Abstract: A rebar forming apparatus includes a malleable material supply station for continuously supplying a malleable planar material and a malleable material forming station for forming the malleable material into first and second corresponding shell portions and related rebar products. The apparatus also includes a core pultrusion station and a cladding forming station for respectively forming core and cladding layers. A shell forming station is positioned downstream of the core and cladding forming stations which unites the first and second shell portions to form an outer shell with the core and cladding layers contained therein. The rebar product includes shell portions which are matably configured to form a disposable outer shell over the core and cladding layers. Related reinforcing composite product forming methods also include the use of a removable outer shell.

Abstract: A rebar forming apparatus includes a malleable material supply station for continuously supplying a malleable planar material and a malleable material forming station for forming the malleable material into first and second corresponding shell portions and related rebar products. The apparatus also includes a core pultrusion station and a cladding forming station for respectively forming core and cladding layers. A shell forming station is positioned downstream of the core and cladding forming stations which unites the first and second shell portions to form an outer shell with the core and cladding layers contained therein. The rebar product includes shell portions which are matably configured to form a disposable outer shell over the core and cladding layers. Related reinforcing composite product forming methods also include the use of a removable outer shell.

Abstract: A rebar forming apparatus includes a malleable material supply station for continuously supplying a malleable planar material and a malleable material forming station for forming the malleable material into first and second corresponding shell portions and related rebar products. The apparatus also includes a core pultrusion station and a cladding forming station for respectively forming core and cladding layers. A shell forming station is positioned downstream of the core and cladding forming stations which unites the first and second shell portions to form an outer shell with the core and cladding layers contained therein. The rebar product includes shell portions which are matably configured to form a disposable outer shell over the core and cladding layers. Related reinforcing composite product forming methods also include the use of a removable outer shell.

Abstract: A rebar forming apparatus includes a malleable material supply station for continuously supplying a malleable planar material and a malleable material forming station for forming the malleable material into first and second corresponding shell portions and related rebar products. The apparatus also includes a core pultrusion station and a cladding forming station for respectively forming core and cladding layers. A shell forming station is positioned downstream of the core and cladding forming stations which unites the first and second shell portions to form an outer shell with the core and cladding layers contained therein. The rebar product includes shell portions which are matably configured to form a disposable outer shell over the core and cladding layers. Related reinforcing composite product forming methods also include the use of a removable outer shell.

Abstract: An apparatus for forming reinforcing structural rebar comprises: resin supply means for supplying a first resin; a first shaping die; means for impregnating a first reinforcing material with the first resin; means for pulling the resin-impregnated first reinforcing material through the shaping die to form the core of the structural rebar; material applying means for applying material for the outer cladding of the structural rebar to the core; and mold means for molding the outer cladding layer into a desired configuration on the core. The material applying means for applying the outer cladding includes means for applying an inner cladding layer over the core and means for applying an outer cladding layer over the inner layer. The inner cladding layer includes a second thermosetting resin containing a second reinforcing material, and the inner cladding layer applying means is configured so that the second reinforcing material is applied substantially unidirectionally along the longitudinal axis of the core.

Abstract: The present invention provides a reinforcing structural rebar. The rebar comprises an inner core formed by pultruding reinforcing fibers through a bath of a first resin material, the inner core typically containing at least about 40 percent by weight reinforcing fibers and an outer cladding of a corrosion resistant and reinforced second resin material.

Abstract: A structural rebar of the present invention comprises: an inner core formed by pultruding reinforcing fibers of a first reinforcing material through a bath or injection system of a first resin material; and an outer cladding comprising an inner cladding layer and an outer cladding layer. The inner core contains at least about 40 percent by weight reinforcing fibers of the first reinforcing material. The inner cladding layer comprises a second resin material reinforced with reinforcing fibers of a second reinforcing material. The fibers of the second reinforcing material are preferably unidirectional and oriented substantially parallel to the fibers of the first reinforcing material. The outer cladding layer comprises a corrosion-resistant third resin material reinforced with a third reinforcing material. Rebar of this configuration can have sufficient strength, rigidity, and corrosion resistance to be suitable for use in cementitious structural members.

Abstract: The present invention provides a reinforcing structural rebar. The rebar comprises an inner core formed by pultruding reinforcing fibers through a bath of a first resin material, the inner core typically containing at least about 40 percent by weight reinforcing fibers and an outer cladding of a corrosion resistant and reinforced second resin material.

Abstract: An apparatus for forming reinforcing structural rebar comprising a core of a thermosetting resin containing reinforcing material and an outer of sheet molding compound is provided. The apparatus comprises layer reinforcing material supply, a thermosetting resin supply means, a shaping die, means for impregnating the reinforcing material the reinforcing material with resin, means for pulling the reinforcing material through the shaping die to form the core of the thermosetting resin containing reinforcing material, sheet molding compound supply, guide means for guiding the sheet molding compound onto the core, and mold means for molding the outer layer of sheet molding compound onto the core.

Abstract: An apparatus for forming reinforcing structural rebar comprising a core of a thermosetting resin containing reinforcing material and an outer of sheet molding compound is provided. The apparatus comprises layer reinforcing material supply, a thermosetting resin supply means, a shaping die, means for impregnating the reinforcing material the reinforcing material with resin, means for pulling the reinforcing material through the shaping die to form the core of the thermosetting resin containing reinforcing material, sheet molding compound supply, guide means for guiding the sheet molding compound onto the core, and mold means for molding the outer layer of sheet molding compound onto the core.