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15/10/2016
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CIV-E1010 Building Materials Technology
Lecture 12. Non-conventional andadvanced building materials
18.10.2016
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• Foamed glass aggregates
• Self-healing (bacterial) concrete
• Cellulose insulation material
• Fiber Reinforced Polymer (FRP) composites rebar
• Quick review of some innovative building materials
Lecture contents
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
1. Knowledge:ü will be able to learn basic theory about main building- and
construction materials:• material composition / Properties• applications in buildings and structures.
2. Skills:ü be able to make right and well-founded choice of materials
3. General competence:ü Learn about non-conventional and innovative building
materials
Lecture outcomes
FOAMED GLASS
AGGREGATES
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Foamed glass aggregates:ü Obtained from recycled
glassü 1980’sà production was
started in Switzerland andGermany
ü 1990’s à for use as athermal barrier in roadconstruction inScandinavia
Introduction
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
1. Waste glass crushingà 6mm
2. Grinding of the crushed glass(Cullet Mill)
3. Sieving of the glass powder
4. Mixing the glass powder with thefoaming materials (silica carbide)
5. Baking of the glass mixtureà950°C
6. Rapid cooling: the foamed glassbreaks up into gravel size pieces
Production process - video
UUSIOAINES OYhttp://www.foamit.fi/
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Properties
http://www.foamit.fi/DowebEasyCMS/?Page=FoamitBrochure
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Properties
Properties Variations recorded intechnical literature
Thermal conductivity- dry 0.10…0.11 W/mK- moist 0.13…0.15 W/mK
Specific thermal capacity 850 J/(kgK)Capillary rise 120…175 mmFreeze/Thaw resistance YESFire resistance YESPossibility to recycle 100 %
http://www.foamit.fi/DowebEasyCMS/?Page=FoamitBrochure
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Structural engineeringü Insulation under ground slabsü Around insulation of basement
wallsü Drainagesü Swimming pool insulationü Terrace insulationü Light loose fillü Industrial roofsü Green roofs and flat roofsü High load bearing roof
constructionsü Floor constructions
Applications
Foundationslab insulation
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Civil engineeringü Light loose fillü Road construction – load bearing
and frost proofü Frost free foundations of paths and
building sitesü Soil stabilizationü Slope stabilizationü DrainageüWater and sewage line
constructionü Thermal insulation of district
heating lines
Applications
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Applications
http://www.misapor.ch/EN/cellular-glass/applications/Passive-houses.html
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Advantagesü 10 times lighter than stone
aggregatesü Highly thermal insulation
from the groundü No capillary formationü Excellent drainageü Repose angle of up to 45
degrees possibleü Thermal insulation prevents
frost damage
Disadvantagesü Inorganic materialà Not
combustibleü Expensiveà about 60 € /
m³
Pros / Cons
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SELF-HEALING
(BACTERIAL)
CONCRETE
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• What is S.H.B.C?ü A new concrete technology
that autonomously repairscracks.
• How does it work?ü Alkaliphilic bacteria added to
concrete matrix.ü Bacteria react to the water
and metabolize crystals,which close the crack andprotect the steel within.
Self healing (bacterial) concrete
Self healingbacterialconcrete
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• Fresh concrete pHà up to 13• Most organisms die in a pH
value of 10 or above.• There are some bacteria that
survive in alkalineenvironments
• These bacteria can be found,for example:ü alkali lakes in Russia,ü carbonate-rich soils in desert
areas of Spainü soda lakes in Egypt.
Bacteria used
Bacillus cohnii
Bacillus filla Bacillus parturii
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Self healing bacterial concrete can be prepared in two ways.
1. By the method of direct applicationü bacterial spores and calcium lactate are added directly
while making the concrete and mixed.ü Here when the crack occurs in the concrete bacterial spores
broke and bacteria comes to life and feed on the calciumlactate and limestone is produced which fill the cracks.
Preparations of bacterial concrete
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
2. By encapsulation methodü the bacteria and its food, calcium lactate, are placed inside treated clay
pellets and concrete is madeü About 6% of the clay pellets are added for making bacterial concreteü When concrete structures are made with bacterial concrete, when the
crack occurs in the structure and clay pellets are broken and bacterialtreatment occurs and hence the concrete is healed.
