A Novel Building Material for Panelized Construction

FRP/AC夹芯板，芯材为轻质高性能加气混凝土（AC）（例如，蒸压加气混凝土、多孔混凝土等）纤维增强塑料（FRP）复合材料的面板具有成为优异的能量吸收建筑材料的潜力，加上其相对便宜并且在地球仪的大部分地区都可获得。与最近对高性能、零维护民用基础设施的兴趣一致，拟议项目将调查FRP/AC夹层板（具有成本效益、寿命长且重量轻）的潜力，并将开发使用该面板建造低成本建筑结构的概念并论证其可行性。FRP/AAC夹层结构部件在包括腐蚀和弹道冲击在内的恶劣环境中也将是耐用的。该计划的结果有可能提供比传统建筑更节能、更便宜的商业和住宅建筑。除了上述特性外，它还有一些特性可能会引起军方和负责保护生命的其他方面的兴趣。这项工作的独特贡献将是应用具有成本效益的VARTM（真空辅助树脂灌注成型工艺）工艺，采用创新的FRP硬化方案，采用最近开发的玻璃纤维和碳纤维结构以及乙烯基酯和环氧树脂类型。该项目还将消除传统的手工铺层工艺，这些工艺被证明是昂贵且耗时的，同时还将推进先进复合材料在民用基础设施中的应用。该项目是实现长期目标的第一步，将解决五个基本问题：1）研究具有损伤容限结构和新树脂体系的FRP/AC夹层板的成本效益制造。2)通过全面的实验项目对FRP/AC夹芯板进行材料表征和结构测试。实验研究预计将提供一个理解的（a）故障机制的拟议的夹层板，（B）的强度，能量吸收，应变和模量特性，（c）的纤维AC混凝土界面的作用，和（d）故障的夹层结构中的复合层。3)开发概念并演示经济实惠生产的夹层板的弹道响应，这些夹层板有希望硬化/加强而不增加重量损失，并且具有成本效益。4)通过分析模拟了解此类结构的结构响应。5)开发模块化系统，展示FRP/AC板如何用于各种类型的建筑结构。将提供安装、组装和连接，以清楚地显示施工如何在现场处理材料。拟议的努力将探索在结构工程应用领域更广泛应用的实际好处。最后，在我们以前的研究中证明，两种经过验证的材料的冲击响应-即，碳纤维增强复合材料（CFRC）和玻璃纤维增强复合材料（GFRC）与工程聚碳酸酯（PC）热塑性塑料结合，通过伴随着在聚碳酸酯-层压材料界面处的分层的聚碳酸酯的压痕表现出期望的失效机制，从而对层压材料造成最小的损坏。动态试验包括使用30-cal弹托辅助弹的弹道冲击加载条件和使用压缩分离式霍普金森压杆（SHPB）的高应变率加载。其基本原理是，通过提供PC饰面，可以增强复合材料结构的抗损伤性，因为PC可以吸收能量，具有最小的重量损失，并且可以起到牺牲层的作用，易于修理或更换。两名研究生和三名本科生将参与该项目。他们将接触到广泛的技术问题，跨越不同的工程学科的边界，如材料科学，结构设计，计算机模拟，基础设施分析，减灾，以及各种制造技术在亚拉巴马大学（伯明翰）校园。雷乌斯还将在UAB校园的大学高中为高中生组织示范。PI之前曾与来自不同团体的雷乌斯合作，获得了有益的经验。

FRP/AC sandwich panel with a core of lightweight high performance Aerated Concrete (AC) (e.g., Autoclave Aerated Concrete, Cellular Concrete etc.) and face sheets of Fiber Reinforced Plastics (FRP) composites has the potential to be an excellent energy absorbing construction material plus it is relatively inexpensive and available over much of the globe. Consistent with the recent interests in high performance, zero maintenance civil infrastructures, the proposed project will investigate the potential of FRP/AC sandwich panels (that are cost effective, long lived, and lightweight), and concepts will be developed and feasibility demonstrated for construction of low cost building structures using the panel. FRP/AAC sandwich components will also be durable in severe environments including corrosion and against ballistic impact. The results of the program has the potential to provide commercial and residential building that is more energy efficient and cheaper than traditional construction. It also has some properties, in addition to those mentioned above, that may be of interest to the military and others responsible for protecting lives. The unique contribution of the effort will be the application of cost-effective VARTM (Vacuum Assisted Resin Infusion Molding process) processing using innovative FRP hardening schemes with recently developed glass-and carbon fiber architectures and vinyl ester as well as epoxy resin types. The proposed effort will also eliminate traditional hand lay-up processing techniques which prove to be expensive and time-wise inefficient, and simultaneously advanced the state of the art of usage of advanced composites in civil infrastructure.This project, a first step towards the long-term goal, will address five fundamental queries: 1) Investigate cost-effective manufacturing of FRP/AC sandwich panels with damage tolerant architectures and new resin systems. 2) Perform material characterization and structural testing of FRP/AC sandwich panels through a comprehensive experimental program. The experimental studies are expected to provide an understanding of the (a) failure mechanisms of the proposed sandwich panels, (b) the strength, energy absorption, strain and modulus characteristics, (c) the role of the fiber-to-AC concrete interface, and (d) failure of the composite layers in the sandwich structure. 3) Develop concept and demonstrate the ballistic response of affordably produced sandwich panels that have promise to harden/strengthen without adding weigh penalty, and are cost-effective. 4) Understand the structural response of such structures through analytical simulations. 5) Develop modular systems to show how the FRP/AC panels can be used for a variety of types of building construction. Erection, assembly, and connections will be provided to clearly show how the construction can handle the material in the field. The proposed effort will explore the tangible benefits for wider application in structural engineering application areas. Finally, it was demonstrated in our previous study that the impact response of two proven materials- i.e., carbon fiber reinforced composite (CFRC) and glass fiber reinforced composite (GFRC), in conjunction with engineered Polycarbonate (PC) thermoplastic exhibits desirable failure mechanisms through indention of the Polycarbonate accompanied by delaminating at Polycarbonate-laminate interface rendering minimal damage to the laminate. The dynamic tests included ballistic impact loading conditions using a 30-cal sabot assisted projectile and high strain rate loading using compression Split Hopkinson Pressure Bar (SHPB). The rationale was that by providing a PC facing, the damage resistance of the composite structure could be enhanced, as the PC can absorb energy, with minimal weight penalty, and can serve the purpose of a sacrificial layer, that is easily repairable or replaceable. Two graduate students and three undergraduate students will be involved in the project. They will be exposed to a wide range of technological issues crossing the boundaries of different engineering disciplines such as materials science, structural design, computer simulations, infrastructure analysis, hazard mitigation, and a variety of fabrication techniques at the University of Alabama (Birmingham) campus. The REUs will also organize demonstration for the high school students at the university high school on the UAB campus. The PI has had prior rewarding experiences working with REUs from diverse groups.