sub-systems design review p14416 concrete arborloo base october 29, 2013
TRANSCRIPT
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Sub-Systems Design ReviewP14416
Concrete Arborloo Base
October 29, 2013
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Team Intro
Member Role
Victoria Snell (ISE) Project Manager
Evan Burley (ME) Engineer
Joe Omilanowicz (ME) Engineer
Mac Keehfus (ME) Engineer
Anthony Deleo (ISE) Engineer
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Agenda• Background• Functional Decomposition/Architecture• Updated Customer Requirements• Subsystems
– Geometry– Composition
• Compression Test Results– Features
• Cost/Trade-off Analysis• Engineering Requirements• Project Management Updates
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• A latrine-like sanitation device designed to function over a small pit and to be moved to a new pit when filled
• Utilize compost by planting tree in used pit• Purpose to provide affordable sanitation in poor,
underdeveloped areas– Originally designed for use in Zimbabwe (Peter Morgan)
Arborloo
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Functional Decomposition
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Functional Architecture
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Meeting with Francius Estimable (Johnny)
• Weight
• Price: ~25 USD = 1100 HTG
• Type of Cement is still unknown
• Prefers a DIY kit to educate locals
• Design should be simple
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Updated Customer Requirements
2) Weight
• 25 dollars• Make it available to
all Haitians coming from different economic states
• Make it transportable through all environments
• Can be moved by 1-2 people comfortably
• Easy to make• Simple mold• Limited materials/
ingredients
1) Cost 2) Simpler the better
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Meeting with Manitou• Self consolidating Concrete
– Self Leveling – Higher Slump– No Vibration– Chemical Needed (Water Reducer)
• More Efficient Mix Ratio– More Aggregate – Less Cement
• Specific Gravities• Finishing Tools• Use of Fibers
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Geometry
• Shape• Thickness• Feasibility of
Molds
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Theoretical Analysis• Maximum allowable
flexural and compressive strength for each mold design:
• Assume square slab• To make up for the
lack of stress concentrations due to the hole: Factor of Safety of 3
Θ
b: width into the board σcomp=σflex=
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Theoretical Graph
0 50 1000
200
400
600
800
1000
1200
Theta (Degrees)
Str
engt
h (p
si)
Flexural Strength vs Theta
Shear Stress
0 50 1000
10
20
30
40
50
60
70
Theta (Degrees)
Str
ess
(psi
)
Compressive Stress vs Theta
Compressive Stress
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Feasibility of Molds
• Wood– Plastic sheets
(release agent)– Reusable– Not as precise
• Metal• Plastic• Plastic injection methods• Foam
– Expensive (concrete canoe~$800)
– Very accurate– Trying to figure out
the release agent
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Composition
• Aggregates• Bind properly• Provide strength• Reduce cost
• Cement Replacements
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Mixtures• 6 different mixtures (each contained cement, course aggregates,
fine aggregates, and water)• Cement (ternary mix)
– Portland, slag, fly ash (improves strength, workability, and requires less water)
• Aggregates (all mixtures contained sand)– Course
• Coconut shells• Rubber• Limestone
– Fine• Sand• Plastic Beads• Styrofoam
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Why?• Slag and fly ash improve strength
of concrete when combined with Portland
• Aggregates can be found in Haiti• Coconut shells
– considered trash/ in abundance
• Rubber– Need to figure out a way
to grind up tires
• Limestone/Sand– In abundance in Haiti
• Plastic Beads/Styrofoam– Could grind up plastic
water bottles
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Cylinder Testing Procedure
• Slump test: General idea on mold capability as well as the proper amount of water
• After 7 days/28 days of curing– ASTM C39: radius= 4” height= 8” Cylinder is loaded
axially. Determines maximum compressive strength (psi)
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Units (lbs) Mix 1 Mix 2 Mix 3 Mix 4 Mix 5 Mix 6 Mix 7 Mix 8 Mix 9
Cement 12.49 12.49 12.49 12.49 12.49 12.49 2.35 4.83 2.96
Slag 5.85 5.85 5.85 5.85 5.85 5.85 0.83 X 1.05
Flyash 4.82 4.82 4.82 4.82 4.82 4.82 0.65 X 0.82
Sand 1.50 1.50 1.50 1.50 1.50 1.50 6.95 8.87 8.87
Rubber 1.20 X X 1.20 X X 2.21 X X
Styrofoam 0.01 0.01 X X 0.01 X 0.04 X X
Plastic X X 0.68 0.68 X 0.68 X X X
Coconut X 1.20 1.20 X X X X 4.14 4.14
Limestone X X X X 1.77 1.77 X X X
Water 7.75 7.75 8.26 7.5 8 8.26 1.72 2.18 2.18
Glenium X X X X X X 10mL 8mL 8mL
Weight/cyl 6.45 6.77 6.70 6.73 6.88 7.08 4.53* 7.16* 7.32*
*weight measured before curing
Test Mixtures (lbs.)
