PROJECTS

PROJECT

Develop innovative technical mortars for renders and floors, multifunctional, with superior performance, which allow minimizing energy costs, increasing durability and mitigating some of the most frequent pathologies that lead to their early degradation.

SCOPE

In this project, it is intended to develop multifunctional technical mortars for application in renders and floors of new buildings or in constructions subject to rehabilitation, which allow reducing energy costs and increasing the durability of coatings and construction elements associated with them.

The composition of EFTM will include photocatalytic elements, which will give them self-cleaning properties and resistance to microorganisms, NIR (Near-Infrared) fluorescent pigments, with high reflectivity of infrared radiation and low thermal emissivity, industrial by-products (waste glass) and agricultural (rice husks and peanut husks), which will improve their thermal and acoustic performance. The inclusion of fluorescent materials will allow the architectural customization of the coverings.

The combination of the characteristics of these materials will result in an increase in the durability of the mortars and other construction elements, through the mitigation of pathologies, also contributing to the minimization of energy costs in buildings. It is intended that the final product corresponds to the requirements of the national and international markets, meeting the requirements of the applicable product standards, and that it is easy to apply (sprayable material in the case of renders and self-levelling in the case of floors and fast curing). The multidisciplinary consortium that constitutes the project is a fundamental characteristic for the development of a product that is considered to have a high commercial value and export potential.

MAIN OBJECTIVES

• Develop innovative, sustainable mortars with high hygrothermal and acoustic performance;
• Ensure self-cleaning properties and resistance to micro-organisms;
• Allow the customization of coatings, including materials with fluorescent properties;
• Valuing the incorporation of by-products from other productive sectors;
• Create an innovative and sustainable product with high functional value in terms of new construction and rehabilitation;
• Develop easily applicable mortars (with the ability to be projected in the case of walls and with self-levelling capacity in the case of floors (screeds)) and of quick curing;
• Create a product with high commercial value and high export potential.

PROJECT ACTIVITIES AND EXPECTED RESULTS

Definition of demands and fundamental requirements of mortars

• Benchmarking analysis of coating solutions available in the national and international market
• Study of regulations and standardization applicable in national and international markets
• Identification of potential by-products/additives/pigments and theoretical study of their compatibility with the intended mortars
• Definition of functional requirements for new coating and filling mortar formulations

Development and characterization of new coating and flooring mortars

• Definition of new mortar compositions
• Characterisation of physical, mechanical, hygrothermal, acoustic, durability and fire reaction properties of the new mortars
• Compatibility analysis of new mortars on different substrates
• Development of numerical models for simulating the mechanical, thermal and acoustic behaviour of constructive solutions (walls and floors)

Manufacturing approach

• Analysis of the manufacturing conditions of new mortars with evaluation and implementation of the necessary changes in the production line
• Production of new mortars in the factory
• Evaluation of mortars’ performance (spraying and filling)

Validation of the performance of the new products

• Application of mortars developed in full-scale prototypes, for validation of results, with "in situ" monitoring
• Numerical simulations to evaluate the mechanical, thermal and acoustic performance of the developed mortars applied in different constructive solutions
• Life cycle assessment

Promotion and dissemination of results

• Definition of guidelines and application rules for new products developed
• Elaboration of contents (technical and scientific publications) and design of promotional material (website, brochures, etc.)
• Preparation of samples for product presentation at technology fairs and other dissemination actions

Carrying out dissemination actions and public/market training actions

MAIN RESULTS ACHIEVED

Definition of requirements and fundamental requirements of mortars

Rendering mortars on the market incorporating by-products were identified, mortars with thermal, acoustic and self-cleaning properties, as well as mortars capable of providing protection and increasing the durability of construction systems. It was verified that, currently, there are no mortars with self-cleaning characteristics or fluorescent pigments on the market. Mortars with EPS and Cork incorporation and also thermal mortars were identified. It was also identified the positioning of the company in the market and the perspectives of development before the analysis carried out.

