P17485: Lightweight Concrete Roofing Tiles
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Integrated System Build & Test with Customer Demo

Table of Contents

Team Vision for System Level Demo with Customer

During this phase, the team:

Test Rig

In this phase we decided that we needed two test rigs overall, one for the water, loudness, solar gain and wind resistance tests and the other one to hold up the zinc roof as a comparison during Imagine RIT to show the current state. The rig for the tests have been completed, and the rig for the zinc roof is almost done.
Completed test rig with 7 tiles resting on it

Completed test rig with 7 tiles resting on it

The picture above shows the completed test rig. As can be seen from the two gaps where two tiles should be, we are using metal battens. There are 4 battens in total supporting the tiles. Visually, the tiles have sufficient overlap. We hope to confirm this with the coming water test.

Preliminary Testing

We replicated last years test to ensure out tile is able to support a person. In the picture below, Rory who is 210 lbs was able to stand on the tile without any damage. Since the force is perpendicular to the tile, the tile will see less direct force when assuming the angle of the roof. We hope to create another test to see the breaking strength of one of the tiles.
210lb Standing Test

210lb Standing Test

Next is a picture of four of our tiles interfacing with each other. We were able to see first hand how well the tiles fit together and they seemed to fit well. We then moved this into the lab where we did another leak test to ensure it would not leak. We have an accompanying video showing our test.

4 tiles overlapped as planned

4 tiles overlapped as planned

Future Testing

In the next phase we are planning to start testing our tiles using the test rigs, as according to the following test plans:

Loudness Test Procedure

Solar Heat Gain Test Procedure

Waterproof Test Procedure

Wind Resistance Test Procedure

Water Exposure Durability Test Procedure

Risk Table

We have not changed any of the risks this phase. The row in yellow is the latest change from last phase.
Current Risk Table

Current Risk Table

Manufacturing Estimations

Below is a picture showing some of the calculations we made to see how many molds are needed for a house and how long it would take to make roof tiles for one house.
Calculations for number of molds needed and how much time taken to make tiles for a full house

Calculations for number of molds needed and how much time taken to make tiles for a full house

Updated Cost Analysis

In this phase we also updated the overall cost analysis as shown in the picture below:
Cost analysis updated from last phase

Cost analysis updated from last phase

Updated Budget

The budget for our project has been updated to reflect the expenditure from this phase as well:
Updated budget

Updated budget

Plans for next phase

1. Build Test rig for Imagine RIT

2. Complete the following testing on tiles using the test rig:

3. Complete poster and paper

4. Prepare for customer hand-off

5. Includes cost analysis, assembly manual, information on molds


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