This dissertation aims at developing novel materials and processing routes using alkali activated aluminosilicate binders for porous (lightweight) geopolymer matrices and 3D-printing concrete applications. The major research objectives are executed in different stages. Stage 1 includes developing synthesis routes, microstructural characterization, and performance characterization of a family of economical, multifunctional porous ceramics developed through geopolymerization of an abundant volcanic tuff (aluminosilicate mineral) as the primary source material. Metakaolin, silica fume, alumina powder, and pure silicon powder are also used as additional ingredients when necessary and activated by potassium-based alkaline agents. In Stage 2, a processing route was developed to synthesize lightweight geopolymer matrices from fly ash through carbonate-based activation. Sodium carbonate (Na2CO3) was used in this study to produce controlled pores through the release of CO2 during the low-temperature decomposition of Na2CO3. Stage 3 focuses on 3D printing of binders using geopolymeric binders along with several OPC-based 3D printable binders. In Stage 4, synthesis and characterization of 3D-printable foamed fly ash-based geopolymer matrices for thermal insulation is the focus. A surfactant-based foaming process, multi-step mixing that ensures foam jamming transition and thus a dry foam, and microstructural packing to ensure adequate skeletal density are implemented to develop foamed suspensions amenable to 3D-printing. The last stage of this research develops 3D-printable alkali-activated ground granulated blast furnace slag mixture. Slag is used as the source of aluminosilicate and shows excellent mechanical properties when activated by highly alkaline activator (NaOH + sodium silicate solution). However, alkali activated slag sets and hardens rapidly which is undesirable for 3D printing. Thus, a novel mixing procedure is developed to significantly extend the setting time of slag activated with an alkaline activator to suit 3D printing applications without the use of any retarding admixtures. This dissertation, thus advances the field of sustainable and 3D-printable matrices and opens up a new avenue for faster and economical construction using specialized materials.

An orthotropic elasto-plastic damage material model (OEPDMM) suitable for impact simulations has been developed through a joint research project funded by the Federal Aviation Administration (FAA) and the National Aeronautics and Space Administration (NASA). Development of the model includes derivation of the theoretical details, implementation of the theory into LS-DYNA®, a commercially available nonlinear transient dynamic finite element code, as material model MAT 213, and verification and validation of the model. The material model is comprised of three major components: deformation, damage, and failure. The deformation sub-model is used to capture both linear and nonlinear deformations through a classical plasticity formulation. The damage sub-model is used to account for the reduction of elastic stiffness of the material as the degree of plastic strain is increased. Finally, the failure sub-model is used to predict the onset of loss of load carrying capacity in the material. OEPDMM is driven completely by tabulated experimental data obtained through physically meaningful material characterization tests, through high fidelity virtual tests, or both. The tabulated data includes stress-strain curves at different temperatures and strain rates to drive the deformation sub-model, damage parameter-total strain curves to drive the damage sub-model, and the failure sub-model can be driven by the data required for different failure theories implemented in the computer code. The work presented herein focuses on the experiments used to obtain the data necessary to drive as well as validate the material model, development and implementation of the damage model, verification of the deformation and damage models through single element (SE) and multi-element (ME) finite element simulations, development and implementation of experimental procedure for modeling delamination, and finally validation of the material model through low speed impact simulations and high speed impact simulations.

