PFI:AIR - TT: Establishing Manufacturing and Large-Scale Casting Process and Structural Design Criteria for Ultra-High Performance Fiber-Reinforced Concrete (UHP-FRC)

这个PFI: AIR技术翻译项目专注于翻译混凝土材料科学研究，以满足先进的下一代建筑材料的需求。这些新一代材料将增强基础设施、建筑和桥梁在承受环境负荷时的可持续性。该项目将产生大型现浇搅拌程序和高能量输入搅拌机，以及超高性能纤维增强混凝土（UHP-FRC）结构构件设计和分析的设计建议和分析模型。UHP-FRC很重要，因为混凝土的主要问题是由于其脆性和有限的耐久性而导致严重的劣化和随之而来的修复工作。混凝土劣化和使用寿命短的后果需要经常修理和最终更换，这消耗了更多的自然资源。使用UHP-FRC将显著提高混凝土结构的可持续性，因为它具有损伤容忍特性。这些特点可以大大减少维修、修复和维护工作的数量，并延长基础设施的使用寿命，所有这些都将最终降低混凝土使用的环境责任，并提高我们未来基础设施的可持续性、安全性、性能和经济性。UHP-FRC具有以下独特的特点：抗压强度高，可达25至30 ksi，具有优异的抗压和抗拉延展性，超过首次开裂，高流动性。新的搅拌程序不需要特殊处理，如加热，压力和真空，从而避免对当前混凝土生产实践的任何重大改变。这使得转换无缝且具有成本效益。此外，与领先的高性能混凝土（要么是专有的，要么需要独特的混合程序）相比，UHP-FRC的使用有望提供更高的耐久性、高损伤容忍度、生命周期成本节约、简化施工和结构效率。该项目与一家小型企业合作伙伴贝利工具制造公司（BTM）合作，开发大容量高剪切混合器和高性能纤维，并与德克萨斯州制造援助中心（TMAC）合作，指导商业化方面，将这项技术从研究发现转化为商业现实。该项目解决了从研究发现到商业应用的以下技术差距：1)开发大型现浇混合设计程序和高能量输入混合器；2)制定UHP-FRC结构构件设计分析的设计建议和分析模型。试验结果将用于制定UHP-FRC结构构件的主要设计方面。一旦建立了代表关系，将进行系统的参数评估，并特别注意UHP-FRC结构构件的抗弯和抗剪设计建议。预计潜在的经济影响将是变革性的，创造出更耐用的产品，并在未来10年内明显节省成本。新设备和技术的实施将有助于美国在下一代建筑市场上的竞争力，并将使国家资助的混凝土安装和维修成本至少降低25%。

This PFI: AIR Technology Translation project focuses on translating concrete material science research to fill the need for advanced next-generation construction materials. These next generation materials will enhance the sustainability of infrastructure, buildings, and bridges when subjected to environmental loadings. The project will result in a large-scale cast-in-place mixing procedure and high energy input mixers, as well as design recommendations and analytical models for the design and analysis of structural members of ultra-high-performance fiber-reinforced concrete (UHP-FRC). The UHP-FRC is important because the major problem of concrete is the considerable deterioration and consequent repair work needed due to its brittleness and limited durability. The consequence of concrete deterioration and short service life requires frequent repair and eventual replacement, which consumes more natural resources. Using UHP-FRC will introduce significant enhancement in the sustainability of concrete structures due to its damage-tolerance characteristics. These characteristics can reduce significantly the amount of repair-rehabilitation-maintenance work and give infrastructure longer service life, all of which will eventually lower the environmental liability of concrete use and lead to enhanced sustainability, safety, performance, and economy of our future infrastructure. UHP-FRC has the following unique features: high compressive strength, up to 25 to 30 ksi, excellent compressive and tensile ductility beyond first cracking, and high flowability. The new mixing procedure requires no special treatments such as heat, pressure, and vacuum, thereby avoiding any major changes to current concrete production practice. This makes the conversion seamless and cost effective. In addition, the use of UHP-FRC is expected to provide greater durability, high damage tolerance, life-cycle cost savings, simplified construction, and structural efficiency when compared to the leading competing high-performance concrete that is either proprietary or requires a unique mixing procedure. The project engages a small business partner, Bailey Tools Manufacturing (BTM), to develop the large-capacity high-shear mixers and high-performance fibers, as well as the Texas Manufacturing Assistance Center (TMAC), to guide commercialization aspects, in this technology translation effort from research discovery toward commercial reality. This project addresses the following technology gap(s) as it translates from research discovery toward commercial application: 1) to develop a large-scale cast-in-place mixing design procedure and high energy input mixers; 2) to formulate design recommendations and analytical models for the design and analysis of UHP-FRC structural members. Experimental results will be used to formulate the major design aspects for UHP-FRC structural members. Once representative relationships are developed, systematic parametric evaluations will be carried out with particular attention paid to the flexural and shear design recommendations of UHP-FRC structural members. The potential economic impact is expected to be transformational, creating a more durable product with cost savings that will be clearly evident in the next 10 years. Implementation of the new equipment and technology will contribute to the U.S. competitiveness in the next-generation construction market and will reduce state funded concrete installation and repair costs by at least 25%.