Cool Roof

abc WEATHER PROOF SRI TILE

Benefits, Cost Analysis, Spec & Fixing Methods

Part -II

INDIA’S FIRST CERAMIC COOL ROOF TILE

(BEPL & NTH tested)

by

AB Ceramic Services,

G.Arivazhagan M.Tech (Ceramics),

+91 9047573230 / +91 9879075864 www.abceramic.in

PROFILE: AB Ceramic Services is a proprietary firm started in 2010 by G.Arivazhagan. Diploma in ceramic and A.I.I.Cer completed in 1984 and 1989 respectively. Worked in various ceramic factories. Then studied M.Tech (ceramics) 1991 – 93 batch in Anna University. I worked in various ceramic factories in India, abroad and handled R & D department. Last ten years worked as freelance consultant in Gujarat to various tile mfg companies. I am one of the Glaze experts. My own house suffered from water seepage and heat ingress. By using suitable ceramic tiles, the problem was solved since 2003 and still in very good condition. I thought of the concept behind ceramic tiles. By combining ceramic and Cool Roof concept, abc Tile brand was created. (ari bhai concept). Why Cool Roofs? Cool roofs are one of the quickest and lowest cost ways, we can reduce our global warming and begin the hard work of slowing down climate change. The US Energy Secretary, Steven Chu. abc Vision: To offer cool roof in ceramic that could last for centuries without much of a problem. abc Mission: The century old method of pressed clay tile weathering course system on roof top has to be eliminated in the present scenario of climate change, power crisis, time management and emerging technological transformation in the field of construction industries / building materials.

About abc COOL ROOF: Solar Reflectance Index (SRI), Accelerated Weathering , Stain resistance and Salt Spray test etc are conducted first time for abc Cool Roof. All white and light colors are Cool Roof but all Cool Roofs are not permanent. Ceramic based Cool Roofs could be everlasting one.

Advantages of Cool Roofs: For example, a project needs about 6 lac sq ft roof tile which is equivalent to 6000 well grown trees (sixty thousands). It is difficult to plant and grow 6000 trees. A tree will take 15 years to give the benefit whereas abc cool roof can give benefit from the day one onwards. A city with white roof is cooler than a city with lot of trees / park etc. I request all concerned experts in govt planning / technical to scrutinize, analyze and validate above two points. It may be hard to believe but all proven fact.

Testimonial: Supply of 20000 sq ft to SIDCO, Guindy and 15000 sq ft to Indian Railway Institute for Civil

Engineers in Pune are landmark supplies.

There are many more repeat customers / builders / architects etc in private sectors.

General Requirements For Roof Tile

Product warranty & Labor warranty

Long lasting waterproofing protection

Low roof maintenances

Low installation cost

No chipping, no cracking, no flaking.

Stain free and better scratch resistance

Attractive and clean finish

Anti slippery during wet conditions

Energy saving radiant barrier

Reduced heat transfer (ECBC norms)

Protection against UV degradations

Roof structural integrity

Corrosion control in sea shore area

Environmentally friendly product

Economical solutions

Test certificates

Long life cycle

abc Tiles are designed to fulfill all above requirements.

10 Benefits of using abc Weather Proof SRI Tile

abc Weather Proof SRI Ceramic tile is being used in an increasing number of settings such as homes, offices, hospitals and laboratories. You can choose from limited colors while keeping in mind the final look you want to achieve. There are several benefits to using this versatile product, particularly on roof top. Highly heat reflective (>90%), high abrasion resistance, light weight, heat proof and water proof ; hence ideal for roof top & other places.

1 – Hygienic and Easy to Clean

abc Weather Proof SRI Roof tile is much easier to maintain than roof paint, or other kind of roof tile materials. To keep the tiles clean, all you need to do is wipe them from time to time. abc Weather Proof SRI tiles are also highly resistant to abrasive, chemicals and cleaners, which make them easy to keep clean. These tiles can also be used in bath rooms due to easy cleaning & water proof.

2 – Moisture Resistant

Because of abc Weather Proof SRI roof tile is resistant to moisture and humidity, it is ideal for damp environments such as bathrooms and kitchens. It does not swell or deform when exposed to high levels of moisture. abc Weather Proof SRI tiles are made water repellent just before fixing.

3 – Stain Proof

abc Weather Proof SRI roof tile will not absorb or retain stains unlike other roof coverings. If you splash stainers, oil, grease or even paint on the roof, you can clean it off with a simple wipe / tile cleaners.

4 – Fire Proof

abc Weather Proof SRI roof tile is resistant to extremes of temperature. It does not react to frost or fire. It is therefore highly safe in any indoor / outdoor applications.

5 – Fade Resistant

Even when subjected to continuous exposure to the sun, abc ceramic roof tiles do not fade or lose color. The appearance of these tiles will remain the same for many long years with minimal care.

