Non conventional materials & techniques applied to cost...
Transcript of Non conventional materials & techniques applied to cost...
Non conventional materials & techniques applied to cost effective housing and rural
buildings: a Brazilian experience
HolmerHolmer SavastanoSavastano JrJr..Rural ConstructionRural Construction
University of University of SãoSão Paulo, BrazilPaulo, Brazil
Science and Technology Knowledgde Forum
Johannesburg, S. A., 20-21 June 2005
Construction industry x Construction industry x sustainabilitysustainability
16% of freshwater consumption16% of freshwater consumption30 30 -- 40% of global energy40% of global energy20 20 -- 30% of total waste30% of total wastePlessisPlessis (2001)(2001)
HighlightsHighlightsAppropriate raw materialAppropriate raw material
Low cost cement Low cost cement Vegetable Vegetable fiberfiberProcessing of composite materialProcessing of composite material
Performance and durabilityPerformance and durabilityRoofing solutions Roofing solutions
Cement based tilesCement based tilesFlat and corrugated sheetsFlat and corrugated sheetsThermal comfort and cost efficiencyThermal comfort and cost efficiency
Different applicationsDifferent applicationsHousingHousingBuildings for intensive animal productionBuildings for intensive animal production
Ordinary Portland Ordinary Portland cement substitutescement 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 reactionPozzolanic reaction
Ashes from agricultural residuesAshes from agricultural residues
ByBy--products from rice husk, products from rice husk, sugarsugar--cane cane bagassebagasse or animal manureor animal manureBurning under controlled conditionsBurning under controlled conditions
Heating up to 600Heating up to 600ooC C GrindingGrinding
Substitution of ordinary Portland cementSubstitution of ordinary Portland cementUp to 30% if amorphous silica is availableUp to 30% if amorphous silica is available
Challenge for swine productionChallenge 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 obtained at burning temperature of 600obtained at burning temperature of 600ooCC
Loss on ignitionMnOTiO2
MgOCaOK2O
Na2OKClSO2
P2O5
SiO2
Fe2O3
Al2O3
Oxides
6.18
1.83
1.51
9.70.142.45
11.583.52
2.501.029.41
42.40
21.70
% by mass
X-ray diffraction
24040202
37-1497 (*) - Lime, syn - CaO - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Cubic - a 4.81059 - b 4.81059 - c 4.81059 - alpha 90.000 - beta 90.000 - gamma 90.000 - Face-centred - Fm3m (225) - 4 - 170-1882 (C) - Mordenite - Ca0.07Al.1629Si0.8375O2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Orthorhombic - a 18.00700 - b 20.26900 - c 7.46500 - alpha 90.000 - beta 90.000 - gamma 90.000 - 77-2355 (C) - Iron Oxide - FeO - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Cubic - a 4.30900 - b 4.30900 - c 4.30900 - alpha 90.000 - beta 90.000 - gamma 90.000 - Face-centred - Fm3m (225) - 4 - 85-0794 (C) - Silicon Oxide - SiO2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Hexagonal - a 4.90000 - b 4.90000 - c 5.39000 - alpha 90.000 - beta 90.000 - gamma 120.000 - Primitive - P3221 (154)Operations: Import24040202 - File: Gustavo-24040202.RAW - Type: 2Th/Th locked - Start: 5.000 ° - End: 80.012 ° - Step: 0.038 ° - Step time: 1. s - Temp.: 25 °C (Room) - Time Started: 2 s - 2-Theta: 5.000 ° - Thet
Lin
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nts)
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2-Theta - Scale5 10 20 30 40 50 60 70 8
d=2,15963
d=13,23
831
d=1,69714
24040102
23-1037 (*) - Grossite, syn - CaAl4O7/CaO·2Al2O3 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Monoclinic - a 12.888 - b 8.888 - c 5.443 - alpha 90.000 - beta 106.93 - gamma 90.000 - Base-centred 71-1397 (C) - Hedengergite, syn - Fe1.5Ca0.5(SiO3)2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Monoclinic - a 9.78100 - b 9.07200 - c 5.24600 - alpha 90.000 - beta 106.550 - gamma 90.000 - Ba85-0794 (C) - Silicon Oxide - SiO2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Hexagonal - a 4.90000 - b 4.90000 - c 5.39000 - alpha 90.000 - beta 90.000 - gamma 120.000 - Primit ive - P3221 (154)Operations: Import24040102 - File: Gustavo-24040102.RAW - Type: 2Th/Th locked - Start: 5.000 ° - End: 80.012 ° - Step: 0.038 ° - Step time: 1. s - Temp.: 25 °C (Room) - Time Started: 2 s - 2-Theta: 5.000 ° - Thet
