Numerical Material Testing of Mineral-Impregnated Carbon Fiber Reinforcement for Concrete.

This work was dedicated to the simulation of fiber composite structures consisting of carbon fibers and mineral impregnation. The aim of this study was to generate a micromodel that predicts the properties of a mineral-impregnated carbon fiber reinforcement. The numerical characterization was based on the discrete microscopic modeling of the individual phases using a representative volume element. In addition, the stochastic nature of the fiber strength, the anisotropic damage mechanisms of the brittle matrix, and the non-linear bonding behavior between the filaments and the matrix were considered in the material models. The material models were adjusted based on the literature sources and our own experimental investigations. This was followed by the validation of the representative volume element, quantifying the evolution of stiffness and damage under longitudinal tensile loading. The numerical results of material stiffness, as well as the tensile strength of the representative volume element, were compared with the results of the experimental investigations. To verify the robustness of the numerical model, significant model parameters were subjected to a sensitivity analysis.

Investigation of Helix-Pultruded CFRP Rebar Geometry Variants for Carbon-Reinforced Concrete Structures.

Carbon concrete is a new, promising class of materials in the construction industry. This corrosion-resistant reinforcement material leads to a reduction in the concrete cover required for medial shielding. This enables lean construction and the conservation of concrete and energy-intensive cement manufacturing. Bar-type reinforcement is essential for heavily loaded structures. The newly developed helix pultrusion is the first process capable of producing carbon fiber-reinforced polymer (CFRP) reinforcement bars with a topological surface in a single pultrusion process step, with fiber orientation tailored to the specific loads. The manufacturing feasibility and load-bearing capacity were thoroughly tested and compared with other design and process variants. Approaches to increase stiffness and strength while maintaining good concrete anchorage have been presented and fabricated. Tensile testing of the helical rebar variants with a 7.2 mm lead-bearing cross-section was conducted using adapted wedge grips with a 300 mm restraint length. The new helix geometry variants achieved, on average, 40% higher strengths and almost reached the values of the base material. Concrete pull-out tests were carried out to evaluate the bond properties. The helix contour design caused the bar to twist out of the concrete test specimen. Utilizing the Rilem beam test setup, the helical contour bars could also be tested. Compared with the original helix variant, the pull-out forces could be increased from 8.5 kN to up to 22.4 kN, i.e., by a factor of 2.5. It was thus possible to derive a preferred solution that is optimally suited for use in carbon concrete.

Using micro-XRF to characterize chloride ingress through cold joints in 3D printed concrete.

Digital fabrication methods with concrete have been rapidly developing, with many problems related to component production and material control being solved in recent years. These processes produce inherently layered cementitious components that are anisotropic, and in many cases, produces a weak interface between layers, which are generally referred to as cold joints. While material strength at these interfaces has been well studied in recent years, durability has received less attention, even though cold joints can function as channels for aggressive agents, such as chlorides. This work presents a method using micro-X-ray fluorescence (µXRF) to image chloride ingress into layer interfaces of 3D printed fine-grained concrete specimens produced with varying layer deposition time intervals, and also compares it to neutron imaging of moisture uptake. The results show that cold joints formed after a 1 day time interval are highly susceptible to chloride ingress, and that curing conditions play a major role in how quickly interfacial transport can take place. The µXRF method is also shown to be useful for study of transport of chlorides in cold joints, due to its spatial resolution and direct analysis of an aggressive species of interest.

Improved Tensile and Bond Properties through Novel Rod Constructions Based on the Braiding Technique for Non-Metallic Concrete Reinforcements.

