series of spaced apart, circumferentially extending tubular members.

24 . A polymer concrete pipe, comprising:

a unitary pipe member formed of polymer concrete and having a primary wall portion defining an elongated pipe axis, and an outer rib extending helically relative to the pipe axis;

a reinforcing member located in the outer rib to provide reinforcement to carry compressive and tensile stresses.

25 . The polymer concrete pipe of claim 24 wherein the reinforcing member comprises a void form member.

26 . The polymer concrete pipe of claim 24 wherein the reinforcing member comprises a solid, rod-type member.

27 . A method for manufacturing a polymer concrete pipe, comprising:

placing at least one reinforcing void member within a pipe form,

introducing polymer concrete into the pipe form, whereby the presence of the reinforcing void form member displaces polymer concrete.