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ConWEEB Workshop
Brussels, 24th May 2018
ConWEEB - Converting construction waste
into energy-efficient buildings
Project
Performance indicators for CDW optimized binder
formulations for High Density Geopolymer layers
and for production of Wood Geopolymer Panels
Coordinator: Adriana Bernardi
CNR – ISAC
Work Programme topics addressed:
EeB-04-2016 New technologies and strategies for the
development of pre-fabricated elements through the reuse and
recycling of construction materials and structures
Project number: 723916 Project cost: 3.36 million €
Starting month: October 2016 Project Duration: 4 years
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https://www.innowee.eu
„This project has received funding from the European Union’s Horizon
2020 research and innovation programme under grant agreement No
723916”
Presenter: Sergio Tamburini – CNR-ICMATE
About geopolymers
What are geopolymers (GP)?
ConWEEB, Brussels, 24th May 2018
INORGANIC materials produced ARTIFICIALLY in a process fromaluminosilicates activated with alkali silicate solutions
• GEO–: they mimic natural compounds such as zeolites present in therocks, which exhibit the main properties i.e. hardness, chemicalstability and geological longevity.
• –POLYMERS: they are obtained by a polymerization process bypolycondensation
[Davidovits, 1989, 429; Duxson et al., 2007, 2917; Song et al., 2008, 363] [Song, 2007; Pacheco Torgal et al.2011].
1 ton of Geopolymer → 0.16 ton of CO2
1 ton of Portland cement → 0.87 ton of CO2
About InnoWEE geopolymers
ConWEEB, Brussels, 24th May 2018
Metakaolin Pozzolanic material Al2O32SiO2 derived from the calcination ofKaolinite (i.e. China clay), a soft clay mineral (Al₂Si₂ O₅(OH)₄), usedmainly as additive for concrete
Furnace slag Ground granulated blast-furnace slags are a glassy by-productobtained during the production of iron from the ore and coke,generally rich in CaO, SiO₂ and Al₂O₃.
They are rapidly quenched below 800°C to improve their reactivity andhydraulicity, to be used as additive in concretes.
Fly-ash Coal combustion product captured in coal-fired power plants, used asa pozzolan additive or partial replacement of Portland cement inconcretes. It is mainly composed by spherical particles between 0.5and 300 μm, with various components (SiO₂, Al₂O₃, Fe₂O₃…).
Class F fly-ash has less than 7% of CaO.
Wikipedia
Heating at 600-800°C
then grinding
About InnoWEE geopolymers
ConWEEB, Brussels, 24th May 2018
Alkali silicate solutions
Secondary Raw Materials (SRM)
selective demolition and processing
They are usually produced from molten quartz sand and alkalicarbonates or silica and alkali hydroxides (e.g. NaOH, KOH)
They have many applications, from Constructions (e.g. in coatings forconcrete and masonry) to several industrial uses.
About InnoWEE geopolymers
ConWEEB, Brussels, 24th May 2018
How geopolymers are used in InnoWEE
ETICS-like panels Radiant elements
Ventilated façade panels Installation test
Optimization of geopolymer mixtures
Optimization of the binder
ConWEEB, Brussels, 24th May 2018
Geopolymermixtures
Systems(panels)
Processes(scaling up)
LCA and Costs
What is involved?
Geopolymermixture
feasibility
suitability & durability
cost effectiveness
• proper workability;
• limited shrinkage;
• etc.
• adequate strength;
• limited efflorescence/leaching;
• freeze-thaw resistance;
• etc.
• high waste content;
• reduction of expensive raw
materials;
• effective scaling-up;
• etc.
What are the desired properties?
Optimization of geopolymer mixtures
Process at laboratory level
ConWEEB, Brussels, 24th May 2018
metakaolin ground blast
furnace slag
class F
fly ash
potassium
silicate
inorganic wastes
MIXER
before milling…
Optimization of geopolymer mixtures
How to find out the best recipes?
ConWEEB, Brussels, 24th May 2018
1) make variations
2) test properties
3) make prototypes
• change ingredients ratios;
• adjust amount and particle size distribution of waste;
• modify the alkali activators;
• vary the curing conditions;
• and so on…
compression splitting bending
shrinkage
open porosity, density, water absorption,
leaching, freeze-thaw, etc.
