This project has received funding from the European Union’s Horizon 2020 research and inno-
vation programme under grant agreement No 657982.
Deliverable D3.2
Upscale of eco-friendly insulating façade panels for demo-site applications
Grant Agreement number 723916
Project acronym
Project full title
InnoWEE
INNOvative pre-fabricated components including different Waste construction materials reducing building Energy and minimising Environmental impacts
Due date of deliverable 28/02/2019 (M29)
Lead beneficiary AMS
Other authors Maria Sachini (AMS)
Maria Pappa (AMS)
Dimitris Patros (AMS)
Sergio Tamburini (CNR)
Marco Natali (CNR)
Dissemination Level
PU Public
CO Confidential, only for members of the consortium (including the Commission Services) X
Cl Classified, as referred to in Commission Decision 2001/844/EC
Ref. Ares(2019)1371411 - 28/02/2019
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Document History
Version Date Authors Description
1 30/10/2018 AMS Creation of the document
2 10/12/2018 AMS Improved draft
3 07/01/2019 AMS Statistical data incorporation
4 22/01/2019 CNR HDG wood panels production for demo sites
5 25/01/2019 AMS Revised draft
6 30/01/2019 AMS Draft for reviewers
7 15/02/2019 CNR-ITC Reviewed draft
8 17/02/2019 RED Reviewed draft
9 25/02/2019 AMS Final version for the Coordinator
10 28/02/2019 CNR-ISAC coordinator Approval by the Coordinator and upload in ECAS
Disclaimer
This document is the property of the InnoWEE Consortium.
This document may not be copied, reproduced, or modified in the whole or in the part for any purpose without written permission from the InnoWEE Coordinator with acceptance of the Project Consortium.
This publication was completed with the support of the European Commission under the Hori-zon 2020 research and innovation programme. The contents of this publication do not neces-sarily reflect the Commission's own position. The document reflects only the author’s views and the Community is not liable for any use that may be made of the information contained therein.
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Contents
Contents ................................................................................................................................ 2
Publishable Summary ............................................................................................................ 6
List of Figures ......................................................................................................................... 7
List of Tables ........................................................................................................................ 12
Abbreviations ...................................................................................................................... 13
Introduction ......................................................................................................................... 15
1 6σ (Six Sigma) – Key to Success .................................................................................... 16
1.1 Define, Measure, Analyse, Improve, Control (DMAIC) ............................................... 16
1.2 “Double Diamond” or “4D Holistic” Tool .................................................................... 18
2 Preliminary Design ...................................................................................................... 22
2.1 Basic Flow Sheet structure ......................................................................................... 23
2.1.1 HDG formulation definition – material balances........................................................23
2.1.2 Key production processes relationships .....................................................................24
2.1.3 Phase 1 - Preparation of raw materials ......................................................................34
2.1.4 Phase 2 - Main HDG production process ....................................................................35
2.1.5 Phase 3 - Casting ........................................................................................................38
2.1.6 Phase 4 - Post-casting processes ................................................................................41
2.1.7 Phase 5 - Logistics .......................................................................................................42
2.2 Generic production’s conditions & utilities identification ......................................... 44
2.2.1 Storage – handling (Raw materials & finished products) ...........................................44
2.2.2 Pre-mixing / mixing .....................................................................................................48
2.2.3 Casting.........................................................................................................................53
2.2.4 Curing & post-curing ...................................................................................................56
2.3 Main Health & Safety issues identification ................................................................. 58
3 Technology Up-scaling Pilot Plant (TUPP) Introduction ................................................ 59
3.1 Location ...................................................................................................................... 59
3.2 TUPP’s layout .............................................................................................................. 60
3.3 TUPP’s history ............................................................................................................. 60
3.4 TUPP’s Utilities - infrastructure - equipment ............................................................. 62
3.5 Licences ....................................................................................................................... 64
3.6 Personnel – Safety ...................................................................................................... 65
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4 Detailed Design ........................................................................................................... 66
4.1 Detailed design principles ........................................................................................... 66
4.1.1 Aim ..............................................................................................................................66
4.1.2 Commercial materials data .........................................................................................66
4.1.2.1 EPS insulator’s properties ....................................................................................67
4.1.2.2 Polypropylene fibres properties ...........................................................................68
4.1.2.3 Adhesion of EPS sheets ........................................................................................69
4.1.2.4 Fiberglass mesh (net) ..........................................................................................70
