technology & technology transfer techniques for low-cost ... · the concrete used in the...
TRANSCRIPT
Technology & Technology Transfer Techniquesfor Low-Cost Sustainable Ecomaterials
for Reconstruction
Robert Day & Fernando MartirenaUniversity of Calgary & Universidad Central de Las Villas
10th East Asia Pacific Conference on Structural Engineering & ConstructionMini-Symposium: Hazard Mitigation and Infrastructure Renewal
SHELTER AS AN URGENT NEED IN SHELTER AS AN URGENT NEED IN THE DEVELOPING WORLDTHE DEVELOPING WORLD
Large social sectors cannot access decent housing and municipal facilities ... millions of people live in shacks...
The needy are the mostsusceptible to:
Tsunamis, Earthquakes, Hurricanes
Floods
VULNERABILITY AGAIVULNERABILITY AGAINNSTSTNATURAL CATASTROPHESNATURAL CATASTROPHES
The Problem
• The Problem– Many building materials use a lot of Portland
cement– Portland cement manufacture consumes
much energy & releases greenhouse gases– Thus, building materials cost a lot; putting
satisfactory housing and house-rebuilding beyond the reach of many people, NGOs and governments
A Solution
• Some ashes from natural and waste materials can be made to be reactive
• Use them to replace some or all of the Portland cement
Why Waste Materialsfor Rebuilding
• lower cost -- $ go further for reconstruction• potentially better quality, more resistant to
storms, earthquakes, etc.• rebuild at lower cost and with revised methods to
produce safer houses• Development $$ go further• reduces impact on
natural resources– coral reefs
• use of waste materials• useful energy production
Types of Waste Ashes• Industrial
– fly ash – coal fired generating stations
– blast furnace slag – steel manufacture
• Natural– volcanic ashes– ash from agricultural waste
incineration• straw, wheat, tea, sugar cane, rice,
etc., etc.
• Urban– municipal solid wastes
Worldwide Deposits of Volcanic Ashesand other Reactive Surface Deposits
Traditional Building Materials
CALCIUMHYDROXIDE
(LIME)
CALCIUM-SILICATEHYDRATE
(THE CEMENT) CONCRETEBLOCKBRICK
ROOF TILEETC.
CALCIUMSILICATES
inPORTLAND
CEMENT
WATER
STONE(AGGREGATE)
SAND
TIME+
Raw ingredients Chemical ReactionProducts Result
Building Materials From Wastes
CALCIUMHYDROXIDE
(LIME)
CALCIUM-SILICATEHYDRATE
(THE CEMENT)
TIME
reducedamount
MORECALCIUM-SILICATE
HYDRATE(THE CEMENT)
WASTE ASH
CALCIUMSILICATES
inPORTLAND
CEMENT
WATER
STONE(AGGREGATE)
SAND
+
TIME
SILICATES INWASTE
ASH
+
LOWER COSTMORE
SUSTAINABLE CONCRETE
BLOCKBRICK
ROOF TILEETC.
Raw ingredients Chemical ReactionProducts
Result
Challenges
• Ashes can be highly variable in reactivity because of variations in combustion / cooling– Chemical activators
• Production process has to be simple – local communities
• Social issues– acceptance in communities– overcome status symbol of
Portland cement– Gender
WHAT IS NEEDED FOR SHELTER?WHAT IS NEEDED FOR SHELTER?
COMMUNITY COMMUNITY PARTICIPATIONPARTICIPATIONas a means to decrease
construction costs....
Labor cost can take up to40% of the construction
budget....
Methodology• establish centres of knowledge and application
excellence within each country for building materials –especially ecomaterials – and housing
• establish ecomaterials workshops (entrepreneurships) that have excellent quality control and management
• reach out to the community through extensive advertising and by building demonstration houses and housing projects using the ecomaterials
• Presence of a strong NGO establishes a strong connection between “Centres of Excellence”(Universities) and the Workshops & Community
Manufacture of ecomaterialsMCR tiles
Pozzolan cement CP-40
Blocks, pavement bricks
Local BM Market
SALE
BricksHouse
construction
Self-helpPaid labor
SALE
Housing market
Higher sale prices
Traditional bank loan schemes
Low sale prices
Social projects
Alternative financing schemes
Other housing projects
Building materials
supply
Housing delivery
Building materials
supply
CROSSFINANCING!!
HOW TO ORGANIZEHOW TO ORGANIZEA LOW COST HOUSING PROJECT?A LOW COST HOUSING PROJECT?
It must be commercially viable, and socially and ecologically sustainable...
• Technical development centred in Cuba
• Economic Development focused around a strong participative NGO
Latin AmericaCase Study
Limestone Pozzolan, lime
OPC, aggregates
OPC, aggregates
Burning(Limekiln)
GrindingBall mill MB-
600)
Cal Hidratada
LPBCP-40
Compacting(block machine)
vibrating(vib table)
Biomass
Solid Fuel Block
Hollow concrete block
Pavement brick
Shells
MCR tile
Floor tiles
TECHNOLOGY + KNOW-HOW
RAW MATERIALS
BASIC PRODUCTS
FINAL PRODUCTS
THE PRODUCTION GOES TO
LOCAL ECOMATERIAL MARKETSOCIAL HOUSING PROGRAMS
COMMERCIAL HOUSING PROGRAMSHOUSING RENOVATION AND REPAIR
Lime mortar
Densification(Briquetting)
Masonry mortar
Clay, admixture
Burning(Brick kiln)
Fired clay brick
Support structure, roof
and floors
Pre-stressing
OPC, aggregate, steel
THE ECOMATERIALSTHE ECOMATERIALSWORKSHOPWORKSHOP
Production wastes are recycled as raw materials for other productions...
