US20100101163A1

US20100101163A1 - Modular elements for structural reinforcement

Info

Publication number: US20100101163A1
Application number: US12/607,985
Authority: US
Inventors: Juan Marcos Cuevas
Original assignee: Individual
Current assignee: Individual
Priority date: 2008-10-28
Filing date: 2009-10-28
Publication date: 2010-04-29

Abstract

A structural element made of a composite material includes a plurality of modular cells disposed within the composite material that have tensile elements that create axially directed tension anchoring elements attached to the tensile elements that create compression with anchoring elements of proximate modular cells. The modular cells may be disposed randomly or in a patterned manner within the composite material. A stackable structural cell facilitates more efficient creation of beams or columns and can include rebar for some of the tension elements that are axially arranged. Additionally, modular cells and/or supported capsules may be added to increase tension and/or decrease mass or weight of the beam or column. The structural cell can further include a boundary layer for containing the composite material prior to hardening.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present U.S. Utility Patent Application claims priority pursuant to 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 61/197,473, filed Oct. 28, 2008, pending.

BACKGROUND

1. Technical Field
The present invention relates to support modules for reinforcing concrete and other composites.
2. Related Art
Concrete is known to have a strong compression strength but weak tensile strength. Reinforcing bars, known as “rebar”, are therefore commonly used to reinforce concrete and other masonry structures. In a foundation, for example, one or more layers of rebar are used. Often, a single layer of rebar is structurally placed in a volume in which concrete is subsequently poured. The rebar then provides tensile strength. The tensile strength, along with the concrete's natural compression strength, then allows the final product to be used as a base for other structures, as a passageway, etc.
The long established method of using rebar is, without other consideration, adequate. The techniques and technology for adding such tensile strength, however, if modified to increase efficiency and/or decrease manufacturing and construction costs, could reduce the high costs of construction and could possibly even allow new structural designs to be implemented that could not be implemented before. What is needed, therefore, is a new structure and method for increasing tensile strength for base materials that have good compression strength but poor tensile strength.

SUMMARY OF THE INVENTION

The present invention is directed to apparatus and methods of operation that are further described in the following Brief Description of the Drawings, the Detailed Description of the Invention, and the claims. Other features and advantages of the present invention will become apparent from the following detailed description of the invention made with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered with the following drawings, in which:

FIGS. 1A and 1B illustrate prior art structures for creating tensile strength.

FIG. 2 is a functional diagram that illustrates creating structural tension within a composite using a plurality of independent modular structures that have outwardly extending tensile elements according to one embodiment of the invention.

FIG. 3 illustrates interlocking between anchoring elements formed at distal ends of tensile elements of a modular cell as well as an anchoring element formed at a center of a modular cell from which the tensile elements extend according to one embodiment of the invention.

FIG. 4 is an embodiment of a modular cell according to one embodiment of the invention.

FIG. 5 is an embodiment of a modular cell according to one embodiment of the invention having a large central anchoring element that displaces a substantial volume of composite material to reduce overall weight of a structure.

FIG. 6 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention.

FIG. 7 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention in which greater amounts of perpendicular tension are created.

FIG. 8 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention in which multidirectional tension is created and in which structural mass and weight is reduced.

FIG. 9 is an embodiment of a structural cell having an exterior boundary layer according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention.

FIGS. 10A and 10B are embodiment of structural cell according to one embodiment of the invention that facilitates creating rectangular or square columns and beams according to one embodiment of the invention.

FIG. 11 is an embodiment of a modular cell that may be used with any of the structural cells of FIGS. 6-10 (and other alternative designs) to create tension perpendicular to the axial direction of the column or beam and to reduce the mass and weight of the beam or column.

FIGS. 12-20 are functional diagrams that illustrate alternative embodiments of the invention.

