Behaviour of composite sandwich panels bonded with epoxy polymer matrix for railway sleepers

PhD Thesis


Ferdous, Wahid. 2017. Behaviour of composite sandwich panels bonded with epoxy polymer matrix for railway sleepers. PhD Thesis Doctor of Philosophy. University of Southern Queensland. https://doi.org/10.26192/5c06151a8a82f
Title

Behaviour of composite sandwich panels bonded with epoxy polymer matrix for railway sleepers

TypePhD Thesis
Authors
AuthorFerdous, Wahid
SupervisorManalo, Allan
Aravinthan, Thiru
Institution of OriginUniversity of Southern Queensland
Qualification NameDoctor of Philosophy
Number of Pages232
Year2017
Digital Object Identifier (DOI)https://doi.org/10.26192/5c06151a8a82f
Abstract

The Australian railway industry spends millions of dollars every year in replacing poor condition railway sleepers in order to maintain the track quality and ensure a safe track
operation. It is estimated that more than 2.5 million timber sleepers per year are required for railway track maintenance. Over the last decade, it has been increasingly difficult to get suitable quality hardwood to keep up with the demand for railway maintenance. Moreover, the global
environmental impact due to felling huge number of trees for manufacturing timber sleepers is a major concern. In recent years, significant efforts have been provided towards the development of polymer composite sleeper alternatives to replace deteriorating timber sleepers. Despite their potential, the uptake of polymer composite sleepers has been extremely limited because of the high production cost of these technologies. An improved understanding of composite sleeper technology such that improved designs and effective material usage needs
to be developed to reduce the overall cost of production.

This study focused on investigating the behaviour of a fibre composite railway sleeper manufactured from composite sandwich panels and the panels are bonded together with epoxy polymer matrix. An intensive characterisation of the epoxy polymer matrix and composite sandwich panels was conducted to determine the effective usage of these materials for railway sleepers. The effect of resin-to-filler ratio on the thermal, physical, mechanical and durability properties of the epoxy polymer matrix were evaluated. Filler materials composed of fire retardant filler, hollow microsphere and fly ash were increased from 0% to 60% in the epoxy based matrix. The results showed that epoxy-based polymer mixes containing 30% to 50%
fillers by volume provided a good balance of thermal, physical, mechanical, and durability properties suitable for coating the composite railway sleepers. The capacity of single composite sandwich beam in resisting bending and shear forces were then determined by testing them in
horizontal and vertical orientations and with a shear span-to-depth ratio varying between 0.5 and 12. The results showed that the horizontal sandwich beams performed better under bending while vertical sandwich beams were more effective in resisting shear. It was also found that
the beam orientation has more influence on the load carrying capacity and stiffness properties than changing the shear span-to-depth ratio.

The structural integrity and composite action between the sandwich panels and epoxy polymer matrix were investigated. The effects of binder properties, bond length, bond thickness and bond width were investigated to evaluate the bond behaviour of a composite sandwich panel and epoxy polymer matrix. The results indicated that the bond thickness has the greatest influence on the bond strength followed by the properties of polymer matrix, bond length and bond width. A bond thickness of 5 mm, bond length of 70 mm and using polymer matrix with 40% filler and 60% resin (by volume) can eliminate failure in the glue line and promote failure in the sandwich panels. Using these bond parameters, full-scale layered sandwich beams were
manufactured and their structural behaviour was evaluated under four-point bending and asymmetrical beam shear tests. Results showed that the binding of sandwich panels using
epoxy polymer matrix can prevent the wrinkling and buckling of the fibre composite skins as well as the indentation in the phenolic core. This concept increased the bending and the shear strength of the vertically oriented beams by as much as 25% and 100%, respectively, compared to single sandwich beams. Using the same amount of material, the vertically layered beams exhibited similar bending strength and 50% higher shear strength but only 7% lower effective
modulus of elasticity compared to horizontally layered beams. More importantly, the layered sandwich beams were found to have strength and stiffness similar to the hardwood timber.

The optimal design of layered sandwich beams for railway sleepers and the performance evaluation under static loads were conducted as the last study. The optimal shape
of sleeper under quasi-static load was obtained using topology optimisation. The optimal sleeper shape requires only 50% volume of materials compared to a rectangular timber sleeper. Moreover, the rail seat and centre bending moments, shear strength, screw holding capacity,
and electrical resistance of optimised composite sleeper are higher than the traditional hardwood timber and exceed considerably the performance requirements for a railway sleeper. The handling, installing and fastening system of this composite sleeper were similar to timber and require the same equipment and machineries. A total of 50 sleepers have been installed on a trial basis in the Southern line rail track at Nobby, Queensland, which are performing very
well and are expected to outperform its design life.

An in-depth understanding of the behaviour of a new type of composite sleepers made from layered sandwich panels bonded by epoxy polymer matrix was the significant outcome
of this study. The experimental data, simplified theoretical models and finite element simulations derived from this study can be used as important tools for a safe design of composite railway sleepers. The optimal sleeper shape proposed in this study can provide a cost-effective alternative to timber sleepers in a mainline track to decrease railway track maintenance, and provide a totally recyclable and sustainable sleeper technology.