Lin
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nts)
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2-Theta - Scale
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22040102
74-1226 (C) - Calcium Oxide - CaO - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Cubic - a 4.76800 - b 4.76800 - c 4.76800 - alpha 90.000 - beta 90.000 - gamma 90.000 - Face-centred - F23 (196) - 472-2297 (C) - Parawollastonite - CaSiO3 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Monoclinic - a 15.33000 - b 7.27000 - c 7.07000 - alpha 90.000 - beta 95.400 - gamma 90.000 - Primit ive - P21/a 38-0471 (*) - Sillimanite - Al2SiO5 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Orthorhombic - a 7.486 - b 7.675 - c 5.7729 - alpha 90.000 - beta 90.000 - gamma 90.000 - Primitive - Pbnm (62) - 4 - 382-1563 (C) - Silicon Oxide - SiO2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Monoclinic - a 6.99790 - b 8.21220 - c 6.51060 - alpha 90.000 - beta 114.930 - gamma 90.000 - Base-centred - C2 (5) -75-0033 (C) - Iron Oxide - Fe3O4 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Cubic - a 8.38400 - b 8.38400 - c 8.38400 - alpha 90.000 - beta 90.000 - gamma 90.000 - Face-centred - Fd3m (227) - 885-0794 (C) - Silicon Oxide - SiO2 - Y: 50.00 % - d x by: 1. - WL: 1.54056 - Hexagonal - a 4.90000 - b 4.90000 - c 5.39000 - alpha 90.000 - beta 90.000 - gamma 120.000 - Primit ive - P3221 (154)Operations: Import22040102 - File: Gustavo-22040102-3-04.RAW - Type: 2Th/Th locked - Start: 5.000 ° - End: 80.012 ° - Step: 0.038 ° - Step t ime: 1. s - Temp.: 25 °C (Room) - Time Started: 2 s - 2-Theta: 5.000 ° -
Lin
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2-Theta - Scale5 10 20 30 40 50 60 70 8
400oC 500oC
600oC
Compressive strength of mortars produced with OPC and ashes
28.124.90
34.632.5335.532.533.832.9230
38.232.2137.633.43
34.433.831.933.922033.834.1135.031.23
35.730.537.230.121034.930.11
28 days7 days28 days7 daysAveragesIndividual results
Compressive strength (MPa)SpecimenAshes content (%)
Ashes calcinated at 600oC
Vegetable Vegetable fibersfibers
Vegetable fiber as Vegetable fiber as reinforcementreinforcement
Main constituentsMain constituentsCellulose Cellulose LigninLigninHemicelluloseHemicellulose
Fibrils disposed in Fibrils disposed in subsequent layerssubsequent layersBunch of individual Bunch of individual cellscells
1- Primary layer2- S1, 3- S2, 4- S3(secondary layers)5- Intercellular layer
Sisal field bySisal field by--productproductCleaning of residual Cleaning of residual fibres by rotary sievefibres by rotary sieveAdditional income for Additional income for producersproducers
Silva & Silva & BeltrãoBeltrão (1999)(1999)
Residues of coir fiberResidues of coir fiber
Savastano, 2003
Coconut husksCoconut husks
Long fibers (~25 cm) & Long fibers (~25 cm) & Short residual fibers (1Short residual fibers (1--3 cm) 3 cm)
Appropriate Appropriate cellulose pulpcellulose pulp
In collaboration with CSIRO In collaboration with CSIRO AustraliaAustralia
Recycled Recycled kraftkraft pulppulp
Residue of Residue of eucalyptus Krafteucalyptus Kraft
Unrefined pulpUnrefined pulp
Peculiarities of Peculiarities of recycled fibres:recycled fibres:
-- lateral shrinkagelateral shrinkage-- twistedtwisted-- short filamentsshort filaments
CTMP pulpingCTMP pulping
ChemiChemi--thermomechanicalthermomechanical pulpingpulping
Individual filamentsIndividual filaments
External and internal fibrillationExternal and internal fibrillation
Original sliverOriginal sliver
Bunch of individual fibresBunch of individual fibres
Pulp and fibre propertiesPulp and fibre properties
