Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/38—Connections for building structures in general
  • E04B1/383—Connection of concrete parts using adhesive materials, e.g. mortar or glue
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/04—Portland cements
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
  • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
  • C04B2201/52—High compression strength concretes, i.e. with a compression strength higher than about 55 N/mm2, e.g. reactive powder concrete [RPC]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor

Definitions

• the present invention relates to a manufacturing method and a structural member.
• structural elements that can be composed of metal parts assembled together by bolting; there are also structural elements that can be composed of wooden parts assembled together by gluing.
• UHPFRC Ultra-High Performance Concrete Reinforced Fiber
• the technical problem aims to achieve structural elements for works subject to strong constraints.
• the applicant has found that it is possible, surprisingly, to produce such structural elements by bonding concrete parts.
• the invention relates to a method of manufacturing a structural element in which at least two concrete modules are assembled by gluing, the compressive strength of the concrete being greater than 80 MPa.
• the compressive strength of the concrete is greater than 90 MPa, preferably greater than 100 MPa.
• the method comprises, before bonding the modules, a step of producing at least one of the flat modules.
• the method comprises a step of heat treatment of at least one of the modules.
• the modules are glued to each other by their facing face, the method comprising a step of treating at least one of the faces of at least one of the modules.
• the step of treating at least one of the faces of at least one of the modules is carried out by sandblasting, shot blasting or application of a retarder then washing after completion of the module.
• the method comprises a step of reinforcing the structural element by external or internal reinforcement to at least one of the modules.
• the concrete is a concrete with very high performance.
• the concrete is an ultra-high performance concrete.
• the concrete comprises fibers.
• the invention also relates to a structural element comprising at least two bonded concrete modules, the compressive strength of the concrete being greater than 80 MPa.
• the compressive strength of the concrete is greater than 90 MPa, preferably greater than 100 MPa.
• the concrete is a concrete with very high performance.
• the concrete is an ultra-high performance concrete.
• the concrete comprises fibers.
• the fibers are made of a material chosen from the group consisting of metallic material, mineral material or organic material.
• the glue is structural glue.
• the modules comprise an internal or external reinforcement.
• the interface between the modules is a broken line in section.
• the described element is obtained according to the process described above. According to one variant, the concrete used will be described below.
• the invention also relates to the structural element obtained by the method described above.
• FIG. 3 an example of an interface within the structure element.
• the invention relates to a method of manufacturing a structural element in which at least two concrete modules are assembled by gluing, the compressive strength of the concrete being greater than 80 MPa.
• the process offers an alternative to already known manufacturing processes.
• the method makes it possible to produce a structural element more easily from unitary modules that are simpler to manufacture.
• the fact of using a concrete whose resistance is greater than 80 MPa allows the realization of modules whose own weight is less which reduces the permanent stress in the glue; the strength of the structural element is therefore better than with conventional concrete.
• FIG. 1 shows a structural element 10.
• the element 10 comprises at least two modules 12 bonded together by adhesive joints 13.
• the modules 12 are preferably made of concrete whose compressive strength of the concrete is greater than 80 MPa; for example, concrete is a very high performance concrete or ultra-high performance fiber concrete, a definition of which will be given below.
• the element 10 is easily obtained because the modules 12 are of a simple shape to obtain. Indeed, the modules 12 can have simple geometric shapes which makes their individual construction easy; the modules 12 are for example parallelepipeds whose construction formwork is simple to achieve.
• Structure element means an assembly used in the construction of a structure.
• the structural element may in particular be a beam.
• the structural element may also be a decorative element or an autonomous concrete element having a specific function.
• the structural element is a collage assembly of units called modules. These modules can be manufactured separately.
• the structural elements are generally subject to very important constraints.
• the element 10 may comprise two modules 12 or more glued together.
• the bonding of the modules makes it possible to transmit from one module to the other the forces undergone by the structural element 10.
• the assembly by bonding between the modules makes it possible to transmit tensile or compressive forces via the seal glue, stressed in shear. Bonding thus ensures continuity in the transmission of efforts from one module to another.
• the element 10 comprises four modules 12, referenced 121, 122, 123, 124.
• the element 10 is for example a beam
• Figure 1 is a cross section.
• the modules 12 may be parallelepipeds with several faces, the modules being glued together according to one of their faces.