KeywordsAustralian Railway; railway sleepers; composite sandwich panels; epoxy polymer matrix
ANZSRC Field of Research 2020400510. Structural engineering
401602. Composite and hybrid materials
Byline AffiliationsSchool of Civil Engineering and Surveying
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Ferdous, Wahid, Ngo, Tuan Duc, Nguyen, Kate T. Q., Ghazlan, Abdallah, Mendis, Priyan and Manalo, Allan. 2018. "Effect of fire-retardant ceram powder on the properties of phenolic-based GFRP composites." Composites Part B: Engineering. 155, pp. 414-424. https://doi.org/10.1016/j.compositesb.2018.09.032
Short-term flexural behaviour of concrete filled pultruded GFRP cellular and tubular sections with pin-eye connections for modular retaining wall construction
Ferdous, Wahid, Almutairi, Ahmed D., Huang, Yuan and Bai, Yu. 2018. "Short-term flexural behaviour of concrete filled pultruded GFRP cellular and tubular sections with pin-eye connections for modular retaining wall construction." Composite Structures. 206, pp. 1-10. https://doi.org/10.1016/j.compstruct.2018.08.025
Modular assembly of water-retaining walls using GFRP hollow profiles: Components and connection performance
Ferdous, Wahid, Bai, Yu, Almutairi, Ahmed D., Satasivam, Sindu and Jeske, Juri. 2018. "Modular assembly of water-retaining walls using GFRP hollow profiles: Components and connection performance." Composite Structures. 194, pp. 1-11. https://doi.org/10.1016/j.compstruct.2018.03.074
Flexural and shear behaviour of layered sandwich beams
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Fam, Amir. 2018. "Flexural and shear behaviour of layered sandwich beams." Construction and Building Materials. 173, pp. 429-442. https://doi.org/10.1016/j.conbuildmat.2018.04.068
Behaviour of composite sandwich beams with different shear span-to-depth ratios
Ferdous, Wahid, Manalo, Allan and Aravinthan, Thiru. 2017. "Behaviour of composite sandwich beams with different shear span-to-depth ratios." Hao, Hong and Zhang, Chunwei (ed.) 24th Australasian Conference on the Mechanics of Structures and Materials (ACMSM24). Perth, Australia 06 - 09 Dec 2016 London, United Kingdom. https://doi.org/10.1201/9781315226460-34
Evaluation of an innovative composite railway sleeper for a narrow-gauge track under static load
Ferdous, Wahid, Manalo, Allan, Van Erp, Gerard, Aravinthan, Thiru and Ghabraie, Kazem. 2018. "Evaluation of an innovative composite railway sleeper for a narrow-gauge track under static load." Journal of Composites for Construction. 22 (2), pp. 1-13. https://doi.org/10.1061/(ASCE)CC.1943-5614.0000833
Bond behaviour of composite sandwich panel and epoxy polymer matrix
Ferdous, Wahid, Manalo, Allan and Aravinthan, Thiru. 2016. "Bond behaviour of composite sandwich panel and epoxy polymer matrix." Teng, Jin-Guang and Dai, Jian-Guo (ed.) 8th International Conference on Fibre-Reinforced Polymer (FRP) Composites in Civil Engineering (CICE 2016). Hong Kong, China 14 - 16 Dec 2016 Hong Kong.
Recent developments and applications of composite railway sleepers
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Remennikov, Alex. 2016. "Recent developments and applications of composite railway sleepers." Conference on Railway Excellence (CORE) 2016. Melbourne, Australia 16 - 18 May 2016
Bond behaviour of composite sandwich panel and epoxy polymer matrix: Taguchi design of experiments and theoretical predictions
Ferdous, Wahid, Manalo, Allan and Aravinthan, Thiru. 2017. "Bond behaviour of composite sandwich panel and epoxy polymer matrix: Taguchi design of experiments and theoretical predictions." Construction and Building Materials. 145, pp. 76-87. https://doi.org/10.1016/j.conbuildmat.2017.03.244
Effect of beam-column joint stiffness on the design of beams
Ferdous, Wahid. 2014. "Effect of beam-column joint stiffness on the design of beams." Smith, Scott (ed.) 23rd Australasian Conference on the Mechanics of Structures and Materials (ACMSM23). Byron Bay, Australia 09 - 12 Dec 2014 Lismore, Australia.
Effect of beam orientation on the static behaviour of phenolic core sandwich composites with different shear span-to-depth ratios
Ferdous, Wahid, Manalo, Allan and Aravinthan, Thiru. 2017. "Effect of beam orientation on the static behaviour of phenolic core sandwich composites with different shear span-to-depth ratios." Composite Structures. 168, pp. 292-304. https://doi.org/10.1016/j.compstruct.2017.02.061
Optimal polymer matrix coating for composite railway sleeper – analytic hierarchy process
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2015. "Optimal polymer matrix coating for composite railway sleeper – analytic hierarchy process." Wu, Zhishen, Wu, Gang and Wang, Xin (ed.) Joint Conference of the 12th International Symposium on Fiber Reinforced Polymers for Reinforced Concrete Structures (FRPRCS-12) & the 5th Asia-Pacific Conference on Fiber Reinforced Polymers in Structures (APFIS-2015). Nanjing, China 14 - 16 Dec 2015 China.
