Barrier for absorbing live fire ammunition and uses thereof

Abstract

This disclosure is directed to an improved ballistic concrete barrier and methods of using the barrier for training with weapons using live ammunition or grenades or other fragmentation devices.

What is claimed is: 
     
         1 . A method for creating a bullet absorbing structural component made from ballistic concrete, the method comprising:
 the bullet absorbing structural component comprising:   (i) about 1 part by mass Portland cement;   (ii) about 0.5 to 1.5 part by mass fine aggregate;   (iii) about 0.005 to 0.15 part by mass fiber;   (iv) about 0.005 to 0.05 part by mass calcium phosphate;   (v) about 0.005 to 0.05 part by mass aluminum hydroxide; and   (vi) about 0.0005 to 0.05 part by mass air entrainment additive;   such that the bullet absorbing structural component is capable of stopping a live-fire test of an M855 round with a bullet fired from an M16A2 rifle at a distance of 82-ft with a penetration depth of between 1 and 5 inches as measured to a back of the bullet from a point of bullet entry on the bullet absorbing structural component.   
     
     
         2 . The method of  claim 1 , wherein the bullet absorbing structural component comprises:
 (i) about 0.8 to 1.2 part by mass, fine aggregate;   (ii) about 0.008 to 0.012 part by mass, fiber;   (iii) about 0.008 to 0.012 part by mass, calcium phosphate;   (iv) about 0.008 to 0.012 part by mass, aluminum hydroxide; and   (v) about 0.0008 to 0.002 part by mass, air entrainment additive.   
     
     
         3 . The method of  claim 2 , wherein the bullet absorbing structural component comprises:
 (i) about 0.9 to 1.1 part by mass, fine aggregate;   (ii) about 0.009 to 0.011 part by mass, fiber;   (iii) about 0.009 to 0.011 part by mass, calcium phosphate;   (iv) about 0.009 to 0.011 part by mass, aluminum hydroxide; and   (v) about 0.0009 to 0.0015 part by mass, air entrainment additive.   
     
     
         4 . The method of  claim 1 , wherein the fiber is a polyolefin fiber. 
     
     
         5 . The method of  claim 4 , wherein the polyolefin fiber is a fibrillated fiber. 
     
     
         6 . The method of  claim 1 , wherein the air entrainment additive is DaraFill® Dry. 
     
     
         7 . The method of  claim 1 , wherein a mixture comprising the Portland cement, the fine aggregate, the fiber; the calcium phosphate; the aluminum hydroxide; and the air entrainment additive mixed until the mixture has a wet density within a range of 88 to 94 pounds per cubic foot. 
     
     
         8 . The method of  claim 1 , wherein the bullet absorbing structural component has air bubbles resulting from the air entrainment additive that are less than about 0.04 inches (1 mm) in diameter. 
     
     
         9 . The method of  claim 1 , wherein the bullet absorbing structural component has air bubbles resulting from the air entrainment additive that are greater than 0.0004 inches (10 μm) in diameter. 
     
     
         10 . The method of  claim 1 , wherein the bullet absorbing component has air bubbles resulting from the air entrainment additive that are less than about 0.04 inches (1 mm) in diameter and greater than 0.0004 inches (10 μm) in diameter. 
     
     
         11 . The method of  claim 1 , wherein the bullet absorbing structural components are made on site at a training facility that will use the bullet absorbing structural component to capture live fire ammunition used at the training facility. 
     
     
         12 . The method of  claim 1  wherein the bullet absorbing structural components are made with a maximum pour drop of the ballistic concrete exceeds 2 feet. 
     
     
         13 . The method of  claim 1  wherein the bullet absorbing structural components are made with a maximum pour drop of the ballistic concrete exceeds 6 feet. 
     
     
         14 . The method of  claim 1  wherein the bullet absorbing structural components are poured with a maximum depth of more than 2 feet while in a mold. 
     
     
         15 . The method of  claim 1  wherein the bullet absorbing structural components are poured with a maximum depth of more than 3 feet while in a mold. 
     
     
         16 . The method of  claim 1  wherein the bullet absorbing structural components are poured with a maximum depth of more than 6 feet while in a mold. 
     
     
         17 . The method of  claim 1  wherein an upright wall panel is poured in place for a wall with a height of more than 6 feet measured from a bottom of the mold. 
     
     
         18 . A method for creating a bullet absorbing structural component made from ballistic concrete, the method comprising:
 obtaining a grout of Portland cement, fine aggregate and water in a mixer;   adding chemical air entrainment additive;   adding fiber to the grout;   mixing until the wet density of the grout falls within a desired density range for use in a bullet absorbing structural component for use with weapon using a particular round with a bullet fired from a particular distance so that a back edge of a bullet from a round fired perpendicularly towards a cured bullet absorbing structural component is within a range of 1 inches to 5 inches as measured from a point of bullet entry on the bullet absorbing structural component.   
     
     
         19 . The method of  claim 18  wherein the round is an M855 round with a bullet fired from an M16A2 rifle at a distance of 82-ft. 
     
     
         20 . The method of  claim 18  wherein mixing continues until the wet density is within a range of 88 to 94 pounds per cubic foot. 
     
     
         21 . The method of  claim 18  wherein the grout is mixed for several minutes after the addition of the chemical entrainment additive before the addition of the fiber. 
     
     
         22 . The method of  claim 18  wherein additives are added to the grout to reduce lead leaching from a bullet absorbing structural component which is used to absorb bullets containing lead. 
     
