🏆 People’s Choice
The Solid Polymer Additive group was assigned to research material properties of concrete formulations using a polyurethane by-product as a cement replacement and discover applications for the new formulations.
Sponsored by: Dr. Don Wardius
Team Members
Dan McFadden Colin Pfingstler Thomas Molnar Jacob Muehlbach
Instructor: Donghai Wang
Project Poster
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Project Video
Project Summary
Overview
Dr. Don Wardius of Covestro presented the team with a plastics-production- byproduct, SPA, and proposed that the material can be used in concrete production. The team developed concrete formulations using increasing weight-percentage replacements of cement with SPA and tested workability level, density, and compressive strength of each formulation and compared to current industry standards. The team was then to research possible applications for which the strength and other properties of the new concrete would be acceptable.
Objectives
The team was responsible for collecting and providing data to the sponsor that either validates or disproves the idea that SPA could be a feasible substitute for cement at certain levels. After discussion with the sponsor and evaluating available resources at Penn State, the team determined the objectives would be testing workability level using a slump test, weighing and checking sample density, and gathering compression strength data to come to a conclusion.
Approach
• Research concrete – building a knowledge base to make more informed choices and decisions.
• Consult those more familiar with concrete: what have they seen before? What would they expect?
• Look at results of other plastic additives in concrete and evaluate those successes or failures.
• Choose which tests were possible with resources available and where they could be completed.
• Develop concrete formulations with SPA replacing cement and gather all other materials, tools, and equipment necessary to complete the tests that had been chosen.
• Mix and pour concrete. Batches were made for each replacement level and 3 sample test cylinders were poured from each batch. Slump tests were done with each batch before being poured.
• Samples were left to cure for a 7-day period in a lime bath, a technique used to hold strength.
• After curing, the mass of each sample was collected, and the density of each sample was calculated.
• Compression testing was completed after 7-day curing. Collected data was then modelled to represent expected results from a 28-day cure. This would better represent results for applications.
Outcomes
The team was able to determine that the estimated 28-day curing strength of the SPA replacement concrete samples did in fact meet standard industry requirements for higher strength applications at the 5% and 7.5% replacement levels.