Reusability assessment of thermoset polymeric composite wastes as reinforcement and filler replacement for polymer concrete materials

The development and applications of thermoset polymeric composites, namely fiber reinforced polymers (FRP), have shifted in the last decades more and more into the mass market [1]. Production and consume have increased tremendously mainly for the construction, transportation and automobile sectors [2, 3]. Although the many successful uses of thermoset composite materials, recycling process of byproducts and end of lifecycle products constitutes a more difficult issue. The perceived lack of recyclability of composite materials is now increasingly important and seen as a key barrier to the development or even continued used of these materials in some markets.

New end-use application for GFRP recyclates as reinforcement for concrete-polymer materials’

Glass fibre-reinforced plastics (GFRP), nowadays commonly used in the construction, transportation and automobile sectors, have been considered inherently difficult to recycle due to both: cross-linked nature of thermoset resins, which cannot be remolded, and complex composition of the composite itself, which includes glass fibres, matrix and different types of inorganic fillers. Presently, most of the GFRP waste is landfilled leading to negative environmental impacts and supplementary added costs. With an increasing awareness of environmental matters and the subsequent desire to save resources, recycling would convert an expensive waste disposal into a profitable reusable material. There are several methods to recycle GFR thermostable materials: (a) incineration, with partial energy recovery due to the heat generated during organic part combustion; (b) thermal and/or chemical recycling, such as solvolysis, pyrolisis and similar thermal decomposition processes, with glass fibre recovering; and (c) mechanical recycling or size reduction, in which the material is subjected to a milling process in order to obtain a specific grain size that makes the material suitable as reinforcement in new formulations. This last method has important advantages over the previous ones: there is no atmospheric pollution by gas emission, a much simpler equipment is required as compared with ovens necessary for thermal recycling processes, and does not require the use of chemical solvents with subsequent environmental impacts. In this study the effect of incorporation of recycled GFRP waste materials, obtained by means of milling processes, on mechanical behavior of polyester polymer mortars was assessed. For this purpose, different contents of recycled GFRP waste materials, with distinct size gradings, were incorporated into polyester polymer mortars as sand aggregates and filler replacements. The effect of GFRP waste treatment with silane coupling agent was also assessed. Design of experiments and data treatment were accomplish by means of factorial design and analysis of variance ANOVA. The use of factorial experiment design, instead of the one-factor-at-a-time method is efficient at allowing the evaluation of the effects and possible interactions of the different material factors involved. Experimental results were promising toward the recyclability of GFRP waste materials as aggregates and filler replacements for polymer mortar, with significant gain of mechanical properties with regard to non-modified polymer mortars.

Recycling of pultrusion production waste into innovative concrete-polymer composite solutions

In this study, the added value resultant from the incorporation of pultrusion production waste into polymer based concretes was assessed. For this purpose, different types of thermoset composite scrap material, proceeding from GFRP pultrusion manufacturing process, were mechanical shredded and milled into a fibrous-powdered material. Resultant GFRP recyclates, with two different size gradings, were added to polyester based mortars as fine aggregate and filler replacements, at various load contents between 4% up to 12% in weight of total mass. Flexural and compressive loading capacities were evaluated and found better than those of unmodified polymer mortars. Obtained results highlight the high potential of recycled GFRP pultrusion waste materials as efficient and sustainable admixtures for concrete and mortar-polymer composites, constituting an emergent waste management solution.

Experimental study on polyester based concretes filled with glass fibre reinforced plastic recyclates – a contribution to composite materials sustainability