ü Minor cracks about 0.5mm width can be treated by using bacterialconcrete
• Among theses two methods encapsulation method is commonlyused, even though it’s costlier than direct application. Bacillusbacteria are harmless to human life and hence it can be usedeffectively.
Preparation of bacterial concrete
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
1. The cracks are formed onthe surface of concretedue to many reasons likeshrinkage, Inadequatewater for hydration …etc.
2. The water is forced intothe crack and the bacteriais activated
Mechanism
1
2
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Ca(C3H5O2)2 + 7O2 → CaCO3 + 5CO2 + 5H2O
3. The activated bacteriaü result in metabolic
conversion of calciumlactate [Ca(C3H5O2)2]into calcium carbonate[CaCO3], limestone
Mechanism
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• The self healing bacterial concrete helps in reduced maintenanceand repair costs of steel reinforced concrete structures.
• Oxygen is an agent that can induce corrosion, as bacteria feedson oxygen tendency for the corrosion of reinforcement can bereduced.
• Self healing bacteria can be used in places where humans find itdifficult to reach for the maintenance of the structures.ü Hence it reduces risking of human life in dangerous areas and
also increases the durability of the structure.• Formation of crack will be healed in the initial stage itself thereby
increasing the service life of the structure than expected life.
Advantages
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• If the volume of self healing agents (bacteria and calciumlactate) mixed becomes greater than 20%, the strength of theconcrete is reduced.
• Preparation of self healing concrete needsbacteria and calcium lactate.ü Preparation of calcium lactate from milk is costlier.ü Hence preparation of self healing concrete costs double than
conventional concrete.
Disadvantages
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Self healing bacterial concretecan be used for sectors such asü tunnel-lining,ü structural basement
walls,ü highway bridges,ü concrete floorsü marine structures.
Applications
Tunnellining
Marinestructure
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CELLULOSE
INSULATION
MATERIAL
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Cellulose insulationü is made by hammer milling
waste paper andcardboards
ü The paper and cardboardsis treated with chemicals,such as boric acid, to retardthe spread of fire.
introduction
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• Roughly 85 % of theinsulation by weight isrecycled wood pulp(newspapers)
• 15 % of the celluloseinsulation by weight is fireretardant (hidastin):ü Ammonium sulfate,ü Boratesü Boric acid
introduction
Cellulose insulation
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
1. Loose Fillü either manually pouring in place,
or compressed air blowing inplace
ü insulation into wall or ceilingcavities.
2. Spray-Onü involves compressed air blowing
of cellulose materials that areimpregnated with adhesivesmaterial to the exposed interiorhorizontal and vertical surfacesof walls and ceilings
Installation Methods
Loose Fill
Spray-On
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3. Board stockü involves cellulosic
materials that arecompressed and formedinto rigid boards orpanels.
ü The panels may bemanufactured with orwithout surfacecoatings, facings, ordecorative finishes.
Installation Methods
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Properties of cellulose insulation
Property Cellulose Insulation
Thermal conductivity, λ [W /m . K]0.035 in ceiling cavities0.038 - 0.040 in walls
Thermal resistance at 100mm [K⋅m2/W] 2.632
Specific Heat Capacity [J/(kg.K)] 2020
Density [kg/m3] 27 to 65
Embodied energy [MJ/kg] 0.45
Vapour permeable Yes
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Cellulose insulation is used in:ü Attics: blown to whatever
depth (with properventilation) and there is nojoints to allow heat loss.
ü Packed into wallso allows little air
infiltrationo fire and insect resistant.
• NOT recommended forbasements due to itssensitivity to moisture.
Applications
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Advantagesü Helps reducing the discarded paper
and cardboardü Cellulose is treated with boric acid,
which increases fire resistance,resists mold and insects.
ü Cellulose is generally cheaper thanfiberglass insulation (up to 25%cheaper, in some cases)
ü Higher R-value of cellulose (2.6 per100 mm)
ü The health risks are fewer thanthose from fiberglass.
Disadvantagesü Cellulose insulation creates an
enormous amount of dust when itis installed, so a certified breathingmask is absolutely essential
ü Dry-blown cellulose sags andsettles, reducing its R-value overtime
ü Cellulose insulation absorbsmoisture easilyà cause theinsulation to mold and rot
ü Both dry- and wet-blown celluloseneed a vapor barrier.