Optimization of geopolymer mixtures
Main parameters that were investigated...
ConWEEB, Brussels, 24th May 2018
suitability of supplied wastes waste content blends of wastes
metakaolin:slagratio
formulation of the alkali activator
curing temperature use of short fibres
fluidity open time
particle size distribution
Drying shrinkage and so on…
Optimization of geopolymer mixtures
ConWEEB, Brussels, 24th May 2018
metakaolin slag
Na/K
silicate
MIXER
Geopolymers with wood waste
waterwood waste
casting and
processing
Optimization of geopolymer mixtures
Geopolymers with wood waste
ConWEEB, Brussels, 24th May 2018
1) Make variations
2) Test properties
• wood content 20→60%
• type of reagents.
• density and water absorption;
• transversal and longitudinal swelling in water;
• bending strength.
UNSW Sidney, School of Materials
Science and Engineeringhttp://www.materials.unsw.edu.au/tutorials/online-
tutorials/2-wood-structure-2
3) Make prototypes
Behaviour at high temperatures
Preliminary tests on geopolymers with inorganic CDW
ConWEEB, Brussels, 24th May 2018
HDG panels after exposure to900°C for 1 h
50%
concrete
50%
fired clay
HDG samples after exposure to 600°C
for 1 h, then 900°C for 1 h
Preliminary fire reaction of geopolymers
with wood waste
WG exposed for some minutes to a butane flame at about 900-950°C
Freeze-thaw resistance
Durability preliminary tests on climatic chamber – 50 cycles
ConWEEB, Brussels, 24th May 2018
Cycles between:+20°C and –23°C
time (min)
tem
pera
ture
(°C
)
RESULTS
Samples with inorganic CDW
Samples with wood
ConWEEB, Brussels, 24th May 2018
Geopolymer adhesive
The influential parameters• chemical bonding between AAM
layer and substrate
• shrinkage/expansion matching
• mechanical interlocking (usually
improved if surface is rough)
• Geopolymeric formulation as potential adhesive material between high density and
insulation layers (EPS, wood panels)
Addition of fly ash:
• improves workability (open time)
• improves bending strength (indirect–
toughness)
• increases pull-off strength
• higher amount of slag
resulted in higher
compressive strength;
• lower water/solid ratio
resulted in a higher
mechanical properties;
• the shrinkage is mainly
related to the water/solid
ratio;
• high mechanical
strength of adhesive
itself does not necessary
mean good adhesion.
Design of geopolymer binder
ConWEEB, Brussels, 24th May 2018
Design of geopolymer binder
Geopolymer adhesive
• High strength / low shrinkage adhesive was developed;
• High bond strength to ceramic tiles or concrete panels can be
achieved;
• Acceptable adhesion to the geopolymer layers;
• Acceptable technological parameters (open time, consistency).
Parameters important for the
applicationSelection of promising mixtures - tested
on different substratesOpen time
Flow in the range
135-250 mm.
Consistency
Workable at least up to 20
minutes.
Pull off (MPa)
Mixture ceramic tiles /
concrete substrate
concrete tile /
concrete substrate
concrete tile / HDG
7mm –Layer HDG W1=50%
HDG /WGP
28 1.07 1.8 0.11 0.5
42 0.01 1.8 0.25 ≥ 0.4
25 1.59 / 0.05 /
Thermal properties
Thermal conductivity λ
ConWEEB, Brussels, 24th May 2018
Representative samples with inorganic CDW
Representative
samples with wood
For comparison (values in W·m‾¹·K‾¹): EPS ≈ 0.03; wood ≈ 0.1-0.15;
concrete ≈ 0.8-1.3; marble ≈ 2-3; steel ≈ 16-50
https://www.innowee.eu
THANK YOU FOR YOUR
ATTENTION
ConWEEB, Brussels, 24th May 2018
„This project has received funding
from the European Union’s Horizon
2020 research and innovation
programme under grant agreement
No 723916”
Optimization of geopolymer binders
Sergio TamburiniCNR-ICMATE
Email: [email protected]
Thermal characterization of binders
Paolo BisonCNR-ITC
Email: [email protected]
Development of geopolymer adhesive
Vilma Ducman ZAG
Email: [email protected]