A comprehensive study was performed on non-proprietary ultra-high-performance concrete (UHPC) material and several design methods were suggested based on numerous experimental results. Several sets of compression tests, direct tensile tests, and flexural tests were performed on UHPC to provide a better understanding of the mechanisms involved in the mechanical behavior of the fiber reinforced material. In addition to compressive tests, flexural tests, based on ASTM C1609 and EN 14651, were performed. The effect of the strain rate on the UHPC material was also investigated through the high-speed tensile tests at different strain rates. Alongside the usual measurement tools such as linear variable differential transformers (LVDT) and clip gages, digital image correlation (DIC) method was also used to capture the full-range deformations in the samples and localized crack propagations. Analytical approaches were suggested, based on the experimental results of the current research and other research groups, to provide design solutions for different applications and design approaches for UHPC and hybrid reinforced concrete (HRC) sections. The suggested methods can be used both in the ultimate limit state (ULS) and the serviceability limit state (SLS) design methods. Closed form relationships, based on the non-linear design of reinforced concrete, were used in the calculation of the load-deflection response of UHPC. The procedures were used in obtaining material properties from the flexural data using procedures that are based on back-calculation of material properties from the experimental results. Model simulations were compared with other results available in the literature. Performance of flexural reinforced UHPC concrete beam sections tested under different types of loading was addressed using a combination of fibers and rebars. The same analytical approach was suggested for the fiber reinforced concrete (FRC) sections strengthened (rehabilitated) by fiber reinforced polymers (FRP) and textile reinforced concrete (TRC). The objective is to validate the proper design procedures for flexural members as well as connection elements. The proposed solutions can be used to reduce total reinforcement by means of increasing the ductility of the FRC, HRC, and UHPC members in order to meet the required flexural reinforcement, which in some cases leads to total elimination of rebars.

With the growth of global population, the demand for sustainable infrastructure is significantly increasing. Substructures with appropriate materials are required to be built in or above soil that can support the massive volume of construction demand. However, increased structural requirements often require ground improvement to increase the soil capacity. Moreover, certain soils are prone to liquefaction during an earthquake, which results in significant structural damage and loss of lives. While various soil treatment methods have been developed in the past to improve the soil’s load carrying ability, most of these traditional treatment methods have been found either hazardous and may cause irreversible damage to natural environment, or too disruptive to use beneath or adjacent to existing structures. Thus, alternative techniques are required to provide a more natural and sustainable solution. Biomediated methods of strengthening soil through mineral precipitation, in particular through microbially induced carbonate precipitation (MICP), have recently emerged as a promising means of soil improvement. In MICP, the precipitation of carbonate (usually in the form of calcium carbonate) is mediated by microorganisms and the process is referred to as biomineralization. The precipitated carbonate coats soil particles, precipitates in the voids, and bridges between soil particles, thereby improving the mechanical properties (e.g., strength, stiffness, and dilatancy). Although it has been reported that the soil’s mechanical properties can be extensively enhanced through MICP, the micro-scale mechanisms that influence the macro-scale constitutive response remain to be clearly explained.

The utilization of alternative techniques such as MICP requires an in-depth understanding of the particle-scale contact mechanisms and the ability to predict the improvement in soil properties resulting from calcite precipitation. For this purpose, the discrete element method (DEM), which is extensively used to investigate granular materials, is adopted in this dissertation. Three-dimensional discrete element method (DEM) based numerical models are developed to simulate the response of bio-cemented sand under static and dynamic loading conditions and the micro-scale mechanisms of MICP are numerically investigated. Special focus is paid to the understanding of the particle scale mechanisms that are dominant in the common laboratory scale experiments including undrained and drained triaxial compression when calcite bridges are present in the soil, that enhances its load capacity. The mechanisms behind improvement of liquefaction resistance in cemented sands are also elucidated through the use of DEM. The thesis thus aims to provide the fundamental link that is important in ensuring proper material design for granular materials to enhance their mechanical performance.

Being a remarkably versatile and inexpensive building material, concrete has found tremendous use in development of modern infrastructure and is the most widely used material in the world. Extensive research in the field of concrete has led to the development of a wide array of concretes with applications ranging from building of skyscrapers to paving of highways. These varied applications require special cementitious composites which can satisfy the demand for enhanced functionalities such as high strength, high durability and improved thermal characteristics among others.

