Les travaux présentés concernent le développement d'un matériau composite (matrice polymère + fibre) pour l'élaboration de profilés de fenêtre mis en œuvre par un procédé de pultrusion. Dans le cadre de ces travaux, plusieurs polymères vinylester biosourcés ont été développés en tant que matrice de ce matériau composite. Une résine vinylester est réalisée en deux étapes : tout d'abord la synthèse du prépolymère vinylester, correspondant à un monomère (méth)acrylé porteur de fonctions ester et qui possède des doubles liaisons polymérisable à ses extrémités. Puis, la formulation du matériau vinylester est effectuée par le mélange du prépolymère vinylester avec un monomère copolymérisable, appelé diluant réactif. Enfin, le matériau est réticulé par polymérisation radicalaire, à l'aide d'un amorceur radicalaire.Dans un premier temps, une étude modèle a été réalisée : de la synthèse du prépolymère vinylester à partir d'une molécule modèle (DGEBA) à la formulation d'un matériau vinylester par polymérisation radicalaire. Plusieurs bioressources ont ensuite été étudiées afin de remplacer le DGEBA qui est issu du bisphénol A, composé CMR, groupe 2. La stratégie a été tout d'abord d'étudier des bioressources commercialisées, tels que les huiles végétales et le cardanol qui est un sous-produit de l'industrie de la noix de cajou. Puis un produit non biosourcé, mais non classé, du nom de TACTIX a été étudié également. Et enfin des bioressources non commercialisées actuellement, tels que l'isosorbide qui est un dérivé du sucre et le phloroglucinol, qui est extrait d'écorce d'arbres ont également été étudié pour la synthèse de prépolymère VE et de matériaux VE. Le diluant réactif le plus utilisé actuellement est le styrène, qui est un composé très volatile et classé nocif. Plusieurs diluants réactifs ont donc été testés avec les prépolymères VE synthétisés afin de remplacer le styrène par des composés peu volatiles et non nocifs. Enfin, trois matériaux composite renforcés par des fibres de lin, ont été fabriqués par mini-pultrusion, à partir des systèmes étudiés (prépolymère VE synthétisé et diluant réactif). / The study presented concern the development of composite material (polymer matrix + fibres) in order to produce windows profiles by a pultrusion process. In the context of this work, several biobased vinylester polymers have been developed as matrix of the composite material. A vinylester resin is formed in two steps: firstly the synthesis of vinylester prepolymer, corresponding to a (meth)acrylated monomer carrying an ester function and having polymerizable double bonds at its ends. Next, the formulation of vinylester material is performed by mixing the vinylester prepolymer with a copolymerizable monomer, called reactive diluent. Finally, the material is crosslinked by radical polymerization, using a radical initiator.First, a model study was conducted: in the synthesis of vinylester prepolymer from a template molecule (DGEBA) to the formulation of a vinylester material by radical polymerization. Severals bioresources were then studied in order to replace the DGEBA which is from bisphenol A, compound CMR, group 2. The strategy was first to study marketed bioresources, such as vegetable oils and cardanol which is a by-product of the cashew nut shell industry. Next, a non-biobased but not listed compound, of the name of TACTIX has also been studied. Finally, bioresources not currently marketed, such as isosorbide which is a sugar derivative and phloroglucinol, which is extracted of bark of trees have also been studied for the synthesis of VE prepolymers and VE materials. The reactive diluent the most currently used is styrene, which is a very volatile and harmful compound. Several reactive diluents were tested with the VE prepolymers synthesized in order to replace the styrene by compounds with low volatility and less harmful. Finally, three composites materials reinforced with flax fibres, were made by mini-pultrusion, from the systems studied (VE prepolymer synthesized and reactive diluent).

