Non conventional materials & techniques applied to cost - - PowerPoint PPT Presentation

Non conventional materials & techniques applied to cost

effective housing and rural buildings: a Brazilian experience Holmer Holmer Savastano Savastano Jr Jr. . Rural Construction Rural Construction University of University of São São Paulo, Brazil Paulo, Brazil

Science and Technology Knowledgde Forum Johannesburg, S. A., 20-21 June 2005

Construction industry x Construction industry x sustainability sustainability

• 16% of freshwater consumption

16% of freshwater consumption

• 30

30 -

• 40% of global energy

40% of global energy

• 20

20 -

• 30% of total waste

30% of total waste

Plessis Plessis (2001) (2001)

Highlights Highlights

• Appropriate raw material

Appropriate raw material

• Low cost cement

Low cost cement

• Vegetable

Vegetable fiber fiber

• Processing of composite material

Processing of composite material

• Performance and durability

Performance and durability

• Roofing solutions

Roofing solutions

• Cement based tiles

Cement based tiles

• Flat and corrugated sheets

Flat and corrugated sheets

• Thermal comfort and cost efficiency

Thermal comfort and cost efficiency

• Different applications

Different applications

• Housing

Housing

• Buildings for intensive animal production

Buildings for intensive animal production

Ordinary Portland Ordinary Portland cement substitutes cement substitutes

SiO2 + Ca(OH)2 + H2O C-S-H

2(Al2O3.2SiO2) + 7Ca(OH)2 + aq 3CaO.2SiO2.aq + 2 (2CaO.Al2O3.SiO2.aq)

Metakaolin

Gehlenite

Pozzolanic reaction Pozzolanic reaction

Ashes from agricultural residues Ashes from agricultural residues

• By

By-

• products from rice husk,

products from rice husk, sugar sugar-

• cane

cane bagasse bagasse or animal manure

• r animal manure
• Burning under controlled conditions

Burning under controlled conditions

• Heating up to 600

Heating up to 600o

• C

C

• Grinding

Grinding

• Substitution of ordinary Portland cement

Substitution of ordinary Portland cement

• Up to 30% if amorphous silica is available

Up to 30% if amorphous silica is available

Challenge for swine production Challenge for swine production

BURNING OF SWINE DEEP BEDDING (40-50% BY MASS OF MANURE)

• Requirement of environmental sustainability in intensive

production areas

• Pressure for the concentration in small areas and for the

increase of productivity

• Requirements for alternative destinations for the

generated residues

Oxide composition of deep bedding ashes Oxide composition of deep bedding ashes

• btained at burning temperature of 600
• btained at burning temperature of 600o
• C

C

Loss on ignition MnO TiO2 MgO CaO K2O Na2O KCl SO2 P2O5 SiO2 Fe2O3 Al2O3 Oxides 6.18 1.83 1.51 9.7 0.14 2.45 11.58 3.52 2.50 1.02 9.41 42.40 21.70 % by mass

X-ray diffraction

24040202

24040102

22040102

400oC 500oC 600oC

Compressive strength of mortars produced with OPC and ashes

28.1 24.9 34.6 32.5 3 35.5 32.5 33.8 32.9 2 30 38.2 32.2 1 37.6 33.4 3 34.4 33.8 31.9 33.9 2 20 33.8 34.1 1 35.0 31.2 3 35.7 30.5 37.2 30.1 2 10 34.9 30.1 1 28 days 7 days 28 days 7 days Averages Individual results Compressive strength (MPa) Specimen Ashes content (%) Ashes calcinated at 600oC

Vegetable Vegetable fibers fibers

Vegetable fiber as Vegetable fiber as reinforcement reinforcement

• Main constituents

Main constituents

• Cellulose

Cellulose

• Lignin

Lignin

• Hemicellulose

Hemicellulose

• Fibrils disposed in

Fibrils disposed in subsequent layers subsequent layers

• Bunch of individual

Bunch of individual cells cells

1- Primary layer 2- S1, 3- S2, 4- S3 (secondary layers) 5- Intercellular layer

Sisal field by Sisal field by-

• product

product

• Cleaning of residual

Cleaning of residual fibres by rotary sieve fibres by rotary sieve

• Additional income for

Additional income for producers producers

Silva & Silva & Beltrão Beltrão (1999) (1999)

