2019 FC&PA STUDENT COMPETITION Sponsored by the FC&PA Education Committee

Transcription

1 2019 FC&PA STUDENT COMPETITION Sponsored by the FC&PA Education Committee FIBER-REINFORCED CONCRETE BOWLING BALL Competition Date: Friday, March 1 ST, 2019 Objective The objective of this competition is to demonstrate the effectiveness of fibers in reinforcing concrete, to gain experience in forming and fabricating a concrete fiber-reinforced element, and to encourage creativity in engineering design and analysis. Competition The Competition is divided into two separate categories; the Bowling Ball Performance Category and the Presentation Category. The Bowling Ball Performance Category will include five performance tests associated with each Team and their Bowling Ball; the Mass Test, the Diameter Consistency Test, the Bowling Test, the Final Deformation Load Test, and the Toughness Load Test. A score from 1 to 10 will be awarded to each team, for each test based upon the performance of the team and its bowling ball. These test scores will be converted into competition points based upon the relative importance of each test. The team rankings for the Bowling Ball Performance Category will be based upon the number of competition points earned as a result of the performance tests. The Presentation Category will require each team to submit a poster. Each of these posters will be judged and awarded a score. The team rankings for the Poster Presentation Category will be based upon the score each poster receives from the judges.

2 Prizes Prizes will be awarded for the combined scores of both the Performance and the Presentation categories. The FC&PA Education Committee shall have the final decision on how to allocate the forfeited Prize money. First Place Prize money is $ Second Place Prize money is $ Third Place Prize money is $ Prizes will be announced at the end of the competition. In the event of a tie, the team with a higher Performance score wins. The FC&PA Education Committee will make the final decision on any potential disputes. Rules 1. The Challenge a. Performance: To design and construct a fiber-reinforced concrete bowling ball which achieves optimal performance under specified criteria. b. Presentation: To document and present the team s work clearly and precisely. 2. The Student Team a. Each team must have a supervising faculty advisor who will see that the team complies with the rules of the competition. The faculty member is permitted to advise more than one team. b. A team is limited to a minimum of two (2) and a maximum of five (5) students currently enrolled in a high school or an undergraduate program. Undergraduate students on cooperative or internship work assignment are eligible to compete. All members of a given team must be from the same school. A student may not be a member of more than one team. c. At least one individual (faculty advisor or student team member) must be designated to represent each team and be present for each of the bowling ball tests. d. Each team must submit a Registration Form attached. There s no limit to the number of teams per school. 3. Materials and Curing a. The bowling ball must use cementitious materials as binder. The cementitious materials shall be Portland cement meeting ASTM C 150, blended cement meeting ASTM C 595, or expansive cement meeting ASTM C 845. Supplementary cementitious materials such as fly ash and natural pozzolan meeting ASTM C 618, silica fume meeting ASTM C 1240, and slag meeting ASTM C 989 may also be used. b. Any type of non-metallic aggregate may be used. c. Chemical admixtures meeting ASTM C 494 or ASTM C 1017 may be used. Glues and similar binders, such as epoxies and other polymers, are NOT allowed. d. Curing shall be at atmospheric pressure. The curing temperatures shall not exceed the boiling point of water. Use of a standard moist curing room is permitted. e. The bowling ball must be constructed from a fiber-reinforced concrete mixture. The fiberreinforced concrete mixture design shall include fibers of maximum 60 mm length and made of