Textile reinforcements have established themselves as a convincing alternative to conventional steel reinforcements in the building industry. In contrast to ribbed steel bars that ensure a stable mechanical interlock with concrete (form fit), the bonding force of smooth carbon rovings has so far been transmitted primarily by an adhesive bonding with the concrete matrix (material fit). However, this material fit does not enable the efficient use of the mechanical load capacity of the textile reinforcement. Solutions involving surface-profiled rods promise significant improvements in the bonding behavior by creating an additional mechanical interlock with the concrete matrix. An initial analysis was carried out to determine the effect of a braided rod geometry on the bonding behavior. For this purpose, novel braided rods with defined surface profiling consisting of several carbon filament yarns were developed and characterized in their tensile and bond properties. Further fundamental examinations to determine the influence of the impregnation as well as the application of a pre-tension during its consolidation in order to minimize the rod elongation under load were carried out. The investigations showed a high potential of the impregnated surface-profiled braided rods for a highly efficient application in concrete reinforcements. Hereby, a complete impregnation of the rod with a stiff polymer improved the tensile and bonding properties significantly. Compared to unprofiled reinforcement structures, the specific bonding stress could be increased up to 500% due to the strong form-fit effect of the braided rods while maintaining the high tensile properties.

Bond Modification of Carbon Rovings through Profiling.

The load-bearing behavior and the performance of composites depends largely on the bond between the individual components. In reinforced concrete construction, the bond mechanisms are very well researched. In the case of carbon and textile reinforced concrete, however, there is still a need for research, especially since there is a greater number of influencing parameters. Depending on the type of fiber, yarn processing, impregnation, geometry, or concrete, the proportion of adhesive, frictional, and shear bond in the total bond resistance varies. In defined profiling of yarns, we see the possibility to increase the share of the shear bond (form fit) compared to yarns with a relatively smooth surface and, through this, to reliably control the bond resistance. In order to investigate the influence of profiling on the bond and tensile behavior, yarns with various profile characteristics as well as different impregnation and consolidation parameters are studied. A newly developed profiling technique is used for creating a defined tetrahedral profile. In the article, we present this approach and the first results from tensile and bond tests as well as micrographic analysis with profiled yarns. The study shows that bond properties of profiled yarns are superior to conventional yarns without profile, and a defined bond modification through variation of the profile geometry as well as the impregnation and consolidation parameters is possible.

Application-Driven Material Design of Printable Strain Hardening Cementitious Composites (SHCC).

The creation of concrete shells from customized prefabricated modules is a novel approach that facilitates the construction of free-form surfaces considerably. In the framework of the Adaptive Concrete Diamond Construction (ACDC) project at TU Dresden, a material for 3D printing of the outer contours of such modules has been developed based on the principles of Strain Hardening Cementitious Composite (SHCC). In addition to its high ductility, the required material must also be suitable for 3D printing while enabling the achievement of high geometric accuracy in the manufacture of the modules. To gain the required performance, cellulose ether and starch ether were used specifically to extend the open time, for a longer period of maintaining initial workability, as well as for enhancing shape stability and surface quality. An extensive experimental program was carried out to evaluate the outcomes of the material modifications, including flow table tests, water retention tests, and several specific tests to determine the adhesiveness of the fresh SHCC. For hardened SHCC, surface roughness was assessed using a laser 3D scanner in addition to testing its mechanical properties.

Rheological Model to Describe the Cyclic Load-Bearing Behaviour of Strain-Hardening Cement-Based Composites (SHCC).

The mechanical behaviour of strain-hardening cement-based composites (SHCC) under monotonic tensile loading has been the subject of research for many years. The recent research on the SHCC's performance under cyclic loading has enabled the identification of a wide variety of damage phenomena different to those observed under monotonic loading. The article at hand first summarises the experimental evidence of such phenomena in the context of the material performance observed. On this basis, the mechanisms behind these phenomena are discussed and explained using rheological modelling.

Increasing the Fatigue Resistance of Strain-Hardening Cement-Based Composites (SHCC) by Experimental-Virtual Multi-Scale Material Design.

Strain-hardening cement-based composites are a promising class of materials for a wide variety of applications due to their considerable tensile strength and pronounced ductility caused by the development of multiple fine cracks. Nevertheless, the safe use of such composites requires sound knowledge of their mechanical behaviour under different types of loading, particularly under fatigue loading, while considering distinct influences like initial crack width and fibre orientation. To deepen this knowledge, single-fibre pull-out tests on PVA-fibres from a cementitious matrix were carried out to gain information about the micro-mechanical and degradation processes of the fibre. It could be shown that the fibres tend to rupture instead of being pulled out under quasi-static loading. When changing the loading regime to alternating loading, this failure mechanism shifts to pull-out. By varying the experimental parameters such as initial crack width, inclination angle or compressive-force level a clear influence on the fibre's crack bridging capacity could be observed associated with effects on the degradation processes. Based on the data obtained, a micro-mechanical numerical model was developed to support the assumptions and observations from single-fibre pull-out tests and to enable predictions of the performance of the material on the microscale under cyclic loading.