The development and applications of thermoset polymeric composites, namely fibre reinforced plastics (FRP), have shifted in the last decades more and more into the mass market [1]. Despite of all advantages associated to FRP based products, the increasing production and consume also lead to an increasing amount of FRP wastes, either end-of-lifecycle products, or scrap and by-products generated by the manufacturing process itself. Whereas thermoplastic FRPs can be easily recycled, by remelting and remoulding, recyclability of thermosetting FRPs constitutes a more difficult task due to cross-linked nature of resin matrix. To date, most of the thermoset based FRP waste is being incinerated or landfilled, leading to negative environmental impacts and supplementary added costs to FRP producers and suppliers. This actual framework is putting increasing pressure on the industry to address the options available for FRP waste management, being an important driver for applied research undertaken cost efficient recycling methods. [1-2]. In spite of this, research on recycling solutions for thermoset composites is still at an elementary stage. Thermal and/or chemical recycling processes, with partial fibre recovering, have been investigated mostly for carbon fibre reinforced plastics (CFRP) due to inherent value of carbon fibre reinforcement; whereas for glass fibre reinforced plastics (GFRP), mechanical recycling, by means of milling and grinding processes, has been considered a more viable recycling method [1-2]. Though, at the moment, few solutions in the reuse of mechanically-recycled GFRP composites into valueadded products are being explored. Aiming filling this gap, in this study, a new waste management solution for thermoset GFRP based products was assessed. The mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the potential added value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. The use of a cementless concrete as host material for GFRP recyclates, instead of a conventional Portland cement based concrete, presents an important asset in avoiding the eventual incompatibility problems arisen from alkalis silica reaction between glass fibres and cementious binder matrix. Additionally, due to hermetic nature of resin binder, polymer based concretes present greater ability for incorporating recycled waste products [3]. Under this scope, different GFRP waste admixed polymer mortar (PM) formulations were analyzed varying the size grading and content of GFRP powder and fibre mix waste. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacities of modified mortars with regard to waste-free polymer mortars.

Re-Use Assessment of Thermoset Composite Wastes as Aggregate and Filler Replacement for Concrete-Polymer Composite Materials: A case study regarding GFRP pultrusion wastes

Glass fibre-reinforced plastics (GFRP), nowadays commonly used in the construction, transportation and automobile sectors, have been considered inherently difficult to recycle due to both the cross-linked nature of thermoset resins, which cannot be remoulded, and the complex composition of the composite itself, which includes glass fibres, polymer matrix and different types of inorganic fillers. Hence, to date, most of the thermoset based GFRP waste is being incinerated or landfilled leading to negative environmental impacts and additional costs to producers and suppliers. With an increasing awareness of environmental matters and the subsequent desire to save resources, recycling would convert an expensive waste disposal into a profitable reusable material. In this study, the effect of the incorporation of mechanically recycled GFRP pultrusion wastes on flexural and compressive behaviour of polyester polymer mortars (PM) was assessed. For this purpose, different contents of GFRP recyclates (0%, 4%, 8% and 12%, w/w), with distinct size grades (coarse fibrous mixture and fine powdered mixture), were incorporated into polyester PM as sand aggregates and filler replacements. The effect of the incorporation of a silane coupling agent was also assessed. Experimental results revealed that GFRP waste filled polymer mortars show improved mechanical behaviour over unmodified polyester based mortars, thus indicating the feasibility of GFRP waste reuse as raw material in concrete-polymer composites.

Fabrication and characterisation of polymer optical fibers for smart sensing and optical amplification

The thesis presented the fabrication and characterisation of polymer optical fibers in their applications as optical amplifier and smart sensors.Optical polymers such as PMMA are found to be a very good host material due to their ability to incorporate very high concentration of optical gain media like fluorescent dyes and rare earth compounds. High power and high gain optical amplification in organic dye-doped polymer optical fibers is possible due to extremely large emission cross sections of oyes. Dye doped (Rhodamine 6G) optical fibers were fabricated by using indigenously developed polymer optical fiber drawing tower. Loss characterization of drawn dye doped fibers was carried out using side illumination technique. The advantage of the above technique is that it is a nondestructive method and can also be used for studying the uniformity in fiber diameter and doping. Sensitivity of the undoped polymer fibers to temperature and microbending were also studied in its application in smart sensors.Optical amplification studies using the dye doped polymer optical fibers were carried out and found that an amplification of l8dB could be achieved using a very short fiber of length lOcm. Studies were carried out in fibers with different dye concentrations and diameter and it was observed that gain stability was achieved at relatively high dye concentrations irrespective of the fiber diameter.Due to their large diameter, large numerical aperture, flexibility and geometrical versatility of polymer optical fibers it has a wide range of applications in the field of optical sensing. Just as in the case of conventional silica based fiber optic sensors, sensing techniques like evanescent wave, grating and other intensity modulation schemes can also be efficiently utilized in the case of POF based sensors. Since polymer optical fibers have very low Young's modulus when compared to glass fibers, it can be utilized for sensing mechanical stress and strain efficiently in comparison with its counterpart. Fiber optic sensors have proved themselves as efficient and reliable devices to sense various parameters like aging, crack formation, weathering in civil structures. A similar type of study was carried out to find the setting characteristics of cement paste used for constructing civil structures. It was found that the measurements made by using fiber optic sensors are far more superior than that carried out by conventional methods. More over,POF based sensors were found to have more sensitivity as well.