3 steel, glass, synthetic or natural materials as described in ACI 544.1R. The fibers may be used at any dosage rate. No other type of reinforcing is allowed. f. Filling of honeycombed surfaces after casting is allowed. Fill materials must be selected from the same materials used in the original concrete mixture. Manual or mechanical grinding of the surface for smoothness is allowed, but the risk of not meeting tolerances is the responsibility of the Team. 4. Specimen a. Each team shall bring two concrete bowling balls to the competition. b. The bowling ball s mass shall not exceed 5.5 kg. c. The bowling balls shall be spherical (no finger holes) and measure 200 mm +/- 15 mm diameter. d. The bowling balls shall be cast or formed monolithically. A ball consisting of smaller precast units bonded together by any means will be disqualified. e. The bowling balls may be solid (homogeneous) or core filled. If core filled, the maximum density of the filler material shall be no greater than 2400 kg/m 3. f. The bowling balls cannot be cast prior to February 1, g. Modification of entries shall not be permitted once they are submitted for the competition. 5. Bowling Ball Performance Category Each test shall be handled by a group of judges appointed by the FC&PA Education Committee, or their assigns. Each team shall submit two balls for Mass and Diameter Testing. Each ball must be permanently marked with the same name of their school or team name that signifies which team the ball represents along with a unique numeral (1 or 2) to distinguish one ball from the other. The individual balls must also be marked with the predicted test load (in kpa or pounds-force) which the team determines is needed to deform it by 25 mm (see Final Deformation Load Test). The Judges will select a Test Ball at random from the two balls submitted by each team. The Test Ball will remain on site for the Mass Test, the Diameter Test and the Bowling Test. The alternative ball will go offsite for the Final Deformation Load Test and the Toughness Load Test. Each team can select a member to witness the testing. Traveling to the offsite location will be the responsibility of the Team. a. Mass Test [10% of the Overall Score]. The Judges shall weigh the Test Ball to verify that it meets the mass requirements set forth in these rules. The mass of each ball will be determined and documented using a scale of the Judges choice. All balls will be weighed using the same scale. The actual mass of the bowling ball in kg will be the mass test score carried through to the Evaluation phase of the competition. If the ball weight exceeds 5.5 kg, the team will receive no points for this Test. b. Diameter Consistency Test [10% of the Overall Score]. The Test Ball will be measured along three different axes arbitrarily selected by the Judges, for adherence to the bowling ball diameter consistency requirements set forth in these rules. Three specific diameter measurements will be recorded (from 185 mm through 215 mm) as the scores for the diameter test to be carried through to the Evaluation Phase of the Competition. If any of the diameter

4 measurements of the bowling ball are 15 mm greater or less than the design standard of 200 mm the team will receive no points for this Test. c. Bowling Test [20% of the Overall Score]. One and only one team member will be identified as the Team Bowler. The Team Bowler, with no assistance from any other members of the team, will position the Test Ball at the top of a V-shaped ramp and release it down the ramp onto a flat, non-oiled, hard-surfaced lane. The ramp shall be 1,220 mm long and raised 400 mm on one end in order to achieve a reasonable ball speed. The bowling lane (or alley) is 600 mm wide and approximately 3,000 mm long. Each team will roll and score three frames of bowling. Six standard sized bowling pins will be used and will be arranged and spaced. Standard Ten-Pin scoring (with carry over for spares and strikes) will be used but adjusted for a Six-Pin format. Since there are only six pins and three frames the maximum score that can be attained (3 18 pins or 5, six-pin strikes in a row) will be a 54. The Team s score at the end of three frames will be the Bowling Test Score to be carried through to the Point Evaluation Phase of the Competition. The inclined ramp must be used to deliver the ball. The ball must be gravity-drawn down the ramp; no physical assistance is allowed to speed the ball down the ramp. Under no circumstances is the ball to be thrown, launched, or catapulted down the alley towards the pins. If the ball rolls off of the side of the alley prior to striking the pins it is considered a gutter ball and no pins will be scored for that roll. Once the bowling ball is released and begins its descent down the incline, the ball may not be retrieved. The resulting pin count will be recorded as the score for that ball. The Judges will be responsible for setting the pins and recording the score. No practice rolls will be given to any team or individual prior to the test. Any practice rolls on FC&PA equipment will result in Team disqualification. d. Final Deformation Load Test [20% of the Overall Score]. Prior to conducting the Final Deformation Load Test, the Team must identify the predicted load at which the alternative ball will be deformed by 25 mm this is the predicted load in kpa (or total load in poundsforce) that is required to be printed on the ball. If the predicted load is not identified prior to the application of the mechanical load, the team will receive no points for this test. The alternative ball will next be placed in a testing apparatus. A load shall be applied with the initial speed of the crosshead displacement set at 10 mm/min. The Load will be applied until the crosshead displacement of the testing apparatus has traveled 25 mm. The load at 25 mm is considered the Final Deformation Load. This Load along with the Load the Team predicted for the 25 mm deformation are the Final Deformation Load Test Scores to be carried through to the Evaluation Phase of the Competition. e. Toughness Load Test [20% of the Overall Score]. While conducting the Final Deformation Load Test the load will be recorded for every 5 mm of crosshead displacement and the average of the five loads will be computed. The average load for these five displacement points will be the Toughness Load Test Score to be carried through to the Evaluation Phase of the Competition. 6. Poster Presentation Category

