Sustainable waste recycling solution for the glass fibre reinforced polymer composite materials industry

In this paper the adequacy and the benefit of incorporating glass fibre reinforced polymer (GFRP) waste materials into polyester based mortars, as sand aggregates and filler replacements, are assessed. Different weight contents of mechanically recycled GFRP wastes with two particle size grades are included in the formulation of new materials. In all formulations, a polyester resin matrix was modified with a silane coupling agent in order to improve binder-aggregates interfaces. The added value of the recycling solution was assessed by means of both flexural and compressive strengths of GFRP admixed mortars with regard to those of the unmodified polymer mortars. Planning of experiments and data treatment were performed by means of full factorial design and through appropriate statistical tools based on analyses of variance (ANOVA). Results show that the partial replacement of sand aggregates by either type of GFRP recyclates improves the mechanical performance of resultant polymer mortars. In the case of trial formulations modified with the coarser waste mix, the best results are achieved with 8% waste weight content, while for fine waste based polymer mortars, 4% in weight of waste content leads to the higher increases on mechanical strengths. This study clearly identifies a promising waste management solution for GFRP waste materials by developing a cost-effective end-use application for the recyclates, thus contributing to a more sustainable fibre-reinforced polymer composites industry.

Processing of continuous fibre reinforced thermoplastics

Towpregs based on different fibres and thermoplastic matrices were processed for highly demanding and more commercial applications by different composite processing technologies. In the technologies used, compression moulding and pultrusion, the final composite pr ocessing parameters were studied in order to obtain composites with adequate properties at industrial compatible production rates. The produced towpregs were tested to verify its polymer content and degree of impregnation. The obtained results have shown t hat the coating line enabled to produce, with efficiency and industrial scale speed rates, thermoplastic matrix towpregs that may be used to manufacture composites for advanced and larger volume commercial markets.

Drilling of fibre reinforced plastic laminates

The use of fibre reinforced plastics – FRP’s – in structures is under a considerable increase. Advantages of their use are related with their low weight, high strength and stiffness. The improvement of the dynamic characteristics has been profitable for aeronautics, automobile, railway, naval and sporting goods industries. Drilling is a widely used machining technique as it is needed to assemble parts in a structure. This is a unique machining process, characterized by the existence of two different mechanisms: extrusion by the drill chisel edge and cutting by the rotating cutting lips. Drilling raises particular problems that can reduce mechanical and fatigue strength of the parts. In this work, quasi-isotropic hybrid laminates with 25% of carbon fibre reinforced plies and 4 mm thickness are produced, tested and drilled. Three different drill geometries are compared. Results considered are the interlaminar fracture toughness in Mode I – GIc –, thrust force during drilling and delamination extent after drilling. A bearing test is performed to evaluate tool influence on the load carrying capacity of the plate. Results consider the influence of drill geometry on delamination. A correlation linking plate damage to bearing test results is presented.

Delamination analysis of carbon fibre reinforced laminates: evaluation of a special step drill

Drilling of carbon fibre/epoxy laminates is usually carried out using standard drills. However, it is necessary to adapt the processes and/or tooling as the risk of delamination, or other damages, is high. These problems can affect mechanical properties of produced parts, therefore, lower reliability. In this paper, four different drills – three commercial and a special step (prototype) – are compared in terms of thrust force during drilling and delamination. In order to evaluate damage, enhanced radiography is applied. The resulting images were then computational processed using a previously developed image processing and analysis platform. Results show that the prototype drill had encouraging results in terms of maximum thrust force and delamination reduction. Furthermore, it is possible to state that a correct choice of drill geometry, particularly the use of a pilot hole, a conservative cutting speed – 53 m/min – and a low feed rate – 0.025 mm/rev – can help to prevent delamination.

Evaluation of tools and cutting conditions on carbon fibre reinforced laminates

The distinctive characteristics of carbon fibre reinforced plastics, like low weight or high specific strength, had broadened their use to new fields. Due to the need of assembly to structures, machining operations like drilling are frequent. In result of composites inhomogeneity, this operation can lead to different damages that reduce mechanical strength of the parts in the connection area. From these damages, delamination is the most severe. A proper choice of tool and cutting parameters can reduce delamination substantially. In this work the results obtained with five different tool geometries are compared. Conclusions show that the choice of an adequate drill can reduce thrust forces, thus delamination damage.