abstract: Pultrusion manufacturing technique stands at the forefront for efficient production of continuous, uniform concrete composites for use in large scale structural applications. High volume and low labor, among other benefits such as improved impregnation and better sample consistency, stand as some of the crucial advances found in automated pultrusion. These advantages introduce textile reinforced concrete (TRC) composites as a potential surrogate for wood, light gauge steel, and other common structural materials into an ever changing and broadening market of industrial grade structural sections. With the potential modifications of textile geometry, textile type, section geometry, and connection type, the options presented by TRC sections seem nearly boundless. Automated pultrusion presents the ability to manufacture many different TRC composite types in at a quickened rate opening up a new field of study of structural materials. The objective of this study centered on two studies including the development of an automated pultrusion system for the manufacturing of TRC composites and ultimately the assessment of composites created with the pultrusion technique and their viability as a relevant structural construction material. Upon planning, fabrication, and continued use of an automated pultrusion system in Arizona State University’s Structures Lab, an initial, comparative study of polypropylene microfiber composites was conducted to assess fiber reinforced concrete composites, manufactured with Filament Winding Technique, and textile reinforced concrete composites, manufactured with Automated Pultrusion Technique, in tensile and flexural mechanical response at similar reinforcement dosages. A secondary study was then conducted to measure the mechanical behavior of carbon, polypropylene, and alkali-resistant glass TRC composites and explore the response of full scale TRC structural shapes, including angle and channel sections. Finally, a study was conducted on the connection type for large scale TRC composite structural sections in tension and compression testing. / Dissertation/Thesis / Masters Thesis Civil Engineering 2017

Two 7" deep FRP deck panels were manufactured and tested in a controlled service environment. The deck panels were 15' by 5' in plan, and were composed of ten 15' long, 6" by 6" by 3/8" standard pultruded FRP tubes. The tubes were sandwiched between two 3/8" thick standard pultruded FRP plates. The material constituents of the FRP were E-glass fibers in a polyester matrix. When subjected to two strength tests, the first deck panel exhibited a safety factor with respect to legal truck loads of greater than 10. The second deck was subjected to AASHTO design loads, and under a simulated HS-25 axle plus impact the deck exhibited a maximum deflection of L/470. Upon completion of the laboratory testing, the second deck was placed in the field for further study. The maximum strain recorded during field testing was approximately 600 microstrain, which is less than 15% of the ultimate tensile strain of the FRP in its weakest direction. After being subjected to approximately 4 million load cycles (assuming 100,000 5-axle truck crossings per month) over a period of 8 months, the deck exhibited no loss in stiffness. In two post-service strength tests, the second deck exhibited a safety factor with respect to legal truck loads of greater than 8 and greater than 13. / Master of Science

This thesis presents research completed on the experimental performance of two 6 3/4 in thick bridge deck panels fabricated by the Stongwell Corporation of Bristol, Virginia. The panels are made of off-the-shelf, pultruded glass fiber-reinforced polymer elements, bonded and mechanically fastened together. The testing involved laboratory stiffness tests performed on one deck panel which afterwards, was placed in a field test site at the I-81 Troutville Weigh Station facility. The daily truck traffic over the deck panel at this site is approximately 5400 vehicles. The second deck panel was constructed as a prototype to test benefits of steel thru-rod mechanical connectors. Further, a rubber tire loading patch was developed for the laboratory stiffness and strength tests performed on this second specimen to investigate modes of failure. Both decks made use of a hook bolt type connection to steel support beams in order to reduce damage seen in previous methods of connection. / Master of Science

Carbon concrete polyacrylonitrile (PAN)/lignin-based carbon fiber (CF) composites are a new promising material class for the building industry. The replacement of the traditional heavy and corroding steel reinforcement by carbon fiber (CF)-based reinforcements offers many significant advantages: a higher protection of environmental resources because of lower CO2 consumption during cement production, a longer lifecycle and thus, much less damage to structural components and a higher degree of design freedom because lightweight solutions can be realized. However, due to cost pressure in civil engineering, completely new process chains are required to manufacture CF-based reinforcement structures for concrete. This article describes the necessary process steps in order to develop CF reinforcement: (1) the production of cost-effective CF using novel carbon fiber lines, and (2) the fabrication of CF rebars with different geometry profiles. It was found that PAN/lignin-based CF is currently the promising material with the most promise to meet future market demands. However, significant research needs to be undertaken in order to improve the properties of lignin-based and PAN/lignin-based CF, respectively. The CF can be manufactured to CF-based rebars using different manufacturing technologies which are developed at a prototype level in this study.

