P17485: Lightweight Concrete Roofing Tiles
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

In this phase we:

Initially there were plans of making a clay model of the tile but it did not go as planned and other things took precedent, so for now we are not going to make the clay tile.

Test Results Summary

The picture below shows the results from our concrete testing so far.
Summary of concrete testing results

Summary of concrete testing results

Going forward we will be using the incoming data to gather further information.

Manufacturing Device

Manufacturing device mock up image. From bottom up: black base is the tire vibration table we have been using, gray base is aluminum plate to keep things flat, thin black layer is rubber/foam material to allow some give, blue piece is flexible plastic

Manufacturing device mock up image. From bottom up: black base is the tire vibration table we have been using, gray base is aluminum plate to keep things flat, thin black layer is rubber/foam material to allow some give, blue piece is flexible plastic "slide" for concrete to move onto mold form, orange piece is clamp used to keep top in place when down, top gray piece is the frame to shape the tiles (can be swapped for the peak tile or main tile), two gray pieces on top flip down to create holes in the tile for attachment method.

Top image shows frame without hole makers down, bottom image shows hole makers flipped down to create holes in the tile.

Top image shows frame without hole makers down, bottom image shows hole makers flipped down to create holes in the tile.

Frame welded by team with holes for handles and hinges done.

Frame welded by team with holes for handles and hinges done.

Modified non mortise hinge and tapped holes in frame shown.

Modified non mortise hinge and tapped holes in frame shown.

MDF wood base shown with holes for attachment to vibration table. Slide with foam glued to underside shown flipped back for access to attachment holes.

MDF wood base shown with holes for attachment to vibration table. Slide with foam glued to underside shown flipped back for access to attachment holes.

Frame shown with hinges clamped to base before fully attached.

Frame shown with hinges clamped to base before fully attached.

Testing hinge clearance off frame before finishing assembly.

Testing hinge clearance off frame before finishing assembly.

Fully assembled manufacturing device.

Fully assembled manufacturing device.

Flat tile test of manufacturing device.

Flat tile test of manufacturing device.

Attachment Method

Feedback from Nicaragua - the Attachment Method
Previously proposed attachment method

Previously proposed attachment method

Updated attachment method

Updated attachment method

The adjustments made on the attachment system prompted us to change the batten spacing as well, as shown in the following picture.

Updated batten spacing

Updated batten spacing

Foam Mold

A mold is to be used in conjunction with the manufacturing device as discussed in the last few phases of MSD I. From our discussions with multiple people concerning the mold, we decided to go with a mold made out of insulation foam. We used the CNC Router at The Construct to cut multiple pieces of the mold shape, then stick them together to form the final mold.
The insulation foam on the CNC Router, getting ready to be cut

The insulation foam on the CNC Router, getting ready to be cut

The CNC Router cutting the shape of the mold in the foam

The CNC Router cutting the shape of the mold in the foam

We had a few extra pieces for the mold so we decided that while the actual mold is being put together, we made a mini-mold and tried making a small tile using the manufacturing device and the mini-mold, as shown below.

Mini tile

Mini tile

Risk Tracking

We updated the risk table for this phase, as shown:
Updated risk table

Updated risk table

Budget

The following picture shows our budget. We have spent about half of our budget. In terms of upcoming expenses we need to make replications of the molds so multiple tiles can be made at once. Additionally we will need to buy more mixing ingredients at some point.
Budget table

Budget table

Project Timeline for the next 3 weeks

Highlight of task for the next phase

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