• the modules 12 have at least one face partially bonded with another unitary module 12.
• the modules 12 may also have several faces partially bonded with other modules 12.
• the module 121 has a face facing the module 122; the face of the module 121 is partially glued to the module 122.
• the module 122 is bonded by two of its faces respectively to the modules 121 and 123.
• the modules 121 and 123 are assembled to the module 124 by gluing; in particular the modules 121 and 123 are fixed to the module 124 by embedding.
• Two grooves are formed on one of the faces of the module 124, the modules 121 and 123 being inserted and glued in these grooves.
• the glue 13 used is for example structural adhesive (in particular epoxy, polyurethane, or a mineral binder, such as for example a high performance concrete or ultra high performance).
• a mineral binder based adhesive is preferably used.
• an epoxy adhesive is preferably used.
• the structural adhesive has sufficient strength to make structural joints.
• An assembly bonded with structural glue is able to withstand significant efforts.
• the method of manufacturing the structural element comprises a step of bonding the modules; this step is performed by applying glue on the face of at least one of the two modules.
• the glue (and the primer if applicable) can be applied to one of the two faces of the modules to be glued; preferably, the adhesive (and the primer if applicable) is applied to both faces of the modules to be bonded. Then the two modules are pressed towards each other.
• one of the modules is placed on the other so as to benefit from weightlessness to promote gluing.
• the advantage is that the assembly is easy because we can assemble small modules easily manipulable. Indeed, because of the use of concrete whose resistance is greater than 80 MPa, it is possible to make less bulky modules which reduces the weight of the modules; this makes it possible to manipulate the modules without lifting means. this is
• the method makes it possible to locally reinforce the structural element.
• the method allows to add additional modules at a given location of the structural element.
• the module 124 may be locally reinforced by gluing additional modules.
• the advantage is therefore to be able to thin the structural element in a place where the efforts are less and to be able to strengthen the structural element in a place where efforts are more important.
• the method further comprises, before bonding the modules, a step of producing at least one of the flat concrete modules.
• the concrete is fiber
• the fibers will be oriented in the horizontal plane of the module 124. which increases the flexural strength of the module 124.
• the preferential fiber is obtained by a compromise between the formulation of the fiber concrete, the geometry of the modules and the casting method adopted. By casting thin elements, flat with a mixture flowing lengthwise, the fibers will be placed in the plane and have an orthotropic orientation. Also it is possible to make a large module and cut this module into modules of smaller sizes, according to the needs.
• Modules can also be manufactured differently; for example the modules can be manufactured by injection into a closed mold in any position, or by extrusion.
• the method may comprise a heat treatment step of at least one of the modules.
• This has the advantage of accelerating the mechanism of hydration of the binder and consequently of stabilizing the withdrawals of the material.
• the modules thus quickly acquire their final dimensions, which makes it possible to accelerate the manufacture of the structural element by gluing. This makes it possible to prevent the glue joints from working and being damaged by the stresses generated by the limited delayed deformations inherent in the concretes.
• the method may also comprise, before bonding, a step of treating at least one of the faces of at least one of the modules to be bonded.
• the facing faces of the modules to be bonded are processed.
• the treatment makes it possible to improve the adhesion of the glue on the modules; indeed, the surface treatment makes it possible to modify the surface state by removing the layer of skin created by the molding of the module.
• the treatment makes it possible to prevent the glue from being applied to a smooth surface as it appears on leaving the formwork of the module; the treatment is a treatment that makes the surface on which the glue is applied rougher. For example, the treatment is carried out by shot blasting or sanding.
• One or more modules may comprise a reinforcement 16. This makes it possible to increase the resistance of the module or modules, and therefore to increase the resistance of the structural element.
• the reinforcement 16 may be made of metal (metal fittings) or composite (glass fibers, carbon fibers 1 de- coated, epoxy).
• This reinforcement 16 may be internal to at least one module.
• This reinforcement 16 integrated within a module can be passive or active (preload by pre-tension).
• the reinforcement 16 may also be external to at least one module. In the latter case, it is possible to strengthen the structural element by inserting during bonding the external reinforcement to the concrete. Metal or composite plates can thus be glued.
• the external reinforcement 16 can also be reported after bonding the concrete modules. Post-tensioning prestressed cables can be slid in the long direction of the bonded structural element (either externally or in bookings made in the modules during their manufacture). Concrete can contain fibers.