6 – Long Lasting

abc Weather Proof SRI roof tiles are very durable and long lasting. They do not crack, fade or break under pressure. For accidental breakage / cracking, we supply crack fillers. We also suggest the best tile fixing method. Weather ability test is conducted and passed.

7 – Beneficial Tile Fixing Method

Special additives are supplied for tile fixing. abc Weather Proof SRI roof tiles are made water water resistant just before fixing, hence the bonding of tiles with cement slurry has to be greatly improved, for ever lasting life. To meet this stringent technical requirement, abc cement slurry is specially designed to fix the tiles which is made by mixing abc plus powder, and regular cement with required water etc.

8 - Mold, Fungus Resistant and Grouting

Abc Weather Proof SRI Tile is impervious to moisture and humidity, as mentioned above. This trait also improves it resistance to mold, bacteria and fungi. As a result, you can keep away toxins and bacteria from developing on your roofs.

Grouting is main source of mold, fungus and cracking. To avoid these problems, abc supplies the most suitable composite grout; on top of the grout (after applying the grout), the most powerful water proofing is done.

9 – Environmentally Friendly

abc Weather Proof SRI roof tile is made in an environmentally friendly process and in ISO certified company.. It is manufactured from natural ingredients obtained from the earth. abc ceramic roof tile is totally free of fumes or toxins. It is completely safe to use in your roof, home or office. abc Weather Proof SRI roof tile is a Green Building material.

Since abc tile comes under Cool Roof, all benefits of Cool Roof are applicable.

10 – Cost Effectives

The purchase and installation of abc Weather Proof SRI roof tile may cost you more money initially. However, if you consider the longevity, attractiveness and durability of abc Weather Proof SRI roof tile, the cost is worth it. Over time, abc ceramic roof tile proves itself to be one of the most cost effective options available for the roof. Once you install abc Weather Proof SRI roof tile, you do not have to worry about frequent repairing or redoing the roof top every few years.

10 to 15 % increase in cost can be recovered from the benefit of Cool Roof.

A detailed study in Hyderabd shows that a saving of 10 rupees / sq ft / year is

confirmed.

Clay Tile Roof Vs abc Roof (cost and weight)

Parameters

PWD Rate

/ Sq Met

abc Rate

/ Sq Met

Roof Weight

Remarks PWD ABC

Weathering course

(By using brick jelly, lime, sand etc

as per PWD spec).

Rs 328/=

----

As per PWD

estimate

Pressed clay tile fixing by using

sand : cement mortar (as per

PWD).With Water proofing

Compound,Curing etc.,complete

Rs 518/=

----

Total cost Rs 846/=

Sloping concrte of 5 Cm thick using

M25 concrete (1:1.5:3) with HBJ 6

to 8 mm to give slope as well as to

get R 2.1

---

Rs 210/=

Abc Tile fixing as per abc system --- Rs 750/=

Tiles,

Additives,

water proofing

& fixing

perfectly etc.

Total Cost Rs 846/=

Pressed clay

tiles

Rs 960/=

Abc Tiles

13.5% more

cost

Weight on roof per sq met 216 kgs

Pressed

Clay tiles

141 kgs

Abc Tiles

35 % less

weight on

roof top for

abc system.

Note: These are only guideline values.

Discussions:

Abbrevations: SRI : Solar Reflectance Index

ECBC: Energy Conservation Building Code IGBC: Indian Green Building Council

LEED AP: Leadership in Environmental & Energy Design Accredited Professionals

10% cost increase in abc tile system can be justified as below:

No unburnt tiles in abc. Even 1% unburnt tile in pressed clay tile is enough to spoil entire

roof. Pressed clay tile roof needs more maintanence, abc tile needs very less or zero

maintanence. This is due to stain free / self cleaning / anti fungal quality in abc tiles, that too

with Moh’s hardness of 6. abc Tile comes under Cool Roof concept and matching with ECBC

guidelines. ECBC guideline is followed by IGBC / LEED AP etc. Surface temperature during

peak summer will be 40 to 45 deg C.

Damage, seepage, corrosion, fungal growth and vegetation growth are common phenomena

in pressed clay tile roofs, particularly in Govt buildings, where pressed clay tiles are selected

based on random sample only. Site Engineer can’t watch each tile quality. Pressed clay tile

system can never be matched with ECBC due to non reflective surface. Surface temperature

during peak summer will be 60 to 65 deg C. Now- a- days quality of pressed clay tiles are not

available in good quality and unburnt tiles are there.

Availability of good quality materials like pressed clay tiles and hydrated lime for weathering

course is very difficult. Time to execute the work is very long. These two problems are not in

abc roofing system.

About 35% reduction in roof weight is estimated and hence building life will be more.

Summery:

In the present scenario of material quality / availability and demand for skilled labour, abc tiles

is only alternative solution, for the roof top for everlasting life.

TECHNICAL INFORMATION

(abc Weather Proof S.R.I Tile)

Cool Roof requirements as per ECBC norms: (Reflective tiles or Heat Resistant tiles)

(ASTM E 1980-11, EN 673:2011 and EN 410:2011)

abc Value

How much weathering course

is required for cool roof?

