Abstract: The present invention provides a multi-storey modular building including at least a first and a second lightweight concrete-based prefabricated modules each having at least a beam, a column, and one horizontal structure selected from a ceiling or a floor at least partially attached to two or more of the beams and columns. A connection system includes at least one vertical alignment connector attached to a horizontal load-distributing plate positioned between the first and second lightweight concrete-based prefabricated modules for connecting the first and second lightweight concrete-based prefabricated modules, where a top portion thereof is positioned in a grout accepting cavity in the bottom end of the column of the second lightweight concrete-based prefabricated module and that in the top end of the column of the first lightweight concrete-based prefabricated module. In-situ grout embeds the vertical alignment connector in each grout accepting cavity.

Abstract: The present invention discloses inorganic pelletized perlitic lightweight granules and a preparation process and use thereof. The present invention develops through encapsulation technology a novel type of lightweight particles, namely, inorganic pelletized perlitic lightweight granules comprising expanded perlite as a core material and a cementitious material as a shell material, forming a core-shell structure in which a perlite core is encapsulated in a cementitious shell. The cementitious material including cement and fly ash is coated onto the surface of expanded perlite particles through an encapsulation process by a pelletizer under controlled water spraying. The resulting inorganic pelletized perlitic lightweight granules are lower in cost and easier to produce, and have better fire resistance, higher crushing strength, and better compatibility with concrete.

Abstract: The invention relates to a modular integrated construction joint which includes a first building module, a second building module or a structural wall and a joint between the first building module and the second building module or structural wall. The joint includes a flexible seamless stitching system, which provides a long-term firestop, smokestop and waterproof for the joint cavity in-between modules in modular integrated construction (MiC).

Abstract: A repaired reinforced concrete structure is provided which includes one or more reinforcing steel bars of cross-sectional area Ax, the one or more reinforcing steel bars having one or more corroded sections of cross-sectional area Ay, wherein Ay is greater than or equal to approximately 0.6 Ax. A reinforced ordinary Portland cement-based repair mortar is positioned directly on the one or more corroded sections of the one or more reinforcing steel bars without the addition of a lapped reinforcing steel bar. The reinforced repair mortar includes at least approximately 1 percent by volume of reinforcing steel fibers such that the reinforced repair mortar restores a strength of a repaired region to greater than approximately 100% of an original strength of the concrete structure in an uncorroded state. The repaired reinforced concrete structure is highly durable, as the repair mortar exhibits an air permeability resistance of greater than 1000 seconds.

Abstract: A self-locking connection system for modular construction (e.g., MiC and PPVC) is provided for interlocking an upper module column to a lower module column. A horizontal load transfer plate has first and second inner sleeve portions positioned beneath and above the plate. The sleeves are configured and dimensioned to be received within the respective module columns. Spring-loaded latches in both sleeve portions engage respective column receiving apertures. Each latch may include a latch plate having a wedge-shaped latch protrusion connecting to a vertical latch surface. The latch plate has one or more latch plate apertures for receiving a rod within a coil spring. An optional second reversible self-locking mechanism interlocks the connected modules to a building load-bearing support such as a core wall. The second self-locking mechanism includes an angled protrusion extending from the horizontal load transfer plate to mate with a protrusion-receiving structure embedded in the load-bearing support.

Abstract: The invention relates to a modular integrated construction joint which includes a first building module, a second building module or a structural wall and a joint between the first building module and the second building module or structural wall. The joint includes a flexible seamless stitching system, which provides a long-term firestop, smokestop and waterproof for the joint cavity in-between modules in modular integrated construction (MiC).

Abstract: The disclosure relates to a method for the surface treatment of a polyester fiber, a modified polyester fiber obtained therefrom, and an engineered cementitious composite containing such modified polyester fibers. The method comprises subjecting the polyester fiber to an alkali hydrolysis to obtain hydrolyzed polyester fiber; applying a solution containing an acid cross-linker and a polyvinyl alcohol to the hydrolyzed polyester fiber, then curing to form a coating having a thickness of sub-micron or micron scale on the polyester fiber, thereby obtaining the modified polyester fiber.