The existing regulations in countries with greater export potential were evaluated in detail. For each of them, the existing climatic and environmental conditions were identified, which would make it possible to establish, at a later stage, the requirements for the thermal performance and healthiness of the new mortars. It was found that most countries follow the guidelines of European standards. With regard to environmental conditions, it was found that the Arab countries have much higher levels of pollution than the rest, with an atmospheric pollution rate 90% higher than the rest.

A state-of-the-art framework was carried out with regard to by-products, additives and adjuvants to be incorporated into mortars. The most appropriate and efficient photocatalytic elements, pigments and by-products for the climatic and environmental conditions of the destination markets identified in the previous tasks were identified. Based on scientific works and technological development studies with international scope, the compatibility between the materials to be incorporated in the mortars was evaluated, as well as the compatibility of these types of mortars with the most common construction systems. The by-products with the greatest regional impact that could be incorporated into mortars were identified and, based on the bibliographical analysis carried out, the most suitable for the purpose for which they were intended were selected.

The final step of the first activity consisted of establishing the functional requirements of the new formulations. Management and systematization of all the information collected in terms of markets, regulations, standardization and the state of the art was carried out, which resulted in the definition of requirements in terms of eco-efficiency, durability, thermal behaviour, acoustic behaviour and reaction to fire. From then on, the guidelines were established for all the development work of the new mortars that served as support for decision-making throughout the remaining activities of the project.

Development and characterization of the elements of the new system

The quantities of each component to be incorporated into the mortars were defined based on the state-of-the-art analysis carried out in Activity 1, which also allowed the definition of the functional requirements of the mortars. Several compositions were considered, with several dosages, and their performance was evaluated in the laboratory. The analysis of the results obtained for the defined compositions allowed optimizing the amounts of each component (pigments, by-products, photocatalytics and adjuvants), in an iterative and dynamic characterization process.

Compositions were studied with:

• ASIC (inert steel aggregate for construction)
• ground roasted peanut shell
• the almond shell
• cork
• Poraver® (recycled glass)
• crushed rubber powder
• efflorescence reducing agents
• common pigments VS IR pigments
• rubber
• charcoal

Some of the formulations with the best performance, incorporating cork, Poraver®, with common pigment and IR pigment, yellow and black, rubber and charcoal, were characterized in the laboratory. Mechanical and physical tests were carried out, in the fresh state and in the hardened state, for mortars with different percentages of incorporation of each material, and reference mortars, without incorporation of by-products or additives, in order to study their influence. The tests carried out were as follows:

• Characterization of the fresh mortar (workability)
• Mechanical strength
• Modulus of elasticity
• Water vapor permeability
• Absorption by capillarity
• Thermal characterization
• Acoustic characterization
• Reaction to fire

The compatibility analysis of mortars on different substrates was carried out by applying them to substrates with different characteristics. Concrete slabs, red clay ceramic bricks, concrete, OSB and maritime plywood were defined as supports to be used. In addition, in some cases, EPS (expanded polystyrene), plasterboard, birch plywood, standard MDF (wood agglomerate), cementitious composite with wood, porcelain (high-resistance ceramic) and ICB (expanded cork agglomerate) supports were used in some cases.

The development of numerical models for simulating the mechanical, thermal and acoustic behaviour of multifunctional mortars took place in parallel with the experimental campaign, based on the results obtained for the various characterized compositions. With the developed models, it was possible to carry out, through numerical simulation, a rigorous prediction of the behaviour of the multifunctional mortars applied either as a wall coating or as a floor filler, for a wide spectrum of constructive solutions.

Factory approach

The existing conditions in the factory for the production of new multifunctional mortars were evaluated. Once all the existing conditions of the production line were measured, all the necessary conditions were met to carry out the preparation and mixing of the dry components and bagging. It was therefore necessary to identify the changes to be implemented in the production line in view of the type of products to be manufactured and to identify the possible need to include pre-treatment and dosing systems for raw materials. This process took place simultaneously with the final characterization phase of the mortars, over a period of 6 months, and took into account the initially defined compositions. In this way, the optimization of the line was carried out progressively, depending on the management of existing resources, the necessary resources and the dosages of new mortars, in order to adapt the existing line to produce, within the scope of the project, the new mortars.

