Chloride ion induced corrosion of reinforcing steel in concrete bridge decks has become a major problem in the United States. Latex modified concrete (LMC), low slump dense concrete (LSDC) and hot-mix asphalt membranes (HMAM) overlays are currently some of the most used rehabilitation methods. Epoxy coated reinforcing steel (ECR) was developed and promoted as a long term corrosion protection method by the Federal Highway Administration (FHWA). However, recent evidence has suggested that ECR will not provide adequate long term corrosion protection. The Reynolds Metals Company has developed an aluminum bridge deck system as a proposed alternative to conventional reinforced steel bridge deck systems. The deck consists of a polymer concrete overlay and an aluminum substrate. The purpose of this investigation is to evaluate the bond durability between the overlay and the aluminum substrate after conditioning specimens in various temperature and humidity conditions. The average critical strain energy release rate, Gcr, for each specimen was measured using a modified mixed mode flexure (MMF) test. In this investigation the strain energy release rate is a measure of the fracture toughness of the interface between the polymer concrete overlay and the aluminum substrate. The different environmental conditionings all had a significant effect on the bond durability. Specimens conditioned at 30 degrees C [86 degrees F], 45 degrees C [113 degrees F] and 60 degrees C [140 degrees F] at 98 % relative humidity all showed a decrease in interfacial bond strength after conditioning. A decrease in the interfacial bond strength was also observed for the specimens conditioned in freezing and thawing cycles as well as specimens conditioned in a salt water soak. Of the exposure conditions used in this investigation, the only one that showed an increase in the bond strength was drying the specimens continuously in an oven at 60 degrees C [140 degrees F]. / Master of Science

The objective of this study is to evaluate the bond durability of an epoxy-based polymer concrete wearing surface bonded to aluminum bridge decks. In the bridge design, an aluminum alloy bridge deck is used with a polymer concrete wearing surface. A modified mixed mode flexure fracture test was developed to assess the bond durability of specimens aged in the following environmental conditionings: 30°C [86°F], 98% RH; 45°C [113°F], 98% RH; 60°C [140°F], 98% RH; freezing and thawing; salt (NaCl) water soak; and 60°C [140°F], dry. The exposure times varied from none to twelve months. The critical strain energy release rate (Gc) of the bond was determined using a compliance technique. In spite of considerable scatter in the data, the results suggested that the interfacial bond toughness had been degraded by exposure conditions. The aging appeared to affect the polymer concrete overlay (silica aggregates/epoxy bond) as well. Fracture analysis and finite element modeling were completed for linear elastic behavior. Analytical and numerical solutions were in reasonably good agreement. Characterization of the bridge components and failure specimens were accomplished using analytical measurements including thermal gravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic mechanical analysis (DMA). Techniques employed in the surface analysis included x-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM). / Master of Science

This diploma thesis sloves usage of the innovative materials in the construction of CNC machining centers for non-rotational components. There are described innovative materials, machines and parts of these machines at first. Further, there is assigned a suitable material for each part of the machine. For the design part of this thesis is chosen a fixed rack made of polymer concrete for vertical machining center. Finally, the rack and its motion system are designed.