FIG. 21 is a side view of a modular cell according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B illustrate prior art structures for creating tensile strength. Referring to FIG. 1A, a single layer of rebar is disposed within a composite (e.g., concrete) creating tensile strength in the X-axis and Y-axis directions as shown. FIG. 1B shows two layers of rebar disposed within a composite that are connected to each other creating tensile strength in the X-axis, Y-axis and Z-axis directions as shown. In the case of FIG. 1A, tensile strength is created only in perpendicular directions (relative to each other) in a single plane. In the case of FIG. 1B, tensile strength also is created primarily in perpendicular directions (relative to each other) though the tensile strength is created vertically (Z-axis) and horizontally (X-axis and Y-axis).
FIG. 2 is a functional diagram that illustrates creating structural tension within a composite using a plurality of independent modular structures that have outwardly extending tensile elements according to one embodiment of the invention. More specifically, FIG. 2 illustrates the interaction of tensile elements of different modular cells to add tension to a structural composite material such as, but not limited to, concrete. Generally, FIG. 2 illustrates the creation of a reinforced composite structure using modular cells in which tension is created in a plurality of directions. The composite material may comprise concrete other composites according to design implementation. The modular cells may comprise hard plastics, metal or other materials that have a desired tensile strength according to application.
Referring now to FIG. 2, a composite material 02, which may be and often will be hardened concrete, includes a plurality of randomly disposed tensile elements 04 each having, at a distal end, an anchoring element 06. The tensile elements 04 generate tension 08 in an axial direction of the tensile elements 04. The anchoring elements 06 generate opposed compression shown generally at 10. Accordingly, the compression 10 keeps the anchoring elements 06 in fixed positions relative to each other. The corresponding tensile elements 04 for each of the anchoring elements 06 then create the tension in random three-dimensional directions according to the random axial direction of the tensile elements 04.
In the example of FIG. 2, the tensile elements 04 are disposed within composite material 02 in a random manner creating tension in random three-directional directions. In contrast, common structural elements using rebar provide tensile strength only in perpendicular directions in a plane defined by a single layer of rebar. Thus, for a plane defined by a single layer of rebar, tensile strength is provided only in X and Y directions. In a deeper construction wherein multiple layers of rebar are included, tensile strength is provided in the X, Y and Z directions if the layers of rebar are coupled as shown in FIG. 1B. Here, however, tensile strength is created in random angled three-dimensional directions including but not limited to the X, Y and Z axis directions.
Alternatively, if the tensile elements 04 disposed in a patterned manner within composite 02, tensile strength may be created in defined three-dimensional directions based on a layout pattern and the structural characteristics of the modular cells and the tensile elements. Subsequent figures herein illustrate many different shapes of the modular cells that may be used, each having its own structural characteristics.
Generally, the various modular cells allow or create the structural effect of interlocking one with another by interlocking with each other. Compression resistance of the composite material locks the modular cells in place. The tensile elements of the modular cells then create tensile strength (axially or otherwise) along the tensile elements to create an overall stronger structure made out of the composite material.
An additional aspect of the embodiments of the present invention is that the modular cells will typically comprise a much lighter weight material than steel (as used for rebar). Accordingly, the total weight of the structure is reduced thereby reducing size and volume requirements for the structure. For example, a thickness of concrete beam is based on the total weight that the beam will be required to support. This total weight, of course, includes the weight of the concrete beam itself as well as other concrete beams that it will support. Thus, if the concrete beams are made to be lighter in weight, then the size of the beams may be reduced.
Not only may the modular cells be made of a lighter material to reduce the weight of the structure (e.g., concrete beam), but the modular cells may be shaped to define lightweight volumes that displace the composite material thereby reducing manufacturing costs as well as weight. Thus, use of the modular cells improves the overall characteristics of the final reinforced structural element by creating tensile strength in additional directions (other than the X, Y and Z axis) and also by creating greater structural integrity for a given size structure through the use of light weight modules that replace some of the heavier weight composite used for the structure.
