20 Reinforced Plastics in Low Cost Housing
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
ARMAND
G.
WINFIELD
and
BARBARA
L.
WINFIELD
A r m a n d G . Winfield Inc., 82 Dale St., West Babylon, Ν. Y . 11704
Our company designed and produced a low cost prototype house for Bangladesh to withstand cyclonic winds in excess of 150 mph and tidal waves. The house was constructed primarily of jute-reinforced polyester with a.010-inchex terior layer of glassfiber-reinforcedpolyester. The two-room house was 10 ft X 20 ft with an average height of 7.5 ft. Constructed of two monocoques, it has a dividing partition. The prototype successfully underwent full scale simulated cyclonic testing. A jet aircraft was used to create winds greater than 230 mph; 750 gal of water/min were released simultaneously to complete the cyclonic conditions. Surface temperatures of 200°F were recorded. Maximum deflection on prototype walls was 2.3 inches. The prototype indicates a major breakthrough in the use of plastics for low cost housing.
" C a r l y i n 1972, C A R E , I n c . i n i t i a t e d a p r o g r a m to establish goals f o r shelter u s i n g plastics m a t e r i a l s f o r the A s i a n s u b - c o n t i n e n t , specifically Bangladesh, where a major w a r for independence fought.
h a d recently been
T h e w a r left t r a g i c d e v a s t a t i o n a n d homelessness,
and on the
I s l a n d o f B h o l a , at t h e m o u t h o f t h e G a n g e s , t h e effects of t h e w a r w e r e m a g n i f i e d b y a 1971 t i d a l w a v e w h i c h l e v e l l e d this i s l a n d a n d k i l l e d 225,000 persons i n a single d a y . T h e A s i a n s u b - c o n t i n e n t — a c c o r d i n g to the U n i t e d N a t i o n s — i s one of t h e areas of t h e w o r l d c r i t i c a l l y i n n e e d of h o u s i n g . T h i s p r o g r a m is p a r t o f C A R E s c o n t i n u i n g effort to p r o v i d e safe a n d i n e x p e n s i v e h o u s i n g i n t h e d e v e l o p i n g countries of t h e w o r l d . Background T h e most i m p o r t a n t l o w cost b u i l d i n g system i n use u n d e r C A R E ' s aegis is t h e C i n v a r a m system. A c o m p o s i t i o n of d i r t , w a t e r , a n d 7 - 1 2 % 207 Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
208
FILLERS
concrete is p r e p a r e d .
A N D REINFORCEMENTS F O R PLASTICS
A $50.00 C i n v a r a m press is o p e r a t e d b y m a n u a l
lever action a n d produces a "green" block.
T w o m e n can produce ap-
p r o x i m a t e l y 300 b l o c k s p e r d a y , a n d t h e b l o c k s m u s t c u r e f o r 28 to 30 days p r i o r to use. C u r e d b l o c k s are p l a c e d o n a p e r i p h e r a l concrete slab a n d are m o r t a r e d together.
R o o f i n g m a d e of c o r r u g a t e d g a l v a n i z e d i r o n
sheets a r e a t t a c h e d to t h e C i n v a r a m b y c o m p l i c a t e d roofing struts a n d trusses. A t y p i c a l C i n v a r a m house 10 ft X 20 f t uses a p p r o x i m a t e l y 1500
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
blocks for walls a n d partitions. A t o t a l of 7500 units w e r e b u i l t i n B a n g l a d e s h u n d e r C A R E
super-
v i s i o n i n late 1972, a n d s e v e r a l t h o u s a n d m o r e w e r e b u i l t i n 1973. T h e C i n v a r a m s t r u c t u r e has m a n y d r a w b a c k s , i n c l u d i n g its i n a b i l i t y t o w i t h s t a n d h u r r i c a n e s , tornadoes, e a r t h q u a k e s , o r tsunamis. H i g h w i n d s c a n r i p a w a y t h e m e t a l roofing, a n d earthquakes a n d floods c a n c r u m b l e o r disintegrate its w a l l s . T o date, h o w e v e r , this seems to b e t h e most exrO-10
2-4 x3-0 [WINDOW, 2-4x6-0 J DOOR I
b. SIDE ELEVATION
Figure
1.
