Composites BLDG Mtrls For Green Building

Composite Building Materials
for Green Building

Presentation prepared by:
December 2011
All statements, information and data presented herein are believed to be accurate and reliable, but are not to be taken as a guarantee, an express warranty, or an implied
warranty of merchantability or fitness for a particular purpose, or representation, express or implied, for which Ashland Inc. and its subsidiaries assume legal responsibility.
1 © 2011, Ashland Inc.
Learning Objectives
• Define and identify a composite material
• Recognize the benefits that composite

materials have to offer for green building and
construction
• Become familiar with tools to gain additional

information on composite building products.
– CompositeBuild.com
– Compositesandarchitecture.com

Composite Building Materials for Green Building
Why Be Concerned With Building Materials?

Course Defining Benefits of Composite CompositeBuild.com
Drivers Composites Composites LCA Composites&Arch.com

Drivers for Green Building Materials
• Buildings consume a large amount of natural
resources to construct and operate
Courtesy of USGBC, 2011

• Green building is the practice of minimizing the

impact a building has on the environment
Courtesy of USGBC, 2011

• LEED green building program

– Leadership in Energy and Environmental Design
– Program developed by the US Green Building
Council (USGBC)
– Provides a framework for implementing practical
green building design, construction, operations
and maintenance solutions
Materials are an important consideration within LEED

and other green building programs
• All materials: Performance & Aesthetic requirements
• Green Materials
– Energy Savings
– Durability
– Low Maintenance
– Healthy Indoor Environment
• Air Quality
• Daylighting
• Air handling
Composite materials provide many of these benefits

What Are Composites?

Drivers Composites Composites LCA Composites&Arch.com

What Is A Composite?
Composite
Engineered or naturally-occurring materials made from
two or more constituent materials with significantly
different physical or chemical properties
At a microscopic level, the constituent materials

remain distinct within the finished structure.

Composites We Are All Familiar With
Wood is a natural composite of

cellulose fibers in a lignin matrix
There are many man-made composites:
Early civilization Disc brake pads are

houses were composites of hard
composites of mud ceramic particles
and straw embedded in soft metal

Focus for this Presentation
Polymer Matrix Composites

A composite made from a polymer and
a reinforcing and/or particulate material
The polymer binds the reinforcement & particulate together.

Reinforcement material Particulate material
– Glass fibers – Sand, talc and other fillers
– Natural fibers – Color chips
– Carbon fibers – Recycled glass
More More
Structural Aesthetic

Examples of Polymer Matrix Composites
• Variety of applications, including:

– Transportation
– Marine
– Infrastructure
– Building & Construction
Photo courtesy: John Deere
Photo courtesy: Composites Advantage Photo courtesy: Campion Boats


How Are Composites Useful?

Drivers Composites Composites LCA Comp&Architecture.com

Benefits of Composites
Extremely
durable
Lightweight
Energy-saving
Flexible
In design
LEED-enabling
15
BENEFITS Durable Lightweight Energy-Saving Flexible in Design LEED-enabling
© 2011, Ashland Inc.
Composites are Durable
• Polymer matrix composites
are extremely durable,
long-lasting materials
• Require low maintenance
• Increased service life vs.

conventional materials
• Re-use opportunities
16
Composites are Durable
Composites have very good environmental
durability relative to wood.
• Do not swell, warp, rot
• Very good resistance to animals and insects
17
Durability
Composites are Corrosion Resistant
• Composites offer very good corrosion
resistance relative to metals and concrete.
• They find widespread use in corrosive

environments.
– Pipes and tanks
– Ductwork
– Cladding for roofs & walls
– Seawalls
Courtesy: Kalwall Courtesy: Creative Pultrusion Courtesy: Xerxes Corp.
18
Extremely
durable
Lightweight
Energy-saving
Flexible
In design
LEED-enabling
19
Composites are Lightweight
• Composites are lighter than steel, aluminum, concrete
and brick.
500
400
Pounds
per
cubic 300
foot 3-D Column 1
3
112 lb / ft
200
100
0
Steel Aluminum Concrete Brick Composite Wood
Lower transportation costs.

