Development of an Automated Pultrusion System for Manufacturing of Textile Reinforced Cementitious Composites

Concrete stands at the forefront of the construction industry as one of the most useful building materials. Economic and efficient improvements in concrete strengthening and manufacturing are widely sought to continuously improve the performance of the material. Fiber reinforcement is a significant technique in strengthening precast concrete, but manufacturing limitations are common which has led to reliance on steel reinforcement. Two-dimensional textile reinforcement has emerged as a strong and efficient alternative to both fiber and steel reinforced concrete with pultrusion manufacturing shown as one of the most effective methods of precasting concrete. The intention of this thesis project is to detail the components, functions, and outcomes shown in the development of an automated pultrusion system for manufacturing textile reinforced concrete (TRC). Using a preexisting, manual pultrusion system and current-day manufacturing techniques as a basis, the automated pultrusion system was designed as a series of five stations that centered on textile impregnation, system driving, and final pressing. The system was then constructed in the Arizona State University Structures Lab over the course of the spring and summer of 2015. After fabricating each station, a computer VI was coded in LabVIEW software to automatically drive the system. Upon completing construction of the system, plate and angled structural sections were then manufactured to verify the adequacy of the technique. Pultruded TRC plates were tested in tension and flexure while full-scale structural sections were tested in tension and compression. Ultimately, the automated pultrusion system was successful in establishing an efficient and consistent manufacturing process for continuous TRC sections.