Adv Materials Final Presen

7/27/2019 Adv Materials Final Presen

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Advance Building Materials

Submitted by

Ar.G.Rajaa.,1st

year M.Arch.,PMU.


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Contents

1.Dry Wall Construction

2.Self Compacting Concrete

3.Aerated Blocks

4. Reinforced polymers

5. Special Use of waste products (broken glass, flyash, micro silica)


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1.Dry Wall Construction

Drywall (also known as plasterboard, wallboard, gypsum board, or gyprock)

is a panel made of gypsum plaster pressed between two thick sheets of paper. It is

used to make interior walls and ceilings. Drywall construction became prevalent as aspeedier alternative to traditional lath and plaste

Gypsum Board evolved between 1910 and 1930 beginning with wrapped

board edges, and elimination of the two inner layers of felt paper in favor of paper-

based facings. Providing efficiency of installation, it was developed additionally as a

measure of fire resistance.


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A wallboard panel is made of a paper liner wrapped around an inner core

made primarily from gypsum plaster.

The raw gypsum, CaSO42 H2O, (mined or obtained from flue-gas

desulfurization (FGD)) must be calcined before use to produce the hemihydrates of

calcium sulfate(CaSO4 H2O).

This is done in kettle or flash calciners, typically using natural gas today. The

plaster is mixed with fiber (typically paper and/or fiberglass), plasticizer, foaming agent,

finely ground gypsum crystal as an accelerator, EDTA, starch or other chelate as a

retarder, various additives that may decrease mildew and increase fire resistance

(fiberglass or vermiculite), waxemulsion or silanes for lower water absorption and water.

This is then formed by sandwiching a core of wet gypsum between two sheets

of heavy paper or fiberglass mats.

When the core sets and is dried in a large drying chamber, the sandwich

becomes rigid and strong enough for use as a building material.

1.Dry Wall Construction- Manufacture of Boards


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Leading Manufacturer of Dry wall

Plaster board in india

Types of Plaster Boards

1.Gyproc Plain Boards

Gyproc gypsum plasterboards are the ultimate wall andceiling solution for today's buildings, providing high levels of performance in terms

of fire rating, acoustic insulation, thermal insulation and moisture resistance to

create modern internal environments that offer comfort and safety for occupants.

They offer superior solutions for walls, ceilings,wall linings, lift shafts, stairwells

and corridors in buildings as diverse as residential, schools, hospitals, offices,

cinemas and hotels. Gyproc is the brand of specialist high performance boardswith special boards for applications like fire, acoustics, moisture, impact and

thermal resistance.


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Characteristics

This gypsum plaster board is enriched with high density core with glass fibre and otheradditives, hence offering high durability

Application

It is suitable for applications where high level of acoustics and impact resistance levels

are specified

3. Gyproc Fireline

Characteristics

This is a fire resistant gypsum plasterboard with glass fibre and other additives The board

capable of withstanding fire for longer duration without physical degradation

Application

It is suitable for application where a higher level of fire protection is required

2. Gyproc Duraline

Characteristics

This is the moisture resistant gypsum plasterboard with water repellent additives in the core and

paper liners

Application

It is most suitable as a base for tiling in moisture-prone areas.

It is also used for external soffits in sheltered positions

3. Gyproc Moisture resistant


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Characteristics

Gyproc

SoundBloc consists of an aerated gypsum core encased in, and firmly bonded to, strongpaper liners.

Gyproc SoundBloc is a plaster board that is suitable for dry lining internal surfaces and offering

high sound insulation

Application

Gyproc SoundBloc is designed for use in walls and partition systems where greater levels of

sound insulation are required

4. Gyproc SoundBloc

Characteristics

Gyproc Fireline with water repellent additives in the core. Gyproc Fireline MR consists of an

aerated gypsum core with glass fibre, water repellent and other additives encased in, and

firmly bonded to, strong paper liners.Gyproc Fireline MR is a plasterboard that is suitable for drylining internal surfaces.

Application

Used in Gyproc partitions & wall lining and ceiling systems to give increased fire protection

and moisture resistance are required. Also used for protection to structural steel

4. Gyproc FR MR


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Self-compacting concrete (SCC) is a flowing

concrete mixture that is able to consolidate under

its own weight.

The highly fluid nature of SCC makes it suitable for

placing in difficult conditions and in sections with

congested reinforcement.

Use of SCC can also help minimize hearing-related

damages on the worksite that are induced by

vibration of concrete.

Another advantage of SCC is that the time

required to place large sections is considerably

reduced

The Requirement of skilled labours reduced

Well proportioned SCC can flow under its

own weight through and around congested

reinforcement, filling forms completely and

producing a void-free mass with little or nomechanical vibration.