Experimental study of the mechanical properties and durability of self-compacting mortars with nano materials (SiO2 and TiO2)

Resumo: Cement, as well as the remaining constituents of self-compacting mortars, must be carefully selected, in order to obtain an adequate composition with a granular mix as compact as possible and a good performance in the fresh state (self-compacting effect) and the hardened state (mechanical and durability-related behavior). Therefore in this work the possibility of incorporating nano particles in self-compacting mortars was studied. Nano materials are very reactive due mostly to their high specific surface and show a great potential to improve the properties of these mortars, both in mechanical and durability terms. In this work two nano materials were used, nano silica (nano SiO2) in colloidal state and nano titanium (nano TiO2) in amorphous state, in two types of self-compacting mortars (ratio binder:sand of 1:1 and 1:2). The self-compacting mortar mixes have the same water/cement ratio and 30% of replacement of cement with fly ashes. The influence of nano materials nano-SiO2 and nano-TiO2 on the fresh and hardened state properties of these self-compacting mortars was studied. The results show that the use of nano materials in repair and rehabilitation mortars has significant potential but still needs to be optimized. (C) 2015 Elsevier Ltd. All rights reserved.

Damage assessment of fibre reinforced laminates

The use of solid wastes and natural fibres to the production of innovative composites is now a matter of environmental need. A set of hybrid composites constituted of waste rubber particles and sugarcane bagasse fibres into a thermoset composite material are drilled to determine the effect of rubber particle addition and size, sugarcane fibre addition and length and fibre chemical treatment on damage extension and related mechanical properties. Damage extension is determined by enhanced radiography for further damage measurement – diameter and areas – and correlated with mechanical test results — bearing test. The results demonstrated significant effect of the rubber and fibre additions on mechanical properties of the composites.

Performance assessment of waste fibre-reinforced mortar

Materials Science Forum Vols. 730-732 (2013) pp 617-622

Pesquisa experimental para avaliação da eficiência da fibra de aço na resistência à punção de lajes lisas reforçadas simetricamente

O presente artigo é dedicado à avaliação experimental da eficiência do reforço com fibra de aço em termos da resistência à punção de lajes lisa carregadas simetricamente. Para este fim, oito lajes de 2550 x 2550 x 150 mm3 foram ensaiadas até a ruína, onde se investigou a influência do consumo de fibras (0, 60, 75 e 90 kg/m3) e da resistência do concreto (50 e 70 MPa). Duas lajes de referência, sem fibras, uma para cada classe de resistência do concreto, e uma laje para cada consumo de fibra e para cada classe de resistência do concreto compuseram o programa experimental. Todas as lajes foram armadas à flexão com barras de aço (armadura convencional) de forma a garantir a ruína por punção das lajes de referência. O único reforço transversal foi garantido pelas fibras de aço hooked ends com comprimento e diâmetro de 37 e 0,55 mm, respectivamente, e resistência à tração de aproximadamente 1100 MPa. Os resultados revelaram que as fibras de aço são muito eficientes em converter uma ruína frágil por cisalhamento em uma ruína dúctil por flexão, aprimorando ambos, carga de ruptura e deslocamento. Neste artigo o programa experimental é abordado em detalhe e os principais resultados são apresentados e discutidos.

Modelo para calcular a contribuição da fibra na resistência à punção de lajes em concreto reforçado com fibra de aço

Neste artigo, formulações analíticas são desenvolvidas para calcular a resistência à punção de lajes lisas de concreto reforçado com fibras de aço (CRFA) e que também são reforçadas à flexão por barras de aço (reforço convencional). A partir de análises estatísticas sobre um banco de dados que reúne resultados experimentais de caracterização do comportamento pós-fissuração do CRFA, equações são estabelecidas para avaliar parâmetros da resistência residual à tração na flexão (fRi) a partir de informações fundamentais que caracterizam a fibra de aço. O parâmetro de resistência fRi, proposto pelo ModelCode10 foi usado para definir a lei tensão-abertura da fissura (σ-w) que simula o mecanismo de reforço da fibra em um material cimentício. A segunda parte do artigo descreve uma formulação analítica baseada nos conceitos propostos por Muttoni e Ruiz, onde a lei σ-w é convenientemente integrada para simular a contribuição da fibra de aço na resistência à punção de lajes em CRFA. A partir de um banco de dados, composto de 154 ensaios de punção, o bom desempenho da proposta apresentada é demonstrado. O desempenho do modelo também é evidenciado comparando-se os seus resultados a outros modelos.

Modelo para calcular a resistência à punção de lajes lisas simétricas reforçadas com fibras de aço

O presente artigo discute a metodologia de um novo modelo para calcular a resistência à punção simétrica de lajes de concreto reforçado com fibras de aço (CRFA). O modelo é fundamentado na teoria da fissura crítica de cisalhamento de Muttoni e seus coautores e na proposta do ModelCode10 para simular o comportamento pós-fissuração do CRFA. O desempenho do modelo é avaliado a partir de um banco de dados (BD), coletado da literatura técnica, que totaliza 154 lajes. Os resultados são avaliados em função da precisão, da dispersão e do nível de conservadorismo, a partir do parâmetro λ=Vexp/Vteo, sendo Vexp e Vteo, respectivamente, os resultados obtidos do BD e do modelo. Finalmente, para confirmar o desempenho do modelo, os seus resultados são comparados a outros 7 modelos da literatura técnica e ambos são classificados segundo o critério modificado de Collins, o Demerit Points Classifications – DPC.

