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.

Pultrusion manufacturing technique stands at the forefront for efficient production of continuous, uniform concrete composites for use in large scale structural applications. High volume and low labor, among other benefits such as improved impregnation and better sample consistency, stand as some of the crucial advances found in automated pultrusion. These advantages introduce textile reinforced concrete (TRC) composites as a potential surrogate for wood, light gauge steel, and other common structural materials into an ever changing and broadening market of industrial grade structural sections. With the potential modifications of textile geometry, textile type, section geometry, and connection type, the options presented by TRC sections seem nearly boundless. Automated pultrusion presents the ability to manufacture many different TRC composite types in at a quickened rate opening up a new field of study of structural materials.

The objective of this study centered on two studies including the development of an automated pultrusion system for the manufacturing of TRC composites and ultimately the assessment of composites created with the pultrusion technique and their viability as a relevant structural construction material. Upon planning, fabrication, and continued use of an automated pultrusion system in Arizona State University’s Structures Lab, an initial, comparative study of polypropylene microfiber composites was conducted to assess fiber reinforced concrete composites, manufactured with Filament Winding Technique, and textile reinforced concrete composites, manufactured with Automated Pultrusion Technique, in tensile and flexural mechanical response at similar reinforcement dosages. A secondary study was then conducted to measure the mechanical behavior of carbon, polypropylene, and alkali-resistant glass TRC composites and explore the response of full scale TRC structural shapes, including angle and channel sections. Finally, a study was conducted on the connection type for large scale TRC composite structural sections in tension and compression testing.