This invention refers to the manufacturing of structural and impervious members by slurry-infiltration in a 3-dimensional mat system, which consists of single layers ( 2 ). The single layers are preferably meshes. The structural system is a composite material consisting of a 3-dimensional micro reinforcing and sieving mat system bonded in concrete. The aggregate ( 1 ) can be precisely positioned horizontally and vertically in the member by variation of the mesh width of the single layers ( 2 ). The sieving effect by the variation of the mesh width in vertical direction guarantees a positioning of aggregate by size. By this effect the load capacity, the stiffness and the crack propagation can be controlled and adjusted precisely.

CROSS-REFERENCE AND PRIORITY CLAIM TO RELATED APPLICATIONS 
   This application is a continuation application of International application PCT/IB00/011369 filed Sep. 27, 2000, now abandoned, and published in German on Apr. 5, 2001 (publication No. WO 01/23685), claiming priority of Swiss patent application 1788/99 filed Sep. 27, 1999. 


   BRIEF SUMMARY OF THE INVENTION 
   3-dimensional mat systems with integrated aggregate ( 1 ) are the basis for a microreinforced high performance concrete. The material performance as high load capacity, durability, energy absorption, impact resistance, electrical and thermal conductivity, density against fluids, high plasticity and crack control can be adjusted precisely by variation of the mesh width and by positioning and variation of the type and size of aggregate ( 1 ). The composite material will be produced by slurry infiltration in a 3-dimensional mat system, performing as sieve and micro-reinforcement. The precise positioning of the aggregate ( 1 ) allows a defined regulation of the material stiffness in the tension and the compression zone of the member by variation of size and specific gravity of the aggregate. Consequently the deflection, the flow of internal forces and the crack propagation of the concrete member can be controlled as well as the adjustment of weight from extreme lightweight to heavyweight structures. The deformation of the 3-dimensional mat system in combination with a monolithic splicing of the mats allows a simplified sectional system ( FIG. 5 ) or any other typical structural profile. The characteristics of the microreinforced, multifunctional material in combination with a simplified execution are the basis for cost effective long term behavior and they open a large spectrum of applications. (table 1.2) 
   Specification 
   The invention relates to a microreinforced high performance concrete for the manufacture of structural and impervious members following claim N°1. The structural system is a composite material consisting of a 3-dimensional reinforcing and sieving mat system bonded in concrete. The aggregate can be precisely positioned horizontally and vertically in the member by variation of the mesh width of the single layers ( 2 ). The sieving effect by the variation of the mesh width in vertical direction guarantees a positioning of aggregate by size.
         System a: positioning of the aggregate ( 1 ) can be determined before fabrication of mat systems with integrated coarse aggregate. During the second step a slurry with fine aggregate will be infiltrated.   System b: the prefabricated 3-dimensional mat system contains no aggregate. The aggregate ( 1 ) will be positioned during the slurry infiltration by the sieving effect of the 3-dimensional mat system.       

   The material of the single layers ( 2 ) is variable, but preferably metallic or plastic. The optimization of cement bonded materials is guaranteed by the precise positioning of aggregate over the member cross section and by the adjustment of the desired material performance. The combination of the positioning and the variation of aggregate ( 1 ) with the load capacity of the 3-dimensional mat system ( 2 ) allow structural members with high performance in flexible rotation, abrasion resistance, impact resistance, durability, load capacity, ductility, crack control and fire resistance. 
   BACKGROUND OF THE INVENTION (STATE OF THE ART) 
   Conventional concrete members will be manufactured with a constant grain size distribution over the cross section of structural members (slabs, walls, girders etc.). The attempt of positioning of the aggregate ( 1 ) in different layers already fails during the compaction by vibration. The result is a random distribution of the aggregate ( 1 ) over the cross section and a large scattering of the material performance. A stress-strain curve of a loaded beam has in contradiction of theoretical assumptions no consistency of the cross sections. The strain curve of the compression zone and the tension zone are different (see FIG.  6 ). The strain in the tension zone of the member is larger than in the compression zone. Conventional concrete members have no positioning and variation of the aggregate size and therefore only a more or less constant stiffness (large stiffness) over the cross section. Consequently the members tend to crack by a small strain. The cracks of reinforced concrete members can only be minimized to w=0.20 mm. The minimum crack width of 0.20 mm doesn't satisfy the requirements of impervious overlays [Lit. 1 ]. In addition reinforced concrete members have a required concrete cover of the reinforcement of at least 25 mm. Consequently the load cannot be taken by the overall cross section of the member and the dead load of the member increases. 


