deliverable d3.4 assessment of the industrial production · 2020-07-13 · innowee d3.4...

Deliverable D3.4

Assessment of the industrial production

Grant Agreement number 723916

Project acronym

Project full title

InnoWEE

INNOvative pre-fabricated components including different

Waste construction materials reducing building Energy and

minimising Environmental impacts

Due date of deliverable 31/07/2019

Lead beneficiary ZAG

Other authors CNR-ISAC/ICMATE/ ITC, AMS, RED, PIETRE,AMS

Dissemination Level

PU Public

CO Confidential, only for members of the consortium (including the Commission

Services) X

Cl Classified, as referred to in Commission Decision 2001/844/EC

Ref. Ares(2019)4253552 - 04/07/2019

InnoWEE D3.4 “Assessment of the industrial production”

04/07/2019 1

Document History

Version Date Authors Description

1 10/01/19 Vilma Ducman (ZAG) Creation of the document

2 14/01/19 Vilma Ducman, Ana Frankovič

(ZAG) First draft for partners

3 21/05/19 Vilma Ducman, Ana Frankovič

(ZAG) Upgraded draft for partners

4 13/06/19

Maria Sachini (AMS), Paolo Bison

(CNR), Giovanni Ferrarini (CNR),

Nataša Knez (ZAG)

Contribution from partners

5 17/06/19 Vilma Ducman (ZAG) Draft for reviewers

6 26/06/19 Giulia Ceschel (ECO), Jakub Pluta

(IZNAB) Reviewed draft

7 27/06/19 Maria Sachini (AMS) Contribution regarding

reviewer’s comments

8 27/06/19 Vilma Ducman (ZAG) Final version for Coordinator

9 01/07/2019 Francesca Becherini (CNR) Revision of final version

10 02/07/2019 Constantinos Tsoutis (AMS) Answers to the revision

11 04/07/2019 Adriana Bernardi (CNR) Definitive revision and upload in

ECASS

Disclaimer

This document is the property of the InnoWEE Consortium.

This document may not be copied, reproduced, or modified in the whole or in the part for any purpose without written permission from the InnoWEE Coordinator with acceptance of the Pro-ject Consortium.

This publication was completed with the support of the European Commission under the Horizon 2020 research and innovation programme. The contents of this publication do not necessarily reflect the Commission’s own position. The document reflects only the author’s views and the Community is not liable for any use that may be made of the information contained therein.


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Contents

Publishable summary......................................................................................................................... 4

List of Figures .................................................................................................................................... 5

List of Tables ..................................................................................................................................... 8

Abbreviations .................................................................................................................................. 10

Symbols .......................................................................................................................................... 11

Introduction .................................................................................................................................... 12

1 Factory Production Control (FPC) ................................................................................................. 13

1.1 Formulation repeatability during production principle ................................................................. 14

1.1.1 Audit tasks prior production ................................................................................................................... 16 1.1.2 Audit tasks during production ................................................................................................................. 17

1.1.2.1 HDG paste viscosity audit Tasks...................................................................................................... 17 1.1.2.2 Quality Audit Tasks during production ........................................................................................... 19

1.2 Quality Objectives (Benchmarks – P.R.S.) ...................................................................................... 20

1.2.1 HDG ETICS panel ..................................................................................................................................... 20 1.2.1.1 General description ......................................................................................................................... 20 1.2.1.2 Mechanical properties .................................................................................................................... 21 1.2.1.3 Surface properties ........................................................................................................................... 21

1.2.2 HDG ventilated facade panel .................................................................................................................. 22 1.2.2.1 General description ......................................................................................................................... 22 1.2.2.2 Mechanical properties .................................................................................................................... 22 1.2.2.3 Surface properties ........................................................................................................................... 22

1.2.3 HDG radiant wall panel ........................................................................................................................... 23 1.2.3.1 General description ......................................................................................................................... 23 1.2.3.2 Mechanical properties .................................................................................................................... 23 1.2.3.3 Surface properties ........................................................................................................................... 23

1.3 FPC for ETICS like panels ................................................................................................................ 24

1.3.1 Audit tasks prior production ................................................................................................................... 24 1.3.1.1 Ambient conditions control ............................................................................................................. 24 1.3.1.2 Raw materials control ..................................................................................................................... 28