Initial house design by Anthony Marchese for Bangladesh proved by CARE, Inc.
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
as ap-
20.
WINFIELD
AND WINFIELD
LOW
Cost
209
HoUStUg
p e d i e n t , e t h n i c a l l y a c c e p t a b l e house for c o n s t r u c t i o n i n m a n y d e v e l o p i n g areas—one w h i c h replaces the o p e n s k y ( or a tree ) for a roof. D u r i n g the U N I D O meetings i n V i e n n a , A u s t r i a , Sept. 2 0 - 2 4 , 1971, e n t i t l e d " E x p e r t G r o u p M e e t i n g o n the U s e of P l a s t i c s i n the B u i l d i n g I n d u s t r y , " one of the i m p o r t a n t conclusions w a s that plastics l e n d t h e m selves best to mass p r o d u c t i o n t e c h n i q u e s
w h i c h are r e q u i r e d i f the
w o r l d ' s h o u s i n g needs are to be met. Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
A l t h o u g h C A R E p e r s o n n e l h a d e x p e r i m e n t e d w i t h plastics i n h o u s i n g i n B a n g l a d e s h , p r i o r to t h e i r w a r for i n d e p e n d e n c e , no successful structures h a d b e e n p r o d u c e d . T h i s w o r k , h o w e v e r , c r e a t e d m u c h l o c a l interest a n d i n d i c a t e d f u t u r e possibilities.
Figure
Research and In
2.
Typical window (wood)
Development
e a r l y 1972, C A R E , Inc. i n i t i a t e d a p r o g r a m w i t h A r m a n d G .
W i n f i e l d Inc. for the m a t e r i a l f e a s i b i l i t y , d e s i g n , p r o t o t y p e and
construction
development,
testing of a l o w cost house for B a n g l a d e s h . C r i t e r i a f o r this house
w e r e to i n c l u d e : ( 1 ) T h e use of j u t e — t h e m a i n staple of B a n g l a d e s h — i n association w i t h a m i n i m u m of plastics m a t e r i a l s . (2)
E t h n i c a n d s o c i a l a c c e p t a b i l i t y to the B a n g l a d e s h p e o p l e .
(3)
U s e of self-help i n construction.
( 4 ) C a p a b i l i t y for h i g h speed, on-site p r o d u c t i o n b y u n s k i l l e d or s e m i - s k i l l e d l o c a l l a b o r , i n excess of 100 c o m p l e t e d houses p e r day. (5)
C o s t u n d e r $300.00 for each 10 ft X 20 ft s t r u c t u r e .
( 6 ) A b i l i t y to w i t h s t a n d c y c l o n i c w i n d s greater t h a n 150 m p h a n d other n a t u r a l p h e n o m e n a , i n c l u d i n g m o n s o o n flooding a n d l a n d u p h e a v a l s . A f t e r C A R E briefings, i n i t i a l designs w e r e c r e a t e d b y the architect, A n t h o n y M a r c h e s e , a n d w e r e a p p r o v e d b y C A R E , Inc. for p r o t o t y p i n g ( F i g u r e 1 ). T h e house was to b e 10 ft X 20 ft b y a n average h e i g h t of
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
210
FILLERS
AND
REINFORCEMENTS FOR
PLASTICS
7.5 ft a n d was to b e b u i l t as t w o m o n o c o q u e s , w i t h a n i n t e r n a l p a r t i t i o n w h i c h w o u l d p r o v i d e t w o rooms. T h e d e s i g n i n c l u d e d three
doors—two
e x t e r n a l a n d one i n t e r n a l — a n d f o u r w i n d o w s , a l l of w h i c h o p e n e d i n w a r d ( a n e t h n i c n e c e s s i t y ) . T h e doors a n d w i n d o w s w o u l d b e w o o d — a v a i l a b l e o n site i n B a n g l a d e s h ( F i g u r e 2 ) .
F l o o r s w e r e n o t a c o n s i d e r a t i o n since
c u s t o m d i c t a t e d a t a m p e d d u n g - e a r t h floor. B a m b o o v e r a n d a h s , screens, a n d a d d i t i o n a l p a r t i t i o n s w o u l d be c o n s t r u c t e d b y the f a m i l y once the Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
b a s i c house was erected. Table I.