2.Self Compacting Concrete- Introduction

SCC delivery in

Torontos International airport for

bottom-up pumping of 101-foothigh

steel-form, steelreinforced columns

that were only 28 inches in diameter.


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Left: Slump flow test. A technician lifts the slump

cone and measures the diameter of SCC spread.

Below: The L-box test measures flow and blocking

resistance of the SCC mix.

SCC development began in

Japan in the early 1980s because of concerns

about concrete durability, with researchers

realizing that poor compaction

of concrete was a major factor in thedeclining quality of construction work


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Materials:

The new generation of superplasticizersbased on polycarboxylated ethers

has been an important factor in making SCC a practical reality. Normal concrete

aggregates are generally suitable for SCC, but the grading probably will be different.

Portland cement and other fines, including ground limestone fines, fly ash, and ground

granulated blast-furnace slag, may be needed in larger proportions than in conventional

concrete to obtain the desired cohesion. Specialized admixtures that control flow

characteristics, workability retention, and viscosity or cohesion of the mix are crucial to

SCC performance. Air-entraining admixtures are also used where necessary.


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Mix design objectives: A specific mix design must be based on the intended

application, suited to anticipated congestion of reinforcement or complexity of the

form. Typically there will be less coarse aggregate and a proportionally largeramount of fines, including portland cement, fly ash, ground slag, and stone

powder. Broadly speaking, the fresh SCC must be able to flow into all the spaces

within the formwork under its own weight. It also must flow through narrow

openings such as the spaces between reinforcing barsa constraint that may limit

the maximum aggregate size. While maintaining this flow, it also must resist

segregation. Meeting all of these demands results in mix proportions that differfrom conventional concrete, as the table shows.

Material Traditional Concrete, by volume SCC, by volume

Admixtures trace 0.01 %

Water 18 % 20 %

Coarse aggregate 46 % 28 %

Sand 24 % 34 %

Fines, including

portland cement

12 % 18 %


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Advantages & Disadvantages

Reduced construction time

Reduced manpower for placing

and compacting

Lower equipment costs and less

noise since vibrators are not required

Ability to fill complex forms and

members with congested reinforcement

Elimination of rubbing and patching

ordinarily required prepared for specific jobs.


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2.Self Compacting Concrete- Examples

An aluminum form panel pulled back from the

wall shows the textured urethane liner. Off-the

form condition of the SCC concrete was excellent,

showing no surface void areas.

Top view of forms with insulation in place at center of

wall. Photo above shows the finished wall after staining.

Blockout for a window reveals the sandwich

construction of the insulated wall.

Hardened SCC, as compared with traditional vibrated concrete of similar water-cement ratio, is expected to have:

The same structural behavior Equal or higher tensile and compressive strength

Equal or lower drying shrinkage Equal or better bond to reinforcement

Lower surface absorption and therefore better durability

Freeze/thaw resistance similar to conventional concrete when non-air

entrained;equal or better when air-entrained mixes are compared


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3.Aerated Blocks

Autoclaved aerated concrete is a versatile lightweight construction material and

usually used as blocks. Compared with normal (ie: dense concrete) aircrete has

a low density and excellent insulation properties.

The low density is achieved by the formation of air voids to produce a cellular

structure. These voids are typically 1mm - 5mm across and give the material its

characteristic appearance. Blocks typically have strengths ranging from 3-9

Nmm-2 (when tested in accordance with BS EN 771-1:2000). Densities range

from about 460 to 750 kg m-3; for comparison, medium density concrete blocks

have a typical density range of 1350-1500 kg m-3 and dense concrete blocks arange of 2300-2500 kg m-3


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3.Aerated Blocks

Autoclaved aerated concrete blocks are excellent thermal insulators and

are typically used to form the inner leaf of a cavity wall.

They are also used in the outer leaf, when they are usually rendered, and infoundations. It is possible to construct virtually an entire house from autoclaved

aerated concrete, including walls, floors - using reinforced aircrete beams, ceilings

and the roof. Autoclaved aerated concrete is easily cut to any required shape.

Aircrete also has good acoustic properties and it is durable, with good resistance to

sulfate attack and to damage by fire and frost.


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Production

Autoclaved aerated concrete is cured in an autoclave - a large pressure

vessel. In aircrete production the autoclave is normally a steel tube some 3

metres in diameter and 45 metres long. Steam is fed into the autoclave at highpressure, typically reaching a pressure of 800 kPa and a temperature of 180 C.