5 Poster Presentation [20% of the Overall Score]: All teams shall prepare a poster that documents their research effort, experimental methodology, design philosophy, manufacturing procedures, and general lessons learned in developing their FRC bowling ball. Each team shall submit one and only one poster. If the designs of the two bowling balls prepared for this competition are significantly different from one another then the poster should address both bowling ball designs. The poster can be created on any rolled medium but it must be light enough to be affixed to a wall or bulletin board using masking tape or push pins. The maximum size of each poster shall be limited to 800 mm horizontal by 1200 mm vertical. An area 150 mm wide by 100 mm high in the lower right-hand corner of the poster shall identify the Team Name, the Team s school association, the same team identification on the bowling balls, the advisor s name, a contact phone number or for the advisor, and the names of the student team members. All material must be accessible without having to lift or turn a page. There may be no mechanical or electrical devices attached to the poster. Use a font size such that the minimum printed height of the font s capital letters are 6 mm. Each poster must be submitted to the judges at Registration and prior to the start of the Testing Phase. Posters will be placed on display during the Performance Category of the Competition. At least two Judges will evaluate each poster individually and provide a documented score for every poster. Final scores for each poster will be posted; however, copies of a team s individual evaluation sheet will be made available only to that team and only at the faculty advisor request. The Poster Presentation is designed to convey information but consideration should be given to doing this in a creative way. A successful poster will stand out from the rest and draw people towards it in a tasteful and situationally appropriate manner. The poster shall adhere to the size and informational requirements identified herein. It shall be well organized and easy to follow. It shall be self-evident and not require any type of supplemental explanation during judging. The information contained on the poster (including spelling and punctuation) must be technically correct. The poster needs to fully identify the mix design used for the bowling ball along with the fiber type and dosage. An explanation of how the properties of the bowling ball change subject to the type and size of the fiber selected as well as variations in the mix design should be provided. The Team s experimental process as well as its manufacturing process should be documented along with an explanation of how both were, or could be improved or economized. Finally, the poster should provide suggestions for potential improvements or process techniques that may warrant further study. Posters must be the original design and creation of the entrants. Each Poster shall be unique to a team. In submitting the poster, each team agrees that the poster may be displayed on FC&PA's website and in Florida Concrete Magazine. Using the evaluation sheets, each judge will calculate a score of 0 through 10 (10 being the best) for each team. The average score of all the Judges becomes the Team s presentation score as well as the total competition points for the Poster Presentation Category for the Competition. 7. Test Evaluation and Competition Points