Master of Science / Department of Architectural Engineering and Construction Science / Kimberly W. Kramer / Pultruded fiber reinforced polymer (FRP) shapes are gaining popularity in the construction industry. Pultruded FRP profiles introduce a new world of construction that could prove to be a viable option to traditional structural materials. The use of pultruded FRP profiles in structures is discussed in this report. First a brief history of FRPs and their applications are addressed before explaining in detail the two main components of FRP; fibers and resin. The manufacturing process known as pultrusion and how two separate materials become one structural member is examined. As a result of pultrusion, engineers and designers can create structural profiles in customizable shapes, sizes, and strengths to suit any project and price. Theoretically, a pultruded FRP profile can be customized to different strengths within the geometrical and material bounds of the profile; however, many manufacturers publish data regarding mechanical and thermal properties along with allowable loads for their nominal profiles. Currently, there are no governing codes or guidelines for pultruded FRPs but there are design manuals and handbooks published by various committees and manufacturers so the design of pultruded FRP profiles is discussed. Ultimate and serviceability limit states are design concerns that engineers always deal with but concerns of heat or fire, chemical or corrosion, and moisture affect pultruded FRPs differently than steel or wood. Pultruded FRPs pose interesting design concerns because increased customizability and workability means the member can be tailored to meet the needs for that project but that would counter the benefit of mass-produced nominal sizes. A lack of uniform codes and standards inhibits the growth of the pultrusion industry in the United States but codes developed in Europe along with the development of specialized agencies and organizations could help gain a foothold. Lastly, a set of beams varying in length and load exhibit a side-by-side comparison to examine how pultruded FRPs match up next to traditional building materials. Although wood, steel, and reinforced concrete have been the preferred materials of construction, pultruded FRP structural shapes are gaining popularity for its economical and physical advantages, and advances in manufacturing and technology stand to usher in the widespread use of pultruded FRP profiles.

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2007. / A refrigerated semi-trailer was designed to solve manufacturing and operational problems. This was achieved by using advanced pultruded composites. The static and dynamic material response was determined. The dynamic loading on the vehicles was also measured and is presented along with static load cases. These boundary conditions were used in a finite element model to determine the structural performance of the trailer. The results show good static performance with some problem areas which still need attention. Initial poor fatigue performance is improved by increasing the ultimate shear stress of the material. A fatigue optimisation technique is suggested for future use.