Probabilistic Finite Element Modeling of Textile Reinforced SHCC Subjected to Uniaxial Tension.

The paper presents a finite element investigation of the effect of material composition and the constituents' interaction on the tensile behavior of strain-hardening cement-based composites (SHCC) both with and without textile reinforcement. The input material parameters for the SHCC and continuous reinforcement models, as well for their bond, were adopted from reference experimental investigations. The textile reinforcement was discretized by truss elements in the loaded direction only, with the constitutive relationships simulating a carbon and a polymer textile, respectively. For realistic simulation of macroscopic tensile response and multiple cracking patterns in hybrid fiber-reinforced composites subjected to tension, a multi-scale and probabilistic approach was adopted. SHCC was simulated using the smeared crack model, and the input constitutive law reflected the single-crack opening behavior. The probabilistic definition and spatial fluctuation of matrix strength and tensile strength of the SHCC enabled realistic multiple cracking and fracture localization within the loaded model specimens. Two-dimensional (2D) simulations enabled a detailed material assessment with reasonable computational effort and showed adequate accuracy in predicting the experimental findings in terms of macroscopic stress-strain properties, extent of multiple cracking, and average crack width. Besides material optimization, the model is suitable for assessing the strengthening performance of hybrid fiber-reinforced composites on structural elements.

Thermoelectric Energy Harvesting from Single-Walled Carbon Nanotube Alkali-Activated Nanocomposites Produced from Industrial Waste Materials.

A waste-originated one-part alkali-activated nanocomposite is introduced herein as a novel thermoelectric material. For this purpose, single-walled carbon nanotubes (SWCNTs) were utilized as nanoinclusions to create an electrically conductive network within the investigated alkali-activated construction material. Thermoelectric and microstructure characteristics of SWCNT-alkali-activated nanocomposites were assessed after 28 days. Nanocomposites with 1.0 wt.% SWCNTs exhibited a multifunctional behavior, a combination of structural load-bearing, electrical conductivity, and thermoelectric response. These nanocomposites (1.0 wt.%) achieved the highest thermoelectric performance in terms of power factor (PF), compared to the lower SWCNTs' incorporations, namely 0.1 and 0.5 wt.%. The measured electrical conductivity (σ) and Seebeck coefficient (S) were 1660 S·m-1 and 15.8 µV·K-1, respectively, which led to a power factor of 0.414 µW·m-1·K-2. Consequently, they have been utilized as the building block of a thermoelectric generator (TEG) device, which demonstrated a maximum power output (Pout) of 0.695 µW, with a power density (PD) of 372 nW·m-2, upon exposure to a temperature gradient of 60 K. The presented SWCNT-alkali-activated nanocomposites could establish the pathway towards waste thermal energy harvesting and future sustainable civil engineering structures.

Dynamic Single-Fiber Pull-Out of Polypropylene Fibers Produced with Different Mechanical and Surface Properties for Concrete Reinforcement.

In strain-hardening cement-based composites (SHCC), polypropylene (PP) fibers are often used to provide ductility through micro crack-bridging, in particular when subjected to high loading rates. For the purposeful material design of SHCC, fundamental research is required to understand the failure mechanisms depending on the mechanical properties of the fibers and the fiber-matrix interaction. Hence, PP fibers with diameters between 10 and 30 µm, differing tensile strength levels and Young's moduli, but also circular and trilobal cross-sections were produced using melt-spinning equipment. The structural changes induced by the drawing parameters during the spinning process and surface modification by sizing were assessed in single-fiber tensile experiments and differential scanning calorimetry (DSC) of the fiber material. Scanning electron microscopy (SEM), atomic force microscopy (AFM) and contact angle measurements were applied to determine the topographical and wetting properties of the fiber surface. The fiber-matrix interaction under quasi-static and dynamic loading was studied in single-fiber pull-out experiments (SFPO). The main findings of microscale characterization showed that increased fiber tensile strength in combination with enhanced mechanical interlocking caused by high surface roughness led to improved energy absorption under dynamic loading. Further enhancement could be observed in the change from a circular to a trilobal fiber cross-section.

