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

(Cou

nts)

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

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

(Cou

nts)

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

2-Theta - Scale

5 10 20 30 40 50 60 70 8

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

(Cou

nts)

0

10

20

30

40

50

60

70

80

90

100

110

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 4114holmersj@usp.brholmersj@usp.brwww.fzea.usp.br/constrambiwww.fzea.usp.br/constrambi