Solar Reflectance Index

>78

96

A building receives most of the heat through roof by radiation.

Heat moves in and out of your home

(or about any other structure) in four

ways: by conduction (which R-Value

measures), and

by convection, radiation (which S.R.I

value measures) and air infiltration.

Hence a minimum R value of 2.1 or 3.5

is specified by ECBC.

Combination of S.R.I and R value will

give the best & everlasting terrace.

abc offers solution for R value also (T&C).

Solar Direct Reflectance

0.70

0.77

Emissivity

0.75 0.92

Energy Conservation Building Code (section 4.3.1 & 4.3.1.1)

Bureau of Energy Efficiency

(Govt. of India, Ministry of Power)

Additional Parameters maintained for abc Tiles:

Sl.No: PARAMETER METHOD /STDs abc VALUE REMARKS

1) Dimension - 300x300x9.0 mm

2) Weight per Sq ft - 1.25 to 1.30 kg

5) Scratch Hardness (Moh’s) IS 13630 (part 13) >6 (6 to 7 for vitrified tile)

Unique property of abc Cool Roof

7) Accelerated Weathering Test IS 101 Passes No change in color or gloss. No blistering, peeling, flaking or cracking observed.

8) Salt Spray Test (5% Na Cl) 100 hrs.

IS 13630 (part 8) 2006

Passes No change in surface. No blistering, peeling, flaking or cracking observed

9) Stain Test (methylene blue & potassium permanganate))

IS 13630 (part 8) 2006

Passes Class I. Stain removed by water.

10) Modulus of Rupture, Kg/Cm2 IS 13630 (part 6) 2006

100 kg/sq cm.

11) Water Absorption, %

24 hours soaking in water

18 by weight 33 by volume

More pores: more insulation. Or less conductivity.

12) Crazing Test IS 13630 (part 9) 4 cycle passes

13) Titanium & Zirconium content in glaze

X-Ray Diffraction 13.0% These two ingredients improve life of glaze coat by providing whiteness, opacity, self cleaning & matt effect.etc.

Cool Roof requirements are mandatory: Additional parameters are optional.

Note on nano coating of abc tiles (water repellent): (Non – standard)

Nano water is prepared by diluting concentrated nano solution with clean water (50 ml in 100

liter water). Soak abc tiles in nano water for one hour just befoe fixing. This process makes

each abc tile as water resistance. Nano water coating is stable up to 130 deg C.

Water resistance was measured as mentioned below:

Test Method I: a conventional practical method used in site

Note initial weight after drying the samples at 110 deg C. Immerse samples in clean water

for 24 hours. Remove samples and wipe out excess water and weigh final weight. Calcluate

the water absorption on percentage.

Result:

Sample No Treatment Nano water treated Remarks

Abc Tile 18% 12.2% Average of 10 samples

Tile Fixing Methods

(Work Instructions) a. Maintain necessary slope as per civil work specification or preferably follow ECBC norms.

Note: abc company has no role in site preparation work.

b. Materials required: abc Weather Proof SRI Tiles, abc Plus powder, abc grout, abc Nano Clear, abc

Nano White, abc 3 mm Spacers, abc Weather Proof Whitener etc. (Seven items).

c. Tile Fixing Mortar: 1: 2: 5 (cement: sand:: lime) or suitable combination. Half to one inch mortar thickness on sloped terrace is sufficient.

d. Soak abc Tiles in to nano water for minimum 1hr. (25 ml abc nano clear in 100 liter clean water).

Consume this water with in 24 hrs. time.

e. Prepare cement slurry as below:

1:3 (abc plus powder: cement): Mix well with clean water to the required level.

f. Fix abc tiles by using abc cement slurry and use 3 mm spacer between tiles. Ensure that each tile is

fixed firmly by scribbling slurry & mortar; excess cement slurry must come out from all four sides of each

tile. Do not walk over the tile for 24 hours. Break joint is ideal towards water flow side.

g. 6 or 4 inch skirting has to be fixed in all sides in slanting / vertical position.

h. Next day, wash the tiled area and inspect for proper fixing of each tile. Apply abc grout paste in 3

mm gap. Mixing: Add ~300 ml abc nano White for one kg abc Grout and required clean water. Apply the

grout paste slowly, firmly and perfectly. Clean the excess paste quickly.

i. During final inspection, if any micro hairline appears which is normally due to handling or pre mature walking etc, here and there, give a touch up by using abc Weather Proof Whitener after scribbling with emery paper.

j. Other tips: Use 5 mm spacers and white slurry (50% plus powder and 50% white cement). This combination also will give good result.

Disclaimer: The above work instructions are based on our practical experience and given in good faith. Final result depends on

following of instructions and end user’s analytical skill. Site conditions and workmanship are beyond abc company control. Our

responsibility is to supply as per sample/specimen shown. These work instructions are only guidelines.