A study of the chemical and physical properties of cashew nut shell ash for use in cement materials.

A study of the chemical and physical properties of cashew nut shell ash for use in cement materials. Ash occupies a prominent place among agro-industrial wastes, as it is derived from energy generation processes. Several types of ash have pozzolanic reactivity, and might be used as replacement material for cement, resulting in less energy waste and lower cost. This work aimed to investigate the physical and chemical properties of the cashew nut shell ash (CNSA), by performing the following measurement tests: chemical analysis, bulk density, specific mass, leaching and solubilization process, X-ray diffraction (XrD), specific surface area (BET) and pozzolanicity analysis with cement and lime. The results indicate a low reactivity of CNSA and the presence of heavy metals, alkalis and phenol.

SEALING ABILITY of CASTOR OIL POLYMER AS A ROOT-END FILLING MATERIAL

Objective: The purpose of this study was to evaluate the sealing ability of castor oil polymer (COP), mineral trioxide aggregate (MTA) and glass ionomer cement (GIC) as root-end filling materials. Forty-five single-rooted human teeth were cleaned and prepared using a step-back technique. The apical third of each root was resected perpendicularly to the long axis direction. All teeth were obturated with gutta-percha and an endodontic sealer. After, a root-end cavity with 1.25-mm depth was prepared using a diamond bur. The specimens were randomly divided into three experimental groups (n = 15), according to the root-end filling material used: G1) COP; G2) MTA; G3) GIC. The external surfaces of the specimens were covered with epoxy adhesive, except the root-end filling. The teeth were immersed in rhodamine B dye for 24 hours. Then, the roots were sectioned longitudinally and the linear dye penetration at the dentin/material interface was determined using a stereomicroscope. ANOVA and Tukey's tests were used to compare the three groups. The G1 group (COP) presented smaller dye penetration, statistically different than the G2 (MTA) and G3 (GIC) groups (p < 0.05). No statistically significant difference in microleakage was observed between G2 and G3 groups (p > 0.05). The results of this study indicate that the COP presented efficient sealing ability when used as a root-end filling material showing results significantly better than MTA and GIC.

Effect of light energy density on conversion degree and hardness of dual-cured resin cement

This study evaluated the effect of different light energy densities on conversion degree (CD) and Knoop hardness number (KHN) of RelyX ARC (RLX) resin cement. After manipulation according to the manufacturer's instructions, RLX was inserted into a rubber mold (0.8 mm X 5 mm) and covered with a Mylar strip. The tip of the lightcuring unit (LCU) was positioned in contact with the Mylar surface. Quartz-tungsten-halogen (QTH) and light-emitting diode (LED) LCUs with light densities of 10, 20 and 30 J/cm2 were used to light-cure the specimens. After light curing, the specimens were stored dry in lightproof containers at 37°C. After 24 hours, the CD was analyzed by FT-Raman and, after an additional 24-hours, samples were submitted to Knoop hardness testing. The data of the CD (%) and KHN were submitted to two-way ANOVA and the Tukey's test (α=0.05). QTH and LED were effective light curing units. For QTH, there were no differences among the light energy densities for CD or KHN. For LED, there was a significant reduction in CD with the light energy density set at 10 J/cm2. KHN was not influenced by the lightcuring unit and by its light energy density. © Operative Dentistry.

