AggreBindNot Just Another Brick in the Wall

IPRO 306:

www.facebook.com/IPRO306 © 2012 Illinois Institute of Technology

From Roads to Bricks…

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

Research Team

Fabrication Team

Documentation Team

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

Beauty Durability

Versatility

Sun baked Sun Baking

Fire Kiln

Concrete Bricks

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

From Roads to Bricks…

Durable, Economical, & Environmentally Friendly

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

Compressive Strength

• Very common test

• Good indication material strength

Testing Information

Courtesy of calstarproducts.com

• Specification used: ASTM C 216

• Testing Method: ASTM C 67

Testing Information

Brick Form

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

Extra AMUs Created for

Testing

Linear Scale for Manual Testing

Future IPROs

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

Questions?