Autoclaved aerated concrete can be produced using a wide range of

cementitous materials, commonly:

Portland cement, lime andpulverised fuel ash (PFA)

or

Portland cement, lime and

fine silica sand. The sand

is usually milled to achieveadequate fineness.

A small amount of

anhydrite or gypsum is

also often added.


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Autoclaved aerated concrete is quite different from dense concrete

(ie: normal concrete) in both the way it is produced and in the composition ofthe final product.

Dense concrete is typically a mixture of cement and water, often with

slag or PFA, and fine and coarse aggregate. It gains strength as the cement

hydrates, reaching 50% of its final strength after perhaps about 2 days and most of

its final strength after a month.

In contrast, autoclaved aerated concrete is of much lower density than

dense concrete. The chemical reactions forming the hydration products go

virtually to completion during autoclaving and so when removed from the

autoclave and cooled, the blocks are ready for use.

Autoclaved aerated concrete does not contain any aggregate; all the

main mix components are reactive, even milled sand where it is used. The sand,

inert when used in dense concrete, behaves as a pozzolan in the autoclave due to

the high temperature and pressure.

3.Aerated Blocks


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4.Reinforced Polymer (FRP)

Carbon-fiber-reinforced polymer (CFRP) has become a notable material

in structural engineering applications. Studied in an academic context as to its

potential benefits in construction, it has also proved itself cost-effective in a

number of field applications strengthening concrete, masonry, steel, cast iron, and

timber structures. Its use in industry can be either for retrofitting to strengthen an

existing structure or as an alternative reinforcing (or prestressing) material instead

of steel from the outset of a project.

1. Flexural strengthening

2.Shear strengthening

GFRP Lleida Pedestrian Bridge in Spain

Carbon, aramid and glass fibres are strong


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FRP - Applications

FRP can be applied to strengthen the beams, columns, and slabs of

buildings and bridges.

It is possible to increase the strength of structural members even after

they have been severely damaged due to loading conditions.

In the case ofdamaged reinforced concrete members, this would first

require the repair of the member by removing loose debris and filling in cavities

and cracks with mortar or epoxy resin. Once the member is repaired,

strengthening can be achieved through the wet hand lay-up process of

impregnating the fibre sheets with epoxy resin then applying them to the

cleaned and prepared surfaces of the member.


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1. Flexural strengthening

For the flexural strengthening of a beam, FRP sheets or plates are

applied to the tension face of the member (the bottom face for a simply

supported member with applied top loading or gravity loading). Principaltensile fibres are oriented in the beam longitudinal axis, similar to its internal

flexural steel reinforcement. This increases the beam strength and

its stiffness (load required to cause unit deflection), however decreases the

deflection capacity and ductility

2.Shear strengthening

Shear strengthening of a beam, the FRP is applied on the web or

side faces of the member with fibres oriented transverse to the beam

longitudinal axis. This is necessary for resisting shear forces, in a similar

manner as internal steel stirrups, by bridging shear cracks that form underloading and restricting their growth

Side bonding, U-wraps or U-jackets, and closed wraps or complete wraps

Slabs may be strengthened by applying FRP strips at their bottom (tension) face.

This will result in better flexural performance


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Special Use of waste products (broken glass, fly ash, micro silica) and industrial

Fly ash, also known as flue-ash, is one of the residues generated

in combustion, and comprises the fine particles that rise with the flue gases. Ash

which does not rise is termed bottom ash. In an industrial context, fly ash usuallyrefers to ash produced during combustion of coal. Fly ash is generally captured

by electrostatic precipitators or other particle filtration equipment before the flue

gases reach the chimneys of coal-fired power plants, and together with bottom

ash removed from the bottom of the furnace is in this case jointly known as coal ash.

Depending upon the source and makeup of the coal being burned, the components

of fly ash vary considerably, but all fly ash includes substantial amounts of silicondioxide(SiO2) (both amorphous and crystalline) and calcium oxide (CaO), both being

endemic ingredients in many coal-bearing rock strata.