High-efficiency and low-carbon remediation of zinc contaminated sludge by magnesium oxysulfate cement.

Electroplating sludge is classified as a hazardous waste due to its extremely high leachability of potentially toxic elements. This study concerns the use of magnesium oxysulfate cement (MOSC) for the stabilisation/solidification (S/S) of Zn-rich electroplating sludge. According to X-ray diffraction and thermogravimetric analyses, Zn was mainly immobilised through both chemical interaction and physical encapsulation in the MOSC hydrates of 5Mg(OH)2·MgSO4.7H2O (5-1-7) phase. The crystal size analysis, elemental mapping, and extended X-ray absorption fine structure (EXAFS) analysis proved that the Zn2+ was also incorporated in the structure of 5-1-7 phase. Unlike Portland cement system, hydration kinetics, setting time, and compressive strength of the MOSC system were only negligibly modified by the presence of Zn, indicating its superior compatibility. Subsequent S/S experiments demonstrated that the MOSC binder exhibited an excellent performance on immobilisation efficiency of Zn (up to 99.9%), as well as satisfying the requirements of setting time and mechanical strength of sludge S/S products. Therefore, MOSC could be an effective and sustainable binder for the treatment of the Zn-rich industrial wastes.

On the Strain Rate Sensitivity of Fused Filament Fabrication (FFF) Processed PLA, ABS, PETG, PA6, and PP Thermoplastic Polymers.

In this study, the strain rate sensitivity of five different thermoplastic polymers processed via Fused Filament Fabrication (FFF) Additive Manufacturing (AM) is reported. Namely, Polylactic Acid (PLA), Acrylonitrile-Butadiene-Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), Polyamide 6 (PA6), and Polypropylene (PP) were thoroughly investigated under static tensile loading conditions at different strain rates. Strain rates have been selected representing the most common applications of polymeric materials manufactured by Three-Dimensional (3D) Printing. Each polymer was exposed to five different strain rates in order to elucidate the dependency and sensitivity of the tensile properties, i.e., stiffness, strength, and toughness on the applied strain rate. Scanning Electron Microscopy (SEM) was employed to investigate the 3D printed samples' fractured surfaces, as a means to derive important information regarding the fracture process, the type of fracture (brittle or ductile), as well as correlate the fractured surface characteristics with the mechanical response under certain strain rate conditions. An Expectation-Maximization (EM) analysis was carried out. Finally, a comparison is presented calculating the strain rate sensitivity index "m" and toughness of all materials at the different applied strain rates.

Tensile Behavior of High-Strength, Strain-Hardening Cement-Based Composites (HS-SHCC) Reinforced with Continuous Textile Made of Ultra-High-Molecular-Weight Polyethylene.

The paper at hand presents an investigation of the tensile behavior of high-strength, strain-hardening cement-based composites (HS-SHCC), reinforced with a single layer of continuous, two-dimensional textile made of ultra-high molecular weight polyethylene (UHMWPE). Uniaxial tension tests were performed on the bare UHMWPE textiles, on plain HS-SHCC, and on the hybrid fiber-reinforced composites. The bond properties between the textile yarns and the surrounding composite were investigated in single-yarn pullout experiments. In order to assess the influence of bond strength between the yarn and HS-SHCC on the tensile behavior of the composites with hybrid fiber reinforcement, the textile samples were analyzed both with, and without, an additional coating of epoxy resin and sand. Compared to the composites reinforced with carbon yarns in previous studies by the authors, the high elongation capacity of the UHMWPE textile established the higher strain capacity of the hybrid fiber-reinforced composites, and showed superior energy absorption capacity up to failure. The UHMWPE textile limited the average crack width in comparison with that of plain HS-SHCC, but led to slightly larger crack widths when compared to equivalent composites reinforced with carbon textile, the reason for which was traced back to the lower Young's modulus and the higher elongation capacity of the polymer textile.