The current study focuses on the fundamental understanding of such functional composites, from their microstructural design to macro-scale application. More specifically, this study investigates three different categories of functional cementitious composites. First, it discusses the differences between cementitious systems containing interground and blended limestone with and without alumina. The interground systems are found to outperform the blended systems due to differential grinding of limestone. A novel approach to deduce the particle size distribution of limestone and cement in the interground systems is proposed. Secondly, the study delves into the realm of ultra-high performance concrete, a novel material which possesses extremely high compressive-, tensile- and flexural-strength and service life as compared to regular concrete. The study presents a novel first principles-based paradigm to design economical ultra-high performance concretes using locally available materials. In the final part, the study addresses the thermal benefits of a novel type of concrete containing phase change materials. A software package was designed to perform numerical simulations to analyze temperature profiles and thermal stresses in concrete structures containing PCMs.

The design of these materials is accompanied by material characterization of cementitious binders. This has been accomplished using techniques that involve measurement of heat evolution (isothermal calorimetry), determination and quantification of reaction products (thermo-gravimetric analysis, x-ray diffraction, micro-indentation, scanning electron microscopy, energy-dispersive x-ray spectroscopy) and evaluation of pore-size distribution (mercury intrusion porosimetry). In addition, macro-scale testing has been carried out to determine compression, flexure and durability response. Numerical simulations have been carried out to understand hydration of cementitious composites, determine optimum particle packing and determine the thermal performance of these composites.

Phase change materials (PCMs) are combined sensible-and-latent thermal energy storage materials that can be used to store and dissipate energy in the form of heat. PCMs incorporated into wall-element systems have been well-studied with respect to energy efficiency of building envelopes. New applications of PCMs in infrastructural concrete, e.g., for mitigating early-age cracking and freeze-and-thaw induced damage, have also been proposed. Hence, the focus of this dissertation is to develop a detailed understanding of the physic-chemical and thermo-mechanical characteristics of cementitious systems and novel coating systems for wall-elements containing PCM. The initial phase of this work assesses the influence of interface properties and inter-inclusion interactions between microencapsulated PCM, macroencapsulated PCM, and the cementitious matrix. The fact that these inclusions within the composites are by themselves heterogeneous, and contain multiple components necessitate careful application of models to predict the thermal properties. The next phase observes the influence of PCM inclusions on the fracture and fatigue behavior of PCM-cementitious composites. The compliant nature of the inclusion creates less variability in the fatigue life for these composites subjected to cyclic loading. The incorporation of small amounts of PCM is found to slightly improve the fracture properties compared to PCM free cementitious composites. Inelastic deformations at the crack-tip in the direction of crack opening are influenced by the microscale PCM inclusions. After initial laboratory characterization of the microstructure and evaluation of the thermo-mechanical performance of these systems, field scale applicability and performance were evaluated. Wireless temperature and strain sensors for smart monitoring were embedded within a conventional portland cement concrete pavement (PCCP) and a thermal control smart concrete pavement (TCSCP) containing PCM. The TCSCP exhibited enhanced thermal performance over multiple heating and cooling cycles. PCCP showed significant shrinkage behavior as a result of compressive strains in the reinforcement that were twice that of the TCSCP. For building applications, novel PCM-composites coatings were developed to improve and extend the thermal efficiency. These coatings demonstrated a delay in temperature by up to four hours and were found to be more cost-effective than traditional building insulating materials.

The results of this work prove the feasibility of PCMs as a temperature-regulating technology. Not only do PCMs reduce and control the temperature within cementitious systems without affecting the rate of early property development but they can also be used as an auto-adaptive technology capable of improving the thermal performance of building envelopes.

This research summarizes the validation testing completed for the material model MAT213, currently implemented in the LS-DYNA finite element program. Testing was carried out using a carbon fiber composite material, T800-F3900. Stacked-ply tension and compression tests were performed for open-hole and full coupons. Comparisons of experimental and simulation results showed a good agreement between the two for metrics including, stress-strain response and displacements. Strains and displacements in the direction of loading were better predicted by the simulations than for that of the transverse direction.

Double cantilever beam and end notched flexure tests were performed experimentally and through simulations to determine the delamination properties of the material at the interlaminar layers. Experimental results gave the mode I critical energy release rate as having a range of 2.18 – 3.26 psi-in and the mode II critical energy release rate as 10.50 psi-in, both for the pre-cracked condition. Simulations were performed to calibrate other cohesive zone parameters required for modeling.