Degree of conversion of polymer-matrix composite assessed by FTIR analysis

Aims and objectives: The behavior of polymer-matrix composite is dependent on the degree of conversion. The aim of this study was to evaluate the degree of conversion of two resin cements following storage at 37°C immediately, 24 and 48 hours, and 7 days after light-curing by FTIR analysis. Materials and methods: The specimens were made in a metallic mold and cured with blue LED with power density of 500 mW/cm2 for 30 seconds. The specimens were pulverized, pressed with KBr and analyzed with FTIR following storage times. Statistical analysis used: ANOVA (two-way) and Tukey's post hoc. Results: To the polymer-matrix composites between 24 and 48 hours does not show a significant increase (p > 0.05), however, the highest values were found after 7 days. Conclusion: The polymer-matrix composites used in this study showed similarity on the degree of conversion and increased of according to the time of storage.

Use of high-resolution thermogravimetric analysis (HRTG) technique in spent FCC catalyst/Portland cement pastes

Thermogravimetric analysis is one of the most common instrumental techniques used for the characterization of pastes, mortars and concretes based on both calcium hydroxide and Portland cement. Important information about pozzolanic materials can be assessed concerning calcium hydroxide consumption and the formation of new hydrated products. Nevertheless, in some cases, problems associated with the overlapped decomposition processes for hydrates make the analysis of obtained data difficult. In this paper, the use of high-resolution thermogravimetric analysis, a powerful technique that allows separating decomposition processes in analysis of hydrated binders, was performed for spent FCC catalyst-Portland cement pastes. These pastes were monitored for 1, 4, 8 h and 1, 2, 3, 7 and 28 curing days. In order to study the influence of the pozzolanic material (spent FCC catalyst), Portland cement replacements of 5, 15 and 30 % by mass were carried out. The presence of spent FCC catalyst in blended pastes modified the amount and the nature of the formed hydrates, mainly ettringite and stratlingite.

Effect of EVA on the fresh properties of cement paste

The improved workability effect of latex in dry mortars has not been fully clarified. The purpose of this research was to investigate the influence of the EVA copolymer on the cement hydration and on the rheological properties of cement pastes. The results pointed to a minor influence of EVA on cement hydration and to a ball-bearing effect. In fact, the shear thinning behavior of reference paste at 15 min after mixing changed to shear thickening owing to the EVA addition. This behavior could be explained by the decrease in the interparticle separation distance as consequence of the solid content increase in case of shearing detachment of weakly adhered EVA particles from the cement particles surfaces. The expected EVA plasticizing effect was observed at 60 min. Such behavior points to the stabilization of EVA on the cement particles surfaces, thus resulting in a steric barrier effect.

Sustainable inorganic Binders and Their Applications in Building Engineering: A Green Alternative to Ordinary Portland Cement

In the last decades, the building materials and construction industry has been contributing to a great extent to generate a high impact on our environment. As it has been considered one of the key areas in which to operate to significantly reduce our footprint on environment, there has been widespread belief that particular attention now has to be paid and specific measures have to be taken to limit the use of non-renewable resources.The aim of this thesis is therefore to study and evaluate sustainable alternatives to commonly used building materials, mainly based on ordinary Portland Cement, and find a supportable path to reduce CO2 emissions and promote the re-use of waste materials. More specifically, this research explores different solutions for replacing cementitious binders in distinct application fields, particularly where special and more restricting requirements are needed, such as restoration and conservation of architectural heritage. Emphasis was thus placed on aspects and implications more closely related to the concept of non-invasivity and environmental sustainability. A first part of the research was addressed to the study and development of sustainable inorganic matrices, based on lime putty, for the pre-impregnation and on-site binding of continuous carbon fiber fabrics for structural rehabilitation and heritage restoration. Moreover, with the aim to further limit the exploitation of non-renewable resources, the synthesis of chemically activated silico-aluminate materials, as metakaolin, ladle slag or fly ash, was thus successfully achieved. New sustainable binders were hence proposed as novel building materials, suitable to be used as primary component for construction and repair mortars, as bulk materials in high-temperature applications or as matrices for high-toughness fiber reinforced composites.