Computational Micro-Macro Analysis of Impact on Strain-Hardening Cementitious Composites (SHCC) Including Microscopic Inertia.

This paper presents a numerical two-scale framework for the simulation of fiber reinforced concrete under impact loading. The numerical homogenization framework considers the full balance of linear momentum at the microscale. This allows for the study of microscopic inertia effects affecting the macroscale. After describing the ideas of the dynamic framework and the material models applied at the microscale, the experimental behavior of the fiber and the fiber-matrix bond under varying loading rates are discussed. To capture the most important features, a simplified matrix cracking and a strain rate sensitive fiber pullout model are utilized at the microscale. A split Hopkinson tension bar test is used as an example to present the capabilities of the framework to analyze different sources of dynamic behavior measured at the macroscale. The induced loading wave is studied and the influence of structural inertia on the measured signals within the simulation are verified. Further parameter studies allow the analysis of the macroscopic response resulting from the rate dependent fiber pullout as well as the direct study of the microscale inertia. Even though the material models and the microscale discretization used within this study are simplified, the value of the numerical two-scale framework to study material behavior under impact loading is demonstrated.

Crack Propagation Velocity Determination by High-speed Camera Image Sequence Processing.

The determination of crack propagation velocities can provide valuable information for a better understanding of damage processes of concrete. The spatio-temporal analysis of crack patterns developing at a speed of several hundred meters per second is a rather challenging task. In the paper, a photogrammetric procedure for the determination of crack propagation velocities in concrete specimens using high-speed camera image sequences is presented. A cascaded image sequence processing which starts with the computation of displacement vector fields for a dense pattern of points on the specimen's surface between consecutive time steps of the image sequence chain has been developed. These surface points are triangulated into a mesh, and as representations of cracks, discontinuities in the displacement vector fields are found by a deformation analysis applied to all triangles of the mesh. Connected components of the deformed triangles are computed using region-growing techniques. Then, the crack tips are determined using the principal component analysis. The tips are tracked in the image sequence and the velocities between the time stamps of the images are derived. A major advantage of this method as compared to the established techniques is in the fact that it allows spatio-temporally resolved, full-field measurements rather than point-wise measurements. Furthermore, information on the crack width can be obtained simultaneously. To validate the experimentation, the authors processed image sequences of tests on four compact-tension specimens performed on a split-Hopkinson tension bar. The images were taken by a high-speed camera at a frame rate of 160,000 images per second. By applying the developed image sequence processing procedure to these datasets, crack propagation velocities of about 800 m/s were determined with a precision in the order of 50 m/s.

An Experimental Investigation of the Behavior of Strain-Hardening Cement-Based Composites (SHCC) under Impact Compression and Shear Loading.

The ductile behavior of strain-hardening cement-based composites (SHCC) under direct tensile load makes them promising solutions in applications where high energy dissipation is needed, such as in earthquakes, impacts by projectiles, or blasts. However, the superior tensile ductility of SHCC due to multiple cracking does not necessarily point to compressive and shear ductility. As an effort to characterize the behavior of SHCC under impact compressive and shear loading relevant to the aforementioned high-speed loading scenarios, the paper at hand studies the performance of a particular SHCC and its constituent, cement-based matrices using the split-Hopkinson bar method. For compression experiments, cylindrical specimens with a length-to-diameter ratio (l/d) of 1.6 were used. The selected length of the sample led to similar failure modes under quasi-static and impact loading conditions, necessary to a reliable comparison of the observed compressive strengths. The impact experiments were performed in a split-Hopkinson pressure bar (SHPB) at a strain rate that reached 110 s-1 at the moment of failure. For shear experiments, a special adapter was developed for a split-Hopkinson tension bar (SHTB). The adapter enabled impact shear experiments to be performed on planar specimens using the tensile wave generated in the SHTB. Results showed dynamic increase factors (DIF) of 2.3 and 2.0 for compressive and shear strength of SHCC, respectively. As compared to the non-reinforced constituent matrix, the absolute value of the compressive strength was lower for the SHCC. Contrarily, under shear loading, the SHCC demonstrated higher shear strength than the non-reinforced matrix.

