Professional Documents
Culture Documents
MANUFACTURING METHODS
FOR COMPOSITES AND
FAILURE PREDICTIONS
Ang, Mendoza, Mission, Temprosa
WHAT IS A
COMPOSITE?
a materials system composed of a
suitably arranged mixture or combination
of two or more micro or macro
constituents that differ in structure
and/or chemical composition, are
essentially insoluble in each other, and
have a clear interface separating them.
FIBER-REINFORCED PLASTIC
COMPOSITE MATERIALS
Fiberglass-Reinforced Plastics & Carbon Fiber–Reinforced Epoxy Resins
OPEN MOLDING CLOSED MOLDING
resin is impregnated into the fibers and composite materials are placed in
they are placed in an open mold, where a two-sided mold, closed to the
they cure or harden. atmosphere
Relatively low cost due to little to
no tooling (the mold)
06 CURING
BATCHING
The process of measuring ingredients or
materials to prepare concrete mix is known as
batching of concrete
VOLUME materials are measured on the basis of volume.
It is less precise method of batching
BATCHING
To make 1:1:2 ratio concrete mix according to volume
batching, one should take one bag of cement (35 liters) , 1
gauge box of fine aggregate (35 liters) and 2 gauge boxes of
fine aggregate (70 liters). If the water-cement ratio is 0.5,
then half of the volume of cement which is 25 liters of water
should be taken
WEIGHT Materials are measured on the basis of weight.
It is accurate method of batching.
BATCHING
To prepare 1:1:2 concrete mix using weigh batching, measured
quantity of materials are 50 kg of cement, 50 kg of fine
aggregate and 100 kg of coarse aggregate.
MECHANICAL ELECTRONIC
WEIGHT BATCHERS WEIGHT BATCHERS
weights are measured using spring and electronic scales and load cells
dial gauge arrangement and it is widely supported by hoppers are used to
used equipment in weigh batching. measure the weight of ingredients of
concrete.
MANUAL
WEIGHT used for small concrete production job
while other two types are used for large
SEMI-AUTOMATIC
aggregate container gates are lifted
manually and it is automatically closed
after reaching required quantity in the
weighing machine.
FULLY AUTOMATIC
all the process will be done automatically and it
also measures the moisture content present in
the aggregate and corrects the required
quantity of water-cement with respect to
moisture content of aggregates
WEIGHT BATCHING VS. VOLUME BATCHING
Weigh batching is Moisture content Compressive Weigh batching Volume batching
most precise presence in the strength of same concrete mix does not require
method of aggregate should concrete mix at 7 gives medium to skilled workers
batching than also be considered days and 28 days very high slump but weigh
volume batching while batching. In is higher for while for the batching.
since it is difficult case of fully weigh batching same mix Selection of
to find the exact automatic weigh concrete mix proportion in batching method
volume of batching it can be than volume volume batching, depends upon
granular materials considered but batching slump differs size of project,
because of their volume batching is concrete mix. from low to high concrete
voids not suitable in such production rate
cases.
MIXING
Proper mixing of concrete ingredients is
of utmost importance in order to
produce good quality fresh concrete. If
the concrete is not well mixed, then it
tends to segregation and bleeding.
CHARACTERISTICS OF
HAND MIXING
Mixing concrete
WELL MIXED CONCRETE
manually without a Concrete should be of uniform colour.
mixer machine All concrete materials like cement, fine
aggregates, coarse aggregates and water
should be homogeneously mixed.
Cement paste should cover all the surface of
MACHINE MIXING the aggregate.
OF CONCRETE Segregation or bleeding of concrete should
Mixing concrete with not occur after the concrete mixing
a mixer machine
READY MIX
CONCRETE
Mixing in automatic
or semi-automatic
batching plant
HAND MIXING
is the process of mixing the
ingredients of the concrete
manually without a mixer machine.
Mixing concrete without a mixer is
used only for small works where
the concrete requirement is less
and quality control is less
important. In the hand mixing of
concrete, uniformity of mixing is
difficult to achieve and requires
special care and efforts.
PRECAUTIONS Base platform must be clean, dirt free
and watertight.
IN HAND Use a good and clean shovel for the
mixing procedure.
IN MACHINE
revolution of mixer drum as per the
recommendation of the manufacturers of the mixer
machine.
Concrete should be used within 30 minutes after
WHEELBARROW
The wheelbarrow is used for
transporting concrete at ground level
CRANE BUCKET
AND ROPEWAY
A tower crane bucket and ropeway
are the methods for transporting
concrete above the ground level
CHUTE
A chute is adapted for transporting
concrete from ground level to the
lower level
TRANSIT MIXER
Transit mixer is one of the most
popular equipment for transporting
concrete over a long distance mostly
in RMC plant (Ready Mixed Concrete
plant)
PUMPS AND
PIPELINES
Pumping of concrete is universally
accepted and more reliable method of
concrete transportation and placing
BELT CONVEYORS
Belt conveyors are used for a small
horizontal distance such as 5-meter to
10-meter.
