US 4,559,881 A · Burglary resistant steel fiber reinforced concrete construction for vault walls and doors and manufacture thereof

Abstract

A new castable steel fiber reinforced concrete composition is described composed of Portland Cement, fly ash, fine aggregate, gravel or crushed stone, water, high range superplasticizing water-reducing admixture, and steel fibers. The concrete may be mixed in conventional mixers and cast in open top molds to form modular panels for use in the construction of security vaults. The cast panels have outstanding engineering properties resistant to burglarious attack measures such that multi-paneled vault walls resist burglarious attack as outlined in Underwriters Laboratories Standard No. 608 in thicknesses of 8 inches for 1 hour and 11 inches for 2 hours. New casting procedures for the concrete and new vault construction procedures using modular panels cast from the concrete also are described.

Claims24

Dependent claims

A burglar resistant castable concrete panel construction for assembly into an integrated secure vault, wherein the improvement comprises:

a concrete composition which can be fully consolidated when cast with water to cement ratios less than 0.30 and steel fiber content of 7.21% to 7.73% by weight, consisting essentially of:
______________________________________ Constituents Weight % ______________________________________ Portland Cement wherein said 18.88 to 19.81 cement is selected from the group consisting of Type I and Type III Portland Cement;
Fly Ash wherein said fly ash is 1.37 to 1.45 selected from the group consisting of Glass F and Class C fly ash;
Fine Aggregate (SSD);
39.12 to 40.86 Gravel wherein said gravel is 25.12 to 26.53 selected from the group consisting of No. 8 gravel and crushed stone, (SSD);
Water;
4.81 to 5.15 Melamine Superplasicizing Water- 0.96 to 1.04 Reducing Admixture;
and, Steel fibers;
7.21 to 7.73. ______________________________________

6 more elements

The method of mixing and casting a metal fiber reinforced concrete composition which can be fully consolidated when cast with water to cement ratios less than 0.30 and steel fiber content of 7.21 to 7.73% by weight, consisting essentially of:

______________________________________ Concrete Constituents [*] [lb/yd.sup.3 ] Weight % ______________________________________ Portland Cement - One [830.5 to 847.5] 18.88 to 19.81 of the Class Consisting of Type I and Type III Portland Cement Fly Ash - One of the Class [60.4 to 61.6] 1.37 to 1.45 Class Consisting of Class F and Class C Fly Ash Fine Aggregate (SSD) [1700 to 1769] 39.12 to 40.86 Gravel - One of the [1098 to 1142] 25.12 to 26.53 Classes Consisting of No. 8 Gravel and Crushed Stone (SSD) Water [212 to 220] 4.81 to 5.15 Melamine Super- [678 to 706] 0.96 to 1.04 plasticizing Water- Reducing Admixture Steel Fibers [317.5 to 330.5] 7.21 to 7.73 [- (0.016 in. diameter .times. 3/4 in. long .+-. 1/4 inch.)] ______________________________________ [*ounces rather than lbs
in a rotatable tumbling concrete mixer to form a castable mixture which may be poured from the mixer into an open top of a generally flat five-sided mold to form a modular panel for multiple panel assembly of an integrated security vault, including the steps of:
(a) introducing said Cement, Fly Ash, Fine Aggregate, Gravel and Water constituents in the stated proportions into such mixer;
(b) then rotating said mixer to tumble and agitate said constituents in the mixer until a mass of crumbly, damp, powder and aggregate is formed;
(c) then adding said Admixture to said mass and continuing mixer rotation until the constituents reach a state of high fluidity;
(d) then adding the Steel Fiber constituent while continuing rotation and agitation of the mixed constituents until a fully integrated mixture thereof is obtained;
and
(e) then pouring the integrated mixture into said mold while externally vibrating the mold to enable the integrated composition to fully consolidate in the mold.

