Development and Analysis of Composite Car Deck Structures

Abstract

This thesis discusses the subjects of joining of and lashing in a composite car deck structure. Systems engineering methods were used to develop concepts for the joining of and lashing in a predetermined composite car deck section. Conceptual designs were evaluated by means of finite element analyses with respect to stakeholder defined criteria, such as strength and the maximum allowed deflection during loading. The evaluation and analyses resulted in a composite car deck design composed of a glass fibre reinforced plastic sandwich with balsa core material. The core has chamfered edges for easy assembly and disassembly by screws through single laminate edges. For lashing of cars, metal inserts in prefabricated holes were proposed. A life cycle analysis was performed to evaluate the commercial possibilities for the current design. Issues of service and maintenance, such as repairs, paints, fire protection and recycling were investigated. The investigation also included production issues such as production method, assembly and mounting of the structure. With respect to the weight, i.e. material cost and an estimated labour factor, the total cost for the current design was estimated to be slightly more than a conventional steel car deck. When compared to other designs it was concluded that the current design was lighter than plywood and steel-type car decks but heavier than aluminium.