   
     ILLUSTRATION, LISTING OF FIGURES 
       FIG. 1.1  3-dimensional mat system with integrated aggregate ( 1 ) (perspective view) Space positioning and variation of aggregate sizes 
       FIG. 1.2  similar to  FIG. 1.1  with 3-dimensional interweaving ( 4 ) or other interconnection elements ( 3 ) 
       FIG. 2  3-dimensional mat system with variation of mesh width (perspective view) (aggregate positioning by sieving effect (sieve  1  to n) during slurry infiltration)
         sieve  1  enclosing mesh layers ( 2 ) for staggered arrangement and positioning of aggregate and performing as reinforcement for load and crack control.   sieve  2  single layers ( 2 ) with small mesh width=template, positioning of displacement elements (=hollow elements)   sieve n single layers ( 2 ) with small mesh width for fine aggregate       
       FIG. 3  Structural system in prestressing bed with eccentric and center prestress. It performs by prestressing the single layers ( 2 ) of the 3-dimensional mat system. 
       FIG. 4  Positioning of the integrated aggregate ( 1 ), performing as displacement elements (i.e. hollow grains, plane view) 
       FIG. 5  Mat-elementation for sectional systems (perspective view) 
       FIG. 6  Strain relation of a loaded beam 
       FIG. 7  Mat system with integrated cable channels 
       FIG. 8  Integrated discs with impervious rings 
       FIG. 9  Girder with single mesh layers (sieve) 
       FIG. 10  Girder with single mesh layers (sieve)+rebar 
       FIG. 11  Positioning of aggregate in wall members (section view) 
       FIG. 12  Positioning of aggregate in plane areas (section view) 
   


   INTENTION OF THE INVENTION 
   The intention of the invention is the variation and precise positioning of the aggregate ( 1 ) over the cross section of a member in order to produce a defined grain size distribution, i.e. for stiffness control. A large stiffness in the compression zone of the member will be achieved by positioning coarse aggregate ( 1 ) and a small stiffness in the tension zone will be produced by crushed and fine aggregate ( 1 ). For example, for a high-strength concrete (100 MPa) the stiffness can be adjusted from 20,000 MPa (fine grain=2 mm) to 50,000 MPa (coarse grain=32 mm) by positioning the aggregate ( 1 ). The large stiffness in the compression zone of a member results in a better load dispersion and a higher load capacity up to the failure strain of a compression member. The small stiffness in the tension zone allows a maximization of the failure strain, so that crack propagation can be avoided even during large torsion, rotation and bending loads until failure. This effect ensures durability and density and consequently a long term behavior of the composite material. In addition the fine aggregate ( 1 ) improves the bonding between concrete and rebar. In general, high load capacity in combination with plasticity and crack minimization in a structural member can be achieved by variation of the material stiffness over the cross section. 
   The development of a specified 3-dimensional mat system, consisting of single layers ( 2 ) of micro meshes, is the foundation for positioning and variation of aggregate ( 1 ) either in the horizontal or in the vertical cross section. By the exact positioning of aggregate ( 1 ) in combination with a 3-dimensional mat system the desired material performance relating to high load capacity, high density, durability, ductility, impact resistance, torsion, rotation, crack control, thermal and electric conductivity, energy absorption etc. can be adjusted precisely. In addition the inconsistency of performance in conventional concrete can be reduced to a minimum. 
   The advantages of high performance concrete and of 3-dimensional mat systems, performing as microreinforcement and as a sieve, will be superpositioned. These advantages are described in a publication by the inventor [Lit. 2 ]. 
   DETAILED DESCRIPTION OF THE INVENTION 
   i) Composition of the Mat System 
   See  FIGS. 1 and 2 
         single layers ( 2 ) enclose the aggregate ( 1 )   single layers ( 2 ) with small mesh width as template for the defined position of the aggregate ( 1 )   single layers ( 2 ) ensure the compression tension capacity of the member   3-dimensional tying or interweaving ( 3 ,  4 ) perform as fixation for the single layers ( 2 ) and ensure the shear capacity of the member (see  FIG. 1 )   the thickness of the 3-dimensional mat system can be defined and adjusted precisely, i.e. for abrasive overlays h mat =10 to 100 mm   3-dimensional mat system with integrated aggregate ( 1 ) allow in addition the integration of cable channels, heating systems etc. (see  FIG. 7 )
 