1.3.2 Audit tasks during production ................................................................................................................. 34 1.3.2.1 Testing schedule ............................................................................................................................. 34 1.3.2.2 HDG paste viscosity......................................................................................................................... 35 1.3.2.3 Water absorption ............................................................................................................................ 37 1.3.2.4 Rebound hardness test (Schmidt hammer test) .............................................................................. 39 1.3.2.5 Optical properties ........................................................................................................................... 41 1.3.2.6 Paint adhesion test ......................................................................................................................... 47 1.3.2.7 Paint thickness ................................................................................................................................ 48

1.4 FPC for ventilated facades ............................................................................................................. 49

1.4.1 Audit tasks prior production ................................................................................................................... 49 1.4.1.1 Ambient conditions control ............................................................................................................. 49 1.4.1.2 Raw materials control ..................................................................................................................... 51

1.4.1 Audit tasks during production ................................................................................................................. 53 1.4.1.1 Testing schedule ............................................................................................................................. 53 1.4.1.1 HDG paste viscosity......................................................................................................................... 54 1.4.1.2 Water absorption ............................................................................................................................ 55 1.4.1.3 Rebound hardness test (Schmidt hammer test) .............................................................................. 56 1.4.1.4 Optical properties ........................................................................................................................... 57 1.4.1.5 Paint adhesion test ......................................................................................................................... 60 1.4.1.1 Paint thickness ................................................................................................................................ 60

1.5 FPC for radiant panels .................................................................................................................... 62

1.5.1 Audit tasks prior production ................................................................................................................... 62 1.5.1.1 Ambient conditions control ............................................................................................................. 62


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1.5.1.2 Raw materials control ..................................................................................................................... 63 1.5.2 Audit tasks during production ................................................................................................................. 65

1.5.2.1 Testing schedule ............................................................................................................................. 65 1.5.2.2 HDG paste viscosity......................................................................................................................... 66 1.5.2.3 Water absorption ............................................................................................................................ 68 1.5.2.1 Rebound hardness test (Schmidt hammer test) .............................................................................. 69 1.5.2.2 Optical properties ........................................................................................................................... 70 1.5.2.3 Paint adhesion test ......................................................................................................................... 72 1.5.2.4 Paint thickness ................................................................................................................................ 72

1.6 Common FPC for all products ........................................................................................................ 73

1.6.1 Panel surface defects identification ........................................................................................................ 73 1.6.2 Other defects and remedial actions ........................................................................................................ 74 1.6.3 Traceability records ................................................................................................................................. 76

2 Initial type testing ....................................................................................................................... 78

2.1 ETICS-like panels ............................................................................................................................ 78

2.2 Ventilated façade panels ................................................................................................................ 78

2.3 Assessment of ETICS like and ventilated facade ............................................................................ 79

2.3.1 Water absorption (Capillarity test) ......................................................................................................... 79 2.3.2 Water vapour permeability ..................................................................................................................... 81 2.3.3 Impact resistance .................................................................................................................................... 83 2.3.4 Freeze – thaw behaviour ......................................................................................................................... 84 2.3.5 Bond strength .......................................................................................................................................... 85

2.3.5.1 Bond strength before 30 cycles of freezing and thawing ................................................................ 85 2.3.5.2 Bond strength after 30 cycles of freezing and thawing .................................................................. 87

2.3.6 Determination of resistance to carbonation ........................................................................................... 88 2.3.7 Alkali reactivity of panels ........................................................................................................................ 89 2.3.8 Length change of samples exposed to a Sulphate Solution .................................................................... 91 2.3.9 Freezing in the presence of de-icing salt resistance ............................................................................... 93 2.3.10 Hydrothermal behaviour ......................................................................................................................... 94 2.3.11 Water tightness of joints for different joint fillings (answer to the expert comments) .......................... 96 2.3.12 Determination of change in mass and volume (answer to the expert comments) ................................ 98 2.3.13 Determination of bond strength of the two EPS layers .......................................................................... 99 2.3.14 Determination of Hg – porosimetry ...................................................................................................... 100 2.3.15 Determination of Volatile Organic Compounds .................................................................................... 102 2.3.16 Fire testing of WGP part of ventilated panel ........................................................................................ 103

2.4 Radiant panels .............................................................................................................................. 107

2.4.1 Stress test .............................................................................................................................................. 107

3 Conclusions .............................................................................................................................. 109

4 Bibliography ............................................................................................................................. 110


04/07/2019 4

Publishable summary

The deliverable D3.4 Assessment of the industrial production is related to Task 3.4 (titled the

same as D3.4) within WP3 which is devoted to the pilot production of three types of InnoWEE

products: ETICS-like panels, ventilated panels and radiant panels. The objective of Task 3.4 is on

one side to set up fundamentals for factory production control (FPC) and on the other to define

which properties should be measured on final products (Initial type testing – ITT).

