LEEMA Low Embodied Energy Insulation Materials and Masonry Components for Energy Efficient Buildings Fibre Boards and Foamed Blocks

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1 LEEMA Low Embodied Energy Insulation Materials and Masonry Components for Energy Efficient Buildings Fibre Boards and Foamed Blocks Dr. A. Gaki National Technical University of Athens This project has received funding from the European Union s Seventh Framework Programme for research, technological development and demonstration under grant agreement no

2 The LEEMA Products 3I FC Boards 2

3 3I FC Boards Objectives The simple approach A. Fibre cement (FC) boards, where the standard lightweight filler is substituted by 3I LFM Adaptation of existing products by substitution of expanded perlite / exfoliated vermiculite by 3I Loose filling material Hatschek Production process Development of a totally new, cement free fibre board B. Fibre boards, where a 3I based (geopolymeric) binder is used combined with 3I LFM Need for new production process development 3

4 3I FC Boards Hatschek Technology A. FC boards with 3I LFM as filler ETEX produces all FC boards by means of the so called Hatschek technology The FC mixture is prepared as a very thin, watery slurry which is (partially) dewatered in the Hatschek machine, by forming thin primary FC layers, which are accumulated one on top of the other to compose the FC product with the required thickness 4

5 3I FC Boards Current Products A. FC boards with 3I LFM as filler CaSi Boards Promatect H with expanded perlite Supalux with exfoliated vermiculite Eterspan with expanded perlite 5

6 3I Fibre Boards A. 3I Fibre Cement boards with 3I Loose Fill Materials replacing expanded perlite Successful large Pilot scale production No significant changes in production process λ 10 0,111 0,133 W/mK increased flexural strength 10 13MPa Colour change (beige marbling, dark spots) B. 3I Fibre Boards with 3I Binder and 3I Loose Filling materials 3I Binders extrusion as shaping method at Pilot scale production λ 10 0,131 0,193 W/mK flexural strength 4 7 Mpa Promising results Need for further development 6

7 The LEEMA Products 3I Foamed Blocks 7

8 3I Foamed Blocks Current Products AAC Blocks Panels Building materials with electrical installation Foamed Concrete Pre cast for walls, floor screeds or roof panels Voidfiller for old buildings restoration. In situ as insulating sub layer for floors/roofs Low density and thermal conductivity Low sound transmission Longer fire rating (fire class A1) Capability to install electrical and plumbing rough in Increased plant precautions due to explosive hydrogen gas Difficulties in production control High temperature & pressure conditions Low capital expenditure on equipment Self compacting, free flowing and pumpable Good thermal and acoustic properties Rapid and simple construction Sensitivity to water content Longer mixing time Weak for direct exposure to traffic and hail (should be protected by a wearing layer) 8

9 Geopolymeric foamed blocks from waste perlite, produced via a low energy foaming process European market: 15 million m 3 of AAC per year 3I Foamed Blocks Market data European perlite production: tons/year 15% WASTES Foamed Blocks 9

10 Production process of Foamed Inorganic polymers 3I Foamed Blocks Production Process Mixing Foaming Shaping Curing Foamed Materials Raw material Perlite wastes (fines) from mineral processing 2 types of activation: Alkaline activation Only sodium hydroxide Alkaline silicate activation Sodium hydroxide AND source of easily dissolved silicon 10

11 Production process of Foamed Inorganic polymers 3I Foamed Blocks Production Process Mixing Foaming Shaping Curing Foamed Materials 2 types of foaming agents Inorganic Organic By controlled and guided foaming it is possible to produce Inorganic Foamed Elements with tailored properties! H 2 O 2 content 11

12 3I Foamed Blocks Production Properties Production process of Foamed Inorganic polymers Viscous foamed pastes easily mixed Shaping using moulding or extrusion Atmospheric conditions, Low temperature (50 70 o C) Easy cutting after 24h Shaping Curing Foamed Materials Material Type Compr. Strength (MPa) λ (W/mK) Density (Kg/m 3 ) Inorganic foaming agent Organic foaming agent Aerated Concrete AAC

13 Production process of Foamed Inorganic polymers 3I Foamed Blocks Production Process Mixing Foaming Shaping Curing Foamed Materials 13

14 Thank you for your attention! Further information Follow us on: LEEMA Project FP7 For more information visit the project s website LEEMA Project FP7 LEEMA Project FP7 LEEMA Project FP7 This project has received funding from the European Union s Seventh Framework Programme for research, technological development and demonstration under grant agreement no