Fabric-Reinforced Cement Composites by Pultrusion: Manufacturing, Properties, and Modeling Aspects

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AbstractThe research is aimed at developing a novel cost-effective method for the production ofhigh performance thin-sheet fabric-reinforced cement composites. Thin elements (about 10 mm thickness)represent a major category of cement-based composites and may be used as wall panels, exterior siding,tiles, roofing members, and pressure pipes. For such elements addition of reinforcement is essential inorder to improve the tensile and flexural performance. The proposed fabric-cement systems have thepotential to be used as structural load bearing members, thus competing with other board type materialssuch as wood, synthetics, or metals. The challenge in developing an industrial production method to producethin sheet cement elements with fabrics is not only technological, but also scientific, as it is demonstratedthat the production method can have substantial impact on the properties of the final product. Topractically use fabric-cement composites, an industrial cost-effective production process such as thepultrusion process is proposed here. The main scientific goals of this research are: 1) development of thepultrusion processing for fabric reinforced cement composites, 2) development of cement mixtures withappropriate rheology for the process, and optimal mechanical performance, and 3) optimization of fabricmaterials and structure for various new and retrofit type products, and 4) development of theoreticalapproaches to help the designers with implementation, commercialization, and use of these materials.The intellectual andeducational components of this work will involve the interaction of two senior personnel with severalstudents in a project that is addressed at an international level. The potential for developing new durable,strong, environmentally friendly, and economical, construction materials is a global challenge as we lookat the diminishing energy and scarce natural resources. The promising combination of fabricreinforcement in cement composite products and the pultrusion process is expected to lead to an effectivenovel technique to produce a new class of high performance fabric-cement composite materials. Suchbreakthrough may open the way for a multitude of new products and applications. It will also address aneconomical means of retrofitting existing reinforced concrete structures and masonry walls. The shortterm objectives include the development of economical materials and processes to manufacture them. Thelong term objective of this project is to present to the engineering community an alternative buildingmaterial fit for the 21st century.