Surface layer formation in polymer melts and in solutions

In this work the surface layer formation in polymer melts and in polymer solutions have been investigated with the atomic force microscope (AFM). In polymer melts, the formation of an immobile surface layer results in a steric repulsion, which can be measured by the AFM. From former work it is know, that polydimethyl siloxane (PDMS) forms a stable surface layer for molecular weights above 12 kDa. In the present thesis, polyisoprene (PI) was investigated apart from PDMS, by a)measuring the steric surface interactions and b)measuring the surface slip in hydrodynamic experiments. If a polymer flows over a surface, the flow velocity at the surface is larger then zero. If case of a surface layer formation the flow plane changes to the top of the adsorbed layer and the surface slip is reduced to zero. By measuring the surface slip in hydrodynamic experiments, it is therefore possible to determine the presence of a stable surface layer. The results show no stable repulsion for PI and only a small decrease of the surface slip. This indicates that PI does not form a stable surface layer, but is only adsorbed weakly to the surface. Furthermore for 8 kDa PDMS the timescale of the formation of a surface layer was investigated by changing themaximal force the tip applied to the surface. With a repulsive force present, applying a higher force than 15 nN resulted in a destruction of the surface layer, indicated by attractive forces. Reducing the applied force below 15 nN then resulted in an increase of the repulsion to the former state during one minute, thus indicating that a surface layer can be formed within one minute even under the influence of continuous measurements. As a next step, mixtures of two PDMS homopolymers with different chain lengths have been investigated. The aim was to verify theoretical predictions that shorter chains should predominate at the surface due to their smaller loss in conformational entropy. The measurements where done in dependence of the volume fractions of short and long chain PMDS. The results confirmed the short chain dominance for all mixtures with less then 90 vol.% long chain PDMS. Surface layer formation in solution was investigated for superplasticizers which are industrially used as an additive to cement. They change the surface interaction between the cement grains from attractive to repulsive and the freshlymixed cement paste therefore becomes liquid. The aimin this part of the thesis was, to investigate cement particle interactions in a close to real environment. Therefore calcium silicate hydrate phases have been precipitated onto an AFM tip and onto a calcite crystal and the interaction between these surfaces have beenmeasured with and without addition of superplasticizers. The measurements confirmed the change from attraction to repulsion upon addition of superplasticizers. The repulsive steric interaction increased with the length of the sidechain of the superplasticizer, and the dependence of the range of the steric interactions on the sidechain length indicated that the sidechains are in a coiled conformation.

How different is water crystallization from polymer crystallization under confinement?

