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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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„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

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https://www.linkedin.com/groups/8523567

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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


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



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.



How geopolymers are used in InnoWEE

ETICS-like panels Radiant elements

Ventilated façade panels Installation test

Optimization of geopolymer mixtures

Optimization of the binder


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?


Process at laboratory level


metakaolin ground blast

furnace slag

class F

fly ash

potassium

silicate

inorganic wastes

MIXER

before milling…


How to find out the best recipes?


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.


Main parameters that were investigated...


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…



metakaolin slag

Na/K

silicate

MIXER

Geopolymers with wood waste

waterwood waste

casting and

processing


Geopolymers with wood waste


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

http://www.materials.unsw.edu.au/tutorials/online-tutorials/2-wood-structure-2

Behaviour at high temperatures

Preliminary tests on geopolymers with inorganic CDW


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


Cycles between:+20°C and –23°C

time (min)

tem

pera

ture

(°C

)

RESULTS

Samples with inorganic CDW

Samples with wood


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


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


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


„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


Development of geopolymer adhesive

Vilma Ducman ZAG


https://www.innowee.eu/

mailto:[email protected]



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