THERMO POLY ROCK

THERMO POLY ROCK Developed by AFFRESOL , UK

Source: http://www.affresol.com/

BACKGROUND
Affresol, a Welsh company, has introduced a line of affordable homes and modular buildings where recycled plastic is used as the core structural material.

Specializes in the manufacture of sustainable housing Buildings and sustainable building products. Affresols primary innovation is Thermo Poly Rock, a material composed mainly of recycled mixed plastics, which pours and sets like concrete. Main contribution could be a sustainable approach to housing.
BUILD LOW CARBON HOUSES FROM THE PLASTIC AND MINERALS.

Affresol and Recycled Plastic The plastic from about 9,000 recycled televisions or 7,200 computers is what it takes to build a three-bedroom house framed with Thermo Poly Rock. Thats about 18 tonnes of recycled plastic (a tonne is 1,ooo kilograms and a U.S. ton is 909 kilograms).

Source: Clean Technica (http://s.tt/12tDD)

MANUFACTURING PROCESS
Low energy cold process converts the plastics into a very strong structural element. It takes selected waste products that have been diverted from landfill. This pre selected waste is recycled then size reduced, after which it is mixed with a Resin and the TPR Polymers. The result is a mouldable liquid compound that is poured like concrete and when it is cured is stronger than concrete. TPR is poured into moulds in the same way as concrete and will be left to cure for 24 hours( but is more flexible and has greater tensile strength).
Recycled Waste

Cast into panels

Reduced to granules

Mouldable liquid

Mixed with granules TPR polymers

APPLICATIONS
TPR Frame Housing
A typical TPR Walling system has a U Value of 0.15 and is made up as follows External cladding (Brick Outer Leaf) will be traditional Brick/Stone/Block. The cladding is not load bearing. Cavity, width will vary. Generally 10 mm. Insulation Will vary subject to the sustainable code specification of the house. TPR wall frames are load bearing and form the inherent strength and substance of the building. 12 mm Plasterboard.

Assembling on site
The panels are bolted together to make a load bearing frame, which is then clad on the outside and dry walled on the inside. The panels have a u value of 0.17, which converts to an American R-Value of 33, so it is certainly a good insulator. TPR panels are sealed and bolted to the steel frame thus ensuring the strength of the whole structure. The external wall cladding is a concrete polymer that is fixed to the Thermo Polymerized Rock Structural Cladding. The wall cladding can be finished as Brick, Stone, Block etc. The cladding is waterproof and also offers protection against fire, extreme weather and accidental damage. The insulation that sits between the sealed Thermo Polymerized Rock cladding and the internal wall is Tiger foam.

PROPERTIES
Compressive strength Thermo Poly Rock (TPR) can be manufactured in different strength grades and the strength grade is denoted by a suffix. TPR1 - Compressive strength range 12 N/mm2 to 18 N/mm2. TPR3 - Compressive strength range 28 N/mm2 to 38 N/mm2. TPR5 - Compressive strength range 58 N/mm2 to 82 N/mm2. Density very low density. Typical densities range from 15kg/m3 to 28kg/m3 . Selecting the correct density is primarily based on the compressive loads that will be applied during its service life. Water Absorption Despite its low density, TPR will absorb only a limited amount of water. Immersion for a year results in approximately 5% by volume water absorption.

Fire Resistance TPR contains a fire retardant that restricts the early stages of fire development.

If the fire takes hold above temperatures of 350-400C the flame retardant in TPR will not prevent further combustion.
Under standard test conditions, burning TPR produces much lower concentrations of asphyxiant carbon monoxide than burning timber. Biological Properties TPR wont damage the environment, impact on the water table or affect the chemistry of ground water. Nor will it offer a breeding ground for micro organisms. TPR does not decay, rot or turn mouldy.

Chemical Resistance At ambient temperatures TPR is chemically resistant to most substances naturally occurring in the ground and a wide range of other substances such as sea water, dilute acids, alkalines and bleaching agents. Substances such as animal fats and diesel fuel will attack the surface of TPR and organic solvents, petrol and concentrated acids can affect TPR to some degree. (If the substances are present in high concentrations).

ECONOMY & MARKET ANALYSIS

Affrasol estimates that it can build at 12% less than standard rates Affrasol has set a target of 3,000 homes in the 2010-2013 with each home diverting 40,000 tons of waste from landfills. The cost is about $60,000 to $75,000 per planned unit.

ADVANTAGES
When TPR3 is in its solid form it has the following intrinsic attributes:
TPR has excellent thermal insulation characteristics; TPR is very durable (estimated at 60 years); TPR is water proof; TPR is fire retardant; TPR is not susceptible to insect infestation; TPR does not rot. TPR does not leech any harmful elements TPR has a Low Carbon Footprint TPR is 100% recycleable. TPR has better flex and tensile characteristics than concrete.

1.Speed of Erection The components are built in the factory (under strict quality controls), which greatly reduces the work to be done on site. This helps to keep sites tidier, easier to control and to reduce on site waste. Frames can be built quickly to order, therefore reducing the design to erection time scale. The TPR frame is very strong and is totally waterproof so the erection process is not dependant on weather conditions, which leaves it suitable for year round construction. 2.Sound Performance TPR is a very dense material The frames are panelled both externally and internally so as to provide optimum sound proofing. 3. Flexibility, Strength, Waterproof, Fire Retardant, and will not Rot TPR frame buildings have excellent design flexibility. Due to the lightweight components, they are easier to transport. This makes them popular for difficult to reach locations. Designs can extend to multi storey construction, flats and hospitals etc. TPR is as strong as concrete, and it also has better tensile and flex characteristics than concrete. The whole of the frame is totally waterproof, it will not rot and it is fire retardant.

4. Excellent Thermal Efficiency TPR frame buildings have excellent thermal efficiency as TPR is a very dense material. The recommended walling system has a U Value rating of 0.15. In addition you can place additional quantities of insulation inside the TPR frame panels which in turn reduce the U Value rating even further. 5. Saves Time and Money Faster Construction Time Energy Savings because the houses are designed to achieve a high sustainability code rating. 6. Compared to traditional building The whole TPR element can be recycled at the end of life. Costs less than traditional structures 7. Cleaner and Healthier TPR is resistant to moisture, mould and mildew Does not leech any toxic materials and the product has been tested at zero Leeching All Affrasol homes come with a Ventilation system.

8.Sustainable built environment

TPR production uses 15-20 % less energy than energy involved in production of Concrete and metals. TPR is a classic example of how utilizing waste as a resource can make a real difference in helping to reduce the amount of waste going to landfill . The insulated TPR frames are very energy efficient.

DISADVANTAGES
If fire takes hold above temperatures of 350400C the flame retardant in TPR will not prevent further combustion.