ii) Material of Mat System
       

   The type and the strength capacity of the material can be composed arbitrarily (preferably high strength and normal strength steel)
         Multiple staggered arrangement of mat material with interconnecting elements
           single layers ( 2 ) in expanded metal   single layers ( 2 ) in welded or woven meshes   
           3-dimensional set-up
           Fabrication of a 3-dimensional mat system by interweaving without additional   interconnecting elements
 
iii) Aggregate
   
               

   General remark: the material stiffness can be adjusted by all different types of aggregate ( 1 ), as different types can be combined. 
                                   Type of aggregate:   standard (coarse, stone chips, sand etc.           light- and heavyweight           hollow core (works as displacement core)       Spec. Gravity:   extends from extreme light-weight (hollow) to           heavy-weight       Shape:   arbitrary (ball, disc, cubic etc.)       Size:   arbitrary (regulation of dead load and spacing of the           single layers (2))       Positioning:   arbitrary formation and positioning in the horizontal           layer of prefabricated 3-dimensional mat system           with integrated aggregate (1) (see. FIG. 4). Vertical           positioning of aggregate (1) by sieving effect of the           3-dimensional mat system during slurry infiltration           (see FIG. 2)                    
Specific Gravity of Aggregate ( 1 )
         aggregate ( 1 ) as hollow core, light-weight→minimization of member dead-load   aggregate ( 1 ) as normal-weight→reduction of the fine particles and the shrinkage of the member, increasing of material stiffness   aggregate ( 1 ) as heavy-weight→i.e. steel or lead for maximization of member dead load, radiation protection and sound insulation by the member
 
Shape of Aggregate ( 1 )
   arbitrary shape   Round shape will fit into the meshes of the single layers ( 2 )=template ( FIG. 4 )   Discs and cubic shapes       
   For impervious structures additional density rings might be added if needed, in order to minimize the soaking of the infiltrating liquid (see  FIG. 8 ) 
   Size of Aggregate ( 1 ) 
   
       
       
         
           Arbitrary adjustable (preferably≦50 mm) 
           Performing as a spacer of the single layers ( 2 ) 
           Regulation of stiffness of the member 
           Regulation of the dead load of the member
 
Positioning of the Aggregate ( 1 )
 
           a) Prefabricated 3-dimensional mat system with integrated aggregate ( 1 ) (FIG.  1 . 1 ).
           =aggregate ( 1 ) is positioned between the single layers ( 2 ) before slurry infiltration   
         
           precise positioning of aggregate ( 1 ) in the horizontal layer regulates the load dispersion like a beam grid and the dead load of the member variants of positioning in the horizontal layer
           i) multiaxial beam grid→maximal load capacity of the member ( FIG. 4 )   ii) diagonal beam grid→minimization of dead load of the member by using hollow aggregate ( 1 ) (grains), maximization of dead load of the member by using lead aggregate ( 1 ) (see  FIG. 4 )   
         
           precise positioning of aggregate ( 1 ) in 3 dimensions controls the stiffness of the member as well as the load bearing capacity, the deflection, the energy absorption and the dead load 
           b) Prefabricated 3-dimensional mat system without integrated aggregate ( 1 ) ( FIG. 2 )
           =the aggregate ( 1 ) will be sieved into the defined position during slurry infiltration   
         
           sieving and positioning of aggregate ( 1 ) by variation of the mesh width of the single layers ( 2 ) 
         
       
     
  
   EXAMPLES OF CONCRETE MEMBERS 
   a) Beam Members 
   
       
       
         
           a 1 ) concrete beam, consisting of the 3-dimensional mat system
 
example see  FIG. 9 
 
           a 2 ) concrete beam, consisting of the 3-dimensional mat system and additional conventional rebars
 
example see  FIG. 10 
 
         
       