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Cylinder Plan• 70% Strength at 7 days• 28 day Accepted
Standard• Fibers add mild
Compression Strength• Limestone/Rubber/
Coconut/Shells/Sand/Stryofoam/Plastic
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Results from 7 Day Cylinders
Trial 1 2 3 4 5 61 (7 days) 22.64 37.67 34.67 21.35 47.07 58.58
2 (28)3
Trial 1 2 3 4 5 61 (7 days) 1801.634 2997.683 2758.95 1698.98 3745.71 4661.65
2 (28) 0 0 0 0 0 03 0 0 0 0 0 0
Trial 1 2 3 4 5 61 (7 days) 270.24509 449.6525 413.843 254.847 561.857 699.247
2 (28) 0 0 0 0 0 03 0 0 0 0 0 0
Max Compressive Force For Mix (Kips)
Max Compressive Strength (psi)
Recorded
Mix Tensile Strength (psi, assume 15% compression)
Area of Test cylinder= 12.56637
A= π*r2 σ=F[lbf]/A[in2]
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Mix performance
104
106
108
110
112
114
116
118
120
122
124
Mixture lb/ft^3
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5 Mix 6
lb/ft
^3
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000Mixture Compressive Strength
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5 Mix 6
Com
pres
sive
Stre
ss (p
si)
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Improvements Moving Forward• Add more aggregates
– Used too much cement in first round of testing– Will reduce weight
• Make more viscous (less water)– Styrofoam floated to the top of cylinders– Use Glenium
• Use of finer aggregates– Sand is more dense than concrete– Higher strength with less voids
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Features• Modular upgrades for additional cost• Prepare basic design to allow for add-ins
• Handles• Textures• Shelter connection points
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Transportability
• Handles• Wheels• Rope Attachments
• Terrain is too rough for wheels• Anchor bolts require $ and drill
• Mold holes in sides for handles/hooks– Can this be done?
• Multi-functional attributes simplicity
$5.98
$2.80
$0.48
All require holes and
screws
$4.12
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Shelter Interface• Holes?
– Consistent with transportability features– Pole connection
• Grooves?– Sheet metal
connection• Small size?
• Also reduces material and weight
• Depends on ground hole
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Odor/Pest Reduction• Cheap, simple cover• What can be reused?• Simple hinge?
• Additional holes for toilet seat cover?
• Recommendation for household materials to use– Five gallon bucket
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How to make it visually appealing and simple at the same time:
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Material CostsMaterials Cost Weight (lb) Cost/lb
Rubber Mulch 10.98$ 19.8 0.55$ Coconut* -$ - -$ Limestone 10.00$ 2000 0.01$ Sand* -$ - -$ Styrofoam 14.99$ 2 7.50$ Plastic 7.99$ 2 4.00$ Cement* 6.28$ 94 0.07$ Slag 90.00$ 2000 0.05$ Fly Ash 70.00$ 2000 0.04$
*Reflects Cost in Haiti
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Fly Ash/Slag?• Need to evaluate cost/strength trade-off
– Fly ash and slag are not produced in Haiti– Shipping costs are unknown– Currently testing mixes with and without flyash and
slag
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Cost Breakdown
Weight Cost/lb Weight Cost Weight Cost Weight Cost Weight Cost1 Cylinder 4.2 0.28$ 1.6 0.06$ 2.0 0.09$ 0.2 0.11$ 0.2 -$ Arborloo 117.0 7.82$ 45.3 1.58$ 54.8 2.47$ 5.6 3.12$ 5.6 -$
Weight Cost Weight Cost Weight Cost Weight Cost1 Cylinder 0.6 0.00$ 0.5 -$ 0.003 0.02$ 0.2 0.92$ Arborloo 16.6 0.08$ 14.1 -$ 0.079 0.59$ 6.5 25.84$
Sand StyrofoamLimestone
Cement Fly Ash Slag Rubber Coconut Shells
Plastic Pellets
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Summary of Results
ScoreMixtures Coarse Ag Fine Ag Total Cost Weight Compressive Tensile* Total Cost Weight Strength TotalMix 1 Rubber Styrofoam 15.58$ 181.41 1801.63 360.33 4 6 2 12Mix 2 Coconut Styrofoam 12.46$ 190.41 2997.68 599.54 6 4 4 14Mix 3 Coconut Plastic 37.71$ 188.44 2758.95 551.79 3 5 3 11Mix 4 Rubber Plastic 40.83$ 189.28 1698.98 339.80 1 3 1 5Mix 5 Limestone Styrofoam 12.54$ 193.50 3745.71 749.14 5 2 5 12Mix 6 Limestone Plastic 37.80$ 199.13 4661.65 932.33 2 1 6 9
Cylinder Strength (psi) Ranking
* Assume 20% of compression strength
PM Arborloo
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Engineering Requirements– Purchase Cost
• Plastic expensive• Ranges from $12-$40• Target <$25
– Load it can support• Compression Results• Only 70% strength• Ranges from 1500 psi to 4600 psi• Target >2500 psi
– Ground Hole size Over design– Weight
• Average weight per/cylinder = 6.832 lbs.• Per/arborloo= 190.36 lbs.
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Project Schedule: Past/Current
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Project Schedule: Future
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Budget Tracker
Item Store Price94 lb Portland Cement Home Depot $10.47
40" PVC Fencing Home Depot $9.97
48"x.25" Round Steel Rod Home Depot $9.26
Bird Netting Home Depot $14.47
.8 cu ft Rubber Mulch Home Depot $5.97
Plastic Sheeting Home Depot $10.98
Hardware Cloth Home Depot $9.22
Chicken Wire Home Depot $7.97
Bean Bag Filler Bed Bath and Beyond $14.99Cement Mixer Lowes $8.54Platic Beads Jo-Ann Fabrics $14.992 gallon Bags Target $8.18
Styrofoam Michael's $8.994”x8” Test Cylinders Forney LP $57.06
Total: $191.06
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Updated Risk Assessment
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Moving Forward• Refining concrete mixtures
– Aggregates for low cost compressive strength• Flexural testing
– Mold for test block– Finalize reinforcements
• Cost estimates– Availability in Haiti– Shipping costs
• Finalizing features– Continue to assess feasibility
• Divide team between mold and mixtures