6 a. Evaluation of the Bowling Ball Performance Category Mass Test: The Mass Test Score is the actual mass of the bowling ball in kg. The intent of the test is to develop a ball with the highest mass without going over the 5.5 kg limit. A team s mass score is represented by MT and the lowest bowling ball mass score, among all team balls, is represented by ML. The competition point value for a team s mass test will be Mass PV where; Mass PV = (10) x [(MT ML) / (5.5 ML)] Mass PV is then modified to represent 10% of the overall competition points for a 100 point base score. If a ball has a mass greater than 5.5 kg, it will receive a zero. Diameter Consistency Test: The Diameter Consistency test scores are three measured ball diameters (in mm) between 185 mm and 215 mm. The intent of the test is to determine the consistency of the spherical shape of the bowling ball within a range of diameter measures. A team s three diameter measures are represented by D1, D2, and D3. The competition point value for any particular team s diameter test will be Diameter PV where; Diameter PV = (10) x [13.33 AVEDEV (D1, D2, D3)] / Diameter PV is then modified to represent 10% of the overall competition points for a 100 point base score. If any of the diameter measurements are greater than 215 mm or less than 185 mm it will receive a zero. Six-Pin Bowling Test: Six-Pin Bowling Points are based upon the score rolled during the three frame game. The highest score for a three-frame, six-pin game is 54. A Team s score in the six- Pin bowling Test is represented by B. The competition point value for any particular team s bowling test will be Bowling PV where; Bowling PV = B / (5.4) Bowling PV is then modified to represent 30% of the overall competition points for a 100 point base score. Final Deformation Load Test: The Final Deformation Load points are based upon how closely the Team predicts the load at a 25 mm deformation. The scores for the test are the load measured at which the ball was actually deformed 25 mm and the load at which the team predicted the ball would be deformed by this amount. A Team s measured load is represented by LM and the predicted load is LP. The competition point value for a team s Final Deformation Load Test will be Final Deformation PV where; Final Deformation PV = (10) x {[LM ǀ(LM - LPǀ)ǀ] / LM} Where PV cannot be less than 0.

7 Final Deformation PV is then modified to represent 20% of the overall competition points for a 100 point base score. Toughness Load Test: The Toughness Load Test points are based upon a team s ability to maximize the average value of the applied load at the five deformation points. The score for the test is the average value of the five applied loads at the 5 mm deformation points. An individual Team score is represented as AVGL. The minimum score for all of the teams is MINL, and the maximum score for all of the teams is MAXL. The competition point value for any particular team s Toughness Load Test will be Toughness Load PV where; Toughness Load PV = (10) x (AVGL-MINL) / (MAXL-MINL) Toughness Load PV is then modified to represent 30% of the overall competition points for a 100 point base score. b. Evaluation of the Poster Presentation Category Poster Presentation Test: Poster Presentation points are based upon the average score awarded by the Judges for the Poster Presentation. Each Judge awards the Team with a score from 0 to 10 in 10 separate categories with 10 being the maximum number of points allowed per category. Competition points total for the Poster will be the summation of all points awarded in all 10 categories divided by the number of judges with 100 being the maximum number of points as set forth in the following equation. Poster Presentation Points = [(Judge 1 score) + + (Judge N score)] / N 8. Judging The competition and presiding judge will be appointed by the Chair of FC&PA Education Committee. This judge will appoint other judges from the FC&PA member representatives or volunteers, as needed. a. The presiding judge shall randomly select the testing order for the competition. b. The judges will determine whether or not the rules have been followed. c. The decision of the judges will be final, and appeals will not be considered. d. The judges retain the right to use any means or method they feel are necessary to verify and enforce the requirements of Parts Three and Four of these Rules. e. The judges and the FC&PA Education Committee retain the right to interpret, modify, or eliminate any section or sections of these rules as special circumstances arise. 9. Submitting the Bowling Ball Entries and Supporting Materials a. Advance Registration is required. The Registration Form must be submitted no later than January 31, b. The bowling balls and the poster must be submitted in person no later than 9:00 a.m. on the day of the competition.

