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