The production of multifunctional mortars in a factory environment was started. Throughout this process, no relevant weaknesses in the production process were identified. The production system was optimized in terms of material and energy resources. A detailed study of the performance of the production line was carried out, which will guarantee the rigor of the process in terms of environmental and economic sustainability and will ensure the quality of the final product.

The performance of mortars resulting from the production line was systematically analysed to assess the quality of the final product. The analysis of the performance of the applied products, on a full scale, took place on large supports and in conditions of external environmental exposure, with the coating mortars directly coming from the production line. All applied mortars showed good workability when applied manually, without resorting to mechanical means.

Validation of the performance of new products

The aim of this task was to evaluate the performance of factory-produced mortars in full-scale prototypes and under conditions of natural environmental exposure. The application of mortars produced in a factory environment and applied according to the previously measured methodologies, allowed its validation in view of the functional requirements initially established. It was verified that the mechanical performance and behaviour in the presence of water of the developed mortars are adequate, with the exception of the mortar with incorporation of charcoal, which shows some signs of cracking and, therefore, is still in the process of being optimized.

The self-cleaning capacity, durability and thermal performance of the various prepared solutions are being monitored. Photocatalytic elements were incorporated into the mortar with Poraver®, in order to evaluate its self-cleaning capacity. The surfaces of the specimens were contaminated with spray paint, microalgae and cell marker, for later evaluation of surface self-cleaning and comparison with the performance of surfaces coated with the same mortar without any type of photocatalytic pigment.

Promotion and dissemination of results

The knowledge and experience acquired throughout the project make it possible to establish the main guidelines for the handling, preparation, application and maintenance of multifunctional mortars. A technical guide is under development, which will include the mechanical, thermal, physical, acoustic, durability and fire reaction properties of the new mortars, and the characteristics obtained by numerical simulation for the main construction systems. The handling and preparation rules will be indicated that will allow to maximize the performance of the mortars in the diverse constructive systems and also the maintenance instructions of the coatings after application.

Technical data sheets for Primelight, Primecork, Primerubber, Primecoal and Primeflow mortars are under development, which will contain application instructions, the main physical, mechanical, thermal and acoustic properties and the framework of the mortars in terms of applicable regulations and standardization and CE marking. The availability of technical sheets with the compilation of the mentioned aspects will ensure greater accessibility of the final consumer to good practices that will allow a good performance of the mortars and of the set of construction solutions.

In order to ensure an attractive promotion of multifunctional mortars, reduced-scale prototypes of Primelight, Primecork, Primerubber and Primecoal mortars have already been developed, which allowed direct dissemination to the public. New prototypes are being developed, with application on different substrates, and tools and methodologies are also being studied that allow the practical application of mortars to substrates on a small scale, during direct dissemination actions to the public, such as fairs and training actions.

The EFTM project has already been publicized at various events. Primelight, Primecork, Primerubber and Primecoal mortars were presented, and the respective incorporated materials: recycled glass (Poraver®), cork, rubber waste and charcoal, respectively, through exhibitors with prototypes and samples of incorporated by-products. Roll-ups, flyers and oral communications were also used in some of these events. It was found that the possibility of handling the incorporated by-products was an added value for the presentation of these mortars, strengthening the connection with the public who, in general, expressed interest in these solutions. Disclosure was made at the following events:

Teckdays 2017 (10/12/2017 - 10/14/2017)

Organization: Sustainable Habitat Cluster

Location: Aveiro, Portugal

6th Conference on Pathology and Rehabilitation of Buildings – PATORREB 2018 (04/04/2018 – 04/06/2018)

Organization: UFRJ, FEUP, UPC

Location: Rio de Janeiro, Brazil

Rehabend - Construction Pathology, Rehabilitation Technology and Heritage Management 2018 (05/15/2018 - 05/18/2018)

Organization: University of Cantabria, University of Extremadura

Location: Caceres, Spain

Tektónica 2018 (05/22/2018)

Organization: FIL + Sustainable Habitat Cluster

Location: Lisbon

Creative Construction Conference 2018 (06/30/2018 – 07/03/2018)

Organization: Budapest University of Technology and Economics; Diamond Congress Ltd.