19982001
2002
2003
2004
2004
2004
WORKSHOPS IN OPERATIONWORKSHOPS IN OPERATIONCUBACUBA
WORKSHOPS IN OPERATIONWORKSHOPS IN OPERATIONREST OF THE WORLDREST OF THE WORLD
1997 1998 1999 2000 2001-2002 2003
Sugar Cane Bagasse
ECOSUR coordination
Cuban UniversityApplied R&DConsultingTechnology
development
Social projectspilot scale
applications
Machine manufacturecommercial contracts
Development agenciesfinancing
Marketcommercial applications
Universities in the developed world
Fundamental research
Academic financingscholarships
Legend
Partnership
Flow of resources
THE PROCESS of CAPACITY BUILDINGTHE PROCESS of CAPACITY BUILDING
Network of Centres of
Excellence in Satellite
Countries
ALTERNATIVES FOR POZZOLANS ALTERNATIVES FOR POZZOLANS IN CUBAIN CUBA
1
2
3
Ashes burnt without control
(Sugar cane bagasseand straw)
Ashes burnt under control in incinerators(Sugar cane straw burnt
at 700 oC)
Ashes from the solid fuel block
(Sugar cane straw and clay mixed and burnt at
900 oC)
The heat generated in thecombustion can be
recovered and used whenburning occurs at
temperatures over 700 oC..
THE SOLID FUEL BLOCKTHE SOLID FUEL BLOCK
The SFB is made out of clayand biomass (rice husk,
sugar cane straw, recycledpaper, etc.)... The ratio
clay/biomass ranges from20/80% (wt.)...
The SFB is an excellent fuel whose ashes are likely reactive...
SOLID FUEL BLOCK
Lime KilnLime burning
Brick KilnBrick firing
Cooking stoveFood cooking
QuicklimeProduction
Ashpozzolana
Food
Lime-pozzolana cement
Small Format Precast Concrete Elements
PrimaryProducts
Combustiondevice
End Products
Fired clay bricks
THE SOLID FUEL BLOCKTHE SOLID FUEL BLOCK
USE OF LIMEUSE OF LIME--POZZOLAN MIXTURES IN THE POZZOLAN MIXTURES IN THE MANUFACTURE OF HOLLOW CONCRETE BLOCKSMANUFACTURE OF HOLLOW CONCRETE BLOCKS
The concrete used in the manufacture of hollow concrete shows a strength in the range 9-12 MPa and has a dry consistency… it does not require superplasticizers…
Manufacture Lime-Pozzolan Cement(zero Portland cement)
• intergrinding 70% by mass of ash with 30% by mass of hydrated lime found to be optimum
• Lower costs for some applications can be achieved by using only 20% lime
• some grinding to produce a finer, more reactive powder is usually necessary
• grinding times of 50-70 minutes, minimize energy requirement, have been found to be adequate
Building Units• most Lime-Pozzolan cements
made from biomass are slow reacting
• for practical manufacture of units– some Portland cement– or chemical activator– or both
• blocks can be cured in a warm, moist environment – in hot countries, placement in plastic tents provides good curing conditions
ACTIVATOR 1 ACTIVATOR 2 ACTIVATOR 3 ACTIVATOR 4
Use of Chemical Activators
IMPACTS OF THE IMPACTS OF THE TECHNOLOGY DEVELOPEDTECHNOLOGY DEVELOPED
Scientific(Full cycle research)
Economic(Resource
savings/technology trading/project financing)
Social(Job creation)
(Wealth generation)
Ecologic(Green house gases
reduction/waste recycling )
The technology transfer is done as a South to South endeavor...
IMPACT: GENDERIMPACT: GENDER
As CommunityLeaders, Women play
a very active role
IMPACT: OPTIMAL USE OF RESOURCESIMPACT: OPTIMAL USE OF RESOURCES
IMPACT: LOAN SCHEMESIMPACT: LOAN SCHEMES
Alternative financing schemes have been set into practice to benefit thosefamilies which do not qualify for traditional bank loans ...
Cost of house Upfront Mortgage Years Interest Monthly paymFamily 1 $9,000.00 $4,000.00 $5,000.00 10 24% $110.24Family 2 $9,000.00 $4,000.00 $5,000.00 10 14% $77.63Family 3 $9,000.00 $4,000.00 $5,000.00 5 9% $103.79
Total payment
$0.00
$2,000.00
$4,000.00
$6,000.00
$8,000.00
$10,000.00
$12,000.00
$14,000.00
1st year 5th year 10th year
$US
dolla
rs Family 1Family 2Family 3
Interest
$0.00
$2,000.00
$4,000.00
$6,000.00
$8,000.00
$10,000.00
$12,000.00
$14,000.00
1st year 5th year 10th year
$US
dolla
rs Family 1Family 2Family 3
IMPACT: BUILDING CAPACITYIMPACT: BUILDING CAPACITY
Hundreds of persons have
been trained in the manufacture
and use of ecomaterials...
Establishment of Local “Centres of Excellence”
promotes the occurrence of Critical Mass
IMPACT: HOUSE UPGRADINGIMPACT: HOUSE UPGRADING
IMPACT: JOB OPPORTUNITIESIMPACT: JOB OPPORTUNITIES
IMPACT: IMPROVING DISASTER VULNERABILITYIMPACT: IMPROVING DISASTER VULNERABILITY
IMPACT. MASS SOLUTIONSIMPACT. MASS SOLUTIONS
The project has provided decent housing tothousands of people in Latin America
IMPACT. MARKET POTENTIALIMPACT. MARKET POTENTIAL
New markets for theecomaterials are envisioned for
the forthcoming years
MCR 10,000 s.q.m. Roof in Dhaka, Bangladesh
Impact: North American MarketImpact: North American Market