Composite materials have a wide range of applications in civil and structural engineering due to their advantages in mechanical properties and higher strengths over the base materials alone. Polymer-concrete composites are particularly attractive for use in industrial and infrastructure applications from combining the higher mechanical properties of the concrete in tension and the high tensile strength and ductile properties of the polymeric materials. However, these materials tend to be more expensive that typical concrete composites. This thesis explores the mechanical properties of two different polymer-concrete composites and their effectiveness in civil and structural applications: polymer concrete for rapid repair and 3D printed plastic-concrete composite members for energy absorption. The North Atlantic Treaty Organization (NATO) requires that emergency repair of military runways should be completed within 4 hours. In coordination with Luna Innovations Incorporated, a polymer concrete was developed by Luna for use as a rapid repair material for military runways to meet this requirement through its rapid heat curing. Its mechanical properties including its compressive and flexural strength, bond strength in various orientations, workability, modulus of elasticity, and coefficient of thermal expansion were tested and compared against another rapid repair material. The Tri-Service Pavements Working Group Manual recommendations for rigid repair materials were used as the requirements in determining whether the polymer concrete was an adequate rapid repair material. The polymer concrete formulation that was down-selected for further testing met these requirements for all tests except for the coefficient of thermal expansion. This was due to the resin itself having a high volumetric expansion when exposed to greater temperatures. As the polymer concrete is still under development, future tests are to be performed to determine the impact of the higher expansion on the surrounding runways. Additionally, inspired from naturally forming nacre found in some seashells, a 3D printed plastic-concrete beam structure was developed and tested in flexure to determine its energy absorption capabilities. The nacreous structure allows the material to experience a strain-hardening behavior, thus allowing for energy dissipation in the beam as it deflects from further applied load. It is theorized that the energy absorption capabilities would be suitable for withstanding the effects of dynamic loadings in structures, such as earthquake and blast loads. Multiple beam structures were developed and tested to determine the impact of percent-polymeric material and layout had on the energy dissipation. Overall, the specimens with more polymer in the cross-section demonstrated larger load vs. crack mouth displacement curves and fracture energy. These specimens demonstrated a higher toughness as well, making them more suitable for use in structural applications. As the project is still in development, future tests and analysis must be performed to determine their strength properties and feasibility as a structural material. The results of this thesis highlight the benefits of novel polymer composites in industrial and infrastructure applications, such as improved rapid setting characteristics and significantly enhanced mechanical and energy absorbing performance. Future work is needed to optimize these performance metrics, such as freeze thaw cycling, fatigue, and durability tests for the polymer concrete and analysis of moment capacity for the bioinspired nacreous composites. / Master of Science / Composite materials have a wide range of applications in civil and structural engineering due to their advantages in mechanical properties and higher strengths over the base materials alone. Polymer concrete composites are not as widely used due to their greater initial costs. However, they are very attractive in industrial and infrastructure applications because of the improved behavior in tension. This thesis explores the mechanical properties of two different polymer-concrete composites and their effectiveness in civil and structural applications: polymer concrete for rapid repair and 3D printed plastic-concrete composite members for energy absorption. The North Atlantic Treaty Organization (NATO) requires that emergency repair of military runways should be completed within 4 hours. In coordination with Luna Innovations Incorporated, a polymer concrete was developed by Luna for use as a rapid repair material for military runways to meet this requirement through its rapid heat curing. Its mechanical properties were tested and compared against another rapid repair material. The polymer concrete formulation that was down-selected for further testing met the requirements of the military for all tests performed except for the coefficient of thermal expansion. As the polymer concrete is still under development, future tests are to be performed to determine the impact of the higher expansion on the surrounding runways. Additionally, inspired from naturally forming nacre found in some seashells, a 3D printed plastic-concrete beam structure was developed and tested in bending to determine its energy absorption capabilities. The nacreous structure allows the material to experience a strain-hardening behavior, thus allowing for energy dissipation in the beam as it deflects from further applied load. It is theorized that the energy absorption capabilities would be suitable for withstanding the effects of earthquake and blast loads in structures. Multiple beam structures were developed and tested to determine the impact of percent-polymeric material and layout had on the energy dissipation. Overall, the specimens with more polymer in the cross-section demonstrated greater energy absorption capabilities. As the project is still in development, future tests and analysis must be performed to determine their strength properties and feasibility as a structural material. The results of this thesis highlight the benefits of novel polymer composites in industrial and infrastructure applications, such as improved rapid setting characteristics and significantly enhanced mechanical and energy absorbing performance. Future work is needed to optimize these performance metrics, such as freeze thaw cycling, fatigue, and durability tests for the polymer concrete and analysis of moment capacity for the bioinspired nacreous composites.