Less equipment required during installation.
20
Composites Have a High Strength to Weight Ratio
• Composites are
lightweight materials
that are strong and stiff.
100
• Composites are much
Steels
stronger and stiffer
Composites
than pure polymers.
10 in
gra
Specific Concrete
W
ith • Relative to wood,
Stiffness d composites are
oo
(Modulus/Density) W stronger and stiffer.
n
1 tg
rai
a ins • Relative to concrete,
Ag composites offer
superior strength.
PMMA
PP
0.1
Nylon • Composites can have
specific strength &
Polymers specific stiffness similar
to steels.
0.01
1 10 100 1000
Specific Strength
(Strength / Density)
21
http://www-materials.eng.cam.ac.uk/mpsite/interactive_charts/spec-spec/NS6Chart.html
Composites are Lightweight
Taking Advantage of High Strength to Weight
Prototype Investigation
• Replace failing masonry cladding in high rise building
• The low weight composite allows floor space to be added
• Uses existing building structure and foundations
CRAFT Engineering Studio
22
Enhancing Performance of Other Building Materials
“Bridge in a Backpack” – Composite arches filled with concrete
• Smaller equipment during install

• Improved corrosion resistance
• Improved freeze-thaw performance
University of Maine, Advanced Infrastructure Technologies
Weight Savings Corrosion Resistance Durability High Strength Material Reduction
Hybrid Composite Beams – Composite skins with concrete and composite re-bar
• 33% lighter than all concrete beam

• High strength
• Improved corrosion resistance
• Estimated 100+ year life span
Photo courtesy of Harbor Technologies
23
Extremely
durable
Lightweight
Energy-saving
Flexible
In design
LEED-enabling
24
Minimizing Energy Consumption
Composites can help conserve energy
• Construction Energy
– Lightweight, easy to transport and install
• Operational Energy
– Offer low thermal conductivity and reduce thermal bridging
• Embodied Energy
– Materials can be designed to be
• Reusable
• More durable
• Manufactured with recycled and rapidly renewable
25
Composites Are Energy-Saving
Composites are insulating
Composite frames offer high thermal
insulation
U-Factor
Aluminum (no thermal break) 1.9 - 2.2
Aluminum (thermal break) 1.0
Aluminum clad wood/reinforced vinyl 0.4 - 0.6
Wood and vinyl 0.3 - 0.5
Composite 0.2 - 0.3
Composites are dimensionally stable

Composites have a very low
coefficient of thermal expansion (CTE)
They are not prone to expansion &
contraction with swings in temperature.
No cracks!
26
Structural Insulated Panels
• Structural Insulated Panels (SIPS)
– Lightweight
– Easy-to-install (modular)
– Very good insulating properties
• Whole wall R value = 14
Courtesy:
SIP Association
Courtesy: AFM Corporation
27
Composites are Energy-Saving
Composite Structural Insulated Panels
• Conventional SIPS have a sandwich construction
– Wood – Insulating Foam Core – Wood
• Polymer matrix SIPS also are a sandwich

– Composite – Insulating Layer – Composite
Wood Wood
Insulating Layer
Composite Composite
More mold, mildew

& insect-resistant
More structurally-sound.
Can contain 100% Hurricane-resistant
recycled fill
28
Energy-Saving
Composite Structural Framing
Weight comparison in a 2000 ft2
Hurricane-built structure
• Composite frames are being used to build
40
hurricane-resistant structures. 35
30
25
Composite
20
Wood
15 Block
10
5
0
Weight (Tons)
Information and photos courtesy Composite Building Systems, Inc.
Energy Savings
During Construction
Transportation
Low weight installation
Operational Energy Savings

Low thermal bridging
Wall panel R-
R-values in the 20’
20’s
29
Extremely
durable
Lightweight
Energy-saving
Flexible
In design
LEED-enabling
30
Composites Offer Flexibility in Design
Process +/- Types of Products
Design flexible, shape and color Sinks, tubs,
Casting Non-structural parts
Low cost molds, appropriate for
counters
small run parts
Moderate mold cost Tanks, building
Lay-up / Spray-up Good for small run parts facades
Complex designs possible
Consistent part Boat parts, car parts
Infusion / RTM Complex design possible
High cost mold
Mid to high volume
Continuous flat sheet Light panels,
Continuous Panel High volume building panels
Limitations on physical design
Options for surface / color
Continuous shape parts I-beam, ladder rail,
Pultrusion High volume window lineals
Moderate design flexibility
Very high volume Car/truck panels,
Press Molding Very consistent part appliance bodies
Complex shape possible
Very high Capital cost
31
Flexible Design
Aesthetics & Performance
32
Cornices
Facades
Courtesy: Architectural Fiberglass

Flexible Design Terminal Tower – Cleveland, OH
Columns
Urban
Renewal
Courtesy: Kreysler & Associates High & Goodale – Columbus, OH
33
Color & Style
Options
Mold/Mildew
Resistance
Courtesy: Monroe Industries

Flexible Design
Courtesy: Monroe Industries
Courtesy: Cosentino Courtesy: Banos10
34
Extremely
durable
Lightweight
Energy-saving
Flexible
In design
LEED-enabling
35
Composites are LEED-Enabling
Composites products offer direct applicability

to LEED under the Materials & Resources Category
• Recycled Content
• Rapidly Renewable Materials
• Regional Materials
• Building Re-use
• Material Re-use
Life Cycle Assessment of Building Assemblies & Materials

Pilot Credit 1
36
Direct LEED Applicability
Recycled Content
Composite fabricators are responding to the green

building industry’s need for more sustainable products
MR Pilot Credit 53 – Prescriptive attributes for non-structural materials
37
Rapidly Renewable Materials
Rapidly renewable materials are being incorporated.

