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IPRO 306: AggreBind BLOCKs

IPRO 306: AggreBind BLOCKs . FALL 2012. Background. AggreBind is a water based geo-polymer and soil stabilizer: Environmentally safe Capable of binding virtually any soil without baking or cement Mixed with soil as liquid and cures to a permanent solid via self cross-linking

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IPRO 306: AggreBind BLOCKs

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  1. IPRO 306: AggreBind BLOCKs FALL 2012

  2. Background AggreBind is a water based geo-polymer and soil stabilizer: • Environmentally safe • Capable of binding virtually any soil without baking or cement • Mixed with soil as liquid and cures to a permanent solid via self cross-linking • Originally developed for road construction using minimal equipment FALL 2012

  3. Summer IPRO • Began experimenting with AggreBind as a binder for blocks for use in developed countries as a greener alternative to bricks or CMUs (aka “cinder blocks”) • Tested various mixtures of sands and other soils in manual brick making process • Goal of 2000 psi compressive strength, reached 537.6 psi

  4. Mission Statement • Establish the maximum compressive strength of AggreBindblock • Explore new production and fabrication processes • Optimizethe cure time of these blocks • Consideralternative non-structural applications of the product FALL 2012

  5. Team Organization FALL 2012

  6. Establish

  7. Establishing Maximum Strength Used the following testing guidelines: • ASTM standard brick size for compression testing • ½ length Utility brick: 3-5/8” x 3-5/8” x 5-13/16” • Intermediate testing using shop press • Final testing in the lab • Goal of 2000 psi

  8. Alternative Comparison FALL 2012

  9. Explore

  10. EXPLOre • Wood vs. Steel Mold • Compaction: hand vs. measured mechanical • New mixture scheme, no longer mixed by hand • Larger pool of brick samples and multiple rounds of bricks

  11. Mix Variation FALL 2012

  12. Fabrication process 1. Pour AGB into soil mixture

  13. Fabrication Process 2. Mix thoroughly

  14. Fabrication process 3. Pour mixture into metal mold

  15. Fabrication process 4. Compact mixture

  16. Fabrication process 5. Remove brick from metal mold

  17. Fabrication process 6. Cure brick for testing

  18. Fabrication Process 6. 1. 5.. 2. 4.. 3. FALL 2012

  19. Elston Block Manufacturing • Our process based on commercial block manufacturing machinery • Elston block tour • Metal mold filled with mixture, compacted, mold slides off upwards and blocks set aside to cure

  20. Round 1 • Test a variety of bricks to determine the effects of: • AggreBind to water ratio • Compaction pressure • Curing time (14 days vs. recommended 28 days) • Soil mixture (more sand vs. more limestone)

  21. ROUND 1 Testing data • Compression to failure test • Basic test using shop press • Cheap and effective initial testing FALL 2012

  22. ROUND 1 Results

  23. RounD 1 Results

  24. Round 2 Built on results of Round 1: • Min. two of each brick mixture • 1000 psi compaction pressure • 1:2 ratio of AGB to water Conducted official strength testing • Computer-controlled • Greater need for flat specimens

  25. Round 2 Results • Strongest Mixture:50% limestone 25% sand 25% light aggregate • Maximum strength of 943.2 psi • Average strength of 820.5 psi

  26. Optimize

  27. Improving Cure Time A variety of methods: Proven by Rounds 1 and 2 • 14 Days • Limestone vs. sand Tested for Round 3 • Oven Curing • Catalyst • Iron Powder (for strength)

  28. Round 3 Results: • Optimum oven cure 4 hrs • 12-day maximum strength: 1157 psi • Iron powder ineffective Test conditions: • All bricks wrapped in foil • All 50% limestone mixture • Oven temp. at 200 F • Durations of 0,2,4,8 hours • Two bricks w/iron powder

  29. Overall Results

  30. Consider

  31. Consider • Recycled Materials • Styrofoam • Rubber • Plastic

  32. Potential Applications Low grade brick applications (1000-1500 psi) -Decorative interior facing brick -Walkway paver -Facing brick outdoors in warmer and drier regions

  33. Competitive block price *No current market price for AggreBind Fall 2012

  34. Future of aggrebind • Optimize oven curing process • Continue to explore additives: • Fly ash • Slag • Further Testing: • Fire • Weathering FALL 2012

  35. Conclusion • Established higher maximum strength of AggreBind block • Compaction Pressure • AGB:Water Ratio • Oven Curing • Limestone Mixture • Effective teamwork and coordinated small groups

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