Submitted by Mariana Dornelles Vargas (marianadv) on 2015-05-15T13:16:30Z No. of bitstreams: 1 concreto_polimero.pdf: 4719718 bytes, checksum: 2d7016e7eb764275fea0249db0eb55eb (MD5) / Made available in DSpace on 2015-05-15T13:16:30Z (GMT). No. of bitstreams: 1 concreto_polimero.pdf: 4719718 bytes, checksum: 2d7016e7eb764275fea0249db0eb55eb (MD5) Previous issue date: 2009 / CAPES - Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / A reciclagem e a reincorporação de um rejeito em um processo produtivo são as soluções mais indicadas para o manejo da grande maioria dos resíduos, reduzindo assim custos, além de preservar recursos naturais não renováveis. A construção civil tem absorvido parte destes resíduos, transformando-os em subprodutos importantes, os quais podem ser igualmente eficientes, além de ecologicamente corretos. Dentre as aplicações mais comuns, destacam-se a incorporação de rejeitos em matrizes cimentícias e poliméricas. O concreto polímero, o qual tem como aglomerante uma resina polimérica, tornou-se uma boa opção para construção civil em aplicações onde são solicitados alto desempenho mecânico, durabilidade e cura rápida, propriedades importantes para materiais que visam a sustentabilidade das edificações. Apesar dos já comprovados elevados valores mecânicos encontrados nestes compósitos, torna-se necessário estimar e adequar as propriedades de combustibilidade com os tipos de demandas do mercado, pois tal propriedade pode comprometer sua aplicação. Para tanto, esta pesquisa tem como objetivo produzir compósitos de concreto polímero de elevada resistência mecânica, durabilidade e resistentes à ação do fogo. Os compósitos serão produzidos com uma resina poliéster insaturada reciclada a partir do PET, com incorporação de resíduos industriais, comparando-os com componentes comerciais. Para tanto, as propriedades dos compósitos serão estudadas através de ensaios de caracterização mecânica, durabilidade e microestrutura, compreendendo: resistência à compressão, resistência à tração na flexão, porosimetria por intrusão de mercúrio e MEV. Além disso, os corpos-de-prova foram submetidos a ensaios de análise térmica, com a finalidade de avaliar o comportamento das adições frente à ação do fogo e sua contribuição para a redução da flamabilidade destes compósitos. Os resultados obtidos mostraram que, as composições com 60% de adição de retardante de chamas resíduo apresentaram uma redução de 85% em relação ao tempo de propagação da chama dos compósitos sem adição de retardantes, bem como um acréscimo na sua resistência mecânica em comparação aos mesmos. / Recycling and the reincorporation of a waste in a production process are the most indicated for the management of the vast majority of waste, thus reducing costs, and, of course, preserving non-renewable natural resources. The civil construction has absorbed these wastes, turning them into important products, which can also be efficient, and environmentally correct. Among the most common applications, it can emphasize the incorporation of tailings in cementations and polymer matrices. The polymer concrete, which binder is a polymeric resin, has become a good option for construction where are required applications with high mechanical performance, durability and rapid healing, important properties for materials aimed at the sustainability of buildings. Despite the already proven high mechanical values found in these composites, it is necessary to estimate and adjust the properties of combustibility to the kinds of demands of the market, once this property may jeopardize your application. Thus, this research aims to produce polymer concrete composites of high mechanical strength, durability and resistance to the action of fire. The composites were produced with an unsaturated polyester resin from recycled PET, with the addition of industrial waste in comparison to commercial items, making them more attractive economically, and environmentally sustainable. Thus, the properties of the composites were studied by mechanical tests durability, including: compressive strength test, tensile strength, mercury intrusion porosimetry and SEM. Moreover, the samples were tested for thermal analysis in order to know the behavior of the action items with the fire and its contribution to reducing the flammability of these composites. The results obtained in the tests described above showed that, the composites with 60% in addition of waste had a reduction of 85% in the time of spread of flame, and an increase in its mechanical resistance in comparison to composite reference, with no addition of retardants.