Renewable based polymers first.
USDA
BioPreferred
Lots of work on-going with natural fiber reinforcements.
38
Recycled Content & Rapidly Renewable Materials
Some fabricators have produced composite materials

from recycled & renewable materials.
This is a growing trend !
39
Building & Material Reuse
Because of their durability, most composites

are capable of being re-used.
40
Composites are LEED-Enabling
Composites products offer functional applicability

to LEED under several categories and credits.
• Storm Water Handling

• Daylight and Views
• On-site Renewable Energy & Green Power
• Storage & Collection of Recyclables
• Mold Prevention
• Innovative Design
41
Functional LEED Applicability
Daylight & Views
• Roof panels
• Curtain walls
• Lineals for windows/doors
Courtesy: Pella Courtesy: Kalwall Courtesy: Kalwall
42
Storm Water Handling
• Durable, corrosion-resistant
• Lightweight
Courtesy: Hubbell
Courtesy: Xerxes Corp
43
On-Site Renewable Energy / Green Power
• High strength and stiffness
• Low weight
• Durability against impact and weathering
• Fatigue resistance
44
How Do Composites Fare From A Life Cycle Perspective?


Life Cycle Analysis (LCA)
• Considers all stages of product life from raw material
extraction through end of life disposal
• Compares environmental & social damages assignable to

products and services
IMPACT
IMPACTCATEGORIES
CATEGORIES Emissions
Emissions
•• Total
TotalEnergy
EnergyResources •• Carbon
Resources Carbondioxide
dioxide
•• Greenhouse
Greenhouse GasEmissions
Gas Emissions •• Carbon monoxide
Carbon monoxide
•• Ozone Depletion
Ozone Depletion •• NOx
NOx
•• Acidification
Acidification •• SOx
SOx
•• Eutrofication
Eutrofication •• Particulates
Particulates
•• Heavy
HeavyMetals •• Volatile
Metals VolatileOrganic
OrganicCompounds
Compounds
•• Carcinogens •• Specific
Carcinogens Specific Process,and
Process, andMaterial-
Material-
•• Summer
SummerSmogSmogFormation
Formation specific waste issues
specific waste issues
•• Winter Smog Formation
Winter Smog Formation
•• Solid
SolidWaste
Waste
Environmental Impact Review
Composites vs. Concrete
• The Need:
– The Monterey Bay Aquarium new
seawater tank
• 20 year lifetime
• Smallest environmental footprint
• Competitive cost
© Monterey Bay Aquarium/Craig Racicot
• The Candidates:
– Fiber-reinforced Composite
– Steel-reinforced Concrete
• Prof. Michael Lepech and a team of

graduate students at Stanford performed a
process–based environmental impact
© Monterey Bay Aquarium/Randy Wilder
review

The Results: Composite vs. Concrete
The energy consumed in the production of the concrete was the most significant
contributor to differences between composite and concrete impacts.
Much smaller
footprint
Composite
Concrete

Composites vs. Steel
• The Need:
– Understand environmental impacts
and initial and long term cost of
railing.
• Lowest environmental impact
• Lowest long term cost
• The Candidates:
– Fiber-reinforced Composite
– Steel
• Review Performed by:

The Results: Composite vs. Steel

Composite vs. Composite
• The Need:
– New cultural center in Baku,
Azerbaijan. Building material
selection.
• 18,000 2m2 panels
• 50 yr building life span
• The Candidates:
– Glass-reinforced Polymer
– Glass-reinforced Concrete
• Review Performed by:

The Results:
Reinforced Concrete vs. Reinforced Polymer
The higher weight of the reinforced concrete resulted in significant
impacts from transportation, especially heavy metals.
Polymer
GRC

Cost of Composites vs. Other Materials
• How do the costs of composites compare to other

materials?
$5.00
$4.00
Cost per Pound
$3.00
$2.00
$1.00
$0.00
Wood Steel Composite Aluminum

• When purchase cost is the only factor:

– Composites always win:
• Tubs & showers
• Boats & heavy truck
• Large wind blades
– Composites rarely win:

• Bridges
• Disposable / consumables
– Composites win at certain volumes

• Automotive body panel

Total life cycle cost analysis is similar to LCA.
LCA
Raw Materials & Construction & Operation & Replacement &

Total Cost =
Manufacturing + Installation + Maintenance + End of Life
Composites can be
more costly to
purchase Composites Durability
typically results in low
They are low weight, resulting in require less replacement
lower cost to transport and install maintenance frequency
Life Cycle Cost Comparisons from LCA

How Can I Easily Find More Information About Composites?


