Deliverable D3.2 Upscale of eco-friendly insulating façade ... · InnoWEE D3.2 “Upscale of eco-friendly insulating façade panels for demo-site applications” 28/02/2019 1 Document

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

InnoWEE D3.2 “Upscale of eco-friendly insulating façade panels for demo-site applications”

28/02/2019 1

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



4.3 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. 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. 60a - 5th Production module layout Fig. 60b - Utilities layout 110

Fig. 61 -5th production module visualisation (left – curing chamber, right – storage shelves) __________________________________________________ 111




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

https://en.wikipedia.org/wiki/Polypropylene

https://en.wikipedia.org/wiki/Expanded_polystyrene

https://en.wikipedia.org/wiki/Ultraviolet_C

https://en.wikipedia.org/wiki/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

Documents

Deliverable D3.2 Upscale of eco-friendly insulating façade ... · InnoWEE D3.2 “Upscale of eco-friendly insulating façade panels for demo-site applications” 28/02/2019 1 Document