La durabilité des matériaux employés en génie civil est remise en question par le vieillissement physico-chimique de ces matériaux pouvant engendrer des dégradations significatives qui peuvent mettre en péril la stabilité des structures du génie civil. Pour pallier à certains inconvénients des bétons hydrauliques, l'utilisation des matériaux composites à l'instar des bétons de résine, qui possèdent des qualités remarquables par rapport aux matériaux de construction conventionnels, s'avère très intéressant.À l'heure actuelle, les freins majeurs quant aux développements des bétons résines sont d'une part le coût de la résine dont le taux varie, selon l'application industrielle, de 5% à 25% et d'autre part leurs comportements aux températures élevées et au feu puisque les liants dans ces bétons sont des substances organiques qui résistent beaucoup moins à la chaleur que les matières inorganiques. L'objectif de l'étude est de favoriser le développement des bétons résines par la diminution du taux de la résine en optimisant les constituants du béton et l'amélioration de leurs ténues aux températures élevées par l'ajout des additions tout en assurant des performances mécaniques raisonnables. L'optimisation de la formulation du béton est menée sur deux étapes ; la première vise à optimiser le squelette granulaire (sable 0/4 et Gravier 4/10, silico-calcaires) expérimentalement en confrontant les résultats à ceux issus du modèle d'empilement compressible. La deuxième étape vise à optimiser la fraction massique du liant époxydique (6%, 9%, 13% et 16%) sur la base des essais de caractérisation mécaniques et physiques. Le deuxième objectif de l'étude a était menée par l'ajout des ignifugeants appartenant à deux familles différentes c'est-à-dire les hydroxydes de métal et les produits phosphorés inorganiques. Les propriétés physiques, thermiques et mécaniques des bétons additionnées et témoins, avant et après exposition à un cycle de chauffage-refroidissement de la température ambiante à une température de consigne de 100°C, 150°C, 200°C, 225°C et 250 °C avec une vitesse de montée fixée à 0.5°C/min, ont été évaluées par les techniques de caractérisation usuelles en plus des essais d'analyses chimiques et thermiques.Cette étude aboutit à la formulation d'un béton optimal en terme de composition et à évaluer l'effet de l'addition des ignifugeants surtout sur les propriétés thermiques et mécaniques.Mots clés : béton de résine, optimisation, température élevée, ignifugeants, propriétés mécaniques, propriétés physiques, propriétés thermiques. / The material used in civil engineering applications must be re-evaluated because of their physicochemical ageing which can generate significant damages and hence put the stability of civil engineering structures in danger.The replacement of the hydraulic concrete by composite materials as the polymer concrete which offer higher properties compared to conventional construction materials seems to be very interesting. At the present time, the major restrain for the development of polymer concrete are on one hand the cost of the polymer whose ratio varies according to the industrial applications between 5% and 25%, and on the other hand their behaviour when exposed to high temperatures or fire since the resin acting as binder in these polymer concretes are organic substances which are more sensitive to heat than the inorganic matters as cement.The aim of this study was to help the development of polymer concrete by optimizing the formulation and improving their behaviour when exposed the high temperatures by incorporating additions while keeping acceptable mechanical performances.The optimisation of the formulation is done in two steps; the first step consists of optimising the aggregates content (Natural River sands 0/4 mm and crushed gravels 4/10 mm). Experimental results are compared to those given by means Compressible Packing Model. The second step consists of optimizing the amount of polymer (6%, 9%, 13% et 16%) based on mechanical and physical tests.The second aim of this work was fulfilled by the incorporation of two flame retardants belonging to metal hydroxide and phosphorous components types. Physical, thermal and mechanical properties of concretes with or without flame retardant, before and after heating-cooling cycle from ambient temperature to exposure temperature of 100°C, 150°C, 200°C, 225°C et 250 °C with a rate of 0.5°C/min, are evaluated by common characterisation tests besides chemical and thermal ones. This study has leading to obtaining an optimum polymer concrete and evaluates the effect of flame retardant particularly on the thermal and mechanical properties.Keywords: polymer concrete, optimization, high temperatures, flame retardant, mechanical properties, physical properties, thermal properties.

The diploma thesis deals with the development of polymeric repair mortars in two qualitative levels ECONOMY and PREMIUM, designed especially for heavy engineering plants and the energy industry. In order to effectively withstand difficult industrial conditions, the developed materials should meet the highest requirements such as increased chemical and heat resistance, excellent adhesion to the concrete substrate, minimal shrinkage and other physical and mechanical properties. The PREMIUM level is aimed to achieve maximum physical and mechanical properties. Within the economy version, the emphasis is placed not only on very good properties, but also the possibility capability of reducing price of the resulting material. The partial aim of this work is the efficient use of secondary raw materials, mainly based on industrial waste in the form of fillers to the developed polymeric repair mortars.