Abstract: A self-locking connection system for modular construction (e.g., MiC and PPVC) is provided for interlocking an upper module column to a lower module column. A horizontal load transfer plate has first and second inner sleeve portions positioned beneath and above the plate. The sleeves are configured and dimensioned to be received within the respective module columns. Spring-loaded latches in both sleeve portions engage respective column receiving apertures. Each latch may include a latch plate having a wedge-shaped latch protrusion connecting to a vertical latch surface. The latch plate has one or more latch plate apertures for receiving a rod within a coil spring. An optional second reversible self-locking mechanism interlocks the connected modules to a building load-bearing support such as a core wall. The second self-locking mechanism includes an angled protrusion extending from the horizontal load transfer plate to mate with a protrusion-receiving structure embedded in the load-bearing support.

Abstract: The present invention provides a multi-storey modular building including at least a first and a second lightweight concrete-based prefabricated modules each having at least a beam, a column, and one horizontal structure selected from a ceiling or a floor at least partially attached to two or more of the beams and columns. A connection system includes at least one vertical alignment connector attached to a horizontal load-distributing plate positioned between the first and second lightweight concrete-based prefabricated modules for connecting the first and second lightweight concrete-based prefabricated modules, where a top portion thereof is positioned in a grout accepting cavity in the bottom end of the column of the second lightweight concrete-based prefabricated module and that in the top end of the column of the first lightweight concrete-based prefabricated module. In-situ grout embeds the vertical alignment connector in each grout accepting cavity.

Abstract: The disclosure relates to a method for the surface treatment of a polyester fiber, a modified polyester fiber obtained therefrom, and an engineered cementitious composite containing such modified polyester fibers. The method comprises subjecting the polyester fiber to an alkali hydrolysis to obtain hydrolyzed polyester fiber; applying a solution containing an acid cross-linker and a polyvinyl alcohol to the hydrolyzed polyester fiber, then curing to form a coating having a thickness of sub-micron or micron scale on the polyester fiber, thereby obtaining the modified polyester fiber.

Abstract: A polymer-modified hybrid-fibers cementitious composition has a one-day compressive strength of at least approximately 17 MPa, a 28-day tensile strength of at least approximately 3.8 MPa, an ultimate tensile strain of approximately 3% to approximately 9%, and a 7-day bond strength of at least approximately 2.3 MPa. A binder of ordinary Portland cement, fly ash, and silica fume is provided. Other components include limestone powder, sand, superplasticizer, and water. The composition further includes one or more of styrene butadiene rubber or ethylene-vinyl acetate copolymer in an amount ranging between approximately 2% and approximately 8% by mass of binder. Fiber additives include steel fibers in an amount ranging between approximately 0.3% and approximately 3.0% by volume of the cementitious composition and polymer fibers in an amount less than approximately 1.0% by volume of the cementitious composition. Chamfers made of the composition are positioned at beam-column joints.

Abstract: A polymer-modified hybrid-fibers cementitious composition has a one-day compressive strength of at least approximately 17 MPa, a 28-day tensile strength of at least approximately 3.8 MPa, an ultimate tensile strain of approximately 3% to approximately 9%, and a 7-day bond strength of at least approximately 2.3 MPa. A binder of ordinary Portland cement, fly ash, and silica fume is provided. Other components include limestone powder, sand, superplasticizer, and water. The composition further includes one or more of styrene butadiene rubber or ethylene-vinyl acetate copolymer in an amount ranging between approximately 2% and approximately 8% by mass of binder. Fiber additives include steel fibers in an amount ranging between approximately 0.3% and approximately 3.0% by volume of the cementitious composition and polymer fibers in an amount less than approximately 1.0% by volume of the cementitious composition. Chamfers made of the composition are positioned at beam-column joints.

Abstract: A repaired reinforced concrete structure is provided which includes one or more reinforcing steel bars of cross-sectional area Ax, the one or more reinforcing steel bars having one or more corroded sections of cross-sectional area Ay, wherein Ay is greater than or equal to approximately 0.6 Ax. A reinforced ordinary Portland cement-based repair mortar is positioned directly on the one or more corroded sections of the one or more reinforcing steel bars without the addition of a lapped reinforcing steel bar. The reinforced repair mortar includes at least approximately 1 percent by volume of reinforcing steel fibers such that the reinforced repair mortar restores a strength of a repaired region to greater than approximately 100% of an original strength of the concrete structure in an uncorroded state. The repaired reinforced concrete structure is highly durable, as the repair mortar exhibits an air permeability resistance of greater than 1000 seconds.