     
  
   b) Wall Members with Staggered Arrangement and Variation of the Size of Aggregate ( 1 )
         advantage: high material stiffness by positioning coarse aggregate ( 1 ) in the compression zone of the member, high bearing load and abrasion resistance
           minimization of crack width by positioning fine aggregate ( 1 ) in the tension zone of the member   crack propagation adjusted by mesh width of the single layers ( 2 ), cracks develop at each mesh node
 
example see  FIG. 11 
 
c) Abrasive Resistant Overlays with Staggered Arrangement and Variation of the Size of Aggregate ( 1 )
   
           example: 3-dimensional mat system for filtration of aggregate ( 1 ), performing as sieve   advantage: high material stiffness by positioning coarse aggregate ( 1 ) near the surface of the overlay (compression zone), results in a high bearing load capacity and high abrasion resistance
           low material stiffness by positioning fine aggregate ( 1 ) near the bottom part of the overlay (compression zone), results in a minimization of the crack propagation and in an increase of durability=long term behavior
 
example see  FIG. 11 
   
               

   ADVANTAGES OF THE DESCRIBED METHOD 
   Listing of advantages of the described method compared to the state of the art. 
                                                           Advantages of the 3-dimensional mat system for staggered arrangement,       positioning and variation of aggregate                                Technical advantages:            •   3-dimensional control of load bearing and deflection of cement           bonded members by precise positioning of the 3-dimensional mat           system and the aggregate (1)       •   Precise positioning of the aggregate (1) in the horizontal layer (beam           grid see FIG. 4)       •   Precise positioning of the aggregate (1) in 3 dimensions over the           cross section of the member (see FIG. 1.1)       •   System without joints by monolithic splicing of the mats       •   Minimization of the concrete embedment       =>   The complete height of the cross section can be taken into account           for static analysis,       =>   Minimization of the member thickness       =>   No additional spacer for the single layers (2) necessary       =>   Cost reduction       •   3-dimensional load bearing capacity       •   High effectiveness because of maximum distance of single layers           (2) to the neutral axis       •   Precise alignment of single layers, performing as reinforcement       •   3-dimensional interconnection of the mat system increases the           shear load capacity of the member       •   steel volume fraction can be adjusted precisely between 0.5 and           15.0% of volume       •   Installation of the 3-dimensional mat system in defined parts of the           member, i.e. only near the member surface       •   Large variety of mat systems possible i.e. with integrated heating           wires, prestress of single layers (2), confinement of structural           members       •   Characteristics           Extremely ductile, high bearing load capacity, minimization of crack           development, minimization of inconsistency in material performance           by variation and positioning of aggregate (1), 3-dimensional structural           performance of the mat system       •   Crack width <<0.03 mm during service limit state (conventional           concrete w ≧0.20 mm)       •   Multifunctional composite material by multiple layer set-up =>           superimposing of a variety of characteristics by one material (i.e.           sound protection, insulation, electric and thermal conductivity,           impact resistance etc.)            Economic advantages:            •   Cost reduction and optimization by variation of the aggregate (1)       •   Minimization of the construction work by a simplified placing of the           prefabricated 3-dimensional mat system       •   monolithic continuous system with high load capacity => no cost           intensive joints necessary       •   multifunctional material, which covers a variety of           performances => no cost intensive additional materials necessary       •   integration of hollow aggregate (1) as displacement core       =>   minimization of dead weight       =>   minimization of cost of transport       =>   enlargement of precasted structural members = acceleration of the           erection of the structure       =>   minimization of duration of the construction       •   Simplified elementation       =>   sectional system with quality assurance, no specialists for the           execution necessary       •   no embodiment of the single layers (2) necessary => minimization of           thickness => minimization of dead weight => small transporters and           cranes                    
3-dimensional Mat System as Prestressing Element
 
Using the Prefabricated Mat System for Prestressing of Concrete Members
 
   The difference in existing methods is, that defined single layers of the 3-dimensional mat system can be prestressed especially in extremely thin concrete members. The prestressing allows an increase of the member span and crack-free structure. 
   Structural System 
   