Toxic constituents depend upon the specific coal bed makeup, but may include one or

more of the following elements or substances in quantities from trace amounts toseveral percent: arsenic, beryllium, boron, cadmium, chromium, hexavalent

chromium, cobalt, lead, manganese, mercury,molybdenum, selenium, strontium, thal

lium, and vanadium, along with dioxins and PAH compounds
http://en.wikipedia.org/wiki/Arsenichttp://en.wikipedia.org/wiki/Berylliumhttp://en.wikipedia.org/wiki/Boronhttp://en.wikipedia.org/wiki/Cadmiumhttp://en.wikipedia.org/wiki/Chromiumhttp://en.wikipedia.org/wiki/Hexavalent_chromiumhttp://en.wikipedia.org/wiki/Hexavalent_chromiumhttp://en.wikipedia.org/wiki/Cobalthttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Manganesehttp://en.wikipedia.org/wiki/Mercury_(element)http://en.wikipedia.org/wiki/Molybdenumhttp://en.wikipedia.org/wiki/Seleniumhttp://en.wikipedia.org/wiki/Strontiumhttp://en.wikipedia.org/wiki/Thalliumhttp://en.wikipedia.org/wiki/Thalliumhttp://en.wikipedia.org/wiki/Vanadiumhttp://en.wikipedia.org/wiki/Polychlorinated_dibenzodioxinshttp://en.wikipedia.org/wiki/Polycyclic_aromatic_hydrocarbonhttp://en.wikipedia.org/wiki/Polycyclic_aromatic_hydrocarbonhttp://en.wikipedia.org/wiki/Polycyclic_aromatic_hydrocarbonhttp://en.wikipedia.org/wiki/Polycyclic_aromatic_hydrocarbonhttp://en.wikipedia.org/wiki/Polychlorinated_dibenzodioxinshttp://en.wikipedia.org/wiki/Vanadiumhttp://en.wikipedia.org/wiki/Thalliumhttp://en.wikipedia.org/wiki/Thalliumhttp://en.wikipedia.org/wiki/Strontiumhttp://en.wikipedia.org/wiki/Seleniumhttp://en.wikipedia.org/wiki/Molybdenumhttp://en.wikipedia.org/wiki/Mercury_(element)http://en.wikipedia.org/wiki/Manganesehttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Cobalthttp://en.wikipedia.org/wiki/Hexavalent_chromiumhttp://en.wikipedia.org/wiki/Hexavalent_chromiumhttp://en.wikipedia.org/wiki/Hexavalent_chromiumhttp://en.wikipedia.org/wiki/Chromiumhttp://en.wikipedia.org/wiki/Cadmiumhttp://en.wikipedia.org/wiki/Boronhttp://en.wikipedia.org/wiki/Berylliumhttp://en.wikipedia.org/wiki/Arsenic


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5.Special Use of waste products (broken glass, fly ash, micro silica)

Owing to its pozzolanic properties, fly ash is used as a

replacement for some of the Portland cement content

of concrete.

Asphalt concrete is a composite material consisting of

an asphalt binder and mineral aggregate. Both Class F

and Class C fly ash can typically be used as a mineral

filler to fill the voids and provide contact points

between larger aggregate particles in asphalt concrete

mixes.

fly ash has been used as a component in geopolymers,

where the reactivity of the fly ash glasses is used to

generate a binder comparable to a hydrated Portland

cement in appearance and properties

There are several techniques for manufacturing

construction bricks from fly ash, producing a wide

variety of products. One type of fly ash brick is

manufactured by mixing fly ash with an equal amount

of clay, then firing in a kiln at about 1000 degrees C.

Finer particles of Fly ash


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Another application of using fly ash is in roller compacted

concrete dams. Many dams in the US have been

constructed with high fly ash contents. Fly ash lowers theheat of hydration allowing thicker placements to occur.

Data for these can be found at the US Bureau of

Reclamation. This has also been demonstrated in

the Ghatghar Dam Project in India.

Waste treatment and stabilization

Fly ash, in view of its alkalinity and water absorption capacity, may be used in

combination with other alkaline materials to transform sewage sludge into

organic fertilizer or biofuel.

Special Use of waste products -broken glass

Fight Artificial glass valued as a raw material for the binder because it containedsilica and alkali oxides, and Al2O3 and CaO. Of particular interest is the battle

bariysilikatnyh glasses. Materials based on it are used in X-ray rooms decoration and

other areas that require special coatings. Fight lead glasses are in the construction

materials used in the construction and decoration of the nuclear industry.
http://en.wikipedia.org/wiki/File:UserKTrimble-AP_Taum_Sauk_Reservoir_UnderConstruction_Nov_22_2009_crop1.jpg


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Microsilica Concrete

Microsilica is used in concrete.

When it is used in concrete, it acts as a filler and as a cementitious material. The

small microsilica particles fill spaces between cement particles and between the

cement past matrix and aggregate particles. Microsilica also combines with

calcium hydroxide to form additional calcium hydrate through the pozzolanic

reaction. Both of these actions result in a denser, stronger and less permeable

material.

Function of adding Silica Fume(microsilica) :

Increase durability

Reduces concrete permeability

Improves resistance to corrosion

Shotcrete - lower rebound


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Thank you

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