Download - AggreBind Not Just Another Brick in the Wall IPRO 306: 2012 Illinois Institute of Technology
AggreBindNot Just Another Brick in the Wall
IPRO 306:
www.facebook.com/IPRO306 © 2012 Illinois Institute of Technology
Mission Statement
“IPRO 306 will explore Aggrebind, a water based polymer, as a binder of local soils for the making of masonry units-- also referred to as
Aggrebind Masonry Units (AMUs) as an alternative to Concrete Masonry Units (CMUs).
We will experiment with a variety of soil and polymer mixes to create a series of a x b x c
AMUs with 28 day and 14 day cures times prior to being structurally tested in the IIT Materials Testing Lab. Our objective is to determine the market / commercial viability of Aggrebind as a
masonry making media."
Goals
• Create a cohesive work environment for teamwork, new ideas, and collaboration between students of different disciplines.
• Explore AggreBind through experimentation using a variety of soil and polymer mixes.
• Create a series of testable bricks
• Compare these results with current competitive products.
• Suggest applications of this material based on our results.
• Present findings in a clear and concise manner.
Instructor
Research
Background Research
Real World Feasibility
Fabrication
Brick Form Module
Wide Range of Brick Tests
Documentation
Document Process,
Develop Final Presentation
Team Structure
6/20 First brick making session
6/28 Midterm Presentation
7/3 Agree upon layout for IPRO day presentation
7/5 Begin creating educational materials for next IPRO
7/9 14 day brick making
7/12 Video shoot
7/16 7 day brick making, Draft of video
7/19 Grainger Presentation, Final video completed, Final boards in progress
7/24 IPRO day rehearsal, Final PowerPoint
7/26 Prep and rehearse for IPRO day
7/27 IPRO Day/ Presentation
Timeline
What is Portland Cement?
•1450oC + Limestone + Clay + Additives
•8% of world’s CO2 emissions
•Up to 40% world energy use
Rock
What is AggreBind?
•Based on Styrene + Acrylic
•Cross-linked organic polymer
•Low heat for production
Plastic
AggreBind in the US
Asia and Pacific Region
North Africa
South America
Middle East?Sub Saharan Africa
The “Competition”
Portland Cement Reality- Safety Issues
- Labor + transportation costs
- Environmental issues
- Fuel consumption
- Release CO2
AggreBind Brick Goals+ Economical*
+ Environmentally friendly
+ Local Materials
+ Waterproof
+ Versatile
*See upcoming slide for details
CONCRETE MASONRY UNIT (CMU)
$1.42Colored, water treated
CALSTAR BLOCK
$1.40
AGGREBIND BLOCK
$1.37 manufacturer's price of $3.50 per liter of AggreBind vs. current manufacturer's price of $5.00 per liter of AggreBind
Competitive Pricing
22 FT x 7.5 FT x 10 FT
Lumenhaus Project
Total Square Footage:165 sq.ft.
8” x 8” x 16” Block= ~490 blocks for facade
490 AMUs x $1.37 = $671.30490 CMUs x $1.42 = $671.30
490 Calstar Blocks x $1.37 = $671.30
Goals of Production
• AggreBind as an effective construction binder
• Develop an effective testing method
• Compare brick strength against competitors
Standards
The American Society of Testing and
Materials (ASTM)
• Methods for the testing of construction materials
• Widely accepted standards
Courtesy of calstarproducts.com
• Specification used: ASTM C 216
• Testing Method: ASTM C 67
Testing Information
Bricks not releasing from mold properly
• Removable side• Holes for gripping sleeve
Compression lines forming in the brick when finished
• Scoring between layers
Problems
Concrete: Cement + Water + Sand + Crushed Rock
AggreBind Brick: AggreBind + Water + ?
Major Materials
Tested
Sand
Limestone
Crushed Rock
Recycled Concrete
Materials Used
Material is mixed (AggreBind & Aggregate)
Mixture placed in mold
Mold is compressed multiple times
Masonry unit removed from mold
Masonry unit is documented
Masonry unit is left to cure/dry
After 28 days, unit is tested
Arbor Press
Bricks Ready for Storage
Creation Process
Bricks created for a 28 day – 14 day – 7 day test
Combinations include:
50% Limestone/50% Sand70% Limestone/30% Sand
50% Limestone/25% Sand/25% Crushed Rock33% Limestone/33% Sand/33% Crushed Rock
Testing
Final Results
More limestone + small rock = stronger bricks
Uneven top surface caused premature failure
Findings:
Final Results
28 day cure time is necessary
More research to develop techniques for a faster cure
Findings:
Final ResultsComparison of Strength
AggreBind Brick:
~ 600 psi
Class 1 Loadbearing Clay Brick:
1,000 psi minimum
Class A Engineered Clay Brick:
10,000 psi minimum
Concrete Facing Brick:
3,000 psi minimum
Completion of Goals• Create a cohesive work environment
• Effective sub-teams
• Explore AggreBind• Aggregates and combinations
• Create a series of testable bricks• ASTM Standards
• Compare these results• Calstar blocks and typical CMUs
• Suggest applications • Case Study/ Housing facades
• Present findings
Future IPROs
• Testing additional bricks • Materials• Amounts of Aggrebind• Finishing?
• Applications in other locations• Urban vs. Rural• Different local materials• Underwater
• Other construction mediums• Mortar• Finishing• Pavers