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 Savastano Savastano Jr Jr. . Holmer Rural Construction Rural Construction University of São São Paulo, Brazil Paulo, Brazil University of 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 (2001) (2001) Plessis

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

Pozzolanic reaction Pozzolanic reaction SiO 2 + Ca(OH) 2 + H 2 O C-S-H Metakaolin 2(Al 2 O 3 .2SiO 2 ) + 7Ca(OH) 2 + aq 3CaO.2SiO 2 .aq + 2 (2CaO.Al 2 O 3 .SiO 2 .aq) Gehlenite

Ashes from agricultural residues Ashes from agricultural residues � By By- -products from rice husk, products from rice husk, � sugar- -cane cane bagasse bagasse or animal manure or animal manure sugar � Burning under controlled conditions Burning under controlled conditions � � Heating up to 600 Heating up to 600 o C o 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 - 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 BURNING OF SWINE DEEP BEDDING (40-50% BY MASS OF MANURE)

Oxide composition of deep bedding ashes Oxide composition of deep bedding ashes obtained at burning temperature of 600 o C obtained at burning temperature of 600 o C Oxides % by mass Al 2 O 3 21.70 Fe 2 O 3 6.18 SiO 2 42.40 P 2 O 5 9.41 SO 2 1.02 KCl 2.50 Na 2 O 1.51 K 2 O 3.52 CaO 11.58 MgO 1.83 TiO 2 2.45 MnO 0.14 Loss on ignition 9.7

X-ray diffraction 24040102 22040102 230 400 o C 110 500 o C 220 210 100 200 190 90 180 170 80 160 150 70 140 Lin (Counts) Lin (Counts) 130 60 120 110 50 100 90 40 80 70 30 60 50 20 40 30 10 20 10 0 0 5 10 20 30 40 50 60 70 8 5 10 20 30 40 50 60 70 8 2-Theta - Scale 2-Theta - Scale 22040102 - File: Gustavo-22040102-3-04.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 ° - 24040102 - 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 Operations: Import Operations: Import 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) 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) 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) - 8 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 - Ba 82-1563 (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) - 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 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 - 3 72-2297 (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 - Primitive - P21/a 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) - 4 24040202 26 25 600 o C 24 23 22 21 20 19 3 4 6 1 1 9 7 3 5 9 1 6 18 8 , , 3 2 1 2 = = , d d 3 17 1 = d 16 Lin (Counts) 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 5 10 20 30 40 50 60 70 8 2-Theta - Scale 24040202 - 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 Operations: Import 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) 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 - 70-1882 (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 - 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 - 1

Compressive strength of mortars produced with OPC and ashes Compressive strength (MPa) Individual results Averages Ashes content (%) Specimen 7 days 28 days 7 days 28 days 0 24.9 28.1 1 30.1 34.9 10 2 30.1 37.2 30.5 35.7 3 31.2 35.0 1 34.1 33.8 20 33.8 34.4 2 33.9 31.9 3 33.4 37.6 1 32.2 38.2 30 2 32.9 33.8 32.5 35.5 3 32.5 34.6 Ashes calcinated at 600 o C

Vegetable fibers fibers Vegetable

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

Sisal field by- -product product Sisal field by � Cleaning of residual Cleaning of residual � fibres by rotary sieve fibres by rotary sieve � Additional income for Additional income for � producers producers Silva & Beltrão Beltrão (1999) (1999) Silva &

Residues of coir fiber Residues of coir fiber Coconut husks Coconut husks Long fibers (~25 cm) & Long fibers (~25 cm) & Short residual fibers (1- -3 cm) 3 cm) Short residual fibers (1 Savastano, 2003

Appropriate Appropriate cellulose pulp cellulose pulp In collaboration with CSIRO In collaboration with CSIRO Australia Australia

Recycled kraft kraft pulp pulp Recycled � 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 Original sliver Original sliver Bunch of individual fibres Bunch of individual fibres Chemi- -thermomechanical thermomechanical pulping pulping Chemi Individual filaments Individual filaments External and internal fibrillation External and internal fibrillation

Pulp and fibre properties Pulp and fibre properties Fines (%) 1 Length (mm) 2 Width ( µ m) 3 Fibre Freeness (ml) 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 Savastano Jr. et al. (2001) 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