Pultrusão é um de vários processos de fabricação de compósitos poliméricos. Seu princípio de funcionamento envolve a utilização de um conjunto de fibras de reforço, impregnadas previamente por uma resina polimérica termorrígida, que percorre o interior de uma matriz aquecida a fim curar a resina e dar o formato a um perfil sólido. Muitas variáveis de processo, tais como a temperatura das zonas de aquecimento sobre a matriz, a velocidade de tracionamento, a impregnação das fibras, a viscosidade da resina, entre outras, afetam a eficiência do processo assim como a qualidade e o desempenho dos compósitos. Neste estudo, foi investigada a influência do teor de fibra de vidro, do teor de carbonato de cálcio e da temperatura do reservatório de resina nas propriedades mecânicas, como a resistência à tração, o módulo de elasticidade, o alongamento até a ruptura e a dureza de barras sólidas circulares que foram fabricadas utilizando uma resina poliéster insaturada e um único peróxido orgânico. Foi constatado que o processo de pultrusão pode ser realizado utilizando um único iniciador de reação. Além disto, os resultados mostraram que a temperatura do reservatório de resina, o teor de carbonato de cálcio e o teor de fibra de vidro influenciaram de forma significativa nas propriedades das barras pultrudadas. Por fim, este estudo mostrou que é possível melhorar as características destes compósitos e, desta forma, desenvolver materiais que apresentem melhor qualidade e desempenho. / Pultrusion is one of several manufacturing processes of polymer composites. Its operating principle involves the use of a set of reinforcing fibers pre-impregnated with a thermoset resin which run through the interior of a heated die in order to cure the resin and to form a solid profile. Many processing variables such as die temperature, pulling speed, fiber impregnation, resin viscosity, among others, affect the process efficiency as well as the quality and performance of the pultruded composites. In this research, the influence of the glass fiber content, calcium carbonate content and the temperature of the resin bath on the mechanical properties, such as tensile strength, elastic modulus, elongation at break and superficial hardness of solid rods made with an unsaturated polyester resin and a single organic peroxide were investigated. It was observed that pultrusion process can be carried out using a single reaction initiator. In addition, the results showed that the temperature of the resin bath, the calcium carbonate and the glass fiber content have influenced significantly in the properties of the solid rods. Finally, this study showed that it is possible to improve the characteristics of such composites and, therefore, to develop materials that have good quality and performance.

Flexible risers that carry hydrocarbon fuels from the subsea facilities to the floatation units above the sea surface are composed of multiple metallic and polymeric layers (in their wall). Among these layers, the tensile armour layer consists of several helically wound metallic wires; these tensile armour layers carry the weight of the riser, provide tensile stiffness & strength and maintain the structural integrity of the riser structure during harsh underwater currents. However, as the oil & gas fields in shallow waters are receding, the oil & gas industry is being forced to move towards deeper offshore waters, where the metallic tensile armour wires pose limitations (fatigue, corrosion, weight, etc.). In this thesis an alternative to metallic tensile armour wires will be presented in form of a flexible hybrid composite formed by stacking seven pultruded composite (carbon and vinyl-ester) circular rods in form of hexagonal pack, held together by an over-braid (Dyneema fibres) sleeve. The manufacturing process for hybrid composite tensile armour wires will be studied and their mechanical properties will be presented. A multi-scale finite element model developed for hybrid composite wires will be presented in this thesis to help further understand the mechanical properties of hybrid composite wires.

Often a manufacturing process may be a bottleneck or critical to a business. This thesis focuses on the analysis and modelling of such processest, to both better understand them, and to support the enhancement of quality or output capability of the process. The main thrusts of this thesis therefore are: To model inter-process physics, inter-relationships, and complex processes in a manner that enables re-exploitation, re-interpretation and reuse of this knowledge and generic elements e.g. using Object Oriented (00) & Qualitative Modelling (QM) techniques. This involves the development of superior process models to capture process complexity and reuse any generic elements; To demonstrate advanced modelling and simulation techniques (e.g. Artificial Neural Networks(ANN), Rule-Based-Systems (RBS), and statistical modelling) on a number of complex manufacturing case studies; To gain a better understanding of the physics and process inter-relationships exhibited in a number of complex manufacturing processes (e.g. pultrusion, bioprocess, and logistics) using analysis and modelling. To these ends, both a novel Object Oriented Qualitative (Problem) Analysis (OOQA) methodology, and a novel Artificial Neural Network Process Modelling (ANNPM) methodology were developed and applied to a number of complex manufacturing case studies- thermoset and thermoplastic pultrusion, bioprocess reactor, and a logistics supply chain. It has been shown that these methodologies and the models developed support capture of complex process inter-relationships, enable reuse of generic elements, support effective variable selection for ANN models, and perform well as a predictor of process properties. In particular the ANN pultrusion models, using laboratory data from IKV, Aachen and Pera, Melton Mowbray, predicted product properties very well.