Depending on the specific design, the modular cells may be randomly poured in the form for a structure (such as a concrete beam or concrete foundation) before pouring the composite into the form. Or they may be spread or assembled evenly in a patterned manner before pouring the composite material within the form. The modular cells also may be added to the composite mixture and poured in the forms as part of the mixture. Or they may be assembled evenly over scaffolding, ground or other surface or structure; to create both the reinforcement structure and the form for the composite in one step. The modular cells may therefore be added to a composite in a variety of method steps according to design requirements and/or processes. The modular cells primarily add tensile strength, but, depending of the specific design and materials used such as metals, plastics, fibers, ceramics, resins, etc. can also add compression strength, decrease overall structural weight, improve corrosion resistance, add thermal insulation, increase flexibility, and construction efficiency by eliminating the labor intensive process of creating the rebar layers (which includes attaching and tightening rebar to each other by using ties or by welding or soldering). In some cases, the time and materials used to create the forms may also be reduced or eliminated. Special modular cells may also be created that support making vertical structural beams which are easier to store and transport.
While fiber additives may be inserted into a composite to create some tensile strength through bonding and created friction of the fibers to the composite, such fiber additives have no real mechanical interlocking action and in many cases also decrease the compression strength of the composite. Thus, the modular cells of the embodiments of the present invention have overlapping anchoring elements that interlock with each other and that, in a hardened composite, create better tensile strength in more directions to create stronger structures.
There are many modular cells may be made with modern high strength plastics, metals, resins and fibers. The choices and possibilities for specific designs and fabrication materials and methods are endless. The following embodiments are exemplary and should not be used to limit the concepts disclosed herein and associated with the present embodiments of the invention.
FIG. 3 illustrates interlocking between anchoring elements formed at distal ends of tensile elements of a modular cell as well as an anchoring element formed at a center of a modular cell from which the tensile elements extend according to one embodiment of the invention. More specifically, a plurality of anchoring elements 06 formed at distal ends of tensile elements 04 are shown as well as anchoring elements 12 formed at a center of each of a plurality of modular cells. The tensile elements 04 extend from the anchoring elements 12. As may be seen, opposed compression 10 is created between anchoring elements 12 and anchoring elements 06 create an interlocking of the modular cells to add tensile strength in a plurality of directions for a structure. As may also be seen, compression 10 also may be created between the anchoring elements and proximate tensile elements 04. Compression 10 between tensile elements and anchoring elements as well as between distant anchoring elements is shown in dashed lines to indicate potentially lower levels of compression in contrast to compression between anchoring elements 06 and 12.
FIG. 4 is an embodiment of a modular cell according to one embodiment of the invention. A modular cell 14 of the embodiment of FIG. 4 has a “jack” shape comprising six outwardly extending tensile elements 04, each of which includes an anchoring element 06 disposed at a distal end. A center of modular cell 14 may be increased in size to create an anchoring element 12 (not shown here). The overall size and shape of modular element 14 allows it to be premixed with the composite (e.g., concrete). The tensile elements 04 and anchoring elements 06 and 12 create tension within a composite in a manner similar as that discussed in relation to FIG. 2.
Different shapes, materials and dimensions for the cells can be designed to meet specific structural needs. For example, modular cells 14 having a length “L” of one inch may be used for a small house beam or column. Generally, in the embodiments of the invention, a diameter of an anchoring element 06 is sized to be in the range of 10 percent to 30 percent of a length L of the modular cells. A diameter of the tensile elements 04 is approximately half of the anchoring elements. Depending on the materials used for the modular cells 14 and the materials used for the composite, these ranges may vary. An anchoring element may therefore be reduced in size to 5 percent of the length L of the modular cell. Similarly, the diameter of the tensile elements 04 may be reduced or increased in relation to the size of the anchoring elements. Thus, the diameter of the tensile elements can range from, for example, 10 percent to 50 percent of the diameter of anchoring elements 06. One factor in selecting a diameter of the tensile elements 04 in relation to distal anchoring elements 06 is the desired tensile strength. Failure of some modular elements can lead to cracks appearing in the structure to warn of an impending failure. Otherwise, a structure may completely fail without warning. One of average skill in the art may readily make such determinations based on application requirements.
The modular cells 14 may be used in place of some or all of the gravel commonly poured into concrete. Modular cells may be made much larger. In one embodiment, modular cells 14 have a length L of 36 inches and may be used for a foundation or column for a large structure such as a bridge. In such an embodiment, gravel and rocks having a 1″ or 2″ diameter may also be dispersed within the concrete or composite. As the length L of the modular cell increases, the proportions discussed above will typically be maintained absent special considerations that result from the increased size.