Using glass-fibre reinforced polymer composites in the production of sustainable water storage vessels

The present work focuses on the use of the life cycle assessment (LCA) and life cycle costing (LCC)methodologies to evaluate environmental and economic impacts of polymers and polymer composites materials and products. Initially a literature review is performed in order to assess the scope and limitations of existing LCA and LCC studies on these topics. Then, a case study, based on the production of a water storage glass-fibre reinforced polymer (GFRP) composite storage tank, is presented. The storage tank was evaluated via a LCA/LCC integrated model, a novel way of analysing the life cycle (LC) environmental and economic performances of structural products. The overarching conclusion of the review is that the environmental and economic performances of polymers composites in non-mobile applications are seldom assessed and never in a combined integrated way.

Pultrusion of fibre reinforced thermoplastic pre-impregnated materials

Fibre reinforced thermoplastic pre impregnated materials produced continuously by diverse methods and processing conditions were used to produce composites using pultrusion. The processing windows used to produce these materials and composites profiles were optimized by using the Taguchi / DOE (Design of Experiments) methods. Composites were manufactured by pultrusion and compression moulding and subsequently submitted to mechanical testing and microscopy analysis. The obtained results were compared with the expected theoretical ones predicted from the Rule of Mixtures (ROM) and with those of similar engineering conventional available materials. The results obtained shown that produced composites have adequate properties for applications in common and structural engineering markets.

Ureasilicate hybrid coatings for corrosion protection of galvanized steel in chloride-contaminated simulated concrete pore solution

Organic-inorganic hybrid (OIH) sol-gel coatings based on ureasilicates (U(X)) have promising properties for use as eco-friendly coatings on hot dip galvanized steel (HDGS) and may be considered potential substitutes for pre-treatment systems containing Cr(VI). These OIH coatings reduce corrosion activity during the initial stages of contact of the HDGS samples with highly alkaline environments (cementitious media) and allow the mitigation of harmful effects of an initial excessive reaction between cement pastes and the zinc layer. However, the behavior of HDGS coated with U(X) in the presence of chloride ions has never been reported. In this paper, the performance of HDGS coated with five different U(X) coatings was assessed by electrochemical measurements in chloride-contaminated simulated concrete pore solution (SCPS). U(X) sol-gel coatings were produced and deposited on HDGS by a dip coating method. The coatings performance was evaluated by electrochemical impedance spectroscopy, potentiodynamic polarization curves measurements, macrocell current density and polarization resistance in contact with chloride-contaminated SCPS. The SEM/EDS analyses of the coatings before and after the tests were also performed. The results showed that the HDGS samples coated with the OIH coatings exhibited enhanced corrosion resistance to chloride ions when compared to uncoated galvanized steel.

Bonded, Thin-Lift, Non-Reinforced Portland Cement Concrete Resurfacing, MLR-77-2, 1977

A research project involving 2, 3, 4, and 5 in. (5.1, 7.6, 10.2, and 12.7 cm) of bonded portland cement concrete (PCC) overlay on a 1.3 mile (2.1 km) PCC pavement was conducted in Clayton County, Iowa, during September 1977, centering on the following objectives: (1) Determine the mixing and proportioning procedures required in using a conventional, central mix proportioning plant to produce a dense PCC mixture using standard mixes with super water reducing admixtures; (2) Determine the economics, longevity and maintenance performance of a bonded, thin-lift, non-reinforced PCC resurfacing course using conventional procedures, equipment and concrete paving mixtures both with and without super water reducing admixtures; and (3) Determine if an adequate bond between the existing pavement and an overlay of thin-lift, dense, non-reinforced PCC can be obtained with only special surface cleaning and no surface removal or grinding. The conclusions are as follows: (1) Normal mixing equipment and proportioning procedures could be used using a conventional central-mix proportioning plant. This was successful when used with super water reducing admixtures. Only minor changes need be made in procedures and timing. (2) The time has been too short since the completion of the project to determine how the new pavement will perform, however, initially it appears that the method is economical and no reason is seen at this time why the life of the pavement should not be comparable to an all new pavement. (3) The initial test results show that bond strength, regardless of which method of cleaning is used, scarifying, sand blasting or water blasting, far exceed what is considered the minimum bond strength of 200 psi (1379 kPa) except where the paint stripes were intentionally left, thus showing that the paint must be removed. (4) It appears that either cement and water grout or sand, cement and water grout may be used and still obtain the required bond.