Aggregate panel system

An aggregate panel system comprising:

• a first base wall of an existing vault;
• the aggregate panel system configured to attach to, reinforce, and seal the first base wall;
• a rigid first panel having:
• a first side comprising a fluid impermeable, non-porous outer layer;
• a second side facing the first base wall of the existing vault to which the first panel is attached, and a plurality of perimeter edges;
• at least one rigid panel brace fixed to and extending from the second side of the first panel offset from the perimeter edges and extending toward the base wall;
• a gap between each panel brace and the base wall;
• each panel brace configured to increase rigidity of the first panel;
• an aggregate fill configured to be poured into a space between the first panel, each panel brace, and the first base wall to fill the space therebetween;
• the aggregate fill configured to harden to a solid aggregate fill;
• the aggregate fill configured to be mechanically bonded to the first panel when hardened and in direct contact with the first base wall;
• the aggregate fill configured to be mechanically bonded to each panel brace when hardened;
• a plurality of panel offsets extending from the first panel to the base wall and attached thereto;
• the panel offsets each comprising a surface defining a transverse conduit therethough;
• each transverse conduit configured for passage of a fastener therethrough;
• and
• each fastener coupled to the base wall and configured to attach the first panel to the base wall.

A method for reinforcing an existing vault formed of at least one base wall, comprising the steps of:

• providing a rigid first panel having:
• a first side comprising a fluid impermeable, non-porous outer layer;
• a second side facing the first base wall to which the first panel is attached, and a plurality of perimeter edges;
• providing at least one panel brace extending from the second side of the first panel offset from the perimeter edges and extending toward the base wall so as to form a gap between each panel brace and the base wall;
• each the panel brace increasing rigidity of the first panel;
• providing a plurality of panel offsets extending from the first panel to the base wall and attaching the plurality of panel offsets thereto;
• the panel offsets each comprising a surface defining a transverse conduit therethough;
• passing a fastener through each conduit to the base wall;
• coupling each fastener directly to the base wall to attach the first panel to the base wall;
• pouring an aggregate fill into a space between the first panel and the first base wall to fill the space therebetween;
• allowing the aggregate fill to harden to a solid aggregate fill;
• the solid aggregate fill mechanically bonded to the first panel when hardened and in direct contact with the first base wall;
• and
• the aggregate fill mechanically bonded to each panel brace when hardened.