4.1.2.5 Joints sealant .......................................................................................................70
4.1.2.6 Tiles adhesive .......................................................................................................71
4.1.2.7 Requested quantities for demo sites ...................................................................72
4.1.3. Up-scaling conditions – limitations on “batch” mode ................................................73
4.1.4. Production’s line conditions – limitations ..................................................................83
4.1.4.1 HDG formulation main conditions - limitations ...................................................83
4.1.4.2 TUPP layout limitations .......................................................................................85
4.2 Production line design ................................................................................................ 86
4.2.1. 1st production module ................................................................................................90
4.2.2 2nd production module ...............................................................................................98
4.2.3 3rd production module ............................................................................................. 101
4.2.4 4th production module ............................................................................................. 106
4.2.5 5th production module ............................................................................................. 109
4.2.6 6th production module ............................................................................................. 112
4.3 Detailed design modelling ........................................................................................ 114
4.3.1 Potassium silicate (Ksil) feed from storage tanks to main mixer ............................ 116
4.3.1.1 Ksil tank No 1 to main mixer (ALL other systems to CLOSED state) .................. 116
4.3.1.2 Ksil tank No 2 to main mixer (No 1 Tank to OPEN State) ................................... 117
4.3.1.3 Ksil tanks No 3 & 4 to main mixer (Auxiliary system) ........................................ 119
4.3.2 HDG paste from main mixer to filling station .......................................................... 120
4.3.2.1 HDG paste from main mixer to filling station (CLOSED state @ 1.00 bar) ....... 120
4.3.2.2 HDG paste from main mixer to filling station (CLOSED state @ 4.00 bars) ..... 122
4.3.2.3 HDG paste from main mixer to filling station (CLOSED state @ 1.25 bars – modified atmosphere – NO flow regulators) .................................................... 124
4.3.2.4 HDG paste from main mixer to filling station (OPEN state @ 1.25 bars – MODIFICATIONS AFTER TRIAL & ERROR PERIOD) ............................................ 126
4.3.3 Water supply system ............................................................................................... 129
4.3.3.1 Cold water supply system ................................................................................. 129
4.3.3.2 Hot water supply system .................................................................................. 130
4.3.4 Compressed air system ............................................................................................ 131
4.3.5 Nitrogen supply system ........................................................................................... 132
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4.3.6 Vacuum supply system ............................................................................................ 135
4.3.7 Fire protection system ............................................................................................. 135
4.3.8 Deionised water supply system ............................................................................... 135
4.3.9 Ventilation system ................................................................................................... 135
5 Moulds Design & Evaluation ...................................................................................... 136
5.1 3D printed moulds .................................................................................................... 136
5.1.1 3D printing materials selection ................................................................................ 136
5.1.2 3D printed moulds design ........................................................................................ 139
5.1.3 3D printed moulds modelling .................................................................................. 142
5.1.4 3D printed moulds development ............................................................................. 148
5.1.5 3D printed moulds performance evaluation ........................................................... 151
5.2 ETICS moulds ............................................................................................................. 154
5.3 Ventilated façade moulds ......................................................................................... 157
6 HDG ETICS panels production in TUPP ....................................................................... 159
6.1 HDG ETICS Production plan ...................................................................................... 159
6.1.1 Production timescale ............................................................................................... 159
6.1.2 Production back-up plan .......................................................................................... 161
6.1.3 “Normal production” mode specific conditions ...................................................... 166
6.2 HDG ETICS panels production processes’ analysis ................................................... 168
6.2.1 Preparation of materials .......................................................................................... 168
6.2.2 Premixing ................................................................................................................. 171
6.2.3 Mixing ...................................................................................................................... 175
6.2.4 Casting...................................................................................................................... 177
6.2.5 Curing ....................................................................................................................... 180
6.2.6 Post – curing ............................................................................................................ 181
6.2.7 Panels assembly ....................................................................................................... 183
6.2.8 Painting .................................................................................................................... 185
6.2.9 Cleaning ................................................................................................................... 187