Purpose
• Increase awareness of composite building
materials
• Enable the design/build community to:
– Learn about the benefits of composites
– Easily connect with composite material fabricators &
distributors

Select a room/area

Select a material or
product of interest
Select a specific
Material type

See general photos,
descriptions
& manufacturers
Identify Specific
Company’s Product
Green Attributes
Identify General
Material Attributes Find Regional
Suppliers
Connect to
a Supplier
Case studies of composites in architecture.
Site maintained by Kreysler & Associates
compositesandarchitecture.com
Bill
BillKreysler
Kreyslerisisaacomposite
compositeindustry
industryveteran
veteranwith
withmore
morethan
than30
30years
yearsofofexperience
experienceinincustom
custom
fabrication. His firm focuses on composite products for architecture, artists and industrial
fabrication. His firm focuses on composite products for architecture, artists and industrial
applications.
applications. Extensive
Extensiveexperience
experienceinincoordinating
coordinatingdesign,
design,engineering,
engineering,estimating
estimatingand
andfabrication
fabrication
tasks to realize a wide variety of objects made of or through the use of composite materials.
tasks to realize a wide variety of objects made of or through the use of composite materials.

Case Study:
Horten Headquarters

Case Study:
Sendai, Japan – FRP Facade

Case Study:
Sheraton Hotel, Spain – Seamless Shell

Case Study:
Composite Clad Terminal at the Cerresco Airport

Case Study:
London – Building Facade

Case Study:
Stanford University – Bing Concert Hall

Connecting Our Industries
Resources
• Compositebuild.com
– Connect design/build industry to composite
products and fabricators
• Compositesandarchitecture.com
– Further innovation and inspiration in the world
of architecture, design, digital fabrication and
composite technology
• ACMAnet.org
– American Composite Manufacturer’s
Association
• ICPA-hq.org
– International Cast Polymer Association
• MasterCast.biz
– Engineered composite surfaces

Thank You !!
All statements, information and data presented herein are believed to be accurate and reliable, but are not to be taken as a guarantee, an express warranty, or an implied
warranty of merchantability or fitness for a particular purpose, or representation, express or implied, for which Ashland Inc. and its subsidiaries assume legal responsibility.

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Composite Building Materials

for Green Building

• Define and identify a composite material

• Recognize the benefits that composite

• Become familiar with tools to gain additional

2 © 2011, Ashland Inc.

Why Be Concerned With Building Materials?

3 © 2011, Ashland Inc.

Courtesy of USGBC, 2011

4 © 2011, Ashland Inc.

• Green building is the practice of minimizing the

Courtesy of USGBC, 2011

5 © 2011, Ashland Inc.

• LEED green building program

Materials are an important consideration within LEED

• All materials: Performance & Aesthetic requirements

Composite materials provide many of these benefits

7 © 2011, Ashland Inc.

What Are Composites?

8 © 2011, Ashland Inc.

At a microscopic level, the constituent materials

9 © 2011, Ashland Inc.

Wood is a natural composite of

There are many man-made composites:

Early civilization Disc brake pads are

10 © 2011, Ashland Inc.

Polymer Matrix Composites

The polymer binds the reinforcement & particulate together.

11 © 2011, Ashland Inc.

• Variety of applications, including:

Photo courtesy: John Deere

Photo courtesy: Composites Advantage Photo courtesy: Campion Boats

12 © 2011, Ashland Inc.

13 © 2011, Ashland Inc.

How Are Composites Useful?

14 © 2011, Ashland Inc.

• Require low maintenance

• Increased service life vs.

• They find widespread use in corrosive

Courtesy: Kalwall Courtesy: Creative Pultrusion Courtesy: Xerxes Corp.

Lower transportation costs.

CRAFT Engineering Studio

“Bridge in a Backpack” – Composite arches filled with concrete

• Smaller equipment during install

University of Maine, Advanced Infrastructure Technologies

Weight Savings Corrosion Resistance Durability High Strength Material Reduction

• 33% lighter than all concrete beam

Composites can help conserve energy

Composites are dimensionally stable

Courtesy: AFM Corporation

• Polymer matrix SIPS also are a sandwich

More mold, mildew

Operational Energy Savings

Courtesy: Architectural Fiberglass

Aesthetics & Performance

Courtesy: Monroe Industries

Courtesy: Monroe Industries

Courtesy: Cosentino Courtesy: Banos10

Composites products offer direct applicability

Life Cycle Assessment of Building Assemblies & Materials

Composite fabricators are responding to the green

MR Pilot Credit 53 – Prescriptive attributes for non-structural materials

Rapidly renewable materials are being incorporated.