Residues of coir fiber Residues of coir fiber

Savastano, 2003

Coconut husks Coconut husks Long fibers (~25 cm) & Long fibers (~25 cm) & Short residual fibers (1 Short residual fibers (1-

• 3 cm)

3 cm)

Appropriate Appropriate cellulose pulp cellulose pulp

In collaboration with CSIRO In collaboration with CSIRO Australia Australia

Recycled Recycled kraft kraft pulp pulp

• Residue of

Residue of eucalyptus Kraft eucalyptus Kraft

• Unrefined pulp

Unrefined pulp

• Peculiarities of

Peculiarities of recycled fibres: recycled fibres:

• lateral shrinkage

lateral shrinkage

• twisted

twisted

• short filaments

short filaments

CTMP pulping CTMP pulping

Chemi Chemi-

• thermomechanical

thermomechanical pulping pulping Individual filaments Individual filaments External and internal fibrillation External and internal fibrillation Original sliver Original sliver Bunch of individual fibres Bunch of individual fibres

Pulp and fibre properties Pulp and fibre properties

Fibre Freeness (ml) Fines (%) 1 Length (mm) 2 Width (µm) 3 Aspect ratio

• E. grandis

685 7.01 0.66 10.9 61 Sisal CTMP 500 2.14 1.53 9.40 163 Banana CTMP 465 1.55 2.09 11.8 177

1 Arithmetic basis, 2 length-weighted basis, 3 average of 20 determinations by SEM

Canadian Standard Freeness (CSF): Canadian Standard Freeness (CSF): Arbitrary measure of the drainage properties of Arbitrary measure of the drainage properties of pulp suspensions pulp suspensions

Savastano Jr. et al. (2001)

Organosolv pulping Organosolv pulping

• Chemical process: organic solvents

Chemical process: organic solvents associated to water associated to water

• Advantages

Advantages

• Better impregnation of the vegetable tissues

Better impregnation of the vegetable tissues

• Easy recover of lignin and polysaccharides

Easy recover of lignin and polysaccharides

• Easy recover of the solvent by distillation

Easy recover of the solvent by distillation

• Low cost and small pulping plants

Low cost and small pulping plants

• Disadvantages

Disadvantages

• Energy consumption may be greater than in Kraft

Energy consumption may be greater than in Kraft

Organosolv pulping results Organosolv pulping results

• Sisal waste

Sisal waste

Organosolv pulping: T = 190oC

3.0 2.9 5.3 11.0 97.6 97.8 94.4 83.0 20 40 60 80 100 1 2 3 4 Pulping Time (h) % componen Lignin H

• locellulose

2h: enough Economy Of Energy

% component

Engineered Engineered synthetic fibres synthetic fibres

Production of engineered PP and PAN fibers with:

• ↑ Modulus of elasticity (10-30 GPa) and tensile strength
• Use of new resins
• ↑ Fiber dispersion
• ↑ Fiber adhesion to the cement matrix
• Use of coatings and fibrillated fibers

Evaluation of their performance in fiber cement composites Anybody interested in this area???

PP & PAN fiber for reinforcement PP & PAN fiber for reinforcement

Processing of fibre Processing of fibre cement composites cement composites

Production of roofing tiles Production of roofing tiles

Roma Jr. et al. (2003)

Transference to the undulate mould Transference to the undulate mould

Physical and mechanical Physical and mechanical properties of the tiles properties of the tiles

Waste eucalyptus pulp as reinforcement (4% by mass) Admissible load = 425 N (Gram & Gut, 1994)

Matrix Clinker free cement Commercial OPC Tightness No mark No mark Age (months) 1 6 1 6 Maximum load (N) 1008 604 837 592