W i n d T u n n e l Tests Terrain
W i n d speed , m p h a
Design load , lbs/ft 6
2
0
Exposure Flat, open country
Center of large city
Suburban area
(1) 100 (2) 150
(1) 100 (2) 150
(1) 100 (2) 150
(1) 15 (2) 34
(1) 29 (2) 65
(1) 48 (2) 106 ( 3 / 4 l b / i n ) 2
Basic wind speeds based on air flow in open, level country at 30 ft above ground and for terrain exposure as noted. Design load = effective velocity pressure multiplied by appropriate pressure coefficient: 1.86. a
6
A w i n d t u n n e l m o d e l was c o n s t r u c t e d f r o m the a p p r o v e d d e s i g n , a n d tests w e r e c o n d u c t e d to p r o v e its d e s i g n a n d c a p a b i l i t i e s to w i t h s t a n d h i g h w i n d loads ( T a b l e I ) .
E n g i n e e r i n g specifications w e r e s u b -
s e q u e n t l y d e v e l o p e d f r o m these d a t a a n d w e r e u s e d to select m a t e r i a l s f r o m w h i c h the p r o t o t y p e w o u l d u l t i m a t e l y b e c o n s t r u c t e d .
A founda-
t i o n a n d a n c h o r i n g system was d e v e l o p e d b y e x t e n d i n g the w a l l s of the house
18 inches b e l o w g r a d e a n d s i m u l t a n e o u s l y e x t e n d i n g a 1 2 - i n c h
peripheral
flange
o u t w a r d a n d p e r p e n d i c u l a r to the w a l l s .
This was
f u r t h e r s t r e n g t h e n e d b y i n c l u d i n g a net m a d e of 2 y 4 - i n c h w i d t h w o v e n p o l y p r o p y l e n e tapes
(450 l b test)
w h i c h were interwoven on 12-inch
centers i n b o t h directions of the house ( F i g u r e 3 ) . T h e c o m p l e t e d house was to be erected i n a n o p e n p i t 12 ft X 22 ft X
18 inches d e e p , a n d
e a r t h w o u l d be filled to g r o u n d l e v e l i n s i d e a n d outside the house.
The
w e i g h t of the e a r t h o n b o t h the e x t e r n a l flange a n d o n t h e i n t e r n a l n e t t i n g w o u l d h o l d the house firm d u r i n g severe w e a t h e r . V a r i o u s jute samples a n d p r o d u c t s w e r e c o l l e c t e d i n m a n y f o r m s — e.g.,
jute " h e a d s , " y a r n , w o v e n c l o t h , fibers, net, a n d rope.
The initial
goals for the h o u s e w e r e b a s e d o n the p h y s i c a l p r o p e r t i e s of g l a s s - r e i n f o r c e d polyester.
U s i n g the c r i t e r i a of 6 5 - 7 5 %
polyester r e s i n i n asso-
c i a t i o n w i t h jute r e i n f o r c e m e n t s , the m i n i m u m values w o u l d h a v e approach
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
to
20.
WINFIELD
AND
Low
WINFIELD
Cost
211
Housing
18,000 p s i flexural s t r e n g t h 850,000 p s i flexural m o d u l u s 9,000 p s i tensile strength. F i r s t considerations dealt w i t h c o m b i n a t i o n s a n d ratios of jute
fibers
to polyester resins. Polyesters w e r e chosen b e c a u s e t h e y c o u l d b e p u r c h a s e d e c o n o m i c a l l y for export, c o u l d b e m a d e s e l f - e x t i n g u i s h i n g , a n d w e r e c o m p a t i b l e w i t h the jute
fibers.
( F o a m e d p o l y u r e t h a n e as a core
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
m a t e r i a l h a d f a i l e d i n earlier b e a m tests. ) J u t e i n association w i t h plastics m a t e r i a l s was l a r g e l y u n e x p l o r e d , except o n a d e c o r a t i v e basis, a n d little h a d b e e n c o m p i l e d o n the p h y s i c a l characteristics of these c o m b i n a t i o n s . T h e soft o r g a n i c jute fibers, u n l i k e i n o r g a n i c glass fibers, absorb resin. E a r l y experiments i n d i c a t e d that the jutes u s e d p r o v i d e d little s t r e n g t h or stiffness i n tensile a n d flexural tests. T h e a d d i t i o n of a glass fiber l a y e r also a d d e d l i t t l e s t r e n g t h to the l a m i n a t e a n d i n some c o m b i n a t i o n s p r o v e d ineffectual or even d e t r i m e n t a l as m o r e r e s i n s o a k e d i n t o the jute layers ( T a b l e I I ) .