The anchoring elements 06 and 12 of the modular cells, including modular cell 14, are sized appropriately in relation to the size of the modular cell 14. For one example of relative dimensions, if modular cell 14 has a length L of 2.5 inches, anchoring elements 06 have a diameter of 0.5 inches while outwardly extending tensile elements 04 have a diameter of 0.25 inches. Thus, the anchoring elements 06 have a diameter that is 20 percent of the total length L while the outwardly extending tensile elements have a diameter that is 10 percent of the total length L and fifty percent of the anchoring elements 06. These relative sizes may be varied. In general, however, the anchoring elements must be large enough to create adequate levels of compression with each other to create interlocking but small enough to readily overlap with each other when disposed in a composite material. Further, especially for a structure, the tensile elements 04 are sized to be smaller than the anchoring elements 06 to allow the tensile elements to break or stretch (according to its material) when the structure is under high levels of stress (e.g., in an earthquake) so that stress of the structure may be noted before a complete failure or collapse occurs.
FIG. 5 is an embodiment of a modular cell according to one embodiment of the invention having a large central anchoring element that displaces a substantial volume of composite material to reduce overall weight of a structure. The embodiment of FIG. 5 includes a modular cell 16 having a central anchoring element 12 that is sized substantially larger in diameter than the anchoring elements 06. Modular cell 16 includes 6 perpendicularly arranged outwardly extending tensile elements 04, each having an anchoring element 06. The outwardly extending tensile elements 04 are perpendicular relative to each other in the X, Y and Z axes as in the example of FIG. 4. Additionally, modular cell 16 includes additional supporting members 18 that reinforce the tensile strength created by outwardly extending tensile elements 04. The three dimensional shape with created by the supporting members 18, which are shaped as rings in this embodiment, and the outwardly extending tensile elements 04, allows modular cell 16 to be randomly dispersed in a composite by pouring the modular cells 16 into a form, before pouring the composite (e.g., concrete). For such an application, the size of the modular cell 16 and elements 04, 06 and 18 must be considered in relation to the characteristics of the composite material to allow the composite material to flow through and around elements 04, 06 and 18 to create the opposed compression upon hardening. Central anchoring element may be made of a hollow shell from, for example, a hard plastic, or alternately may comprises a light weight solid material. In either case, heavy composite material (e.g., concrete) is replaced thereby reducing the weight of the structure.
FIG. 6 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention. A structural cell 20 include a plurality of axially disposed first tensile elements 22 that are mechanically coupled to each other by a plurality of supporting members 24 that are ring shaped similar to the supporting members 18 of FIG. 5. Tensile elements 22 create axially directed tension 26 (in the direction of tensile elements 22) while supporting members 24 effectively create a tension perpendicular to the axial tension of tensile elements 22. In one embodiment, tensile member 22 comprises rebar. Such structural cells may be stacked to create a column or beam.
FIG. 7 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention in which greater amounts of perpendicular tension are created. Here, a structural cell 28 is similar to structural cell 20 and includes the same elements. Additionally, structural cell 28 includes outwardly radiating (relative to an axial center) tensile elements 30 that cross-connect tensile elements 22 and are perpendicular to tensile elements 22. Thus, outwardly radiating tensile elements 30 create tension 32 that is perpendicular to the tension 26 of tensile elements 22. In one embodiment, outwardly radiating tensile elements 30 comprise rebar.
FIG. 8 is an embodiment of a structural cell according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention in which multidirectional tension is created and in which structural mass and weight is reduced. A structural cell 40 in the embodiment of FIG. 8 is similar to FIG. 6 with the addition of modular cells coupled in a lattice structure. The modular cells include anchoring elements 12 that have outwardly extending tension elements 46 that either couple to other anchoring elements 12 or to tension elements 22 or supporting members 24.
This lattice structure, on its own, creates multidirectional tension according to the angled disposition of the tension elements 34. Additionally, multi-directional tension may be created by adding a plurality of modular cells such as, but not limited to, modular cells 14 and 16. The anchoring elements of such modular cells 14 and 16 (for example) may create compression not only with each other but also with anchoring elements 12 of the modular cells coupled in a lattice structure.
For each of the embodiments of structural cells 20, 28 and 40 of FIGS. 6-8, and any other embodiment for a structural cell, a first end of the first tensile elements 22 may include interlocking element 42 while a second end of tensile elements 22 may include interlocking element 44. Interlocking elements 42 and 44 are shaped and sized to mechanically engage each other to allow structural cells 20, 28 or 40 to be stacked in a coupled manner to facilitate the creation of a beam. Thus, the geometric shape of the exemplary embodiment of structural cells 20, 28 and 40 allows the assembly of a plurality of such cells to create reinforcement for a round column, pier or other round structure. In this case, the structural cells 20, 28 and 40 are assembled in such a manner prior to a composite being poured to create the column, pier, beam or other structure.