• the fibers used in the concrete may be metal, organic or mineral fibers.
• the fibers make it possible to improve the transfer of forces between the concrete and the continuous reinforcement, in particular when the thicknesses of concrete are small.
• the nature of the fibers used may vary from one module to another depending on the performance expected for each of them. Mixtures of different kinds of fibers are possible.
• FIG. 2 shows another exemplary embodiment of the structural element 10.
• the element 10 is another example of a beam obtained from modules of smaller dimension.
• the element 10 comprises modules 121, 122, 123, 124, 125, 126.
• the modules 124, 125, 126 are for example less thick than the modules 121, 122, 123.
• the modules 121, 122, 123 are glued between
• the modules 124, 125, 126 are also glued together by glue joints 13, but also glued to the modules 121, 122, 123 by glue joints 13.
• the joints glue 13 between the modules 121, 122, 123 are offset relative to the glue joints 13 between the modules 124, 125, 126. This reinforces the polluting areas between the modules 121, 122, 123.
• the modules 121, 122 , 123 allow for example to achieve a beam of a certain length, with unit modules of smaller length, which facilitates the construction of the beam.
• the modules 124, 125, 126 make it possible to reinforce and stiffen the beam formed by the modules 121, 122, 123; the use of modules 124, 125, 126 facilitates bonding with the beam, because they are easier to handle during bonding.
• Reinforcement 16 may also be implemented in one or more modules.
• the modules are made of concrete with a compressive strength greater than or equal to 80 MPa. Preferably, the compressive strength is greater than 90 MPa, preferably greater than 100 MPa. Concrete is for example concrete to very high performance (abbreviated BTHP).
• the modules 12 may also be ultra-high performance concrete, particularly ultra-high performance fiber concrete (abbreviated BFUP).
• the modules 12 are for example at least 2 cm thick, preferably between 2 and 10 cm thick, preferably between 2 and 4 cm thick. This allows to embed the frames and arrange them closest to the lower surface of the modules. This also makes it possible to promote the orthotropic orientation of the fibers during casting.
• Very high performance concretes comprise a cement matrix as described below. Their compressive strength is greater than 80 MP, preferably greater than 90 MPa, preferably greater than 100 MPa.
• Ultra-high performance fiber concretes are concretes having a cement matrix as described below containing fibers. It is referred to the document entitled "Ultra High Performance Fibers" of the Road and Motorway Technical Studies Department (Setra) and the French Association of Civil Engineering (AFGC). The resistance of these concretes to compression is greater than 120 MPa, generally greater than 150 MPa.
• the fibers are metallic, organic, or a mixture of both.
• the binder dosage is high (the E / C ratio is low, generally the E / C ratio is at most about 0.3).
• the cementitious matrix generally comprises cement (Portland), a pozzolanic reaction element (in particular fumed silica) and a fine sand.
• the respective dimensions are selected intervals, depending on the nature and the respective quantities.
• the cementitious matrix may comprise: Portland cement of fine sand - a fumed silica element, possibly quartz flour and / or a limestone filler, the quantities being variable and the dimensions of the various elements being chosen between the range micron or submicron and millimeter, with a maximum dimension not exceeding in general 5mm. a superplasticizer being added in general with the mixing water.
• the fibers have characteristics of length and diameter such that they effectively confer the expected mechanical characteristics. Their quantity is generally low, for example between 1 and 8% by volume.
• matrices are BPR, reactive powder concretes, while the examples of UHPC are BSI concrete from Eiffage, Ductal® from Lafarge, Cimax® from Italcementi and BCV from Vicat.