Location: Ljubljana, Slovenia

Teckdays 2018 (10/11/2018 - 10/13/2018)

Organization: Sustainable Habitat Cluster

Location: Aveiro

3rd Symposium on Mortars and Thermal Coating Solutions (10/11/2018 and 10/12/2018)

Organization: Itecons, UC and APFAC

Location: Coimbra

Exhibition of Sustainable Construction Materials

Organization: ITeCons / CCDRC / Alma Shopping

Location: Alma Shopping – Coimbra

15th Congress of Architects (10/25/2018 to 10/28/2018)

Organization: Order of Architects

Location: Lagoa – Algarve

Jornal dos Arquitetos - September 2018 (Advertising)

Sustainable Habitat Cluster Congress (five's 18) (07/12/2018)

Organization: Sustainable Habitat Cluster

Venue: Exhibitions Aveiro 

COMMUNICATIONS LIST

Torres, Isabel; Gina Matias; Philip King; Philip Gomes. Multifunctional Technical Mortars - Light Thermal Mortars. In: 6th CONFERENCE ON PATHOLOGY AND REHABILITATION OF BUILDINGS – PATORREB 2018, 2018. Rio de Janeiro. 6th Conference on Pathology and Rehabilitation of Buildings – PATORREB 2018. 2018.

Matias, Gina; Isabel Torres; Philip King; Philip Gomes. Multifunctional Technical Mortars - Self-levelling Screeds with Rubber. In: 6th CONFERENCE ON PATHOLOGY AND REHABILITATION OF BUILDINGS – PATORREB 2018, 2018. Rio de Janeiro. 6th Conference on Pathology and Rehabilitation of Buildings – PATORREB 2018. 2018.

Matias, Gina; Isabel Torres; Philip King; Philip Gomes. Mutifunctional Technical Mortars with Improved Thermal Performance. In: REHABEND - CONSTRUCTION PATHOLOGY, REHABILITATION TECHNOLOGY AND HERITAGE MANAGEMENT, 2018. Cáceres, Spain. Rehabend - Construction Pathology, Rehabilitation Technology and Heritage Management. 2018.

Matias, Gina; Isabel Torres; Philip King; Philip Gomes. Ecological and functional technical mortars with rubber. In: CREATIVE CONSTRUCTION CONFERENCE, 2018. Ljubljana. Creative Construction Conference 2018. 2018.

LIST OF PUBLICATIONS

Matias, Gina; Torres, Isabel; King, Philip; Gomez, Filipe. Ecological and functional technical mortars with rubber. Proceedings of the Creative Construction Conference, 2018 (Edited by: Miroslaw J. Skibniewski & Miklos Hajdu DOI 10.3311/CCC2018-114);

Matias, Gina; Isabel Torres; Philip King; Philip Gomes. Mutifunctional Technical Mortars with Improved Thermal Performance. Proceedings of Rehabend - Construction Pathology, Rehabilitation Technology and Heritage Management. 2018.

Torres, Isabel; Gina Matias; Philip King; Philip Gomes. Multifunctional Technical Mortars - Light Thermal Mortars. Proceedings of the 6th Conference on Pathology and Rehabilitation of Buildings – PATORREB 2018. 2018.

Matias, Gina; Isabel Torres; Philip King; Philip Gomes. Multifunctional Technical Mortars - Self-levelling Screeds with Rubber. Proceedings of the 6th Conference on Pathology and Rehabilitation of Buildings – PATORREB 2018. 2018.

“Characterization of multifunctional mortars with the introduction of residues” (Manuscript in preparation)

“Analysis of the functionality of several mortars incorporating residues” (Manuscript in preparation)