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

该PFI：AIR技术翻译项目的重点是翻译混凝土材料科学研究，以满足对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、建筑物和桥梁在承受环境负荷时的可持续性。 该项目将产生大规模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需要相当大的退化和随之而来的维修工作。混凝土老化和使用寿命短的后果是需要频繁维修和最终更换，这消耗了更多的自然资源。由于UHP-FRC的损伤容限特性，它将显著提高混凝土结构的可持续性。这些特性可以显著减少维修-恢复-维护工作量，并延长基础设施的使用寿命，所有这些最终都将降低混凝土使用的环境责任，并提高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：高抗压强度，高达25至30 ksi，卓越的压缩和拉伸延展性超过第一次开裂，和高流动性。新的搅拌程序不需要特殊的处理，如加热，压力和真空，从而避免了对当前混凝土生产实践的任何重大改变。这使得转换无缝和成本效益。此外，与领先的竞争性高性能混凝土相比，UHP-FRC的使用预计将提供更高的耐久性，高损伤容限，生命周期成本节约，简化施工和结构效率，这些混凝土要么是专有的，要么需要独特的混合程序。 该项目与小型商业合作伙伴Bailey Tools Manufacturing（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协助中心（TMAC）合作，指导商业化方面的工作，将技术从研究发现转化为商业现实。 该项目解决了以下技术差距，因为它从研究发现转化为商业应用：1）开发大规模现浇搅拌设计程序和高能量输入搅拌机; 2）为UHP-FRC结构构件的设计和分析制定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。一旦建立了代表性关系，将进行系统的参数评估，特别注意UHP-FRC结构构件的弯曲和剪切设计建议。 潜在的经济影响预计将是变革性的，创造出一种更耐用的产品，节省成本，这将在未来10年内明显显现。新设备和技术的实施将有助于提高美国在下一代建筑市场的竞争力，并将减少国家资助的混凝土安装和维修成本至少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%.