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Sustainable low effort building system for production of polymer concrete blocks using locally available materials (e.g. desert sand) and their simple modular assembly to temporary or permanent buildings/shelters (refugee camps, slum clearance, ...)

Country of Origin: Germany
Reference Number: TODE20180108002
Publication Date: 10 January 2018

Summary

German SME has developed a sustainable building technology for fast construction of simple buildings/shelters (permanent or dismantable). The innovative system includes the production process of LEGO-style polymer concrete blocks using mainly locally available materials e.g. desert sand or mining/excavation materials as well as their simple modular assembly to buildings/shelters as refugee camps, after natural disasters or permanent housing after slum clearance. SME seeks commercial agreements.

Description

A German SME has developed a novel sustainable building technology for the low cost and fast construction of simple buildings/shelters which are needed after natural disasters or for refugee camps, but also for permanent low cost housing in case of large slum clearances initiatives. The innovative building system includes the production process of polymer concrete blocks on the one hand and their simple modular assembly to buildings/shelters on the other hand. 
The production facility is designed as a mobile unit which can be used for temporary or permanent local production, thus allowing quick response to local needs and minimising logistic costs. The production process itself is simple and based on automated and computerized dosing and mixing systems. Using locally available materials e.g. desert sand or mining/excavation materials as fillers the process preserves crucial raw material resources and saves major transportation efforts. After filling the prepared mixture into specific moulds of various shapes, the polymer concrete material is fully cured within a few hours and ready to use. Through the innovative modular assembly system these jointlessly pluggable polymer concrete blocks can now be arranged to single or multi story buildings with flexible ground sizes and shapes.
The special composition of the novel polymer concrete material is made up of almost 90% local sand or excavation materials as fillers, mixed in a special ration and process with unsaturated polyester resin adhesive, various hardeners/accelerators, additives and inhibitors, thus resulting in excellent chemical and physical properties (list of advantages below).
In addition, the innovative building system has a very low carbon footprint because of reduced logistic efforts and no heat is needed in the process as it is in the cement production.

The production process of the building blocks as well as the assembly of the buildings is very simple and doesn’t require specific qualifications. Apart from the initial set up of the production plant and some training within a first demonstration object the long-term operation can be continued by unskilled local workers.

The company is seeking industry partners for commercial agreements from the building sector, but also organisations dealing with humanitarian aid/emergency management, multipliers and stakeholders for development and third countries.
There is also great interest in opening up new fields of application for the very efficient technology.
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Advantages and Innovations

1.  the novel polymer concrete and the production process:                    
-the novel recipe uses much less and more reasonably prised polyester resin than conventional polymer concrete materials
-very fast curing, within a few hours ready to use
-use of very cheap, locally available filler materials e.g. sand or excavation material, thus 85-90 % less material to be transported
-corrosion, abrasion, fire, temperature and UV resistant
-high resistance to aggressive media, acids and bases, petrol, mineral oil, vapours and gases, water, frost, harsh weather conditions, parasites, termites
-good insulation properties
-very high pressure and bending tensile strength, 3 to 5 times stronger than cement concrete
-high-yielding material and therefore cost efficient (excellent physical properties allow to reduce the wall thickness, thus achieving much more wall area with less material compared to cement concrete)
-fire protection: DIN 4102: flame-resistant class B2, DIN EN 1363 (Fire resistance > 30 Min.)
-flexible shape and surface structure of the building blocks
-meets all quality requirements and EU building standards
-high energy efficient production process
-simple production of the blocks, no special qualification necessary
-mobile, easy to use production plant - flexible use worldwide
-suitable for both industrial mass production and mobile low-volume production
-environmentally risk-free material for long-term use e.g. in water protection areas (chemically bound substances don’t react with the environment)
-no energy/heat needed for the production process - low carbon footprint
-no waste material due to pre-cast elements
-recyclable through mechanical demolition
-cost advantage of >20 % compared to conventional buildings

2. Assembly process:
-easy on site erection by modular assembly system (“plug and built”)
-no heavy duty equipment necessary
-no separate foundation necessary
-feasible for unskilled labour

Stage Of Development

Available for demonstration

Requested partner

Industry partner in the building sector involved in low cost / large scale housing / emergency shelters; multipliers/stakeholders for humanitarian aid / development countries, third countries, 

Expected type of cooperation / role of envisaged partner:
- commercial agreements are envisaged, technical assistance and engineering services will be provided for planning and implementation of low cost housing projects

Role of potential partners:

- Building industry partners: joint adaptation of the building block production and the assembly of individualised buildings/shelters, scaling of the project, access to local resources (materials, workers)
- Organisations dealing with humanitarian aid: access to relevant projects, joint project development, i.e. refugee camps
- Multipliers/stakeholders for development countries, third countries: access to relevant projects, joint project development

Cooperation offer ist closed for requests