       
       
         
           =Prestressing in a prestressing bed 
         
       
       a) eccentric prestress by prestressing defined single layers ( 2 ) consisting of high strength or equivalent material (see  FIG. 3.1 ) 
       b) center prestress by prestressing either all single layers ( 2 ) or defined layers by keeping the symmetry to the center axis (see  FIG. 3.2 )
 
Usability of the Invention (Application)
 
     
  
   Restoration, retrofit and damp proofing of existing structures as well the production of new structures with long term behavior are important projects for the future. Besides the economic advantages the improved characteristics of the composite material, like high load bearing capacity, durability, energy absorption, impact resistance, electrical thermal conductivity, density against fluids, high plasticity and crack control open a large spectrum of applications. 
   Preferred applications of the composite material (mat system+concrete with positioning and variation of aggregate) are abrasive and impervious overlays, blast barriers, precast elements, arbitrary profiles and shapes. The utilization of the thermal conductivity of the 3-dimensional mat system ensures a heatable material. This heating effect can be activated in members or areas, which are supposed to be free of ice and snow. (see table 1.2) 
   A special monolithic splicing of the 3-dimensional mat system has been developed, which allows structures free of joints. In addition, the deformation of the 3-dimensional mat system in combination with a monolithic splicing of the mats are the foundation for a simplified sectional system (FIG.  5 ), consisting of standard-, angle- and edge-elements. This simplified system ensures an execution with constant high quality and does not require specialized workers. 
   In addition, precast members will be part of the application. Based on the flexibility of the 3-dimensional mat system the precast members can be produced in arbitrary shapes (tubes, cylindric tanks and any other typical structural profiles). The prestressing of high loaded thin members allow slim and crack free structures. In addition structures with high energy absorption such as blast barriers, earthquake resistant structures, safes and bunkers, can be created by defined spatial positioning of the aggregate ( 1 ). 
   The material characteristics open up a wide spread field of applications: 
                         TABLE 1.2               Spectrum of applications of the 3-dimensional mat system with       staggered arrangement and positioning of aggregate (1)       Application                                Overlays       Highway and airport pavements, bridge deck overlays, runways, coastal       environment, stilling pools, settlement poinds, gas stations, industry floor       slabs, loading areas etc.       Energy absorption (blast)       military shelters, safety rooms, safes, refuse bunkers, bullet-proof and       blast barriers, plastic hinge connections, retrofit of existing structures etc.       Precast structures       tubes, thin facade plates, sacrifice formwork, structural profiles       Heatable areas       runways, ramps, bridges, car-wash, pipes, housing       Others       precast panels, any profile shapes, containers for liquids, tubes, chimneys,       radiation absorber, tunnel shells, thin panels, confinement, prestressed and       composite structures, sound insulation members etc.                    
Literature
     [Lit. 1 ] Deutscher Ausschuβ für Stahlbeton: DAfStb-Richtlinie für Umgang mit wassergefährdenden Stoffen, 1996 (Germany)   [Lit. 2 ] Hauser, S.: DUCON ein innovativer Hochleistungsbeton, Beton-u. Stahlbetonbau, February +March 1999 (Germany)   
   
     
       
             
           
             
             
           
         
             
                 
             
             
               List of references (abbreviations) 
             
           
        
         
             
               No. 
               Content 
             
             
                 
             
             
               1 
               Aggregate 
             
             
               2 
               Single layers of the 3-dimensional mat system 
             
             
               3 
               Elements of fixation 
             
             
               4 
               3-dimensional interweaving 
             
             
               5 
               High-strength steel 
             
             
                 
             
           
        
       
     
   
   
     
       
             
           
             
             
             
           
             
             
             
           
         
             
                 
             
             
               Designation of figures 
             
           
        
         
             
               Figure 
               Position 
               Content 
             
             
                 
             
           
        
         
             
               1.1 
               — 
                 
             
             
               1.2 
               — 
             
             
               2 
                2a 
               Sieve 1 (large mesh width) 
             
             
                 
                2b 
               Sieve 2 (medium mesh width) 
             
             
                 
                2c 
               Sieve n (small mesh width) 
             
             
               3 
                3.1 
               Eccentric prestressing 
             
             
                 