A l t h o u g h the i n i t i a l tests
u s e d jute, polyester r e s i n ( P o l y l i t e 94-158, R e i c h h o l d C h e m i c a l s , I n c . ) a n d glass fibers h a d e s t a b l i s h e d the d i r e c t i o n for m a t e r i a l composites; the r a t i o b e t w e e n t h e jute a n d polyester r e m a i n e d to b e d e v e l o p e d f u r t h e r — a s w o u l d t h e stiffness a n d strength.
I?
ITER. M U - U
/ /
FLOOR
/ /
UNE
Τ.g. ror-*|
ZZZZZL
ι-ο O.C. BOTH WAVS T o i m p r o v e the
flexural
Figure
3.
Anchonng flange and
system netting
showing
strength a n d m o d u l i , it w a s necessary
to
i n t r o d u c e finely d i v i d e d i n o r g a n i c fillers w h i c h w o u l d pass t h r o u g h the apertures
of
the
Florida, Inc.).
airless s p r a y - u p
C a l c i u m carbonate
equipment filler
(Glas-Mate, Ransburg
( A t o m i t e 319, W h i t a k e r , C l a r k ,
a n d D a n i e l s , I n c . ) , 20 w t % to t h e polyester resin, p r o v i d e d the accept a b l e properties.
A s s h o w n i n T a b l e I I I , p a n e l 1 A w a s m a d e of f o u r
layers of jute s a t u r a t e d w i t h u n f i l l e d polyester resin. T h e flexural m o d u l i r e c o r d e d w e r e 444,000, 634,000 a n d 447,000 p s i , r e s p e c t i v e l y . P a n e l 1 B ,
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
212
FILLERS
Table II.
AND
REINFORCEMENTS
Flexural
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
Panel 1°, resin-soaked #1 11,700 #2 6,800 #3 6,400
PLASTICS
F R P Test Laminates" Tensile
h
Strength, psi
FOR
Modulus, psi
Thickness, inch
jute 232,000 120,000 63,000
Strength, psi
Thickness, inch
0.037 0.034 0.034
2,600 1,900
0.032 0.035
0.054 0.052 0.052
6,600 5,900
0.050 0.052
Panel 16 , 1 jute/1 resin and glass #1 21,500 576,000 #2 22,200 563,000 #3 9,000 510,000
0.066 0.068 0.067
4,000 4,300
0.072 0.072
Panel 13, S jute/2 resin and glass #1 15,200 643,000 #2 15,000 577,000 #3 12,000 588,000
0.153 0.157 0.156
7,600 10,000
0.164 0.161
Panel 11, 4 jute/S resin and glass #1 11,700 548,000 #2 17,200 736,400 #3 13,900 642,300
0.238 0.235 0.235
8,200 8,300
0.260 0.259
Panel 15 , 1 resin and glass only #1 23,000 674,000 #2 21,200 613,000 #3 18,800 555,000 d
6
d
f
0
9
Standard conditions after 48-hr post cure at 150°F. Samples # 1 and 2 were tested with resin rich side in compression; sample # 3 was tested with glass side in compression. Jute only; note low physicals. Panels 15 and 16 were made simultaneously. Note higher physicals for glass alone. Note that addition of jute weakened the laminate. Note the more jute layers added, the weaker the composite became because the jute was absorbing resin and the glass became ineffectual. a
b
c
d
e
s
0
w h i c h w a s m a d e of f o u r layers of jute staturated w i t h 20 w t % A t o m i t e to the p o l y e s t e r r e s i n , shows
flexural
m o d u l i of 549,000, 527,000, a n d
480,000 p s i . T e n s i l e strengths of p a n e l 1 A are 5400 a n d 5100 p s i vs. p a n e l 1 Β w i t h readings of 7900 a n d 8200 p s i . C r i t e r i a for the p o l y e s t e r - j u t e c o m p o s i t e w e r e d e t e r m i n e d b y t w o factors : ( 1 ) It w a s necessary to use a filler to a c h i e v e stiffness w i t h o u t affect i n g other p r o p e r t i e s . (2)
I n i t i a l l y , w o v e n jute cloths, nets, a n d tapes w e r e a b s o r b i n g r e s i n
i n excessive a m o u n t s . Studies of the jute itself s h o w e d that its fibers are e x t r e m e l y porous a n d a b s o r b resin. It w a s also d e t e r m i n e d that a d o u b l e sheared a n d c a l e n d e r e d w e a v e of jute w o u l d m i n i m i z e r e s i n a b s o r p t i o n . T h u s , a 22 X 22 ( t h r e a d c o u n t ) B e n g a l o n f a b r i c w a s chosen as the f a b r i c
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
20.