5 more elements

The method of casting a burglar resistant modular panel for multiple panel assembly of an integrated security vault having a castable metal fiber reinforced concrete composition which can be fully consolidated when cast with water to cement ratios less than 0.30 and steel fiber content of 7.21 to 7.73% by weight, consisting essentially of:

______________________________________ Concrete Constituents [*] [lb/yd.sup.3 ] Weight % ______________________________________ Portland Cement - One [830.5 to 847.5] 18.88 to 19.81 of the Class Consisting of Type I and Type III Portland Cement Fly Ash - One of the [60.4 to 61.6] 1.37 to 1.45 Class Consisting of Class F and Class C Fly Ash Fine Aggregate (SSD) [1700 to 1769] 39.12 to 40.86 Gravel - One of the [1098 to 1142] 25.12 to 26.53 Classes Consisting of No. 8 Gravel and Crushed Stone (SSD) Water [212 to 220] 4.81 to 5.15 Melamine Super- [678 to 706] 0.96 to 1.04 plasticizing Water- Reducing Admixture Steel Fibers - [317.5 to 330.5] 7.21 to 7.73 [0.016 in. diameter .times. 3/4 inch long .+-. 1/4 inch.)] ______________________________________ [*ounces rather than lbs.
including the steps of:
(a) providing a rectangular mold cavity formed by a generally flat horizontally disposed mold bottom wall and separable side and end walls;
(b) while mixing and agitating said concrete composition in a rotatable concrete mixer, pouring said mixed concrete composition into said mold cavity while also externally vibrating said mold;
(c) then completely filling said mold cavity and permitting said metal fiber reinforced concrete composition in said mold cavity during continued mold vibration to consolidate;
(d) then curing said composition in said mold to form a modular panel having a flat top panel surface adapted to provide a flat vault wall outer surface portion when multiple panels are assembled to form a vault;
(e) providing complementary overlapped formations selectively on mold cavity bottom, side and end walls, adapted to mold complementary overlapped formations selectively on respective cured panel bottom, side and end surfaces;
(f) opening said mold cavity forming side and end walls to release said panel;
and
(g) removing said panel from said mold bottom wall for multiple panel assembly to form a vault.

7 more elements

A burglar resistant castable concrete panel for assembly into an integrated secure vault, having a concrete composition which can be fully consolidated when cast with water to cement ratios less than 0.30 and steel fiber content of 7.21 to 7.73% by weight, consisting essentially of:

______________________________________ Constituents Weight % ______________________________________ Portland Cement wherein 18.88 to 19.81 said cement is selected from the group consisting of Type I and Type III Portland Cement;
Fly Ash wherein said 1.37 to 1.45 Fly Ash is selected from the group consisting of Class F and Class C Fly Ash;
Fine Aggregate (SSD);
39.12 to 40.86 Gravel wherein said gravel 25.12 to 26.53 is selected from the group consisting of No. 8 gravel and crushed stone (SSD);
Water;
4.81 to 5.15 Melamine Superplasticizing 0.96 to 1.04 Water-Reducing Admixture;
and Steel Fibers;
7.21 to 7.73 ______________________________________
prepared by a process comprising the steps of:
introducing together said Cement, Fly Ash, Fine Aggregate, Gravel and Water constituents in the foregoing proportions;
then mixing by mixing means said Cement, Fly Ash, Fine Aggregate, Gravel, and Water constituents until a mass of crumbly damp powder and aggregate develops;
then introducing said Admixture in the stated proportions to said mass;
then mixing by mixing means said mass and Admixture until said constituents reach a high fluidity state;
then introducing said Steel Fiber constituent in the stated proportions to the Admixture, Water, Gravel, Fine Aggregate, Fly Ash, and Cement constituents;
then mixing by mixing means said constituents until said constituents reach a fully integrated state;
then introducing said constituents into a mold;
and,
then vibrating the mold by a vibrating means whereby said fully integrated constituents fully consolidate in said mold.

15 more elements

Dependencies are inferred from the claim text.

Burglary resistant steel fiber reinforced concrete construction for vault walls and doors and manufacture thereof

Life of this patent

Burglary resistant steel fiber reinforced concrete construction for vault walls and doors and manufacture thereof

Life of this patent

Abstract

Claims24