Fibre Freeness (ml) Fines (%) 1 Length (mm) 2 Width (µm) 3 Aspect ratioE. grandis 685 7.01 0.66 10.9 61Sisal CTMP 500 2.14 1.53 9.40 163Banana 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 suspensionspulp suspensions
Savastano Jr. et al. (2001)
Organosolv pulpingOrganosolv pulping
Chemical process: organic solvents Chemical process: organic solvents associated to water associated to water AdvantagesAdvantages
Better impregnation of the vegetable tissuesBetter impregnation of the vegetable tissuesEasy recover of lignin and polysaccharidesEasy recover of lignin and polysaccharidesEasy recover of the solvent by distillationEasy recover of the solvent by distillationLow cost and small pulping plantsLow cost and small pulping plants
DisadvantagesDisadvantagesEnergy consumption may be greater than in KraftEnergy consumption may be greater than in Kraft
Organosolv pulping resultsOrganosolv pulping results
Sisal wasteSisal wasteOrganosolv pulping: T = 190oC
3.02.95.311.0
97.697.894.483.0
0
20
40
60
80
100
0 1 2 3 4
Pulping Time (h)
% c
ompo
nen
Lignin Holocellulose
2h: enough
EconomyOf
Energy
% c
ompo
nen
t
Engineered Engineered synthetic fibressynthetic 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 reinforcementPP & PAN fiber for reinforcement
Processing of fibre Processing of fibre cement compositescement composites
Production of roofing tilesProduction of roofing tiles
Roma Jr. et al. (2003)
Transference to the undulate mouldTransference to the undulate mould
Physical and mechanical Physical and mechanical properties of the tilesproperties 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 tilesSmall scale production of tiles
Optimized formulationOptimized formulationVacuum chamber and Vacuum chamber and light pressinglight pressingTiles being transferred Tiles being transferred to the mould just after to the mould just after productionproduction
Patent depositedPatent deposited
Potential Potential applicationsapplications
Individual shelters for calvesIndividual shelters for calves
Thermal comfort (-1oC in comparison with asbestos cement roofing)
48,049,050,051,052,053,054,055,056,0
27/se
t29
/set
1/out
3/out
5/out
7/out
9/out
17/ou
t19
/out
21/ou
t23
/out
25/ou
t27
/out
29/ou
t31
/out
2/nov
Data
Freq
. Res
p. (m
ov/m
in)
400,0
420,0
440,0
460,0
480,0
500,0
520,0
540,0
CTR
(W/m
2 )
FR CTR
Respiratory frequency (FR) &Radiant thermic load (CTR)
FR
Day
Roofing systemRoofing system
Rural shelter for cattleRural shelter for cattle
Thermal comfortThermal comfort00
:00
01:0
002
:00
03:0
004
:00
05:0
006
:00
07:0
008
:00
09:0
010
:00
11:0
012
:00
13:0
014
:00
15:0
016
:00
17:0
018
:00
19:0
020
:00
21:0
022
:00
23:0
024
:00
10
15
20
25
30
35
40
45
50SURFACE TEMPERATURE
Asbestos Ceramics No-Asbestos Zn-Metal
Tem
pera
ture
(°C
)
Hour
Skin temperatureSkin temperatureHolandês
28,029,030,031,032,033,034,035,036,037,038,0
06:00 14:00
Horário
Tem
pera
tura
de
Pele
(oC
)
ICA IFB IFC
Physiological performance of Physiological performance of Holstein vealsHolstein veals
ICA = asbestos cementIFB = new technologyIFC = NT + acclimatization
Skin
tem
pera
ture
(o C
)
Time
Pressed & air cured Pressed & air cured pads of cellulosepads of cellulose--cementcement
Slurry deSlurry de--watering & pressingwatering & pressing
Evacuable casting box
Tamping flat
Pressing pads
MORMOR
0 4 8 12
fibre content (%by mass)
0
5
10
15
20
25
30
MO
R(M
Pa)
P. radiata
E. grandis
Banana
Sisal
OPC based compositesat 28 days
DurabilityDurability
Weathering of sisal CTMP in BFSWeathering 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
MO
R (M
Pa)
1 month4 months13 months25 months60 months
Fiber degradationFiber degradation
Slag based mortar with Slag based mortar with coir fibercoir fiber
Alkaline attackAlkaline attackCrackingCrackingPetrifactionPetrifaction
Mechanical Mechanical modellingmodelling
In collaboration with In collaboration with Princeton University, USAPrinceton University, USA
Laboratory facilitiesLaboratory facilities