The first part of D3.4 is devoted to the factory production control, that has been established to

demonstrate and guarantee the constancy of the quality of products and their suitability for

intended use. The factory production control is documented and will be of support to the

producer when regular production will take place. Within the factory production control the

parameters which might have impact on the process itself or on the final properties of panels are

identified. These parameters include the properties of raw materials, the process itself, and the

operating conditions. Some tests foreseen on final products are also part of FPC.

The second part of D3.4 deals with the selection of parameters to be assessed during the initial

type testing of the three types of panels. Tests have been performed following mainly provisions

of ETAG 004, ETAG 034, methodology established within Rilem TC DTA (durability testing of alkali

activated materials). Radiant panels, that were already tested for thermal performance, have

been tested in a customized setup dedicated to verify their durability under hot-cold inlet cycles.

Results of FPC have confirmed that it is possible to obtain constancy of the quality in geopolymer based panels, and also that the properties of such panels meet the requirements for the intended use (façade panels, radiating panels).


04/07/2019 5

List of Figures

Figure 1: Audit tests during production ...................................................................................................... 18

Figure 2: ETICS panel dimensions ............................................................................................................... 20

Figure 3: Edge lips cover ............................................................................................................................. 20

Figure 4: Ventilated façade panel dimensions ............................................................................................ 22

Figure 5: Radiant ceiling panel dimensions ................................................................................................ 23

Figure 6: Monitoring systems in TUPP ........................................................................................................ 25

Figure 7: Monitoring systems in TUPP ........................................................................................................ 25

Figure 8: Production’s line control boards .................................................................................................. 25

Figure 9: Production timescale & ambient conditions ............................................................................... 26

Figure 10: Modified atmosphere in silos .................................................................................................... 28

Figure 11: Moisture testing in raw materials .............................................................................................. 29

Figure 12: Moisture content in raw materials ............................................................................................ 29

Figure 13: CDW sieve test ........................................................................................................................... 31

Figure 14: CDW morphology per batch ...................................................................................................... 32

Figure 15: Testing schedule during ETICS production ................................................................................ 34

Figure 16: HDG paste specimens ................................................................................................................ 34

Figure 17: Viscosity test .............................................................................................................................. 35

Figure 18: Viscosity pattern of HDG paste per batch ................................................................................. 36

Figure 19: Water absorption test ................................................................................................................ 37

Figure 20: Water absorption values pattern............................................................................................... 38

Figure 21: Schmidt hammer test @ 50 % RH .............................................................................................. 39

Figure 22: Schmidt hammer test pattern per batch ................................................................................... 40

Figure 23: Pattern of measurements (left) & in situ measurements (right) ............................................... 41

Figure 24: Sample images from MetaVision software ................................................................................ 42

Figure 25: Pattern of texture roughness values per sample panel ............................................................. 44

Figure 26: Pattern of porous depth values per sample panel .................................................................... 46

Figure 27: Paint thickness test .................................................................................................................... 48

Figure 28: Pattern of paint thickness values per batch .............................................................................. 49

Figure 29: Production timescale & ambient conditions ............................................................................. 50



Figure 32: Testing schedule during ventilated façade panels production .................................................. 53


Figure 34: Water absorption values pattern............................................................................................... 55


Figure 36: Pattern of measurements .......................................................................................................... 57




Figure 40: Production timescale & ambient conditions ............................................................................. 62



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Figure 43: Testing schedule during ventilated façade panels production .................................................. 65


Figure 45: Water absorption values per batch ........................................................................................... 68





Figure 50: Most usual categories of panels surface defects ....................................................................... 74

Figure 51: Maintenance record for the Nitrogen supply system ................................................................ 76

Figure 52: Panels traceability system ......................................................................................................... 76

Figure 53: ETICS-like façade panels in different colour edition. ................................................................. 78

Figure 54: Front and backside of ventilated façade panel. ......................................................................... 79

Figure 55: Two phases (immersion in water and drying) of three cycles for ETICS-like panels ................. 80

Figure 56: Two phases (immersion in water and drying) of three cycles for ventilated panels ................. 80

Figure 57: Preparation of testing samples according to “dry cup” method. .............................................. 81

Figure 58: Tested samples of rendering layer of ETICS – like panels without insulation and with two different coatings. ....................................................................................................................... 81

Figure 59: Mass changing of ETICS-like samples depending on the time. .................................................. 82