6.3 HDG ETICS panels production statistical data .......................................................... 189
6.3.1 Production schedule - Deliveries on Demo sites ..................................................... 189
6.3.2 Production statistics as per 6σ methodology .......................................................... 190
6.3.2.1 Mechanical or equipment failures .................................................................... 190
6.3.2.2 Defective products ............................................................................................ 191
6.3.2.3 6σ performance - ranking ................................................................................. 194
6.3.2.4 Testing .............................................................................................................. 195
6.3.2.5 Health & Safety issues ...................................................................................... 195
6.3.2.6 Personnel .......................................................................................................... 195
6.3.3 Cost per panel in “Normal Production” mode ......................................................... 196
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7 HDG ventilated façade panels production in TUPP ..................................................... 198
7.1 Production plan ........................................................................................................ 198
7.1.1 Production back-up plan .......................................................................................... 199
7.1.2 “Normal production” mode specific conditions ...................................................... 200
7.2 HDG ventilated façade panels production process’s analysis .................................. 201
7.2.1 Production of Wood-Geopolymers Panels (WGP)................................................... 201
7.2.1.1 Production of the recycled wood aggregate by ECO ........................................ 201
7.2.1.2 Characteristics of the Wood-geopolymer binder .............................................. 202
7.2.1.3 Characteristics of the Wood-geopolymer binder .............................................. 203
7.2.2 Steel cord for ventilated panels ............................................................................... 206
7.2.3 Preparation of materials .......................................................................................... 207
7.2.4 Premixing ................................................................................................................. 208
7.2.5 Mixing ...................................................................................................................... 209
7.2.6 Casting...................................................................................................................... 209
7.2.7 Curing ....................................................................................................................... 211
7.2.8 Post – curing ............................................................................................................ 211
7.2.9 Panel’s assembly ...................................................................................................... 212
7.2.10 Painting .................................................................................................................... 213
7.2.1 Cleaning ................................................................................................................... 214
7.3 Ventilated façade panels production statistical data ............................................... 214
7.3.1 Production schedule - Deliveries on Demo sites ..................................................... 214
7.3.2 Production statistics as per 6σ methodology .......................................................... 215
7.3.2.1 Mechanical or equipment failures .................................................................... 215
7.3.2.2 Defective products ............................................................................................ 216
7.3.2.3 6σ performance - ranking ................................................................................. 217
7.3.2.4 Testing .............................................................................................................. 218
7.3.2.5 Health & Safety issues ...................................................................................... 218
7.3.2.6 Personnel .......................................................................................................... 218
7.3.3 Cost per panel in “Normal Production” mode ......................................................... 218
Conclusions ........................................................................................................................ 219
References ......................................................................................................................... 224
APPENDIX .......................................................................................................................... 227
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Publishable Summary
Deliverable D.3.2 “Upscale of eco-friendly insulating façade panels for demo-site applications” presents the overall process upscaling both HDG ETICS and ventilated façade panels required for the installation at all demo sites.
For every technology, scaling up from laboratory processes to a pilot plant case is an operation with an increased degree of difficulty and risk. Sometimes this process might encrypt technical and engineering challenges that are not easy to foresee.
Therefore, a step by step up-scaling methodology was developed based on industrial tech-niques and tools, with constant feedback loops of actions and corrective actions during design, testing, and finally at the production.
Processes identification was defined from the lab tests results and prototypes and with the aid of 6σ methodology. These data were analyzed and converted on a detailed design with the help of modelling simulations for the critical tasks and finally were incorporated in a “modular” production line in the Technology Upscaling Pilot Plant (TUPP) in Greece.
Statistical data from the production efficiency, the defective products and their causes, were analyzed in every production step and corrective actions were adopted and implemented in order to improve the performance of the overall production line and the product’s quality.
Moreover, benchmarks and production validation tests were executed during the production duration, aiming not only to verify the integrity of the HDG paste to the original formulation but also to identify any hidden issues related to the quality of the produced panels.
Finally, over 2.700 kg of HDG paste was produced, and transformed to ETICS, ventilated façade panels and radiant panels, respecting the shipment dates for the demo sites in very a tight time schedule.
