Patent expansively covers Geosynthetic Cementitious Composite Mat concept

A patent just issued to Santa Monica, Calif.-based Cortex Composites Inc. embodies key aspects of an emerging alternative to cast-in-place, shotcrete or precast concrete surfaces or structures—Geosynthetic Cementitious Materials Composite Mats (GCCM)—for channel, canal or ditch lining, erosion control and slope protection. Weighed against conventional concrete in heavy/civil, mining or oil & gas work, GCCM afford time, labor and material savings realized from the expedited placement and in-situ hydration of rolled products bearing layered reinforcements and portland cement-based mortar dry mix.

The Cortex GCCM uses hydration of a cement-rich dry mix and polypropylene filaments for a 1/2-in. thick composite of inordinate flexural and tensile strength. The recently patented concept sandwiches the cementitious mixture and fused loop filaments between water permeable top and waterproof base layers.

Cortex Composites underscores the strength of claims in its GCCM concept (U.S. Patent 10870964), primarily around four components: water impermeable and permeable layers; cementitious mixture between the layers; and, a structural material to connect the layers. Its market-ready mat is packaged in rolls, with top to base layers of polyvinyl acetate water-soluble fabric; fused loop polypropylene filaments; and, waterproof polypropylene membrane. Upon application of water to an unrolled, edge-anchored mat along a channel, slope or other field condition, the top layer dissolves and enables the cementitious mixture to bind the polypropylene filaments into a 1/2-in. thick composite equal to heavy loads. The concept abides ASTM D8173 – 18, Standard Guide for Site Preparation, Layout, Installation, and Hydration of Geosynthetic Cementitious Composite Mats.

Venture capital-backed Cortex Composites has been developing a broad intellectual property portfolio on many different types of GCCM materials and concepts, including mats using nonwovens, staples, pins, geogrids, thermoformable resin, needle-punching, male-female connection pins, blocks with water conduits, connection wires, sewing, and adhesive injected elements. Company officials believe that the patent, issued in December 2020 with a 2036 expiration, gives considerable protections over a wide range of GCCM materials. —