• concretes 1) those resulting from mixtures of a - a Portland cement selected from the group consisting of ordinary Portland cements called "CPA”, high performance Portland cements called “CPA-HP”, cements High-performance, quick-setting Portland “CPA-HPR” and Portland cements with low tricalcium aluminate (C3A) content, normal or high-performance, fast-setting type; b - a vitreous microsilica whose grains have for the most part a diameter in the range 100 A -0.5 micron, obtained as a by-product in the zirconium industry, the proportion of this silica being from 10 to 30% by weight; weight of the cement; c - a super reducing plasticizer agent and / or a fluidizing agent in an overall proportion of 0.3% to 3% (weight of dry extract relative to the weight of cement); d - a quarry sand consisting of quartz grains, most of which has a diameter in the range 0.08 mm - 1.0 mm; e - possibly
• the predominant granular elements have a maximum grain size D at most equal to 800 micrometers, in that the predominant metal fibers have an individual length 1 in the range 4 mm - 20 mm, in that the ratio R between the average length L of the fibers and said maximum size D of the granular elements is at least 10 and in that the quantity of the predominant metal fibers is such that the volume of these fibers is from 1.0% to 4.0% of the volume of the concrete after taking
• a - cement those resulting from the mixing of: a - cement; b - granular elements having a maximum grain size Dmax of at most 2 mm, preferably at most 1 mm; c - pozzolanic reaction elements having a size of elementary particles of at most 1 micron, preferably at most 0.5 microns; d - constituents capable of improving the toughness of the matrix chosen from acicular or platelet elements having an average size of at most 1 mm, and present in a volume proportion of between 2.5 and 35% of the cumulative volume of the elements granular (b) and pozzolanic reaction elements (c); e - at least one dispersing agent and satisfying the following conditions:
• the weight percentage of water E relative to the cumulative weight of cement (a) and elements (c) is in the range 8-24%;
• the ratio R between the average length L of the fibers and the maximum grain size Dmax of the granular elements is at least 10;
• the amount of fiber is such that its volume is less than 4% and preferably 3.5% of the volume of the concrete after setting.
• a - cement those resulting from the mixing of: a - cement; b - granular elements; c - pozzolanic reaction elements having a size of elementary particles of at most 1 micron, preferably at most 0.5 microns; d - constituents capable of improving the toughness of the matrix chosen from acicular or platelet elements having an average size of at most 1 mm, and present in a volume proportion of between 2.5 and 35% of the cumulative volume of the elements granular (b) and pozzolanic reaction elements (c); e - at least one dispersing agent; and satisfying the following conditions: (1) the weight percentage of water E relative to the cumulative weight of cement (a) and elements (c) is in the range 8-24%; (2) the fibers have an individual length L of at least 2 mm and an L / phi ratio, phi being the diameter of the fibers, of at least 20; (bis) the ratio R between the average length L of the fibers and the grain size D75 of all the constituents (a), (b),
• the organic fibers have an individual length L of at least 2 mm and an L / phi ratio, phi being the diameter of the fibers, of at least 20; (g) the ratio R between the average length L of the fibers and the maximum grain size D of the granular elements is at least 5, h) the amount of fibers is such that their volume represents at most 8% of the concrete volume after setting.
• a - cement those resulting from the mixing of: a - cement; b - granular elements; c - pozzolanic reaction elements having a size of elementary particles of at most 1 micron, preferably at most 0.5 microns; d - at least one dispersing agent; and satisfying the following conditions: the percentage by weight of water E relative to the cumulative weight C of cement (a) and elements (c) is in the range 8-24%; (2) the fibers have an individual length L of at least 2 mm and an L / phi ratio, phi being the diameter of the fibers, of at least 20; (3) the report
• R between the average length L of the fibers and the grain size D75 of all of the components (a), (b) and (c) is at least 5, preferably at least 10; (4) the amount of fiber is such that its volume is not more than 8% of the volume of the concrete after setting; (5) all the components (a), (b) and (c) have a grain size D75 of at most 2 mm, preferably at most 1 mm, and a grain size D50 of at least plus 150 ⁇ m, preferably not more than 100 ⁇ m.
• a - at least one hydraulic binder of the group consisting of Class G Portland cements (API), Portland Class H cements (API) and other low aluminate hydraulic binders b - a microsilica of particle size in the range 0.1 to 50 micrometers, at a rate of 20 to 35% by weight relative to the hydraulic binder, c - an addition of medium particles, mineral and / or organic, particle size in the range 0 , 5-200 micrometers at a rate of 20 to 35% by weight relative to the hydraulic binder, the amount of said addition of average particles being less than or equal to the amount of microsilica, -a super-plasticizer and / or water-soluble fluidifying agent in proportion between 1% and 3% by weight relative to the hydraulic binder, and water in an amount at most equal to 30% of the weight of the hydraulic binder.