WINFIELD
AND
for t h e p r o t o t y p e .
LOW Cost
WINFIELD
213
Housing
( B e n g a l o n is i m p o r t e d i n t o the U n i t e d States f r o m
I n d i a b y W h i t e , L a m b , F i n l a y of M o n t c l a i r , N . J . ) U l t i m a t e l y , P a n e l 1 Β ( T a b l e I I I ) b e c a m e t h e i n n e r s k i n of t h e house c o m p o s i t e . S i n c e the f o a m e d p o l y u r e t h a n e c o r e p o t e n t i a l w a s a b a n d o n e d because o f core failures, a substitute c o r e w a s necessary. A c o r r u g a t i o n
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
Table III.
F R P Test Laminates" Tensile
Flexural
b
Strength, psi
Modulus, psi
Panel 1A , 4 layers jute/unfilled 10,700 444,000 #1 12,100 #2 634,000 #3 8,700 447,000 C
Strength, psi
Thickness, inch resin 0.0895 0.079 0.077
5,400 5,100
0.084 0.088
7,900 8,200 —
0.080 0.086
Panel lB , 4 layers jute/with 20% #4 15,100 549,000 #5 12,500 527,000 #6 11,700 480,000
Atomite in 0.077 0.0775 0.079
Panel lC , 2 layers jute/with 20% #7 11,800 54,200 #8 12,900 65,200 #9 10,600 53,600
Atomite in resin 0.0445 5,000 0.044 5,600 0.0455 —
d
e
Thickness, inch
resin
Panel 1D , 1 layer jute/resin with 20% Atomite #10 6,400 59,200 0.0375 #11 4,300 65,000 0.0465 #12 7,000 60,500 0.033
0.047 0.046
{
Panel 2A ', 2 jute/unfilled resin/2 strands glass #13 17,300 575,000 0.111 #14 18,800 573,000 0.118 #15 13,200 416,000 0.097
4,100 3,700 —
0.028 0.040
13,100 10,500 —
0.111 0.104
Panel 2B°, 1 jute/resin with 20% #16 16,200 510,000 #17 13,200 378,000 #18 13,700 422,000
Atomite/2 strands glass 0.0855 7,800 0.083 9,800 0.077 —
Panel 2C", 2 jute/resin with 20% #19 13,200 553,000 #20 14,300 528,000 #21 11,500 616,000
Atomite/2 0.092 0.091 0.084
strands glass 12,900 13,600 —
0.094 0.077
0.087 0.086 —
" Tests done under standard conditions. Specimens # 1 and 2 were tested with resin-rich surface in compression; specimen # 3 was tested with glass rich surface in compression. Unfilled resin shows low flexural strength and modulus. Atomite increases flexural strength and modulus. ' Reduction of jute reduces flexural strength and modulus. Too weak. ' Used to determine criterion for outer skin. 6
e
d
f
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
214
FILLERS
A N D REINFORCEMENTS F O R PLASTICS
of jute r e i n f o r c e d polyester p r o v e d satisfactory.
Cements w h i c h could
m e e t t h e p h y s i c a l r e q u i r e m e n t s n e e d e d to fasten t h e core to t h e skins w e r e d e v e l o p e d a n d tested. T h e final f o r m u l a t i o n w a s m a d e f r o m r i g i d a n d flexible polyester resins stiffened w i t h a t h i x o t r o p i c filler ( C a b - o - s i l , Cabot Corp.). T h e final c o m p o s i t e f o r t h e s t r u c t u r e consisted of f o u r layers of jute r e i n f o r c e d polyester f o r the i n n e r s k i n ; three layers of jute r e i n f o r c e d p o l y Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
ester f o r t h e c o r r u g a t i o n s ; a n d one l a y e r of jute r e i n f o r c e d polyester a n d one
l a y e r o f .010-inch glass r e i n f o r c e d polyester
(Figure
4).