Ziel der vorliegenden Dissertation war es, Einblicke in das Kristallisationsverhalten weicher Materie („soft matter“), wie verschiedener Polymere oder Wasser, unter räumlicher Einschränkung („confinement“) zu erlangen. Dabei sollte untersucht werden, wie, weshalb und wann die Kristallisation in nanoporösen Strukturen eintritt. Desweiteren ist Kristallisation weicher Materie in nanoporösen Strukturen nicht nur aus Aspekten der Grundlagenforschung von großem Interesse, sondern es ergeben sich zahlreiche praktische Anwendungen. Durch die gezielte Steuerung der Kristallinität von Polymeren könnten somit Materialien mit verschiendenen mechanischen und optischen Eigenschaften erhalten werden. Desweiteren wurde auch räumlich eingeschränktes Wasser untersucht. Dieses spielt eine wichtige Rolle in der Molekularbiologie, z.B. für das globuläre Protein, und als Wolkenkondensationskeime in der Atmosphärenchemie und Physik. Auch im interstellaren Raum ist eingeschränktes Wasser in Form von Eispartikeln anzutreffen. Die Kristallisation von eingeschränktem Wasser zu verstehen und zu beeinflussen ist letztlich auch für die Haltbarkeit von Baumaterialien wie etwa Zement von großem Interesse.rnUm dies zu untersuchen wird Wasser in der Regel stark abgekühlt und das Kristallisationsverhalten in Abhängigkeit des Volumens untersucht. Dabei wurde beobachtet, dass Mikro- bzw. Nanometer große Volumina erst ab -38 °C bzw. -70 °C kristallisieren. Wasser unterliegt dabei in der Regel dem Prozess der homogenen Nukleation. In der Regel gefriert Wasser aber bei höheren Temperaturen, da durch Verunreinigungen eine vorzeitige, heterogene Nukleation eintritt.rnDie vorliegende Arbeit untersucht die sachdienlichen Phasendiagramme von kristallisierbaren Polymeren und Wasser unter räumlich eingeschränkten Bedingungen. Selbst ausgerichtetes Aluminiumoxid (AAO) mit Porengrößen im Bereich von 25 bis 400 nm wurden als räumliche Einschränkung sowohl für Polymere als auch für Wasser gewählt. Die AAO Nanoporen sind zylindrisch und parallel ausgerichtet. Außerdem besitzen sie eine gleichmäßige Porenlänge und einen gleichmäßigen Durchmesser. Daher eignen sie sich als Modelsystem um Kristallisationsprozesse unter wohldefinierter räumlicher Einschränkung zu untersuchen.rnEs wurden verschiedene halbkristalline Polymere verwendet, darunter Poly(ethylenoxid), Poly(ɛ-Caprolacton) und Diblockcopolymere aus PEO-b-PCL. Der Einfluss der Porengröße auf die Nukleation wurde aus verschiedenen Gesichtspunkten untersucht: (i) Einfluss auf den Nukleationmechanismus (heterogene gegenüber homogener Nukleation), (ii) Kristallorientierung und Kristallinitätsgrad und (iii) Zusammenhang zwischen Kristallisationstemperatur bei homogener Kristallisation und Glasübergangstemperatur.rnEs konnte gezeigt werden, dass die Kristallisation von Polymeren in Bulk durch heterogene Nukleation induziert wird und das die Kristallisation in kleinen Poren hauptsächlich über homogene Nukleation mit reduzierter und einstellbarer Kristallinität verläuft und eine hohe Kristallorientierung aufweist. Durch die AAOs konnte außerdem die kritische Keimgröße für die Kristallisation der Polymere abgeschätzt werden. Schließlich wurde der Einfluss der Polydispersität, von Oligomeren und anderen Zusatzstoffen auf den Nukleationsmechanismus untersucht.rn4rnDie Nukleation von Eis wurde in den selben AAOs untersucht und ein direkter Zusammenhang zwischen dem Nukleationstyp (heterogen bzw. homogen) und der gebildeten Eisphase konnte beobachtet werden. In größeren Poren verlief die Nukleation heterogen, wohingegen sie in kleineren Poren homogen verlief. Außerdem wurde eine Phasenumwandlung des Eises beobachtet. In den größeren Poren wurde hexagonales Eis nachgewiesen und unter einer Porengröße von 35 nm trat hauptsächlich kubisches Eis auf. Nennenswerter Weise handelte es sich bei dem kubischem Eis nicht um eine metastabile sondern eine stabile Phase. Abschließend wird ein Phasendiagramm für räumlich eingeschränktes Wasser vorgeschlagen. Dieses Phasendiagramm kann für technische Anwendungen von Bedeutung sein, so z.B. für Baumaterial wie Zement. Als weiteres Beispiel könnten AAOs, die die heterogene Nukleation unterdrücken (Porendurchmesser ≤ 35 nm) als Filter für Reinstwasser zum Einsatz kommen.rnNun zur Anfangs gestellten Frage: Wie unterschiedlich sind Wasser und Polymerkristallisation voneinander unter räumlicher Einschränkung? Durch Vergleich der beiden Phasendiagramme kommen wir zu dem Schluss, dass beide nicht fundamental verschieden sind. Dies ist zunächst verwunderlich, da Wasser ein kleines Molekül ist und wesentlich kleiner als die kleinste Porengröße ist. Wasser verfügt allerdings über starke Wasserstoffbrückenbindungen und verhält sich daher wie ein Polymer. Daher auch der Name „Polywasser“.