High Strength, Low Cost Pultruded Panel Structures for High Expansion Ratio, Hybrid Shelters

KaZaK Composites Incorporated (KCI) proposes to develop critical material technologies for high expansion ratio tactical shelters. The critical material and component requirements are developed by formulating shelter concepts meeting the habitability, operational deployment, and loading requirements outlined in the solicitation. It is shown that the critical material technologies will be in the construction of lightweight, high stiffness panels for roof, sidewalls, and floor of this shelter. It is further shown that integrally stiffened panels have significant operational and packaging advantages for this shelter concept. Novel sandwich technologies including hybrid foam/composite cores and open cellular construction also promise important advantages for a 12:1 expansion ratio shelter. In order to produce the desired shelter components at affordable prices, KCI proposes extensive ost/performance/processing tradeoffs during Phase I. These tradeoffs will include applicable manufacturing processes such as RTM, SCRIMP, and Pultrusion. These tradeoffs allow cost- and performance-effective materials and components to be selected for fabrication and testing in Phase I. The components tested will include principally skin panels subjected to ending, impact, joint integrity, and thermal insulation testing. The results of said testing will be fed back into the shelter design analysis to update and confirm shelter configurations to be pursued during Phase II. BENEFITS: Material developments achieved under this project will have significant benefit to KCI commercial refrigerated container design development. The overall high expansion ratio shelter concept will further have wide applicability to disaster relief and refugee housing by the Red Cross, UN, and other international aid groups.