T h e exterior glass r e i n f o r c e d
f o r t h e outer
layer provided
skin
a barrier
against w e a t h e r i n g . T h e c o m p o s i t e w a s a n a e r o d y n a m i c structure—i.e., t h e s k i n c o u l d b e p i e r c e d w i t h a s h a r p b l o w , b u t t h e flexural m o d u l i w o u l d p r e c l u d e f a i l u r e i n h i g h w i n d a c t i v i t y . F i n a l b e a m tests o n t h e c o m p l e t e d c o m p o s i t e structures p r o v e d that loads greater t h a n 1800 l b s c o u l d b e a p p l i e d , w i t h deflections u p to .68 i n c h ( T a b l e I V ) . WALL PANEL ~ OlATElR I. " .
SECTION
SKIN
Figure 4. Field
CROSS
Final composite sandwich for prototype
structure
Testing
A l t h o u g h laboratory testing h a d been conducted
throughout the
entire r e s e a r c h a n d d e v e l o p m e n t phase, i t was felt that f u l l scale p r o t o t y p e t e s t i n g w o u l d b e m o r e significant a n d c o n c l u s i v e t h a n a n y single o r sect i o n a l test.
F u r t h e r , t h e f o u n d a t i o n / a n c h o r i n g system c o u l d o n l y b e
tested u n d e r c y c l o n i c c o n d i t i o n s . G r u m m a n A e r o s p a c e E n g i n e e r i n g C o r p . p r o v i d e d its C a l v e r t o n , L . I . test f a c i l i t i e s f o r this p u r p o s e . T h e f u l l y a s s e m b l e d p r o t o t y p e house w a s t r a n s p o r t e d f r o m A r m a n d G . W i n f i e l d I n c . to C a l v e r t o n w h e r e i t w a s a n c h o r e d i n t h e g r o u n d . T h e a n c h o r i n g c o n d i t i o n s w e r e s i m i l a r to those i n B a n g l a d e s h ( F i g u r e 5 ). It w a s p l a c e d 50 ft f r o m a n d p a r a l l e l to a cross section of a i r p o r t r u n w a y ( F i g u r e 6 ) . U s i n g a N a v y A - 6 A I n t r u d e r jet fighter, t h e engine p r o f i l e i n d i c a t e d that w i n d speeds a p p r o a c h i n g c y c l o n i c forces c o u l d b e g e n -
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
20.
WINFIELD
AND
Table IV.
LOW Cost
WINFIELD
215
Housing
Flexure Test of Flat Sandwich Construction
0
Panel 1-1
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
1- 2
2- 1
2-2
3- 1
4-layer core, new c e m e n t , tested w i t h w o v e n r o v i n g side i n c o m pression u l t i m a t e l o a d — 1 8 1 0 lbs u l t i m a t e deflection—0.65 i n c h m o d e of f a i l u r e — c o r e failure S a m e as 1-1, tested w i t h w o v e n r o v i n g i n t e n s i o n u l t i m a t e l o a d — 1 6 5 0 lbs u l t i m a t e deflection—0.52 i n c h m o d e of f a i l u r e — c o m p r e s s i o n i n s k i n a n d core 6
3-layer core, tested w i t h w o v e n r o v i n g side i n compression u l t i m a t e l o a d — 1 3 5 0 lbs ultimate deflection—0.68 inch m o d e of f a i l u r e — c o r e failure S a m e as 2 - 1 , tested w i t h w o v e n r o v i n g i n t e n s i o n u l t i m a t e l o a d — 1 0 5 0 lbs u l t i m a t e deflection—0.51 i n c h m o d e of f a i l u r e — c o m p r e s s i o n i n s k i n a n d core 3-layer core, o l d c e m e n t , tested w i t h w o v e n r o v i n g i n tension u l t i m a t e l o a d — 7 3 0 lbs ultimate deflection—0.63 inch m o d e of f a i l u r e — c o r e failure 0
° Round steel bars, 2 inches in diameter, were used in loading. Specimens were loaded at two quarter-span points with the span length equal to 18 inches. The panel width was 6 inches. Load was applied at the rate of 0.10 inch/min, and defletion measured was crosshead movement. Ultimate formulation of rigid and flexible polyesters stiffened with a thixotropic filler (see text). Earlier, unsatisfactory cement formulation. b
c
e r a t e d against the p r o t o t y p e at a d i s t a n c e of 50 ft. H o w e v e r , the surface t e m p e r a t u r e o n the p r o t o t y p e s k i n at this distance w o u l d r e a c h over 200°F.