FIG. 9 is an embodiment of a structural cell having an exterior boundary layer according to one embodiment of the invention that facilitates creating columns and beams according to one embodiment of the invention. In this embodiment, a structural cell such as 20, 28 or 40 includes an outer boundary layer 48 that is used to contain composite material when the composite material is poured into the structural cell. In one embodiment, boundary layers 48 define an ornamental patterned mold to create an aesthetic surface for the column or beam being formed. Thus, after the composite material has hardened to form the beam or other structure, boundary layer 46 may be removed to reveal the beam or other formed structure. Boundary layer 48 may be made of plurality of different materials including plastic, reinforced cardboard, or metal. In one embodiment, boundary layer 48 comprises a male lip at a first end and a female lip at a second end for engaging a male tip of another structural cell to support stacking of structural cells 20 having boundary layers 48.
FIGS. 10A and 10B are embodiment of structural cell according to one embodiment of the invention that facilitates creating rectangular or square columns and beams according to one embodiment of the invention. The construction of the structural cell 50 of FIG. 10A and 52 for FIG. 10B is similar to and can include any of the aspects of the embodiments of FIGS. 6-9. Any of the aforementioned aspects for creating tension may be included. Further, the aspects of using a boundary layer to contain the composite material may be included. In this example of a modular cell 50, the geometric shape of the cell is designed to create a rectangular structure, such as a column, beam, contention wall, etc. In the example of FIG. 10B, the geometric shape of the cell could be used for construction of flat structures such as floors, roof tops, highways, sidewalks, foundations, etc.
FIG. 11 is an embodiment of a modular cell that may be used with any of the structural cells of FIGS. 6-10 (and other alternative designs) to create tension perpendicular to the axial direction of the column or beam and to reduce the mass and weight of the beam or column. In this example, the modular cell 52 is designed to provide not only the required tensile strength for the structure but also to create the form for the composite; including a light weight capsule 54 at the center to reduce the amount of required composite and overall structural weight. As may be seen, capsule 54 is supported by second tensile elements 56 and 58. Capsule 54 may comprise a hollow structure or, alternatively, a solid material that is substantially lighter than the composite material. As before, second tensile elements 56 and 58, as well as any of the axially arranged first tensile elements of FIGS. 6-10, may be made of a plurality of different materials. In one particular embodiment for each of the structural cells of FIGS. 6-10, the first and second tensile elements include rebar. In the described embodiments, the tensile elements of the modular cells, however, do not comprise rebar.
The above described concepts may readily be modified without departing from the scope of the invention. FIG. 12 shows an embodiment of a modular cell in which a centered anchoring element 12 defining a shape similar to a sphere has outwardly extending tensile elements 60 with anchoring elements 64. Elements 60 and 62 are substantially flat. In one embodiment, the modular cell of FIG. 12 is made by cutting a desired pattern from sheet metal and is then bent according to a desired shape. In the example of FIG. 12, tension elements 60 extend away from anchoring element 12 in an angled manner rather than a perpendicular manner. The tension elements may be bent to extend in any desired angle and need not be consistent as shown in FIG. 12.
FIGS. 13A and 13B further illustrate the embodiment of FIG. 12. FIG. 14 illustrates modular cell in which a central anchoring element 12 is many orders of magnitude larger than anchoring elements 06 disposed at the distal ends of the outwardly extending tensile elements 04. FIG. 15 is similar to FIG. 14 except that tension elements 04 extend outwardly in an angled manner similar to that of FIG. 12. FIG. 16 illustrates an embodiment of a modular cell 66 that includes anchoring elements 06 disposed at the end of tensile elements 04 which radiate from anchoring elements 68. Anchoring elements 68 are coupled to each other by supporting members 70 that are similar to supporting members 18. FIG. 17 illustrates a modular cell 72 that is similar to that of FIG. 12 except that anchoring element 12 is replaced by flat anchoring element 74. FIGS. 18A and 18B further illustrate the embodiment of FIG. 17. FIG. 19 is an aspect view of the embodiment of the embodiment of FIG. 16. FIG. 20 is an exemplary embodiment of structural cell as described in relation to FIGS. 6-11.
FIG. 21 is a side view of a modular cell according to one embodiment of the invention. For plastic modular cells, the modular cells may be manufactured in two pieces using a mold or other technique that are then permanently bonded to each other using common fabrication techniques. Thus, the dimensions for this embodiment of the modular cell are as shown. A total length L is equal to 1 and ⅞ inches. The tensile elements 04 and supporting elements 18 are each ⅛ inch diameter. The anchoring elements 06 and 12 are each ⅜ inch diameter.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and detailed description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but, on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the claims. As may be seen, the described embodiments may be modified in many different ways without departing from the scope or teachings of the invention.