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List of Figures
Fig. 1 - DMAIC methodology _______________________________________________ 16
Fig. 2 - “Double Diamond Tool” ____________________________________________ 19
Fig. 3 - Preliminary Design Structure ________________________________________ 22
Fig. 4 - Production Phases _________________________________________________ 25
Fig. 5 – Basic Flow Sheet __________________________________________________ 29
Fig. 6 - “Continuous” v “Batch” mode comparison _____________________________ 31
Fig. 7 - Process time relationships* _________________________________________ 31
Fig. 8 - Key production processes relationships ________________________________ 33
Fig. 9 - Phase 1 - Schematic flow sheet diagram _______________________________ 34
Fig. 10 - Phase 2 - Schematic flow sheet diagram ______________________________ 37
Fig. 11 - Phase 3 - Schematic flow sheet diagram ______________________________ 40
Fig. 12 - Phase 4 - Schematic flow sheet diagram ______________________________ 42
Fig. 13 - Phase 5 - Schematic flow sheet diagram ______________________________ 43
Fig. 14 - TUPP location ___________________________________________________ 59
Fig. 15 - Acharnes VI.PA. __________________________________________________ 59
Fig. 16 - TUPP exterior view _______________________________________________ 60
Fig. 17 - Process flow chart for multifunctional coatings production _______________ 61
Fig. 18 - Process flow chart for plasters production _____________________________ 61
Fig. 19 - ETICS panel dimensions ___________________________________________ 66
Fig. 20 - EPS insulator Durosol External ______________________________________ 67
Fig. 21 - Durosol External properties ________________________________________ 67
Fig. 22 - Masterfiber 012 _________________________________________________ 68
Fig. 23 - INSTA-STIK MP___________________________________________________ 69
Fig. 24 - THERMONET fiberglass net _________________________________________ 70
Fig. 25 - ISOMAT MULTIFIL ________________________________________________ 70
Fig. 26 - ISOMAT MULTIFLEX ______________________________________________ 71
Fig. 27 - “Net productive time”, “casting” duration in minutes / panel & panel’s production comparison _______________________________________ 76
Fig. 28 - Production’s critical tasks __________________________________________ 77
Fig. 29 - Working stations diagram __________________________________________ 78
Fig. 30 - Working stations diagram and critical tasks on improved “casting” duration __ 80
Fig. 31 - TUPP’s Production area floor plan ___________________________________ 85
Fig. 32 - “Tower” or “Gravitational” plant setup _______________________________ 87
Fig. 33 - LEEMA Project production line ______________________________________ 87
Fig. 34 - “Modular” production line concept __________________________________ 88
Fig. 35 - Production modules layout in TUPP __________________________________ 89
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Fig. 36 - 1st production module location in TUPP _______________________________ 91
Fig. 37a - 1st production module layout Fig. 37b – Utilities layout _________ 91
Fig. 38 - 1st production module visualisation __________________________________ 92
Fig. 39 - Design data for pipe auger type 152 (provided by BMsilobabrik - DK) _______ 93
Fig. 40 - Conversion of the existing trough auger to premixing buffer ______________ 95
Fig. 41 - Weighting platform dimensions & load cells diagram ____________________ 96
Fig. 42 - Representation of flexible auger type 90 in TUPP _______________________ 97
Fig. 43a-j - Construction details of the 1st production module ____________________ 98
Fig. 44 - 2nd production module location in TUPP ______________________________ 99
Fig. 45a - 2nd production module layout Fig. 45b - Utilities layout 99
Fig. 46 - 2nd Production module visualisation _________________________________ 100
Fig. 47a-f - Construction details of the 2nd production module ___________________ 101
Fig. 48 - 3nd production module location in TUPP _____________________________ 102
Fig.49a - 3rd production module layout Fig. 49b - Utilities layout 102
Fig. 50 - 3rd Production module visualisation _________________________________ 103
Fig. 51 - Main mixer 3d view ______________________________________________ 103
Fig. 52 - Main mixer drawings _____________________________________________ 104
Fig. 53 - Main mixer updated top cover drawing ______________________________ 105
Fig. 54a-f - 3rd Production module visualisation _______________________________ 106
Fig. 55 - 4th Production module location in TUPP ______________________________ 107
Fig. 56a - 3rd Production module layout Fig. 56b - Utilities layout _____________________________________ 107