Abstract: A composition for forming fire resistant concrete block, that includes a cementitious binder material comprising alumina cement, recycled fine aggregate, and recycled coarse aggregates, the recycled fine aggregates including 10-50 wt % recycled particulate glass cullet having a particle size of 600 microns or less, a concrete block formed from the composition exhibiting a decrease in thermal conductivity with increasing temperature at temperatures causing the particulate glass cullet to melt. A concrete block fabricated from the composition exhibits a fire resistance of at least three hours, a density below 2000 kg/m3, and a compressive strength of at least 7 MPa.

Abstract: A composition for forming fire resistant concrete block, that includes a cementitious binder material comprising alumina cement, recycled fine aggregate, and recycled coarse aggregates, the recycled fine aggregates including 10-50 wt % recycled particulate glass cullet having a particle size of 600 microns or less, a concrete block formed from the composition exhibiting a decrease in thermal conductivity with increasing temperature at temperatures causing the particulate glass cullet to melt. A concrete block fabricated from the composition exhibits a fire resistance of at least three hours, a density below 2000 kg/m3, and a compressive strength of at least 7 MPa.

Abstract: Synthetic aggregates are fabricated from greater than approximately 70 wt % waste starting materials. Starting materials may be selected from granulated ground blast furnace slag, waste concrete fines, or sewage sludge ash, and mixtures thereof. The starting materials are bound together by a hydraulic cementitious binder either added to the starting materials or formed in situ. The waste starting materials, binder, and water are formed into pellets and subjected to a hydraulic reaction and carbonation in an atmosphere of greater than approximately 50% carbon dioxide at temperatures less than approximately 100° C. The resulting synthetic aggregate has a crush strength after a period of hardening equal to or greater than approximately 0.5 MPa.

Abstract: A high-workability, fire-resistant, anti-spalling concrete composition is provided. The concrete composition has a slump value of at least approximately 150 mm, a fire-resistant period of at least 4 hours, a compressive strength of at least 120 MPa at room temperature, and a compressive strength of at least 20 MPa at 700° C. The composition includes cement, fly ash, silica fume, aggregate particles having a particle size D90 of approximately 20 mm or less and superplasticizer. The composition includes fiber additives including steel fibers in an amount ranging between approximately 0.1% and approximately 0.4% by volume of the concrete composition and polypropylene fibers having a melting point of approximately 200° C. or less in an amount ranging between approximately 0.05% and 0.3% by volume of the concrete composition. Carbon nanotubes are also present in an amount ranging between approximately 0.1% and approximately 0.3% by volume of the concrete composition.

Abstract: A high-workability, fire-resistant, anti-spalling concrete composition is provided. The concrete composition has a slump value of at least approximately 150 mm, a fire-resistant period of at least 4 hours, a compressive strength of at least 120 MPa at room temperature, and a compressive strength of at least 20 MPa at 700° C. The composition includes cement, fly ash, silica fume, aggregate particles having a particle size D90 of approximately 20 mm or less and superplasticizer. The composition includes fiber additives including steel fibers in an amount ranging between approximately 0.1% and approximately 0.4% by volume of the concrete composition and polypropylene fibers having a melting point of approximately 200° C. or less in an amount ranging between approximately 0.05% and 0.3% by volume of the concrete composition. Carbon nanotubes are also present in an amount ranging between approximately 0.1% and approximately 0.3% by volume of the concrete composition.

Abstract: Synthetic aggregates are fabricated from greater than approximately 70 wt % waste starting materials. Starting materials may be selected from granulated ground blast furnace slag, waste concrete fines, or sewage sludge ash, and mixtures thereof. The starting materials are bound together by a hydraulic cementitious binder either added to the starting materials or formed in situ. The waste starting materials, binder, and water are formed into pellets and subjected to a hydraulic reaction and carbonation in an atmosphere of greater than approximately 50% carbon dioxide at temperatures less than approximately 100° C. The resulting synthetic aggregate has a crush strength after a period of hardening equal to or greater than approximately 0.5 MPa.

Abstract: The present invention provides a composition for forming a lightweight, low shrinkage and hydrophobic cementitious matrix, and a method for preparing thereof. The present cementitious matrix formed by the composition is lightweight, hydrophobic (or water repelling) and with low shrinkage which is useful in building and construction industry as non-structural wall resistant to water, heat and sound entry. The present invention also provides a method of preparing the composition and the cementitious matrix formed from the composition.