Abstract: A method of forming a hollow composite construction member of the type suitable for use as building material includes providing an elongated inflatable mold assembly having a longitudinal axis, a flexible tubular bladder wall defining an elongated inflatable cavity, a reinforcing fabric positioned concentrically around the flexible bladder wall, and a flexible air-impervious outer layer positioned concentrically around the fabric. The bladder wall and the outer layer define an elongated annular space with the fabric positioned therein. Tension is applied longitudinally to the fabric and fluid is introduced into the cavity to at least partially inflate the mold and shape the fabric. The mold is shaped to a desired shape while maintaining the fabric under tension. The elongated annular space and the fabric are infused with a rigidification material. The rigidification material is hardened while maintaining the fabric in tension to form a rigid hollow composite construction member.

Abstract: A design and manufacturing methods for reusable, stackable shipping containers made from composite materials is described. The composite material is embedded with optical fibers, data and electrical paths, and various types of components. These embedded devices are capable of detecting intrusions through the container walls, securely storing and processing information, and securely communicating information to other containers and to remote devices.

Abstract: A rapidly-erectable lightweight load resisting system for the construction of buried arched bridges, tunnels or underground bunkers, has a plurality of lightweight arched tubular support members which are formed of a fiber reinforced polymer material and are substantially oriented in a vertical plane. The lightweight tubular support members are connected by at least one or more lateral force resisting members which are positioned in a direction perpendicular to the vertical plane of the tubular support members, and which are capable of transferring vertical loads to the tubular support members and of providing lateral-load capacity to the load resisting system. The tubular support members are fitted with one or more holes near the top which allows them to be filled with a suitable material to provide additional strength or stiffness.

Abstract: An elongated sheet piling panel has a length and width, and opposed side edges, and has elongated voids positioned within the interior of the panel. The voids are oriented in the direction of the length of the panel, and the edges of the panel are configured to be connected to the edges of additional similar panels.

Abstract: A method of forming a composite beam includes cutting an elongated piece of wood to produce strands having cross sections with a substantially symmetrical equilateral polygonal shape. Resin is then applied to the strands, and the strands are formed into a composite beam.

Abstract: The present invention is a resin-starved pultruded-impregnated panel, wood composites utilizing said panel, and a method of making the same. The panel of the present invention comprises a pultruded center portion made from a plurality of fibers bound together by a resin such that the surfaces of the center portion contain significantly less resin than the core, and a layer of an impregnating adhesive, having similar chemical properties to chemical properties of a bonding adhesive used to laminate layers of the wood composite, bonded to each surface to form the surfaces of the panel. The wood composite of the present invention comprises a plurality of wooden members disposed in substantially parallel relation to one another, at least one resin starved pultruded panel disposed at a predetermined location between two of the members; and a bonding adhesive disposed between the surfaces of the members the panel to bond them together.

Abstract: The present invention is method of making a fiber-reinforced polymer (FRP) used to reinforce a wood composite member, in which the FRP may be consolidated and substantially cured at the same time as the wood-wood bond lines. The method of manufacturing partially cured FRP composites of the present invention includes drawing fiber reinforcements in tension, combining the reinforcements into a dry fiber reinforcement layer, wetting the dry fiber reinforcement layer with a wet resin to form a wetted fiber reinforcement layer, and partially curing the wetted fiber reinforcement layer to form a partially cured FRP composite for consolidation and substantially simultaneous curing an uncured wood composite.

Abstract: The present invention is a prestressing system for wood elements and structures and a method from prestressing wood beams. In its most basic form, the system for prestressing structures comprises a plurality of members arranged in a predetermined configuration, at least one non-metallic prestressing tendon, having a material stiffness less than that of steel, disposed in such a manner as to fasten together the members, and stressing means attached to at least one end of the prestressing tendon to exert a tensile force on the tendon and an equal and opposite compressive force drawing the members together. In the preferred embodiment, the tendons are manufactured from fiber reinforced plastic and the members are arranged in side by side relation to form a deck. The deck includes a series of aligned holes through the members, through which the prestressing tendons pass and are secured and prestressed.