Inorganic matrix-fabric system and method

Abstract

A method of reinforcing a structural support, includes applying a reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix to the structural support. The AR-glass fibrous layer has a sizing applied thereon, and a resinous coating applied is applied over the sizing. The inorganic matrix is adherent to the resinous coating and the resinous coating is adherent to the sizing.

1 . A method of reinforcing a structural support, comprising applying a reinforcement system comprising an AR-glass fibrous layer embedded in an inorganic matrix to the structural support, wherein said AR glass fibrous layer has a sizing applied thereon, and a resinous PVC plastisol coating applied over said sizing, said inorganic matrix being adherent to said resinous coating, and said resinous coating being adherent to said sizing. 
   
   
       2 . The method of  claim 1 , wherein the fibrous layer is a bi-directional open fibrous layer having two rovings per inch in a weft direction and one roving per inch in a warp direction 
   
   
       3 . The method of  claim 1 , wherein the fibrous layer is a bi-directional open fibrous layer having one roving in a weft direction and one roving in a warp direction. 
   
   
       4 . The method of  claim 1 , wherein the fibrous layer is comprised of AR-glass yarns. 
   
   
       5 . The method of  claim 1 , wherein the fibrous layer is formed by needling, weaving, knitting, or adhesive bonding of cross laid mesh. 
   
   
       6 . The method of  claim 1 , wherein the fibrous layer is formed from continuous or discontinuous fibers randomly oriented in a non-woven mat. 
   
   
       7 . The method of  claim 1 , wherein the inorganic matrix comprises a cementitious material. 
   
   
       8 . The method of  claim 7 , wherein in the inorganic matrix includes a resin which forms an adhesive bond with said resinous coating. 
   
   
       9 . The method of  claim 1 , wherein the cementitious material includes chopped alkali-resistant glass fibers. 
   
   
       10 . The method of  claim 1 , wherein the coating comprises at least one polymer containing one or more of an acrylate and a vinyl chloride. 
   
   
       11 . The method of  claim 1 , wherein the structural support is comprised of an unreinforced masonry. 
   
   
       12 . The method of  claim 1 , wherein the structural support is comprised of concrete. 
   
   
       13 . The method of  claim 1 , wherein the structural support is comprised of bricks. 
   
   
       14 . The method of  claim 1 , wherein the inorganic matrix is applied in two or more layers. 
   
   
       15 . The method of  claim 1 , wherein the sizing comprises a blend of anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant 
   
   
       16 . A method of reinforcing a structural support, comprising:
 applying a first layer of an inorganic matrix to the structural support;   embedding a first AR-glass open fibrous layer into the matrix, said AR-glass fibrous layer having a sizing applied thereon, and a resinous coating applied over said sizing, said inorganic matrix being adherent to said resinous PVC plastisol coating, and said resinous coating being adherent to said sizing; and applying a second layer of the inorganic matrix to the first AR-glass open fibrous layer.   
   
   
       17 . The method of  claim 16 , wherein the steps of applying a first and second layer of the inorganic matrix includes trowelling the matrix. 
   
   
       18 . The method of  claim 16 , wherein the fibrous layer is embedded into the matrix by hand. 
   
   
       19 . The method of  claim 16 , further comprising:
 embedding a second AR-glass fibrous layer into the second layer of matrix; and   applying a third layer of the inorganic matrix to the second AR-glass fibrous layer.   
   
   
       20 . The method of  claim 16 , further comprising:
 embedding a third AR-glass fibrous layer into the third layer of the inorganic matrix, and   applying a fourth layer of the inorganic matrix to the third AR-glass fibrous layer.   
   
   
       21 . The method of  claim 19 , wherein the first and second fibrous layer is a bi-directional fibrous layer comprising two rovings of fibers per inch in the weft direction and one roving of fibers per inch in the warp direction. 
   
   
       22 . The method of  claim 21 , wherein one of the first or second fibrous layers is orientated so that the weft direction is parallel to the bottom of the support structure and the other of the first or second fibrous layers is orientated so that the weft direction is perpendicular to the bottom of the support structure. 
   
   
       23 . The method of  claim 21 , wherein one of the first or second fibrous layers is oriented at a clockwise 45° angle to the bottom of the structural support and the other of the first or second fibrous layers is oriented at a counterclockwise 45° to the bottom of the structural support. 
   
   
       24 . The method of  claim 20 , wherein each of the first, second and third fibrous layer is a bi-directional fibrous layer comprising two rovings of fibers in the weft direction and one roving of fibers in the warp direction, and wherein one of the fibrous layers is oriented at a clockwise 45° angle to the bottom of the structural support, one of the fibrous layers is oriented at a counterclockwise 45° angle to the bottom of the structural support, and one of the fibrous layers is oriented so that the weft direction of the fibrous layer is parallel to the bottom of the structural support. 
   
   
       25 . The method of  claim 16 , wherein the layers of inorganic matrix are approximately ⅛ inch thick. 
   
   
       26 . The method of  claim 16 , wherein the wetting step comprises spraying the structural support with water. 
   
   
       27 . The method of  claim 16 , further comprising wetting the structural support, and wherein the step of wetting the structural support is performed prior to applying the first layer of inorganic matrix. 
   
   
       28 . The method of  claim 16 , wherein the sizing comprises a blend of anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant. 
   
   
       29 . A method of reinforcing a structural support, comprising:
 applying a first layer of an inorganic matrix to the structural support;   embedding a first AR-glass open fibrous layer into the matrix, said AR-glass fibrous layer having a resinous PVC plastisol coating applied thereon, said inorganic matrix being adherent to said resinous PVC plastisol coating;   applying a second layer of the inorganic matrix to the first AR-glass open fibrous layer;   embedding a second AR-glass fibrous layer into the second layer of matrix; and   applying a third layer of the inorganic matrix to the second AR-glass fibrous layer; wherein the first and second fibrous layer is a bi-directional fibrous layer, and wherein one of the first or second fibrous layers is orientated so that the weft direction is parallel to the bottom of the support structure and the other of the first or second fibrous layers is orientated so that the weft direction is perpendicular to the bottom of the support structure.   
   
   
       30 . The method of  claim 1 , wherein the AR-glass fibrous layer has AR glass fibers comprising about 25% of Zirconia. 
   
   
       31 . The method of  claim 1 , wherein said AR-glass fibrous layer is formed by the steps of:
 applying the sizing on AR glass fibers before forming the AR glass fibers into the fibrous layer, and   applying the resinous coating over the fibrous layer forming the AR glass fibers into the fibrous layer.   
   
   
       32 . The method of  claim 29 , wherein the AR glass fibrous layer is formed from AR glass fibers having a sizing applied thereon before forming the AR glass fibers into the fibrous layer, the sizing comprising a blend of anhydrous polymerized epoxy amine, vinyl and amine coupling agents and a non-ionic surfactant. 
   
   
       33 . The method of  claim 1 , wherein the coating further comprises a water resistant additive, from the group consisting of paraffin, a combination of paraffin and ammonium salt, fluoro chemicals, organohydrognpolysiloxanes, wax asphalt emulsions and polyvinyl alcohol, and polyvinyl acetate. 
   
   
       34 . The method of  claim 33 , wherein the coating further comprises one of the group consisting of bromated phosphorous complex, halogenated paraffin, colloidal antimony pentoxide, borax, unexpanded vermiculate, clay, colloidal silica and colloidal aluminum.