Red mud-enhanced magnesium phosphate cement for remediation of Pb and As contaminated soil.

Lead (Pb) and arsenic (As) contaminated soil poses severe threats to human health. This study proposes a novel approach for synchronous stabilisation/solidification (S/S) of Pb and As contaminated soil and explains the immobilisation mechanisms in red mud-modified magnesium phosphate cement (MPC). Experimental results show that incorporation of red mud in MPC binder retarded over-rapid reaction and enhanced compressive strength via the formation of (Al,Fe,K)PO4·nH2O compounds as indicated by X-ray diffractometer (XRD) and elemental mapping. The presence of Pb had a marginal effect on the MPC reaction; however, the presence of As suppressed the generation of MgKPO4·6H2O, leading to a significant delay of setting time and a reduction of compressive strength. Extended X-ray absorption fine structure (EXAFS) analysis proved that Pb2+ strongly coordinated with the PO43-, whereas AsO2- gently coordinated with K+. The MPC binder displayed an excellent immobilisation efficiency for Pb (99.9%), but was less effective for As. The use of red mud enhanced the As immobilisation efficacy to 80.5% due to strong complexation between AsO2- and Fe3+. The treated soils fulfilled requirements of metal(loid) leachability and mechanical strength for on-site reuse. Therefore, red mud-modified MPC can be an effective binder for sustainable remediation of Pb and As contaminated soil.

Evaluating the environmental impacts of stabilization and solidification technologies for managing hazardous wastes through life cycle assessment: A case study of Hong Kong.

Proper management of hazardous materials arouses widespread environmental concerns due to its enormous ecological and health impacts. The development of green stabilization/solidification (S/S) technology for resourceful utilization of hazardous materials, as well as the immobilization of potentially toxic elements is of great scientific interests. Cement-based S/S is often considered a low-cost and highly efficient technology, but the environmental sustainability of a broad spectrum of S/S technologies has yet to be evaluated. Therefore, this study assessed the environmental sustainability of S/S technologies for managing two common types of hazardous wastes, i.e., contaminated marine sediment and municipal solid waste incineration fly ash (MIFA) by using life cycle assessment (LCA). A total of 17 scenarios under three strategies for sediment and two strategies for MIFA S/S technologies were comprehensively evaluated. The LCA results identified the most preferable S/S technology in each strategy. In particular, Scenario 1 (mixture of sediment with a small percentage of ordinary Portland cement and incinerated sewage sludge ash) of Strategy 1 (use as fill materials) would be the preferred option, as it reduces about 54% and 70% global warming potential compared to those of Scenarios 2 and 3, respectively. This is the first initiative for evaluating the environmental impacts of a wide range of recently developed S/S technologies using green/alternative binders for diverting hazardous wastes from disposal. The results can serve as a decision support for the practical application of the environmentally friendly S/S technology for sustainable remediation.

Influence of Crack Width in Alternating Tension-Compression Regimes on Crack-Bridging Behaviour and Degradation of PVA Microfibres Embedded in Cement-Based Matrix.

The use of high-performance polymeric microfibres in enhancing the ductility of cementitious composites is widespread. A vivid example is the application of strain-hardening cement-based composites (SHCCs) in the construction industry. However, there are a few challenges which need to be addressed with respect to material design. For instance, the ductility of SHCC diminishes under alternating tension-compression loading, where the fibres lose their crack-bridging capacity due to specific damage mechanisms. The damage development and its influence on crack-bridging capacity have been studied in previous works by the authors. The paper at hand focuses on the influence of crack width on the crack-bridging capacity of polymeric microfibres in conjunction with the number of cycles in an alternating tension-compression regime with different cyclic compressive force levels. It shows that bridging capacity can be markedly influenced by crack width: an increase in crack width leads to more severe damage to the fibres and thus to lower crack-bridging capacity. Then, after analysing the specimens by means of electron microscopy, a hypothesis is presented to address the effect of crack width on damage development. Finally, a simple approach is proposed for estimating the influence of different parameters on fibre degradation.