PrePre--crackingcrackingFarFar--field compressionfield compression
Three point bending Three point bending testtest
Department of Mechanical & Department of Mechanical & Aerospace EngineeringAerospace Engineering
Princeton University, USAPrinceton University, USA
RR--curves to aged sisal pulp in BFScurves to aged sisal pulp in BFSComparison with Paris & Sih modelComparison 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)
Stre
ss In
tens
ity F
acto
r, K
(MPa
√m)
sisal-BFS 2yo 1-5 sisal-BFS 2yo 1-2sisal-BFS 2yo 1-3 sisal-BFS 2yo 1-4sisal-BFS 9m sisal-BFS 1-4 Paris&Sih
BSEI BSEI -- Composite bridgesComposite bridgesDirection of crack growth
Crack
Bridging fiber
Hybrid Hybrid reinforcement with reinforcement with synthetic fibersynthetic fiber
Composite with unrefined sisal Composite with unrefined sisal pulp and PP fiberpulp and PP fiber
0,00 0,01 0,02 0,030
2
4
6
8
10
12
Sisal Organosolv Pulp
28 Days 100 Cycles 100 Cycles after carbonation
σ(M
Pa)
ε (mm/mm)
0,00 0,01 0,02 0,03 0,04 0,05 0,060
2
4
6
8
10
12
Sisal Organosolve Pulp with PP
28 Days 100 Cycles 100 Cycles after carbonation
σ (M
Pa)
ε(mm/mm)
Effect of soak dry cycles and carbonation
High toughnessHigh toughness
HatschekHatschek methodmethod(industrial scale)(industrial scale)
Fiber preparation
Fiber Cement WaterMineral
additions
Mixer
Final product
Moldingvats
Press cylinder
Transport of the fiber cement film
Testing of corrugated sheetsTesting of corrugated sheetsPVA and PVA and PinusPinus cellulose fiber cementcellulose fiber cement
Testing at Escola Politécnica - USP, Brazil
Loading simulationLoading simulationBasis for functionally graded materialsBasis for functionally graded materials
Heat rain testHeat rain test
Facility for the accelerated aging of the Facility for the accelerated aging of the corrugated sheetscorrugated sheets
Mechanical propertiesMechanical properties
0
2
4
6
8
10
12
0 5 10 15 20 25 30 35Flecha (mm)
Tens
ão (M
Pa)
0 ciclos25 ciclos
Curvas médias
Stre
ss
Deformation (mm)
Average curves
0 cycles25 cycles
Hg porosimetryHg porosimetry
0.000
0.005
0.010
0.015
0.020
1.E+001.E+011.E+021.E+031.E+041.E+051.E+06Diâmetro (nm)
Vol
ume
de m
ercú
rio
intru
dido
(mL/
g)
Curva média_sem envelhecimento
Curva média_25 ciclos
0 cycles
25 cycles
Volu
me
of in
trud
ed m
ercu
ry
Diameter
CommentsComments
Effect of the heat rain cycles:Effect of the heat rain cycles:Matrix improvementMatrix improvement
Increase of the LOPIncrease of the LOPReduction of the porosityReduction of the porosityCarbonationCarbonation
DegradationDegradationToughness reductionToughness reductionDegradation of the cellulose fiberDegradation of the cellulose fiberDensification of the fiber/matrix interfacial zoneDensification of the fiber/matrix interfacial zone
Additional roofing Additional roofing solutionssolutions
Cost efficient solutionCost efficient solution
Polyethylene shade net – ∆I / ∆C = 8.1
Acclimatized housing – ∆I / ∆C = 0.6
Bamboo shelterBamboo shelterColombiaColombia
Poultry housingPoultry housing
Final remarksFinal remarks
Innovate materialsInnovate materialsfiber cementsfiber cementsadequate techniquesadequate techniques
Materials performance & durabilityMaterials performance & durabilityAffordable housing and infrastructureAffordable housing and infrastructureHuman developmentHuman development
Governmental sponsorsGovernmental sponsors
AcknowledgementsAcknowledgements
National Science Foundation National Science Foundation -- NSF, USANSF, USAWorld Bank Institute World Bank Institute –– WBIWBINMISCINCENMISCINCE
Thank you Thank you very much for very much for your attention!!!your attention!!!
Contact detailsContact details
Holmer Savastano Jr.Holmer Savastano Jr.Rural Construction Group Rural Construction Group -- FZEA FZEA -- USPUSPP.O. Box 23 P.O. Box 23 -- 1363513635--900 Pirassununga SP 900 Pirassununga SP BrazilBrazil
Tel +55 19 3565 4153Tel +55 19 3565 4153Fax +55 19 3565 4114Fax +55 19 3565 [email protected]@usp.brwww.fzea.usp.br/constrambiwww.fzea.usp.br/constrambi