Samples of tested T800/F3900 coupons were processed and examined with scanning electron microscopy to determine and understand the underlying structure of the material. Tested coupons revealed damage and failure occurring at the micro scale for the composite material.

Concrete is relatively brittle, and its tensile strength is typically only about one-tenth of its compressive strength. Regular concrete is therefore normally uses reinforcement steel bars to increase the tensile strength. It is becoming increasingly popular to use random distributed fibers as reinforcement and polymeric fibers is once such kind. In the case of polymeric fibers, due to hydrophobicity and lack of any chemical bond between the fiber and matrix, the weak interface zone limits the ability of the fibers to effectively carry the load that is on the matrix phase. Depending on the fiber’s surface asperity, shape, chemical nature, and mechanical bond characteristic of the load transfer between matrix and fiber can be altered so that the final composite can be improved. These modifications can be carried out by means of thermal treatment, mechanical surface modifications, or chemical changes The objective of this study is to measure and document the effect of gamma ray irradiation on the mechanical properties of macro polymeric fibers. The objective is to determine the mechanical properties of macro-synthetic fibers and develop guidelines for treatment and characterization that allow for potential positive changes due to exposure to irradiation. Fibers are exposed to various levels of ionizing radiation and the tensile, interface and performance in a mortar matrix are documented. Uniaxial tensile tests were performed on irradiated fibers to study fiber strength and failure pattern. SEM tests were carried out in order to study the surface characteristic and effect of different radiation dose on polymeric fiber. The interaction of the irradiated fiber with the cement composite was studied by a series of quasi-static pullout test for a specific embedded length. As a final task, flexural tests were carried out for different irradiated fibers to sum up the investigation. An average increase of 13% in the stiffness of the fiber was observed for 5 kGy of radiation. Flexural tests showed an average increase of 181% in the Req3 value and 102 % in the toughness of the sample was observed for 5 kGy of dose.

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.

As green buildings become more popular, the challenge of structural engineer is to move beyond simply green to develop sustainable, and high-performing buildings that are more than just environmentally friendly. For decades, Portland cement-based products have been known as the most commonly used construction materials in the world, and as a result, cement production is a significant source of global carbon dioxide (CO2) emissions, and environmental impacts at all stages of the process. In recent years, the increasing cost of energy and resource supplies, and concerns related to greenhouse gas emissions and environmental impacts have ignited more interests in utilizing waste and by-product materials as the primary ingredient to replace ordinary Portland cement in concrete systems. The environmental benefits of cement replacement are enormous, including the diversion of non-recycled waste from landfills for useful applications, the reduction in non-renewable energy consumption for cement production, and the corresponding emission of greenhouse gases. In the vast available body of literature, concretes consisting activated fly ash or slag as the binder have been shown to have high compressive strengths, and resistance to fire and chemical attack. This research focuses to utilize fly ash, by-product of coal fired power plant along with different alkaline solutions to form a final product with comparable properties to or superior than those of ordinary Portland cement concrete. Fly ash mortars using different concentration of sodium hydroxide and waterglass were dry and moist cured at different temperatures prior subjecting to uniaxial compressive loading condition. Since moist curing continuously supplies water for the hydration process of activated fly ash mortars while preventing thermal shrinkage and cracking, the samples were more durable and demonstrated a noticeably higher compressive strength. The influence of the concentration of the activating agent (4, or 8 M sodium hydroxide solution), and activator-to-binder ratio of 0.40 on the compressive strengths of concretes containing Class F fly ash as the sole binder is analyzed. Furthermore, liquid sodium silicate (waterglass) with silica modulus of 1.0 and 2.0 along with activator-to-binder ratio of 0.04 and 0.07 was also studied to understand its performance in contributing to the strength development of the activated fly ash concrete. Statistical analysis of the compressive strength results show that the available alkali concentration has a larger influence on the compressive strengths of activated concretes made using fly ash than the influence of curing parameters (elevated temperatures, condition, and duration).