8 10. Compliance with FC&PA-Bowling Ball Competition Rules FC&PA reserves the right to perform detailed examination and check entries for compliance with the competition rules. Examination will also be done after the competition. If examination shows that a team did not follow the rules, the team, their advisor and teams from the same school will be disqualified. FC&PA will further document recommendations to sanction the team, their advisor, and/or school/university participation in future competitions. 11. Contact Information For technical inquiries: Mr. Gordon McLellan GMclellan@lehighcement.com 12. Special Awards Category a. Most Spirited Award shall be given to the Team showing the best school spirit before and during the competition. The FC&PA Education Committee shall decide prior to competition testing. Winner will be announced at the end of the competition. b. Most Artistic Award shall be given to the Team with the best art work decorated on their bowling ball. The art work must be tasteful and appropriate. It should not interfere with competition testing. The responsibility is on the Team. The FC&PA Education Committee shall decide prior to competition testing. Winner will be announced at the end of the competition.

9 FRC Bowling Ball Competition Questions Q: What kind of apparatus will be used for testing the bowling balls a hydraulic press or a handy machine like the previous competition? Also, what is the capacity of the apparatus? A: The bowling balls will be tested on a hydraulically operated testing machine. The capacity of the machine will be in excess of 100,000 lb. Q: According to the Rules, the density of the filler material for bowling balls must be less than 24 kg/m³, but the lightest suitable filler in our region has a density of 70 kg/m³. Are we allowed to use this filler? A: No. In accordance with the Rules, the filler material must be less than 24 kg/m³ If you use a higherdensity filler material, your bowling ball will be disqualified Q: May we use fibers with a 0.3 mm diameter and 50 mm length? A: Yes. You may use fibers of 0.3 mm diameter and 50 mm length, provided that the fiber material is of steel, glass, or synthetic or natural materials as described in ACI 544.1R. Q: How is the bowling ball going to be tested? How is the load going to be applied to the bowling ball? A: The load to the bowling ball will be applied in compression with the ball seated between two loading plates (similar to the ASTM C39 cylinder). The rate of loading shall be between psi/s in accordance with ASTM C39. Q: We understand that we can fill in any honeycombing that is present after we remove the mold, but are we able to perform any grinding? A: Grinding, as a measure of finishing the ball, only such techniques as are possible on "fresh cement paste and fresh concrete" are permissible. Q: Are we allowed to sand/grind any areas that we have filled or another section of the ball? A: The sanding/grinding of the surface of the ball should only be done over the filled area. Q: Understanding that the ball may be core-filled, are we then allowed to use materials other than concrete outside the central portion to hold the core material/structure in place? A: Materials not specifically listed in the rules can be used for forming purposes only. The stated objective of the competition and Rules 1 and 3 are for determining what materials to use. The presiding judges will have the final say on whether the intent of the rules has been followed, as implied in Rule 8. Q: Can I use a concrete mix I can readily purchase at a concrete supplier and then add my reinforcing fibers? Or, do I have to develop our mix design from scratch? A: See the rules, especially Sections 3 and 8. As long as the concrete mixture meets the material requirements of Section 3 and can be reported as required in Section 8, the mix will be acceptable.

10 The ten categories in which the posters will be evaluated include: 1. Adherence to the specified poster format; 2. General presentation and appearance of the poster; 3. Organization and clarity of scientific/engineering principles used in the development of the mixture; 4. Soundness of the scientific/engineering principles used in the development of the mixture design; 5. Presentation of intermediate experimental results; 6. Explanation of the choice of fiber(s); 7. Explanation of any changes in the performance of the mixture as it relates to fiber dosage; 8. Clarity and economy (cost-effective) of the manufacturing process; 9. Guidance and suggestions for further study; and 10. Economy (short & concise) of information presented. 1 Kilopascal: One kilopascal (kpa) is equal to exactly 1000 pascals. A pascal (Pa) is the SI unit for pressure define as one newton per square meter. 10 kpa = 1.45 psi = 10,000 N/m 2 10 psi = kpa Newton is a measure of force in unit of kilogram-meter per second square. 1 N = lbf ; 1 lbf = 4.45 N