Fig. 57 - 4th Production module visualisation _________________________________ 107
Fig. 58a-f - 4th Production module visualisation _______________________________ 109
Fig. 59 - 5th Production module location in TUPP ______________________________ 110
Fig. 60a - 5th Production module layout Fig. 60b - Utilities layout 110
Fig. 61 -5th production module visualisation (left – curing chamber, right – storage shelves) __________________________________________________ 111
Fig. 62a-f - 5th Production module visualisation _______________________________ 112
Fig. 63 - 6th Production module location in TUPP ______________________________ 113
Fig. 64a-f - 6th Production module visualisation _______________________________ 114
Fig. 65 - HDG modular production _________________________________________ 115
Fig. 66 - Tank No 1 to main mixer modelling (Ksil) _____________________________ 116
Fig. 67 - Pump performance on Tank No 1 to main mixer modelling _______________ 117
Fig. 68 - Tank No 2 to main mixer modelling (Ksil) _____________________________ 118
Fig. 69 - Pump performance on Tank No 2 to main mixer modelling _______________ 118
Fig. 70 - Auxiliary system (T3 & T4) performance _____________________________ 120
Fig. 71 - HDG paste from main mixer to filing station performance @ 1.00 bar ______ 121
Fig. 72 - Pump performance from main mixer to filling station @ 1.00 bar _________ 121
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Fig. 73 - HDG paste from main mixer to filing station performance @ 4.00 bars _____ 123
Fig. 74 - Pump performance from main mixer to filling station @ 4.00 bars _________ 123
Fig. 75 - HDG paste from main mixer to filing station performance @ 1.25 bar (NO flow regulators) ________________________________________________ 125
Fig. 76 - Pump performance from main mixer to filling station @ 1.25 bar _________ 125
Fig. 77 - Production line simulation ________________________________________ 127
Fig. 78 - Production line pumps performance ________________________________ 128
Fig. 79 - Cold water supply simulation ______________________________________ 129
Fig. 80 - Hot water supply simulation _______________________________________ 130
Fig. 81 - Compressed air supply simulation __________________________________ 132
Fig. 82 - Nitrogen supply simulation @ 10.00 bars_____________________________ 133
Fig. 83 - Nitrogen supply simulation @ 1.25 bar ______________________________ 134
Fig. 84 - ABS filament ___________________________________________________ 137
Fig. 85 - PLA filament ___________________________________________________ 138
Fig. 86 - ASA filament ___________________________________________________ 139
Fig. 87 - 45o angle joint __________________________________________________ 140
Fig. 88 - Triangular @ 120o angle joint ______________________________________ 140
Fig. 89 - Square @ 90o angle joint _________________________________________ 141
Fig. 90 - Vertical sections, top & bottom covers ______________________________ 141
Fig. 91 - Vertical sections interconnections __________________________________ 141
Fig. 92 - Mould dimensions _______________________________________________ 142
Fig. 93 - Mould’s 3d view ________________________________________________ 142
Fig. 94 - Mesh facet view ________________________________________________ 143
Fig. 95 - Green pointers indicate pressure ___________________________________ 143
Fig. 96 - Displacement modelling __________________________________________ 144
Fig. 97 - Strain modelling ________________________________________________ 146
Fig. 98 - Safety factor modelling ___________________________________________ 147
Fig. 99 - 3d simulation by Simplify3D software _______________________________ 148
Fig. 100 - Moulds 3D printing (left – PLA print, middle – ABS print, right – ASA print) _ 150
Fig. 101 - 3D printed moulds (Blue – ABS print, yellow – PLA, Brown – ASA) ________ 150
Fig. 102 - Casting and oven curing of HDG paste on 3D printed moulds ____________ 150
Fig. 103 - Moulds deformation after oven curing of 12 hours at 50oC _____________ 151
Fig. 104 - PLA mould after attempting to remove top cover _____________________ 151
Fig. 105 - Samples taken out of moulds (a: ABS, b: PLA, c: ASA) __________________ 152
Fig. 106 - ABS & PLA mould’s bottom cover __________________________________ 152
Fig. 107 - ASA mould after its use __________________________________________ 152
Fig. 108a & b - EPS shrinkage on mould’s edges ______________________________ 153
Fig. 109 - EPS height reduction ____________________________________________ 153
Fig. 110 - ETICS mould dimensions _________________________________________ 156
Fig. 111 - ETICS mould visualisation ________________________________________ 156