Small scale production of tiles Small scale production of tiles

• Optimized formulation

Optimized formulation

• Vacuum chamber and

Vacuum chamber and light pressing light pressing

• Tiles being transferred

Tiles being transferred to the mould just after to the mould just after production production

• Patent deposited

Patent deposited

Potential Potential applications applications

Individual shelters for calves Individual shelters for calves

Thermal comfort (-1oC in comparison with asbestos cement roofing)

48,0 49,0 50,0 51,0 52,0 53,0 54,0 55,0 56,0

2 7 / s e t 2 9 / s e t 1 /

• u

t 3 /

• u

t 5 /

• u

t 7 /

• u

t 9 /

• u

t 1 7 /

• u

t 1 9 /

• u

t 2 1 /

• u

t 2 3 /

• u

t 2 5 /

• u

t 2 7 /

• u

t 2 9 /

• u

t 3 1 /

• u

t 2 / n

• v

Data

• Freq. Resp. (mov/min)

400,0 420,0 440,0 460,0 480,0 500,0 520,0 540,0 CTR (W/m2) FR CTR

Respiratory frequency (FR) & Radiant thermic load (CTR)

FR Day

Roofing system Roofing system

Rural shelter for cattle Rural shelter for cattle

Thermal comfort Thermal comfort

00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 24:00

10 15 20 25 30 35 40 45 50

SURFACE TEMPERATURE

Asbestos Ceramics No-Asbestos Zn-Metal

Temperature (°C) Hour

• Skin temperature

Skin temperature

Holandês 28,0 29,0 30,0 31,0 32,0 33,0 34,0 35,0 36,0 37,0 38,0 06:00 14:00 Horário Temperatura de Pele (oC) ICA IFB IFC

Physiological performance of Physiological performance of Holstein veals Holstein veals

ICA = asbestos cement IFB = new technology IFC = NT + acclimatization

Skin temperature (oC) Time

Pressed & air cured Pressed & air cured pads of cellulose pads of cellulose-

• cement

cement

Slurry de Slurry de-

• watering & pressing

watering & pressing

Evacuable casting box Tamping flat Pressing pads

MOR MOR

4 8 12 fibre content (%by mass) 5 10 15 20 25 30 MOR(MPa)

• P. radiata
• E. grandis

Banana Sisal

OPC based composites at 28 days

Durability Durability

Weathering of sisal CTMP in BFS Weathering of sisal CTMP in BFS

100.0% 59.7% 60.3% 75.5% 42.0% 55.1% 71.2% 28.9% 38.8% 72.4% 8.4% 24.4% 73.8% 0.00 5.00 10.00 15.00 20.00 25.00 Lab Exp ext Victoria AU Exp ext Sao Paulo BR

Environment MOR (MPa)

1 month 4 months 13 months 25 months 60 months

Fiber degradation Fiber degradation

• Slag based mortar with

Slag based mortar with coir fiber coir fiber

• Alkaline attack

Alkaline attack

• Cracking

Cracking

• Petrifaction

Petrifaction

Mechanical Mechanical modelling modelling

In collaboration with In collaboration with Princeton University, USA Princeton University, USA

Laboratory facilities Laboratory facilities

• Pre

Pre-

• cracking

cracking

• Far

Far-

• field compression

field compression

• Three point bending

Three point bending test test

Department of Mechanical & Department of Mechanical & Aerospace Engineering Aerospace Engineering Princeton University, USA Princeton University, USA

R R-

• curves to aged sisal pulp in BFS

curves to aged sisal pulp in BFS Comparison with Paris & Sih model Comparison with Paris & Sih model

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 0,0 1,0 2,0 3,0 4,0 5,0 6,0 Crack Growth, ∆a (mm) Stress Intensity Factor, K (MPa√m) sisal-BFS 2yo 1-5 sisal-BFS 2yo 1-2 sisal-BFS 2yo 1-3 sisal-BFS 2yo 1-4 sisal-BFS 9m sisal-BFS 1-4 Paris&Sih