A n o n o m e t e r s w o u l d be u s e d to c l o c k the a i r speed of a s i n g l e
jet engine. T o c o o l the p r o t o t y p e s k i n a n d to s i m u l a t e c y c l o n i c c o n d i tions f u r t h e r , 750 g a l / m i n of w a t e r f r o m a h i g h s p e e d p u m p e r fighting
(fire
e q u i p m e n t ) w o u l d b e d i r e c t e d i n t o the p a t h of the jet.
F o u r tests w e r e p l a n n e d — e a c h to last at least 5 m i n u t e s ( T a b l e V ). Tests 5 a n d 6 w e r e to be f u l l jet blasts a n d w o u l d b e r u n "to d e s t r u c t . " Tests 1, 2, a n d 5 w o u l d be a i m e d at w a l l N o . 1—i.e., t h e 10 X 10 ft e n d — w h i l e tests 3, 4, a n d 6 w o u l d be a i m e d at the 10 X 20 ft side. Results N o p r e v i o u s jet tests w e r e m a d e to c h e c k o u t the l o c a t i o n of the anonometer i n r e l a t i o n to the jet blasts. I n the first test, b o t h jet engines w e r e o p e r a t i n g a l t h o u g h o n l y the use of one engine h a d b e e n p l a n n e d .
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
216
FILLERS
Figure 5.
Completed
AND
REINFORCEMENTS FOR
PLASTICS
prototype prior to testing at Grumman Aerospace neenng Corp., June 1972
Engi-
I n a c c u r a t e anonometer readings s h o w e d that this a p p a r a t u s w a s b e t w e e n t h e jets r a t h e r t h a n i n l i n e w i t h the blasts. W h e n the p i l o t a c c e l e r a t e d b o t h engines to get a r e a d i n g , this blast r i p p e d a w a y the v e r a n d a , the t a p e g r i d , a n d e x t e r n a l t e m p e r a t u r e gages.
T h e p u m p e r h a d not
yet
been turned on ( F i g u r e 7 ) . E x t r a p o l a t i o n of the d a t a f r o m the s p a s m o d i c r e a d i n g s o n the a n o n o m e t e r , c o u p l e d w i t h the e n g i n e profiles as t h e y r e a c h e d p e a k a c c e l e r a t i o n , p r o v i d e d a conservative estimate ( G e o r g e L u b i n a n d Peter D o n a h u e , G r u m m a n A e r o s p a c e E n g i n e e r i n g C o r p . ) t h a t b y the t i m e the w a t e r w a s
Figure
6.
Ground pZan of prototype to airport taxiways
adjacent
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
20.
WINFIELD
AND
Low
WINFIELD
Table V .
Cost
Planned Test Sequence and Conditions Wind
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
217
Housing
Test No.
Wall No.
1 2 3 4 5 6
1 1 2 2 1 2
Velocity, mph 50 100 50 100 136 136
Water Spray, gpm 750
750
—Courtesy CARE, Inc.
Figure 7.
?rototype
dunng testing at Grumman
Aerospace Corp., June
1972
released a n d the test c o m p l e t e d , the force o n the p r o t o t y p e was a p p r o x i m a t e l y 200 knots—i.e., ca. 230 m p h . T h e e x t e r n a l s k i n o n the e n d h a d b u c k l e d s l i g h t l y f r o m the heat ( 2 0 0 ° F ) b u t r e l a x e d after c o o l i n g .