     
         23 . The method of  claim 22  wherein the additives are calcium phosphate and aluminum hydroxide. 
     
     
         24 . The method of  claim 18  wherein the ballistic concrete is poured into a mold such that a maximum height of the poured ballistic concrete exceeds 2 feet. 
     
     
         25 . The method of  claim 18  wherein the ballistic concrete is poured into a mold such that a maximum height of the poured ballistic concrete exceeds 3 feet. 
     
     
         26 . The method of  claim 18  wherein the ballistic concrete is poured into a mold such that a maximum height of the poured ballistic concrete exceeds 6 feet. 
     
     
         27 . The method of  claim 18  wherein ballistic concrete is poured into a mold having removable side walls and the side walls are removed from the mold within 24 hours of completing a pour into the mold. 
     
     
         28 . The method of  claim 18  wherein bullet absorbing structural component is made from ballistic concrete poured into a mold and the bullet absorbing structural component is removed from all portions of the mold within three days of completing the pour into the mold. 
     
     
         29 . The method of  claim 18  wherein the ballistic concrete is made without an addition of a wet foam comprising water, a foaming agent, and a foam stabilizing agent. 
     
     
       30. A method for creating a bullet absorbing structural component made from ballistic concrete by combining multiple components in a mixer, the method comprising:
 obtaining a grout of cement, fine aggregate and water in a mixer;   adding chemical air entrainment additive without adding foam;   forming the bullet absorbing structural component by mixing until the wet density of the grout falls within a desired density range for use in a bullet absorbing structural component; and   wherein the bullet absorbing structural components are poured with a maximum depth of more than 6 feet while in a mold.    
     
     
       31. The method of  claim 30 , wherein ballistic concrete is poured into a mold having removable side walls and the side walls are removed within 24 hours of completing a pour into the mold.  
     
     
       32. The method of  claim 30 , wherein the bullet absorbing structural component is made from ballistic concrete poured into a mold and the bullet absorbing structural component is removed from all portions of the mold within three days of completing the pour into the mold.  
     
     
       33. A method for creating a bullet absorbing structural component made from ballistic concrete, the method comprising:
 forming the bullet absorbing structural component by combining multiple components in a mixer, comprising:   (i) approximately 1 part by mass cement;   (ii) approximately 0.5 to 1.5 parts by mass fine aggregate;   (iii) fiber; and   (iv) approximately 0.0005 to 0.05 part by mass air entrainment additive without adding aluminum;   wherein the bullet absorbing structural components are made with a maximum pour drop of the ballistic concrete exceeding 6 feet.    
     
     
       34. The method of  claim 33 , wherein the bullet absorbing structural component comprises:
 (i) about 0.8 to 1.2 part by mass, fine aggregate;   (ii) about 0.008 to 0.012 part by mass, fiber; and   (iii) about 0.0008 to 0.002 part by mass, air entrainment additive.    
     
     
       35. The method of  claim 34 , wherein the bullet absorbing structural component comprises:
 (i) about 0.9 to 1.1 part by mass, fine aggregate;   (ii) about 0.009 to 0.011 part by mass, fiber; and   (iii) about 0.0009 to 0.0015 part by mass, air entrainment additive.    
     
     
       36. The method of  claim 33 , wherein the fiber is a fibrillated polyolefin fiber.  
     
     
       37. The method of  claim 33 , wherein a mixture comprising the cement, the fine aggregate, the fiber, and the air entrainment additive without aluminum is mixed until the mixture has a wet density within a range of 88 to 94 pounds per cubic foot.  
     
     
       38. The method of  claim 33 , wherein the bullet absorbing component has air bubbles resulting from the air entrainment additive that are less than about 0.04 inches (1 mm) in diameter and greater than 0.0004 inches (10 μm) in diameter.  
     
     
       39. The method of  claim 33 , wherein the bullet absorbing structural components are poured with a maximum depth of more than 2 feet while in a mold.  
     
     
       40. The method of  claim 33 , wherein an upright wall panel is poured in place for a wall with a height of more than 6 feet measured from a bottom of the mold.  
     
     
       41. A method for creating a bullet absorbing structural component made from ballistic concrete by combining multiple components in a mixer, the method comprising:
 obtaining a grout of cement, fine aggregate and water in a mixer;   adding chemical air entrainment additive without adding foam;   adding fiber to the grout;   forming the bullet absorbing structural component by mixing until the wet density of the grout falls within a desired density range; and   wherein the bullet absorbing structural components are made with a maximum pour drop of the ballistic concrete exceeding 6 feet.    
     
     
       42. The method of  claim 41 , wherein the desired density range is for use in a bullet absorbing structural component for use with a weapon using a particular round with a bullet fired from a particular distance.  
     
     
       43. The method of  claim 41 , wherein mixing continues until the wet density is within a range of 88 to 94 pounds per cubic foot.  
     
     
       44. The method of  claim 41 , wherein the grout is mixed for several minutes after the addition of the chemical entrainment additive before the addition of the fiber.  
     
     
       45. The method of  claim 41 , wherein additives are added to the grout to reduce lead leaching from a bullet absorbing structural component which is used to absorb bullets containing lead.  
     
     
       46. The method of  claim 41 , wherein ballistic concrete is poured into a mold having removable side walls and the side walls are removed from the mold within 24 hours of completing a pour into the mold.  
     
     
       47. The method of  claim 41 , wherein bullet absorbing structural component is made from ballistic concrete poured into a mold and the bullet absorbing structural component is removed from all portions of the mold within three days of completing the pour into the mold.