Figure 60: ETICS – like panel with injury after testing impact with 10 Joule steal ball (marked with blue) ............................................................................................................................................. 83

Figure 61: Ventilated façade panel with injury after testing impact with 10 Joules steal ball ................... 83

Figure 62: Failures detected during visual control of panels with coating after 30 cycles of freezing and thawing ........................................................................................................................................ 84

Figure 63: Locations of the failures of pull-off test determined on ETICS-like panels ............................... 85

Figure 64: 80% failure in adhesive layer and 20% failure between adhesive layer and wood base geopolymer panel of ventilated façade panel. ............................................................................ 86

Figure 65: Adhesive layer between High density geopolymer and Wood - base geopolymer layer. ......... 86

Figure 66: Locations of the failures of pull-off test determined on ETICS-like panels after 30 cycles of freezing and thawing ................................................................................................................... 87

Figure 67: Locations of the failures of pull-off test determined on ventilated façade panels after 30 cycles of freezing and thawing ............................................................................................................... 88

Figure 68: Testing chamber with 60 ± 10% RH and were testing samples were exposed to the 1% concentration of CO2 .................................................................................................................. 89

Figure 69: Resistance to carbonation (a) before exposure to CO2, (b) after 7 days, (c) after 28 days and (d) after 56 days of exposure to 1% concentration of CO2 .............................................................. 89

Figure 70: Dilatometer – equipment for measurement of length expansion of samples .......................... 90

Figure 71: Length change of samples through period of 5 months ............................................................ 91

Figure 72: Surface of samples after 4 weeks immersion in limewater and samples immersed in Na2SO4 solution after 1 month immersion in limewater. ........................................................................ 91

Figure 73: Length change of samples through period of 15 weeks ............................................................ 92

Figure 74: Surface deformation of ETICS-like façade panel after exposal to 3 cycles of freezing and thawing in the presence of de-icing salt ................................................................................................... 93

Figure 75: ETICS-like facade samples exposed to hydrothermal conditions .............................................. 94

Figure 76: ETICS-like facade samples after exposure in hydrothermal chamber ....................................... 95


04/07/2019 7

Figure 77: Locations of the failures of pull-off test determined on ETICS-like panels after exposure in hydrothermal chamber ............................................................................................................... 96

Figure 78: Failure location after Pull – off test between two EPS layers .................................................. 100

Figure 79: Pore size distribution in rendering layer of tested ETICS-like panels from pilot production .. 100

Figure 80: Pore size distribution in rendering layer of tested ventilated facade panels from pilot production ................................................................................................................................................... 101

Figure 81: Pore size distribution in rendering layer of laboratory produced panels ................................ 101

Figure 82: Specimen made of boards containing 40% of wood chips (No. IW78) before the test (left), during the test (middle) and after the test (right). ............................................................................... 104

Figure 83: Specimen made of boards containing 50% of wood chips (No. IW79) before the test (left), during the test (middle) and after the test (right). ............................................................................... 104

Figure 84: Specimen with 40% of wood chips: heat release rate (HRR / kW) and average of HRR over 30 seconds (HRR(30) / kW), total heat release (THR / MJ) and growth rate index (FIGRA / W/s) 105

Figure 85: Specimen with 50% of wood chips: heat release rate (HRR / kW) and average of HRR over 30 seconds (HRR(30) / kW), total heat release (THR / MJ) and growth rate index (FIGRA / W/s) 105

Figure 86: Specimens with 50% and 40% of wood chips: average of heat release rate over 30 seconds (HRR(30) / kW) ........................................................................................................................... 105

Figure 87: Specimens with 50% and 40% of wood chips: average of smoke production rate over 60 seconds (SPR(60) / m2/s). ....................................................................................................................... 106

Figure 88: The water inlet to the panel is cycled between hot and cold. A full cycle lasts one hour. ..... 107

Figure 89: Thermal images of the panel. The water inlet to the panel is cycled between hot and cold. 108


04/07/2019 8

List of Tables

Table 1: Audit tasks prior production ......................................................................................................... 17

Table 2: Audit tasks during production ....................................................................................................... 19

Table 3: Ambient conditions values per batch ........................................................................................... 27

Table 4: Numerical values of moisture (%) for each raw material per batch ............................................. 30

Table 5: CDW sieve tests results ................................................................................................................. 32

Table 6: Viscosity values of HDG paste per batch ....................................................................................... 36

Table 7: Water absorption values per batch .............................................................................................. 38

Table 8: Schmidt hammer test per batch ................................................................................................... 39

Table 9: Texture roughness peak values per point sample of each panel per batch ................................. 43