Claims

1. A structural element, comprising:

a composite material; and

a plurality of modular cells disposed within the composite material, wherein each of the modular cells includes:

tensile elements that create tension axially along an axis of the tensile elements; and

anchoring elements that create compression with anchoring elements of proximate modular cells, wherein each the anchoring elements is attached to at least one tensile element.

2. The structural element of claim 1 wherein the plurality of modular cells are disposed in a random manner within the composite material and create tension in associated random directions.

3. The structural element of claim 2 wherein the tension created in associated random directions corresponds with an axial direction of each tensile element of modular cells.

4. The structural element of claim 1, the modular cells comprising a plurality of orthogonally arranged tension elements.

5. The structural element of claim 1, the modular cells comprising six tension elements.

6. The structural element of claim 1 wherein the anchoring elements are sized to be in the range of 10 percent to 30 percent of a length of the modular cells.

7. The structural element of claim 1 wherein the anchoring elements are sized to be in the range of 5 percent to 30 percent of a length of the modular cell tension elements.

8. The structural element of claim 1 wherein the anchoring elements are sized to have a diameter that is larger than a diameter of the tension elements.

9. The structural element of claim 1 comprising anchoring elements characterized by a first size at a distal end of each tension element and at least one modular cell having an anchoring element characterized by a second size from which at least two tension elements extend.

10. The structural element of claim 9 wherein the second size is approximately the same as the first size.

11. The structural element of claim 9 wherein the second size is substantially larger than the first size.

12. The structural element of claim 1 comprising at least one structural cell wherein the structural element comprises one of a beam or column.

13. The structural element of claim 1 comprising a plurality of structural cell that are mechanically engaged with each other and wherein the structural element forms one of a beam or column.

14. A structural element, comprising:

a composite material; and

at least one structural cell wherein the at least one structural cell further includes:

axially arranged first tension elements that are substantially parallel to each other;

at least one supporting member coupled to all of the axially arranged tension elements to define a shape of the structural element; and

first and second interlocking elements, wherein:

the first interlocking elements are disposed at a first end of each of the axially arranged tension elements;

the second interlocking elements are disposed at a second end of each of the axially arranged tension elements; and

the first and second interlocking elements are shaped and sized to mechanically engage each other so that other similar structural elements may be stacked to form a column or beam.

15. The structural element of claim 14 further including a boundary layer for holding the composite material until the composite material has hardened.

16. The structural element of claim 15 wherein the boundary layer is removable after the composite material has hardened.

17. The structural element of claim 14 further including second tension elements disposed perpendicularly to the axially arranged first tension elements.

18. The structural element of claim 17 further including at least one capsule that reduces an amount of composite required to form the structural element, wherein each capsule of the at least one capsule is supported by the second tension elements.

19. The structural element of claim 14 further including a plurality of modular cells that are arranged either in a pattern or randomly or both.

20. The structural element of claim 19 wherein at least a portion of the plurality of modular cells are coupled to at least one of the first tension elements or second tension elements.

21. A structural element, comprising:

axially arranged first tension elements;

second tension elements disposed substantially perpendicular to the first tension elements;

a composite material wherein the first and second tension elements are disposed within the composite material; and

modular cells disposed within the composite material to create tension in a plurality of directions, the modular cells each having tension elements and anchoring elements disposed at distal ends of the modular cell tension elements.

22. The structural element of claim 21 further including at least one of gravel and rocks within the composite material.

23. The structural element of claim 21 wherein the modular cells are disposed in a patterned manner to create tension along desired directions.

24. The structural element of claim 21 wherein the modular cells are disposed in a random manner to create tension along a plurality of directions that are not necessarily orthogonal to first and second tension elements.