Tapes
a n d gages w e r e b l o w n off a n d c o u l d n o t b e u s e d as c o n c l u s i v e e v i d e n c e . T h e i n t e r i o r a n d exterior cameras w e r e s o a k e d b y w a t e r w h i c h p e n e t r a t e d the w o o d e n w i n d o w shutters. I n t e r n a l t e m p e r a t u r e rises w e r e u n d e t e c t e d . A l t h o u g h the p r o t o t y p e v i b r a t e d f r o m this force, i t d i d not m o v e .
The
f o u n d a t i o n h e l d , a n d the house was left i n t a c t w i t h o n l y m i n o r d a m a g e to its glass fiber r e i n f o r c e d p o l y e s t e r s k i n surface.
T h e 10-ft w a l l s p a n
h a d deflected o n l y 2.3 inches o v e r a l l . T e s t N o . 1 h a d , i n effect, b e c o m e tests 5 a n d 6 ( T a b l e V I ) .
T h e other tests w e r e a n t i c l i m a c t i c a n d are
covered i n Table V I .
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.
218
FILLERS A N D R E I N F O R C E M E N T S FOR PLASTICS
A n a d d i t i o n a l series of tests o n c o m p l e t e d panels u s i n g a n e w j o i n i n g system r e q u i r e d f o r t h e second p r o t o t y p e w a s c o n d u c t e d at the D e B e l l and Richardson Testing Institute ( H a z a r d v i l l e , C o n n . ) based o n A S T M E-72. inches
T h e s e tests s h o w e d deflection r e a d i n g s f a r i n excess of the 2.3 of deflection
noted
i n t h e s p e c t a c u l a r l y effective
but limited
G r u m m a n tests.
Downloaded by HONG KONG UNIV SCIENCE TECHLGY on May 6, 2018 | https://pubs.acs.org Publication Date: June 1, 1974 | doi: 10.1021/ba-1974-0134.ch020
Table V I .
Revised Test Sequence and Conditions Wind
Test No.
Wall No.
1 2 3 4
1 2 2 2
Velocity, mph
220-230 40 115 170
Water Spray, gpm 750
750
Conclusions O n l y b y u s i n g i n e x p e n s i v e fillers as stiffeners (i.e., c a l c i u m c a r b o n a t e a n d j u t e ) w a s this project successful.
J u t e as a r e p l a c e m e n t
filler
for
glass fibers p r o v e d its effectiveness once t h e e x t e r n a l fibers w e r e r e m o v e d by double shearing a n d calendering.
J u t e - r e i n f o r c e d polyester i n s u c h
c r i t i c a l a p p l i c a t i o n s suggests m a n y potentials i n this d i r e c t i o n b u t i n d i cates t h e n e e d f o r m o r e research a n d d e v e l o p m e n t . rials d e s c r i b e d a v e r a g e d $ . 4 1 2 5 / f t
2
T h e use of t h e m a t e -
of c o m p o s i t e a n d b r o u g h t t h e c o m -
p l e t e d s t r u c t u r e to p a p e r costs w i t h i n 1 5 % of t h e $300 g o a l . T h e project f r o m i n i t i a t i o n t h r o u g h m a t e r i a l f e a s i b i l i t y studies, p r o t o t y p e d e s i g n a n d c o n s t r u c t i o n , a n d f u l l scale testing w a s a c c o m p l i s h e d i n 16 weeks. This development
u s i n g plastics m a t e r i a l s a n d i n o r g a n i c fillers i n
association w i t h i n d i g e n o u s n a t i v e r a w m a t e r i a l s m a y result i n t h e c r e a t i o n of safe, d u r a b l e , a n d e t h n i c a l l y a c c e p t a b l e
l o w cost h o u s i n g f o r
d e v e l o p i n g a n d d e v e l o p e d countries. Acknowledgments T h e authors t h a n k C A R E , I n c . , a n d p a r t i c u l a r l y L o u i s S a m i a , R a l p h Devone, H e n r y Sjaardema, Robert C o w a n , a n d W i l l i a m W o u d e n b e r g for their cooperation.
T h e y also t h a n k G e o r g e L u b i n f o r s p e c i a l t e c h n i c a l
assistance. RECEIVED October 11, 1973.
Deanin and Schott; Fillers and Reinforcements for Plastics Advances in Chemistry; American Chemical Society: Washington, DC, 1974.