Table 10: Porous peak values per point sample of each panel per batch .................................................. 45

Table 11: Adhesion standard ratings .......................................................................................................... 47

Table 12: Coating’s adhesion classification ................................................................................................ 47

Table 13: Paint thickness values ................................................................................................................. 48

Table 14: Ambient conditions values per batch ......................................................................................... 50

Table 15: Numerical values of moisture % for each raw material per batch ............................................. 52

Table 16: CDW sieve tests results ............................................................................................................... 53

Table 17: Viscosity values of HDG paste per batch ..................................................................................... 54

Table 18: Water absorption values per batch ............................................................................................ 55

Table 19: Schmidt hammer test per batch ................................................................................................. 56

Table 20: Texture roughness peak values per point sample of each panel per batch ............................... 58




Table 24: Ambient conditions values per batch ......................................................................................... 62

Table 25: Numerical values of moisture % for each raw material per batch ............................................. 64

Table 26: CDW sieve tests results ............................................................................................................... 65

Table 27: Viscosity values of HDG paste per batch ..................................................................................... 66

Table 28: Water absorption values per batch ............................................................................................ 68

Table 29: Schmidt hammer test per batch ................................................................................................. 69

Table 30: Texture roughness peak values per point sample of each panel per batch ............................... 70




Table 34: Possible defects and their remedial actions ............................................................................... 75

Table 35: Results with limited values .......................................................................................................... 80

Table 36: Results of determination of water-vapour transmission properties – Cup method .................. 82

Table 37: Bond strength and location of the failure of ETICS-like façade panel ........................................ 85

Table 38: Bound strength and location of the failure of ventilated façade panel ...................................... 86

Table 39: Bound strength of ETICS-like façade panels after 30 cycles of freezing and thawing ................ 87

Table 40: Bound strength and location of the failure of ventilated façade panel ...................................... 87

Table 41: Results of determination of Alkali reactivity of aggregates ........................................................ 90


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Table 42: Results of determination of length change of samples exposed to a Sulphate Solution ........... 92

Table 43: Average Loss of mass after n-cycles in mg/mm2 ........................................................................ 93

Table 44: Criteria of freezing in the presence of salt .................................................................................. 93

Table 45: Bound strength of ETICS-like façade panels with transparent coating after exposure in hydrothermal chamber ............................................................................................................... 95

Table 46: Bound strength of ETICS-like façade panels with white coating after exposure in hydrothermal chamber ....................................................................................................................................... 95

Table 47: Test unit preparation for testing the water tightness of joints .................................................. 97

Table 48: Results of for testing the water tightness of joints ..................................................................... 97

Table 49: Loss of mass and volume of tested samples ............................................................................... 98

Table 50: Bond strength determined with Pull-off test between two EPS layers ...................................... 99

Table 51: Material parameters determined with Hg - porosimetry ......................................................... 102


04/07/2019 10

Abbreviations

InnoWEE INNOvative pre-fabricated components including different Waste construction

materials reducing building Energy and minimising Environmental impacts

CPR Construction Product Regulation

hEN harmonized European Norm

EAD European Assessment Document

FPC Factory Production Control

ITT Initial Type Testing

ETICS External Thermal Insulation Composite Systems

HDG High Density Geopolymers

CDW Construction Demolition Wastes

6σ Six Sigma methodology

MK MetaKaolin

SL Furnace SLag

K-SIL Potassium Silicate

SiO2 Silicon Dioxide

K2O Potassium Oxide

FA Fly Ash

KOH Potassium Hydroxide

QAP Quality Assurance Plan

CO2 Carbon Dioxide

CO Carbon Monoxide

LEL Lower Explosive Limit

N.P.T. Net Production Time

https://en.wikipedia.org/wiki/Lower_explosive_limit


04/07/2019 11

Symbols

T temperature [°C]

d thickness [mm]

V Water – vapour transmission rate [g/m2 day]

sd Water – vapour diffusion - equivalent air layer thickness [m]

µ water – vapour resistance factor [/]

Δm change in mass [%]

ΔV change in volume [%]

m1 mass of dry and empty metal rings weighed on air [g]

m2 mass of dry and empty metal rings weighed in test liquid [g]

m3 mass of filed metal rings with sealant weighed on air [g]

m4 mass of filed metal rings with sealant weighed in test liquid [g]

m5 mass of samples weighed on air [g]

m6 mass of samples weighed in test liquid [g]

deliverable d3.4 assessment of the industrial production · 2020-07-13 · innowee d3.4...

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