                3a 
               Prestressing anchor 
             
             
                 
                3.2 
               Center prestressing 
             
             
               4 
               A 
               Defined multiple axial load dispersion 
             
             
                 
                 
               (main axis + diagonals) 
             
             
                 
               B 
               Maximum utilization of space (diagonal load 
             
             
                 
                 
               dispersion) 
             
             
               5 
                5a 
               Angle-element 
             
             
                 
                5b 
               Edge-element 
             
             
                 
                5c 
               Standard-element 
             
             
               6 
                6a 
               Compression zone 
             
             
                 
                6b 
               Crack 
             
             
                 
                6c 
               Tension zone 
             
             
                 
                6d 
               Elongation under compression 
             
             
                 
                6e 
               Elongation under tension 
             
             
               7 
                7a 
               i.e. cable channel, power heating etc. 
             
             
               8 
                8a 
               Perimeter lips 
             
             
                 
                8b 
               Disc with perimeter lips 
             
             
               9 
                9.1 
               Staggered arrangement of the aggregate size over the 
             
             
                 
                 
               cross section 
             
             
                 
                9a 
               High concrete stiffness (E c  > 50,000 N/mm 2 ) 
             
             
                 
                9b 
               Medium concrete stiffness 
             
             
                 
                 
               (30,000 < E c  < 50,000 N/mm 2 ) 
             
             
                 
                9c 
               Small concrete stiffness (E c  < 30,000 N/mm 2 ) 
             
             
                 
                9.2 
               Staggered arrangement and variation of the single 
             
             
                 
                 
               layers over the cross section 
             
             
                 
                9d 
               i.e. large mesh width (w = 16 mm) 
             
             
                 
                9e 
               Medium mesh width (w = 8 mm) 
             
             
                 
                9f 
               Small mesh width (w < 4 mm) 
             
             
               10 
               10.1 
               Staggered arrangement and variation of the aggregate 
             
             
                 
                 
               size over the cross section 
             
             
                 
               10a 
               High concrete stiffness (E c  > 50,000 N/mm 2 ) 
             
             
                 
               10b 
               Medium concrete stiffness 
             
             
                 
                 
               (30,000 < E c  < 50,000 N/mm 2 ) 
             
             
                 
               10c 
               Small concrete stiffness (E c  < 30,000 N/mm 2 ) 
             
             
                 
               10.2 
               Staggered arrangement and variation of the single 
             
             
                 
                 
               mesh layers over the cross section 
             
             
                 
               10d 
               i.e. large mesh width (w = 16 mm) 
             
             
                 
               10e 
               Medium mesh width (w = 8 mm) 
             
             
                 
               10f 
               Small mesh width (w < 4 mm) 
             
             
                 
               10g 
               Steel reinforcement, rebars 
             
             
               11 
               11.1 
               Cross section of a wall 
             
             
                 
               11a 
               Tension zone 
             
             
                 
               11b 
               Compression zone 
             
             
                 
               11c 
               Slurry infiltration by the side with large aggregate 
             
             
                 
               11d 
               Small stiffness 
             
             
                 
               11e 
               Large stiffness 
             
             
                 
               11.2 
               i.e. horizontally loaded basement wall 
             
             
                 
               11f 
               Exposed concrete quality (interior) 
             
             
                 
               11g 
               Load (exterior) 
             
             
               12 
               12.1 
               Positioning of the single layers over the cross section 
             
             
                 
                 
               of a slab 
             
             
                 
               12a 
               Large mesh width 
             
             
                 
               12b 
               Small mesh width 
             
             
                 
               12.2 
               Staggered arrangement and variation of aggregate over 
             
             
                 
                 
               the cross section of a slab 
             
             
                 
               12c 
               Compression zone 
             
             
                 
               12d 
               Tension zone 
             
             
                 
               12e 
               Part of member with large stiffness 
             
             
                 
               12f 
               Part of member with small stiffness 
             
             
                 
               12.2 
               Staggered arrangement and variation of aggregate over 
             
             
                 
                 
               the cross section of a slab 
             
             
                 
               12f 
               Exposed concrete quality (interior) 
             
             
                 
               12g 
               Load (exterior)