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Fig. 112 - Ventilated façade mould dimensions _______________________________ 157
Fig. 113 - 3D visualization of ventilated façade panels _________________________ 158
Fig. 114 - Visualization of ventilated façade panels ____________________________ 158
Fig. 115 - Production timescale ___________________________________________ 160
Fig. 116 - DUROSOL panels edges __________________________________________ 169
Fig. 117 - DUROSOL cut on shape __________________________________________ 169
Fig. 118 - Grooves on DUROSOL sheet ______________________________________ 169
Fig. 119 - Preparation of KOH solution ______________________________________ 170
Fig. 120 - K-sil feeding to the main mixer ____________________________________ 171
Fig. 121 - PP fibres to K-sil at the main mixer _________________________________ 171
Fig. 122 - Premixing of solid raw materials to the premixing buffer _______________ 173
Fig. 123 - Transferring solid raw materials to main mixer _______________________ 174
Fig. 124 - Main mixing sub-process ________________________________________ 176
Fig. 125 - Mould’s filling _________________________________________________ 178
Fig. 126 - Mould’s assembly ______________________________________________ 179
Fig. 127 - Mould’s curing ________________________________________________ 181
Fig. 128 - Demoulding ___________________________________________________ 182
Fig. 129 - Post curing ____________________________________________________ 182
Fig. 130 - Post curing storage _____________________________________________ 183
Fig. 131 - Commercial panel assembly ______________________________________ 184
Fig. 132 - Two layers coating application on HDG panels _______________________ 186
Fig. 133 - Production schedule ____________________________________________ 189
Fig. 134 - Mechanical or equipment failures distribution _______________________ 190
Fig. 135 - Production line failures time line & distribution ______________________ 191
Fig. 136 - Defective panels distribution timeline ______________________________ 192
Fig. 137 - % of failures by cause ___________________________________________ 193
Fig. 138 – Visualisation of defects _________________________________________ 193
Fig. 139 - TUPP’s Performance ranking in 6σ methodology ______________________ 194
Fig. 140 - TUPP’s performance improvement timescale ________________________ 194
Fig. 141 - TUPP’s operational diagram ______________________________________ 196
Fig. 142 - HDG ventilated façade panel’s production timeline ___________________ 198
Fig. 143 - Treatment of wood construction wastes ____________________________ 201
Fig. 144 - Outcomes of particle size analysis of typical wood waste aggregates ______ 202
Fig. 145 - Weighting of: (a) wood aggregates; (b) extra water; (c) Na-silicate; and (d) metakaolin and slag (together) ________________________________ 203
Fig. 146 - Mixing reagents: (a) wood aggregates; (b) extra water; (c) Na-silicate; (d) soaked wood chips; (e) addition of metakaolin and slag; (f) loose dry particles obtained as final result _______________________________ 204
Fig. 147 - Moulding panels _______________________________________________ 205
Fig. 148 - Demoulding and finishing panels __________________________________ 206
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Fig. 149 – Steel cord for ventilated façade panels _____________________________ 206
Fig. 150 - Scheme of steel cord reinforcement grid and relation with holes drilled in the anchoring lips ___________________________________________ 207
Fig. 151 - Assembly of steel cord reinforcement for ventilated façade panels _______ 207
Fig. 152 - Wood panels preparation ________________________________________ 208
Fig. 153 - Mould’s assembly ______________________________________________ 210
Fig. 154 - Demoulding ___________________________________________________ 211
Fig. 155 - Ventilated façade panel’s assembly ________________________________ 212
Fig. 156 - Ventilated façade panel painting __________________________________ 213
Fig. 157 - Mechanical failures distribution ___________________________________ 215
Fig. 158 - Mechanical failures timeline ______________________________________ 216
Fig. 159 - Defective panels distribution timeline ______________________________ 217
NOTE: Some of the figures might appear blurry or partially difficult to be read in normal pc or printing resolution. This is because either their original dimensions are too big e.g. drawings and plans, or are screenshots from other software which do not have “export to” function e.g. Pipeflow, or are scanned from of low quality hard copies e.g. MSDS’s provided by products’ manufacturers.