TREMIE
Tremie is the most common method
for underwater transportation of
concrete, tremie pipe is used for that
MONORAIL SYSTEM
Monorail system consists of a track
and a power wagon mounted on the
single rail track, which can move at a
speed of 80-90 meter/minut
RODDING
It is a method of poking with
2m long, 16 mm diameter rod at
HAND
COMPACTION
sharp corners and edges. The
thickness of layers for rodding
should be 15 to 20 cm. A piece
of bamboo maybe used for
rodding the concrete.
RAMMING
It is generally used for compaction
on ground in plain concrete. It is not
used either in RCC or on upper
floors.
TAMPING
It is adopting in compacting roof or
floor or road pavements where the
thickness of concrete is
comparatively less and surface to be
finished smooth and level.
FORMWORK
VIBRATOR
Formwork vibrator is used for the
concreting columns , thin walls or in
the casting of precast units. The
machine is clamped onto the external
walls surface of the formwork.
TABLE VIBRATOR
This is the special case of formwork
vibrator, where the vibrator is
clamped to the table or table is
mounted on springs which are
vibrated transferring the vibration to
the table. They are commonly used
for vibrating concrete cubes. This is
adopted mostly in the laboratories
and in making small but precise
prefabricated R.C.C. members
PLATFORM VIBRATOR
Platform vibrator is nothing but a
table vibrator, but it is larger in size.
This is used in the manufacture of
large prefabricated concrete
elements such as electric pole ,railway
sleepers, prefabricated roofing
elements etc.
SURFACE VIBRATOR
Surface vibrator is sometimes knows
as, “Screed Board Vibrator”. A small
vibrator is placed on the screed board
gives an effective method of
compacting and levelling of thin
concrete members, such as floor slab ,
roof slab and road surface. Mostly ,
floor slabs and roof slabs are so thin
that vibrator or any other type of
vibrator cannot be easily employed
CURING
Curing is the process or operation which
controls the loss of moisture from concrete
after it has been placed in position, or in the
manufacture of concrete products, thereby
providing time for the hydration of the
cement to occur.
Curing Methods
There are three basic ways of curing concrete.
1. The first involves keeping the surface of the concrete moist by the use
ponding, spraying/sprinkling, damp sand or damp hessian.
2. The second prevents the loss of moisture from the concrete by covering it
with polythene sheeting or leaving the formwork in place.
3. The third involves the use of spray or roller applied curing compounds.
WATER CURING
Water curing, if properly carried out, can
be the most efficient - and the most
appropriate for some types of work, e.g.
floors, and include ponding, sprinkling,
and wet coverings.
PONDING
SPRINKLING
A fine spray of water applied continuously
through a system of nozzles provides a constant
supply of moisture. This prevents the possibility
of "crazing" or cracking caused by alternate
cycles of wetting and drying
WET COVERINGS
Wet coverings such as hessian or other moisture
retaining fabrics are extensively used for curing.
The coverings should be kept continuously moist
so that a film of water remains on the concrete
surface throughout the curing period.
SHEET CURING
Sheet curing methods may not be so
efficient but are usually satisfactory for
all except very special work, and they
have the big plus point that they can be
carried out more easily on both
horizontal and vertical surfaces.
POLYTHENE SHEET
CURING
USING POLYTHENE
Wait until the water sheen has evaporated, but
not so long that the concrete starts to dry out.
When the surface of the slab has a special finish -
such as a texture - the polythene should be
spread over light frames above the concrete.
FORMWORK PROTECTION
formwork protects concrete against loss of
moisture, and thus allows curing to proceed. It is
only after it has been struck that further curing -
of columns, walls and beams, for instance - may
be necessary.
MEMBRANE CURING
Membrane curing methods are likewise,
not as efficient as sheet curing
methods, but have the advantage over
the previous two methods in that they
do not need any further supervision
once applied.
SPRAY-ON COMPOUNDS
WHEN TO SPRAY
The compounds should never be applied to dry
surfaces since these will absorb the compound,
and staining or discoloration may result. If the
surface is dry, that is a sign that the curing has
been left too late.
USING COMPOUNDS
There are various points to watch when you are
applying a curing compound. Before you start,
make sure that you have enough stock in for the
job in hand- you will need about a litre for each 4
of surface area - and sufficient cleaning solvent,
too.
EXPOSED CONCRETE
All concrete that will be permanently exposed to
the weather needs to be cured with extra care,
and for at least seven days. This is particularly
important for visual concrete, including white
and coloured concrete, plus special architectural
finishes created by abrasive blasting or tooling.
