A Novel Building Material for Panelized Construction

以轻质高性能加气混凝土（AC）为核心的FRP/AC夹层板（例如，高压灭菌加气混凝土，蜂窝混凝土等）和纤维增强塑料（FRP）复合材料的面板具有成为一种极好的吸能建筑材料的潜力，而且它相对便宜，在全球大部分地区都可以买到。与最近对高性能、零维护民用基础设施的兴趣一致，拟议的项目将调查FRP/AC夹层板的潜力（具有成本效益、寿命长、重量轻），并将开发概念，并论证使用该面板建造低成本建筑结构的可行性。FRP/AAC夹层组件也将在恶劣的环境中耐用，包括腐蚀和抗弹道冲击。该项目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。除了上面提到的那些，它还有一些可能对军方和其他负责保护生命的人感兴趣的特性。这项工作的独特贡献将是采用具有成本效益的VARTM（真空辅助树脂注射成型工艺）加工，采用创新的玻璃钢硬化方案，结合最近开发的玻璃和碳纤维结构以及乙烯基酯和环氧树脂类型。拟议的努力还将消除传统的手工铺层加工技术，这种技术被证明是昂贵和时间效率低下的，同时还将推动先进复合材料在民用基础设施中的使用。该项目是迈向长期目标的第一步，将解决五个基本问题：1)研究具有耐损伤结构和新树脂系统的FRP/AC夹层板的成本效益制造。2)通过综合实验方案对FRP/AC夹芯板进行材料表征和结构测试。实验研究有望提供以下方面的理解：(a)拟议夹层板的破坏机制，(b)强度、能量吸收、应变和模量特性，(c)纤维-交流混凝土界面的作用，以及(d)夹层结构中复合材料层的破坏。3)开发概念并演示经济实惠的夹层板的弹道响应，该夹层板有望在不增加重量损失的情况下硬化/强化，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，以展示FRP/AC面板如何用于各种类型的建筑结构。将提供安装、装配和连接，以清楚地显示施工如何在现场处理材料。本研究将探讨其在结构工程应用领域的实际效益。最后，我们之前的研究表明，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）热塑性塑料的冲击响应表现出理想的破坏机制，聚碳酸酯的压痕伴随着聚碳酸酯-层压板界面的分层，对层压板的损伤最小。动态试验包括使用30卡炮弹辅助弹丸的弹道冲击加载条件和使用压缩分离式霍普金森压杆（SHPB）的高应变率加载条件。其基本原理是，通过提供PC面，可以增强复合结构的抗损伤性，因为PC可以吸收能量，以最小的重量损失，并且可以作为牺牲层，易于修复或更换。两名研究生和三名本科生将参与该项目。他们将接触到跨越不同工程学科边界的广泛技术问题，如材料科学、结构设计、计算机模拟、基础设施分析、危害缓解以及阿拉巴马大学伯明翰分校的各种制造技术。REUs还将在UAB校园为大学高中的高中生组织演示。PI之前与来自不同群体的reu合作的经验颇有收获。

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.