OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Materials OBJECTIVE: The Defense Logistics Agency (DLA) seeks to promote responsive, best value supplies of related materials, components, and systems to Department of Defense (DoD) customers and other DoD stakeholders. DLA investigates advancements in technologies and business processes for new and improved materials, more efficient means of their production, and competitive domestic supply chains which will lead to greater innovation in current and future defense systems combined with benefits to other commercial and government applications. Currently, many rapid-setting cement have a shelf-life of on the average of six months to one year. DLA is interested in exploring future defense industrial base development and production of rapid-setting cement with a shelf-life of 5-7 years that meets military specifications and standards. Proposed solution must not be cost prohibitive and demonstrates organic ability for large-scale testing and production. Given the important properties of rapid setting cement with long shelf-life in Airport Damage Repair (ADR) and other military applications, DLA is interested in engaging small businesses with the capability to develop and rapidly expand the industrial base production capacity of rapid-setting cement with long shelf-life for DoD end-uses. DESCRIPTION: Rapid strength cements have limited shelf life. This can be due to the reaction of calcium sulfoaluminate (CSA) with moisture or physical water. The use of rapid strength cement in practice has been hindered by its unstable performance and short shelf-life caused by the prehydration of CSA clinker. The effect of ambient humidity on the prehydration rate and process of CSA clinker is detrimental. Experiments revealed that the ambient humidity of 60% Relative Humidity (RH) can be considered a threshold value for the storage of a CSA clinker. Exposure of CSA clinker to RH higher than 60% will not only result in a significant decrease of hydraulic reactivity, but also in agglomeration of the clinker. Moisture is present in the process of cement production, transportation, and storage. Although improved packaging may help, the prehydration of cement cannot be fully prevented. Chemical changes and improvements are needed. A recent study shows that the exposure of commercial CSA cement to RH above 60% (ranging from 67% 78%) has negative effects on the hydration and strength development of both CSA and calcium sulfoaluminate-ordinary portland cement (CSA-OPC) pastes. In fact, fast and unpredictable prehydration of CSA cement resulting from accidental moisture exposure has long been a problem in practical applications, especially in tropical and subtropical coastal regions. As a result, CSA have limited shelf life. Some rapid-strength cement manufacturers claim a 6-month shelf life while a few may claim up to 3 years; many claim about one year. Nevertheless, these expiration lifespans must be increased. DLA seeks SBIR project opportunities in new and innovative materials, processing, and manufacturing of rapid setting cement that has five to seven-year (5 7-year) shelf-life. DLA seeks opportunities that include strong industry partners with established rapid-setting cement manufacturing capabilities and capacities with relevant experience in the Department of Defense and industry. DLA desires SBIR opportunities with small businesses that has relevant experience with DLA Troop Support Construction and Equipment and United States Army Corps of Engineers. Respondents must be ITAR-certified to qualify for submission of a proposal and receive any subsequent data for this project. PROJECT DURATION and COST: Proposals exceeding these limits will not be evaluated. PHASE I: Not to exceed a duration of 12 months and cost of $100,000. PHASE II: Not to exceed a duration of 24 months and cost of $1,000,000. PHASE I: Phase I will demonstrate proof of concept in rapid-setting cement that shows at least 5 years of shelf-life. A technology development and commercialization roadmap will be produced along with a preliminary business case analysis for transition and industrial scale up. Strong DLA Troop Support Construction and Equipment and United States Army Corps of Engineers relevant experiences in the experimentation and production of rapid setting cement are required. PHASE II: Depending on Phase I results, Phase II will consist of establishing pilot scale or low-rate production of rapid-setting cement with 5 years shelf-life successfully demonstrated in Phase I. Additional activities may include further materials and processing testing, characterization, demonstration in military operational environments, and further extension of shelf-life up to 7 or more years. Development of a detailed business case analysis and commercialization plan will be required. Innovative materials and processes, and commercially viable sources of supply shall be developed with the goal of transitioning readily towards production in support of DLA and Military Services supply chains. PHASE III Phase III is any proposal that derives from, extends or completes a transition from a Phase I or II project. Phase III proposals will be accepted after the completion of Phase I and or Phase II projects. There is no specific funding associated with Phase III, except Phase III is not allowed to use SBIR/STTR coded funding. Any other type of funding is allowed. Phase III proposal Submission. Phase III proposals are emailed directly to DLA SBIR2@dla.mil. The PMO team will set up evaluations and coordinate the funding and contracting actions depending on the outcome of the evaluations. A Phase III proposal should follow the same format as Phase II for the content and format. There are, however, no limitations to the amount of funding requested, or the period of performance. All other guidelines apply. Transition Plan 1. Period of Performance: TBD 2. Budget: $ TBD This Phase of the project should include: 1. Delivery of a production level product to J68 ready for integration into the overall DLA Enterprise system. 2. Develop a sustainment plan to support the delivered system for the lifetime of the program. REFERENCES: 1. Craig W. Hargisa, Antonio Telesca b, Paulo J.M. Monteiroa, Calcium sulfoaluminate (Ye'elimite) hydration in the presence of gypsum, calcite, and vaterite, Cement and Concrete Research 65 (2014) 15 20 2. Leyang Lv, Branko avija, Lin Li, Hongzhi Cui, Ningxu Han, Feng Xing, 3. Cement and Concrete Research, Volume 144,2021,106423,ISSN 0008-8846, 4. https://doi.org/10.1016/j.cemconres.2021.106423. 5. Effect of calcium sulfoaluminate cement prehydration on hydration and strength gain of calcium sulfoaluminate cement-ordinary portland cement mixtures(Ramanathan, S., Halee, B., Suraneni, P. Cement and Concrete Composites, Volume 112, September 2020, Article number 103694, DOI: 10.1016/j.cemconcomp.2020.103694 https://www.royalwhitecement.com/CSA-Binder.pdf https://www.csacement.com/uploads/file/csa-cement-42.5.pdf https://www.scioncsacement.com/store/p1/Cement.html KEYWORDS: calcium sulfoaluminate, Relative Humidity, rapid setting cement, domestic supply chain, manufacturing capacity,