BSEI BSEI -

• Composite bridges

Composite bridges

Direction of crack growth

Crack Bridging fiber

Hybrid Hybrid reinforcement with reinforcement with synthetic fiber synthetic fiber

Composite with unrefined sisal Composite with unrefined sisal pulp and PP fiber pulp and PP fiber

0,00 0,01 0,02 0,03 2 4 6 8 10 12

Sisal Organosolv Pulp

28 Days 100 Cycles 100 Cycles after carbonation

σ(MPa)

ε (mm/mm)

0,00 0,01 0,02 0,03 0,04 0,05 0,0 2 4 6 8 10 12

Sisal Organosolve Pulp with PP

28 Days 100 Cycles 100 Cycles after carbonation

σ (MPa)

ε(mm/mm)

Effect of soak dry cycles and carbonation

High toughness High toughness

Hatschek Hatschek method method

(industrial scale) (industrial scale)

Fiber preparation Fiber Cement Water Mineral additions Mixer Final product Molding vats Press cylinder Transport of the fiber cement film

Testing of corrugated sheets Testing of corrugated sheets PVA and PVA and Pinus Pinus cellulose fiber cement cellulose fiber cement

Testing at Escola Politécnica - USP, Brazil

Loading simulation Loading simulation

Basis for functionally graded materials Basis for functionally graded materials

Heat rain test Heat rain test

Facility for the accelerated aging of the Facility for the accelerated aging of the corrugated sheets corrugated sheets

Mechanical properties Mechanical properties

2 4 6 8 10 12 5 10 15 20 25 30 35 Flecha (mm) Tensão (MPa) 0 ciclos 25 ciclos Curvas médias

Stress Deformation (mm) Average curves 0 cycles 25 cycles

Hg porosimetry Hg porosimetry

0.000 0.005 0.010 0.015 0.020 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06

Diâmetro (nm) Volume de mercúrio intrudido (mL/g)

Curva média_sem envelhecimento Curva média_25 ciclos

0 cycles 25 cycles

Volume of intruded mercury Diameter

Comments Comments

• Effect of the heat rain cycles:

Effect of the heat rain cycles:

• Matrix improvement

Matrix improvement

• Increase of the LOP

Increase of the LOP

• Reduction of the porosity

Reduction of the porosity

• Carbonation

Carbonation

• Degradation

Degradation

• Toughness reduction

Toughness reduction

• Degradation of the cellulose fiber

Degradation of the cellulose fiber

• Densification of the fiber/matrix interfacial zone

Densification of the fiber/matrix interfacial zone

Additional roofing Additional roofing solutions solutions

Cost efficient solution Cost efficient solution

Polyethylene shade net – ∆I / ∆C = 8.1 Acclimatized housing – ∆I / ∆C = 0.6

Bamboo shelter Bamboo shelter Colombia Colombia

Poultry housing Poultry housing

Final remarks Final remarks

• Innovate materials

Innovate materials

• fiber cements

fiber cements

• adequate techniques

adequate techniques

• Materials performance & durability

Materials performance & durability

• Affordable housing and infrastructure

Affordable housing and infrastructure

• Human development

Human development

Governmental sponsors Governmental sponsors Acknowledgements Acknowledgements

National Science Foundation National Science Foundation -

• NSF, USA

NSF, USA World Bank Institute World Bank Institute – – WBI WBI NMISCINCE NMISCINCE

Thank you Thank you very much for very much for your attention!!! your attention!!!

Contact details Contact details

Holmer Savastano Jr. Holmer Savastano Jr. Rural Construction Group Rural Construction Group -

• FZEA

FZEA -

• USP

USP P.O. Box 23 P.O. Box 23 -

• 13635

13635-

• 900 Pirassununga SP

900 Pirassununga SP Brazil Brazil Tel +55 19 3565 4153 Tel +55 19 3565 4153 Fax +55 19 3565 4114 Fax +55 19 3565 4114 holmersj@usp.br holmersj@usp.br www.fzea.usp.br/constrambi www.fzea.usp.br/constrambi