• API Class G Portland cements
• API Portland Class H cements
• other low aluminate hydraulic binders b - a microsilica of particle size in the range
• the metal fibers have an average length Lm of at least 2 mm, and a ratio h / dl, d1 being the diameter of the fibers, of at least 20; (3) the Vi / V ratio of the volume Vi of the metal fibers to the volume V of the organic fibers is greater than
• the ratio Lrn / Lo of the length of the metal fibers to the length of the organic fibers is greater than 1; (4) the ratio R between the average length Lm of the metal fibers and the size Dg of the granular elements is at least 3; (5) the quantity of metal fibers is such that their volume is less than 4% of the concrete volume after setting and (6) the organic fibers have a melting point of less than 300 ° C, an average length Lo greater than 1 mm and a diameter C of at most 200 microns, the amount of organic fibers being such that their volume is between 0.1 and 3% of the volume of the concrete.
• a heat treatment (or cure) can be implemented on these concretes.
• the heat treatment comprises, after the hydraulic setting, heating at a temperature of 90 ° C. or more for several hours, typically 90 ° C. for 48 hours.
• FIG. 3 shows an exemplary interface within the structure element 10.
• the interface is between two modules 12 referenced 121 and 122.
• the interface is the zone located between two faces of different modules; the interface corresponds to the application area of the glue 13.
• the interface may comprise different forms. It can be a plane, the faces facing the modules being flat.
• the interface between the modules is flat and perpendicular to the plane of the figures; the interface may also be inclined relative to that shown.
• the structural element 10 is shown in section, the interface being a broken line (shear key).
• the modules comprise " grooves 18 and grooves 20 cooperating respectively with grooves 20 and grooves 18 of a module facing each other.This permits the mechanical effect (gearing effect) of the shear forces thus relieving the stresses in glue 13.
• the blocks of UHPC are made from a base formulation (premix 1: see Table 2) comprising 2% of metal fibers.
• the molds used are made of steel.
• the test pieces are demolded after 7 days. No specific treatment was performed.
• the average compressive strengths measured at 28 days on specimens with a diameter of 70 mm are 152 ⁇ 6 MPa for all series.
• the surface treatment by sandblasting is carried out after demolding at 7 days.
• the blocks are then glued using glue.
• a double gluing is performed (application of the glue on the two faces of concrete to be assembled).
• the specimens are then assembled vertically and then a horizontal pressure is exerted to remove any excess glue.
• the average thickness of the joints is evaluated at 0 ' .S mm for series 1 and 3, 0.5 mm for series 2 and 2 mm for series 4.
• test tubes of series 1 are maintained at a temperature of 60 ° C. ⁇ 2 in water for a period of 48 hours, and then they are tested (at 28 days).
• test tubes of series 2 are maintained at 20 ° C. for 7 days and then are tested at 28 days.
• test tubes of the 3 series are sanded then pasted at 7 days, preserved in water for 7 days, then tested at 28 days.
• test specimens are sanded at 7 days, glued at 35 days and tested at 65 days.
• the instrumentation makes it possible to evaluate the average slip along the glue joint during loading thanks to inductive displacement sensors LVDT (Linear Variable Differential Transformer) brand RDP®, stroke ⁇ 5 mm, precision 10-3 mm.
• LVDT Linear Variable Differential Transformer
• This sensor is disposed between the parts 123 and 122 of FIG.
• a force sensor 1000 IcN, precision ⁇ 1 IcN, is disposed between the press and the top of the central concrete block (above the element 122 of Figure 1).
• the information obtained by the various sensors is recorded by a Vishay 4000 acquisition chain with a frequency of 1 record per second throughout the loading.
• the latter is driven in displacement with a ramping speed of 0.5 mm / min.
• the use of flexible polyurethane glue provides an assembly 5 times more flexible but has however a resistance 9 times lower compared to the epoxy glue.
• the average breaking strength with polyurethane glue is 1.1 MPa and 9.7 MPa for epoxy bonding.
• the average tensile strength is 5.6 MPa with a very high rigidity of the assembly (3 times higher than that of epoxy bonding).
• a behavior of the elastic-fragile type assembly is noted.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Structural Engineering (AREA)
• Architecture (AREA)
• Ceramic Engineering (AREA)
• Physics & Mathematics (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Electromagnetism (AREA)
• Civil Engineering (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Rod-Shaped Construction Members (AREA)
• Ceramic Products (AREA)
• Bridges Or Land Bridges (AREA)

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