COLOUR UNIFORMITY
The colour of concrete can vary according
to how long the formwork is left is position
after placing, and whether the day on
which it is struck is dry or wet.
PAVING & FLOOR
SLABS
Always start the curing soon after the
water sheen has disappeared. However, if
you are using polythene sheeting, allow the
concrete to stiffen slightly first, so that the
surface will not be marked or damaged as
the sheet is placed on top of it.
MINOR ROADS,
PATHS & DRIVES
A curing membrane, applied by a hand-operated
garden-type spray, is most convenient for small
paved areas built by semi-manual methods of
construction. Always use a white pigmented or
aluminised super grade of compound, if available,
because this will reflect the suns rays
REINFORCED CONCRETE
Concrete containing steel reinforcements in the form of rods,
wires, wire mesh, etc., are referred to as reinforced concrete.
TENDONS
are steel reinforcements and may be a tensioned steel rod or cable. The
advantage of prestressed concrete is that the compressive stresses
introduced by the steel tendons have to be counteracted before the
concrete is subjected to tensile stresses.
PRETENSIONED POSTTENSIONED
(PRESTRESSED) (PRESTRESSED)
CONCRETE CONCRETE
METAL MATRIX COMPOSITE
The manufacturing and production of metal matrix composites can be done
one of four different ways. There are solid state methods, semi-solid state
methods, liquid state methods, and through vapor deposition.
SOLID STATE Powder Blending and
Powder blending and consolidation
is when a manufacturer takes a
METHODS
powdered metal and some
Consolidation discontinuous reinforcing material,
mix them together, and then bond
them through a process of
compaction, degassing, and
Solid state methods, as the
thermo-mechanical treatments
terminology implies, typically (often through isostatic pressing or
involves two or more solid extrusion).
materials, and these
materials are often
sandwiched together or
infused via thermal or Foil diffusion bonding is when the
mechanical means. manufacturer takes copious layers
Powdered materials can also Foil Diffusion Bonding of some metal foil and then
act as the matrix material, sandwiches long fibers from
another material between each
and these powders are often
layer.
used to coat the outer layers
of a base or reinforcing
material.
Powder Blending and Consolidation Foil Diffusion Bonding
SEMI-SOLID Semi-Solid Powder
Semi-Solid Powder Processing is a
process where a powder mixture is
METHODS Electroforming
containing metal ions loaded with
reinforcing particles are co-
deposited forming the composite
material.
METHODS
Reactive processing is processing
Reactive Processing involving a chemical reaction where
one of the reactants forms the
matrix and the other forms the
reinforcement.
CRACKS
are fractures in the
matrix or fibers
CUT
fibers severed
by a sharp edge
DELAMINATION
VISUAL DAMAGE
Aesthetics is important as it makes the
separation of
composite product attractive and
adjacent plies
pleasing to look at.
DENT
a concave depression
that does not rupture
plies or debond the
structure
GOUGE
a special type of dent
where some, but not
all, composite plies
are severed
VISUAL DAMAGE
HOLE Aesthetics is important as it makes the
composite product attractive and
penetration through pleasing to look at.
the outer composite
laminate with damage
to the core material
SCRATCH
an elongated surface
discontinuity due to
damage that is very small
in width compared to
length
MECHANICAL
FAILURE
4 forces are important in composite
structures: Tensile, Compressive, Shear,
and Flexural. All of the forces are
important to determine the behavior of
composites.
TENSILE FORCE
is the stretching forces acting upon
the material and has two
components - tensile stress (σ) and
tensile strain (ε).
COMPRESSIVE FORCE
occurs when a physical force presses
inward on a material. This yields
information about the compressive
strength and stiffness of the material.
The flexural strength of a material is
defined as the maximum bending stress
FLEXURAL FORCE that can be applied to that material
before it yields.
SHEAR FORCE
Shearing forces are unaligned forces
pushing one part of a body in one
specific direction, and another part
of the body in the opposite direction.
IMPACT FORCE
a high force or shock applied over a
short time period when two or more
bodies collide.
FATIGUE
Fatigue failure is the formation and
propagation of cracks due to a
repetitive or cyclic load.
FATIGUE AND 01 FIBER FRACTURE
is the main damage mode in
03 MATRIX CRACKING
The most common low-load
cracking mechanism in composite
structures
VIBRATIONS
When a composite material receives a
sudden impact, it vibrates which should
be avoided in developing composites.
FINITE ELEMENT
METHOD
is a widely used method for numerically
solving differential equations arising in
engineering and mathematical
modeling.
FINITE ELEMENT
ANALYSIS
allows detailed stress and deformation
solutions to complex shapes. The
analysis is based on dividing the
structure into a large number of small
elements and assigning each element
the appropriate material properties.
END.
Thank You!