P17485: Lightweight Concrete Roofing Tiles
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Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase

Concrete Mixing

Why switch from Compression testing to Three Point Load test?

Three Point Load Specimen Molding

New Three Point Mold Plans

Design of Experiment

Independent Variables

Water Content

Biochar Particle Size

Plastic Bottle Fibers

Curved Mold Testing

Feasibility: Tile Designs

Three common tile designs are currently being considered; the flat tile, the S tile and the W tile. The 3D Cad models of the tiles are as shown:
Flat Tile Design

Flat Tile Design

S Tile Design

S Tile Design

W Tile Design

W Tile Design

Simulations

A simulation was ran for each tile, where the tiles were fixed on the bottom surface as well as the nail holes and the only load applied to the system was gravity. Since we do not have a final mix yet, there is no fixed density to be used, so a generic concrete density was used.

The results were looked at in two points of view:

When comparing the different tile design simulations, things to take note are the areas marked in red and the highest value on the top right corner.

The results are as shown:

Flat Tile Displacement Simulation

Flat Tile Displacement Simulation

Flat Tile Stresses Simulation (bottom surface view)

Flat Tile Stresses Simulation (bottom surface view)

S Tile Displacement Simulation

S Tile Displacement Simulation

S Tile Stresses Simulation (bottom surface view)

S Tile Stresses Simulation (bottom surface view)

W Tile Displacement Simulation

W Tile Displacement Simulation

W Tile Stresses Simulation (bottom surface view)

W Tile Stresses Simulation (bottom surface view)

Conclusions from the initial simulations

The main aspect that we are looking at is where and how much the loads are, from one tile to another. Since the density used in these calculations are for generic concrete and not what we intend to make the tiles out of, the values are only valuable when compared with each other in this case, and is not to be a reference value for future use.

As we can see from the pictures, the flat tile has the highest stress values of the three. However, given that its basic geometry is easy to manufacture, the flat tile will be the backup plan, should all other tiles fail to meet any other criteria.

When comparing the W and S tiles, their stress values are similar to each other, and there does not seem to be any major stress points that we need to worry about on either of them. From the pictures it seems that the W-tile has a better distribution of load than the S, but more research has to be done. Currently there is no obvious better tile between the S and the W.

Some future plans to improve the simulations are:

Initial House Model

An initial house structure was also modeled in CREO to estimate how the tiles will be placed on the house, how many tiles will be needed, and possibly how much the whole roof will weigh.
Initial House Design with S-tiles

Initial House Design with S-tiles

Possible Tile Overlap, where about 1/4 of the tile above is overlapping with the tile below it

Possible Tile Overlap, where about 1/4 of the tile above is overlapping with the tile below it

Preliminary Concrete Mixing Procedure

Here is a detailed Preliminary Concrete Mixing Procedure that describes the details of our testing.

Design Testing Goals

Testing parts of the system to answer these questions as early as possible:

Testing with full system

How sucessful is our solution How durable are they What improvements can be made in the next iteration

Risk Assessment

Risks Table

Risks Table

Project Plan

Project Plan

Project Plan

Design Review Materials

Preliminary Detailed Design Presentation presented on 1st November 2016.

Here is the link to the video shown during the review: https://www.youtube.com/watch?v=gInN22guhG8

This video demonstrates how to set up the concrete on a vibrating table, then sliding it off the table and onto a mold to make a tile.

Plans for next phase

Luqman Three Week Plan

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