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List of Tables
Table 1 - HDG panels quantities per demo site _________________________________ 21
Table 2 - Recipes for obtaining 1 kg of fresh HDG with 50% of inorganic waste _______ 24
Table 3 - Storage requirements for solids raw materials _________________________ 45
Table 4 - Storage requirements for liquid raw materials _________________________ 45
Table 5 - Stock refilling system for both solid and liquid raw materials ______________ 46
Table 6 - Storage of insulators requirements __________________________________ 47
Table 7- Storage of finished product requirements _____________________________ 48
Table 8 - Buffer mixer for solid raw materials premixing requirements ______________ 49
Table 9 - Main mixer requirements __________________________________________ 50
Table 10 - Feeding system to main mixer requirements __________________________ 51
Table 11 - Feeding system of liquids to main mixer requirements __________________ 52
Table 12 - Controlling systems requirements __________________________________ 52
Table 13 - Transferring system of the HDG paste requirements ___________________ 54
Table 14 - Filling station requirements _______________________________________ 55
Table 15 - Moulding requirements __________________________________________ 56
Table 16 - Curing chamber requirements _____________________________________ 57
Table 17 - Painting area requirements _______________________________________ 58
Table 18 - BASF Masterfiber 012 properties ___________________________________ 68
Table 19 - INSTA-STIK MP properties ________________________________________ 69
Table 20 - THERMONET fiberglass net properties ______________________________ 70
Table 21 - ISOMAT MULTIFIL properties ______________________________________ 71
Table 22 - ISOMAT MULTIFLEX properties ____________________________________ 72
Table 23 - ETICS panels quantities ___________________________________________ 72
Table 24 - Ventilated façade panels quantities _________________________________ 73
Table 25 - Pipe auger type 152 performance (provided by BMsilobabrik - DK) ________ 94
Table 26 - Flexible auger type 90 performance (provided by BMsilobabrik - DK) ______ 96
Table 27 - Main properties of ABS filament __________________________________ 137
Table 28 - Main properties of PLA filament __________________________________ 138
Table 29 - Main properties of ASA filament __________________________________ 139
Table 30 - Displacement modelling results ___________________________________ 145
Table 31 - Strain modelling results _________________________________________ 146
Table 32 - RIGA-FORM properties __________________________________________ 155
Table 33 - AMS coating properties developed in CommONEnery Project compared to other commercial coatings _______________________________________________ 185
Table 34 - Example recipes of 1 kgr of fresh wood geopolymer ___________________ 202
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Abbreviations
InnoWEE INNOvative pre-fabricated components including different Waste con-struction materials reducing building Energy and minimising Environmen-tal impacts
CNR Consiglio Nazionale delle Ricerche ZAG ZAvod za Gradbeništvo Slovenije LEEMA Low Embodied Energy Insulation MAterials and Masonry Components for
Energy Efficient Buildings CommONEnergy Re-Conceptualize shopping malls from cONsumerism to Energy conserva-
tion AMS Advanced Management Solutions Ltd ECO ECO G. S.R.L ETICS External Thermal Insulation Composite Systems HDG High Density Geopolymers CDW Construction Demolition Wastes 6σ Six Sigma methodology DMAIC Define, Measure, Analyse, Improve, Control (part of 6σ methodology) DMADV Define, Measure, Analyze, Design, Verify (part of 6σ methodology) TUPP Technology Upscaling Pilot Plant PERT Program Evaluation and Review Technique mh manhours MK MetaKaolin SL Furnace SLag K-SIL Potassium Silicate SiO2 Silicon Dioxide
K2O Potassium Oxide FA Fly Ash KOH Potassium Hydroxide PP PolyPropylene MR Molecular Ratio HDPE High-Density PolyEthylene EPS Expanded PolyStyrene QAP Quality Assurance Plan PPE Personal Protective Equipment HEPA High-efficiency Particulate Air TUPP Technology Upscaling Pilot Plant SME Small and Medium-sized Enterprises UV-C UltraViolet C NIR Near Infra Red PLC Programmable Logic Controller W Width L Length H Height CO2 Carbon Dioxide CO Carbon Monoxide LEL Lower Explosive Limit
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O Oxygen N Nitrogen V Volt UPS Uninterruptible Power Supply CNC Computerized Numerical Control UV UltraViolet AC Alternating Current (electricity) DC Direct Current (electricity) UV / VIS UltraViolet / VISible light ΠΠΔ Prototype Environmental Obligations (translated from Greek language) XPS EXtruded PolyStyrene PVC PolyVinyl Chloride NPSH Net Positive Suction Head FDM Fused Deposition Modelling DLP Digital Light Processing ABS Acrylontrile Butadiene Styrene PLA PolyLactide Acid ASA Acrylonitrile Styrene Acrylate FEA Finite Element Analysis IR InfraRed (lamp) LCD Liquid-Crystal Display MPa MegaPascal N.P.T. Net Production Time VOC Volatile Organic Compounds rpm revolutions per minute m2 Square metre nO Number gr - grams grams kg Kilogramme M Molarity l Litres kW kiloWatt m meter °C Celsius m3 Cubic metre mm millimetres cm3 cubic centimetre kN/m2 kiloNewton per square meter N/mm2 Newton per square millimetre
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