Thermo-mechanical behaviour of epoxy based polymer matrix
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2015. "Thermo-mechanical behaviour of epoxy based polymer matrix." 27th Biennial National Conference of the Concrete Institute of Australia (Concrete 2015) in conjunction with the 69th RILEM Week: Construction Innovations, Research into Practice. Melbourne, Australia 30 Aug - 02 Sep 2015 Sydney, Australia.
Effect of ultraviolet radiation on the physical and mechanical properties of polymer matrix
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2015. "Effect of ultraviolet radiation on the physical and mechanical properties of polymer matrix." 27th Biennial National Conference of the Concrete Institute of Australia (Concrete 2015) in conjunction with the 69th RILEM Week: Construction Innovations, Research into Practice. Melbourne, Australia 30 Aug - 02 Sep 2015 Sydney, Australia.
Design of epoxy resin based polymer concrete matrix for composite railway sleeper
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2014. "Design of epoxy resin based polymer concrete matrix for composite railway sleeper." Smith, Scott T. (ed.) 23rd Australasian Conference on the Mechanics of Structures and Materials (ACMSM23). Byron Bay, Australia 09 - 12 Dec 2014 Lismore, Australia.
Properties of epoxy polymer concrete matrix: Effect of resin-to-filler ratio and determination of optimal mix for composite railway sleepers
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2016. "Properties of epoxy polymer concrete matrix: Effect of resin-to-filler ratio and determination of optimal mix for composite railway sleepers." Construction and Building Materials. 124, pp. 287-300. https://doi.org/10.1016/j.conbuildmat.2016.07.111
Composite railway sleepers: new developments and opportunities
Ferdous, Wahid, Aravinthan, Thiru, Manalo, Allan and Van Erp, Gerard. 2015. "Composite railway sleepers: new developments and opportunities." 11th International Heavy Haul Association Conference: Operational Excellence (IHHA 2015). Perth, Australia 21 - 24 Jun 2015 United States.
Structural performance of heavy duty composite railway sleeper
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2015. "Structural performance of heavy duty composite railway sleeper." 11th International Heavy Haul Association Conference: Operational Excellence (IHHA 2015). Perth, Australia 21 - 24 Jun 2015
Composite railway sleepers – recent developments, challenges and future prospects
Ferdous, Wahid, Manalo, Allan, Van Erp, Gerard, Aravinthan, Thiru, Kaewunruen, Sakdirat and Remennikov, Alex. 2015. "Composite railway sleepers – recent developments, challenges and future prospects." Composite Structures. 134, pp. 158-168. https://doi.org/10.1016/j.compstruct.2015.08.058
Geopolymer concrete-filled pultruded composite beams: concrete mix design and application
Ferdous, Wahid, Manalo, Allan, Khennane, Amar and Kayali, Obada. 2015. "Geopolymer concrete-filled pultruded composite beams: concrete mix design and application." Cement and Concrete Composites. 58, pp. 1-13. https://doi.org/10.1016/j.cemconcomp.2014.12.012
Review of failures of railway sleepers and its consequences
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Remennikov, Alex. 2014. "Review of failures of railway sleepers and its consequences." Li, Chun Qing, Setunge, Sujeeva and de Silva, Saman (ed.) 1st International Conference on Infrastructure Failures and Consequences (ICIFC 2014). Melbourne, Australia 16 - 20 Jul 2014 Melbourne, Australia.
Composite railway sleeper: a cost effective and eco-friendly alternative
Ferdous, Wahid, Manalo, Allan, Aravinthan, Thiru and Van Erp, Gerard. 2014. "Composite railway sleeper: a cost effective and eco-friendly alternative." IEEE Australia and New Zealand Student and Young Professional Congress (ANZSCON 2014). Brisbane, Australia 03 - 05 Jul 2014
Failures of mainline railway sleepers and suggested remedies – review of current practice
Ferdous, Wahid and Manalo, Allan. 2014. "Failures of mainline railway sleepers and suggested remedies – review of current practice." Engineering Failure Analysis. 44, pp. 17-35. https://doi.org/10.1016/j.engfailanal.2014.04.020
Benefits of geopolymer concrete-filled FRP beams and its flexural behaviour
Ferdous, Wahid, Manalo, Allan, Khennane, Amar and Kayali, Obada. 2014. "Benefits of geopolymer concrete-filled FRP beams and its flexural behaviour." Australasian Composites Conference (CA 2014): Materials for a Lighter and Smarter World. Newcastle, Australia 07 - 09 Apr 2014 Melbourne, Australia.
Structural optimisation of composite railway sleeper
Ferdous, Wahid, Manalo, Allan and Van Erp, Gerard. 2014. "Structural optimisation of composite railway sleeper." Australasian Composites Conference (CA 2014): Materials for a Lighter and Smarter World. Newcastle, Australia 07 - 09 Apr 2014 Melbourne, Australia.