Cellulose Insulation Pros and Cons
http://www.solar365.com/green-homes/insulation/cellulose-insulation-pros-cons
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FIBER REINFORCED
POLYMER (FRP)
COMPOSITES REBAR
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• A structural reinforcing barmade from filaments or fibersheld in a polymeric resinmatrix binder.
a) Fibers such as Glass (GFRP)or Carbon (CFRP).
b) Matrix à Polyester, Epoxy,Vinyl Ester
What is FRP rebar?
http://www.fdot.gov/materials/structural/meetings/crrb/4_frprebar.pdf
Fibers Matrix
Provide strengthand stiffness
Protects and transfersload between fibers
• Creates a material with attributes superiorto either component alone!
• fibers and matrix both play critical roles inthe composites material
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Materialsü Glass/ vinylesterü Carbon/ vinylester
Formsü Solid
Surfaceü Ribbedü Sand Coatedü Wrapped and Sand Coatedü Deformed and Helical
Bar sizesü 6 – 32 mm
What is FRP rebar?
Composite (Matrix + Fibers)
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
The Pultrusion Process:a process where compositeparts are manufactured by:ü pulling layers of
fibers/fabricsü impregnated with resinü through a heated dieü thus forming the desired
cross-sectional shapewith no part lengthlimitation
Resin types in pultrusion including:ü polyester,ü polyurethane,
ü vinylesterà for rebarü epoxy
Manufacturing process
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Pultrusion Process
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• Type of fiber• Fiber volume• Type of resin• Fiber orientation• Quality control procedures
during manufacturing• Rate of curing• Void content• Service temperature
Factors Affecting Material Characteristics
TensileStrength
ElasticModulus
Strain atBreak
(MPa) (GPa) (%)
Glass FRP 480-1600 35-51 1.2-3.1
Carbon FRP 1720-3690 120-580 0.5-1.9
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Tensile Stress-Strain Characteristics
• Linear elasticbehavior tofailure
• No yielding
• HigherUltimateStrength
• Lower Strainat Failure
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Standards & Specifications
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
• Any concrete member susceptible to corrosion by chloride ionsor chemicals
• Any concrete member requiring non-ferrous reinforcement dueto Electro-magnetic considerations
• As an alternative to epoxy, galvanized, or stainless steel rebars
• Where machinery will “consume” the reinforced member ie.Mining and tunneling
• Applications requiring Thermal non-conductivity
Where should FRP rebar be used?
http://www.fdot.gov/materials/structural/meetings/crrb/4_frprebar.pdf
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
FRP rebar applications
Sierrita de laCruz Creek
BridgeUSA
Pierce StreetBridge, Lima
OHUSA
Wotton,QuebecCanada
Taylor BridgeManitoba
Canada
http://www.fdot.gov/materials/structural/meetings/crrb/4_frprebar.pdf
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FRP rebar applications
http://www.fdot.gov/materials/structural/meetings/crrb/4_frprebar.pdf
Seawalls
INNOVATIVE
BUILDING
MATERIALS
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Translucent concrete
ü concrete based buildingmaterial with lighttransmissive properties dueto embedded light opticalelementsà optical fibers.
Innovative Building Materials
Shanmugam and Kumar. Innovative building materials - presentation.Department of civil engineering, Thiagarajar polytechnic college
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Solar Panel Roofing Tiles
ü Transform the solar energyinto useable electricity
Innovative Building Materials
Shanmugam and Kumar. Innovative building materials - presentation.Department of civil engineering, Thiagarajar polytechnic college
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Nanomaterials
ü When combined with ultra-high-strength concrete,nanomaterials such as CarbonNanotubes (CNTs) create amaterial so strong in bothtension and compression thatsteel rebar is no longerneeded in construction,therefore expediting thebuilding process.
Innovative Building Materials
http://architizer.com/blog/material-trends-for-2014-and-beyond/
Kaohsiung National Stadium, China
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CIV-E1010 Building Materials TechnologyFahim Al-Neshawy
Concrete Canvas
ü A flexible cementimpregnated fabric thathardens on hydration to forma thin, durable water proofand fire proof concrete layer.
ü Essentially, it's concrete on aroll Just Add Water.
Innovative Building Materials
http://voices.nationalgeographic.com/2013/03/20/concrete-canvas-goes-beyond-fast-deploying-shelters/
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