#	Pagina
attuale pagina	/open-h2020/projects/205409/results.html

Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - Wall-ACE (Wall insulation novel nanomaterials efficient systems)

Teaser

Summary

Wall-ACE aims at developing a system of new advanced sustainable insulation products, complementary to each other. The whole wall of a building is closely considered. This system called HONEST (High performance Optimized Nanomaterial Energy efficient SysTem) is a set of solutions that will address most of the complex challenges raised by thermal refurbishment issues and during construction of new buildings. HONEST includes: insulating thermal coating-finishing with low emissivity, internal high performance insulating plaster, insulating interior patching filler, external high performance insulating render, and insulation clay bricks. In total 5 products/systems for a wall, which exhibit top insulation performance as well as improved comfort, indoor air quality, fire safety, durability and sustainability. The development of these products occurs through strong synergies between the 13 different members: industrial partners, public institutes, engineering and consulting companies. The key component for HONEST is the silica aerogel, an advanced nano-technological and fully mineral material with high insulation performance and sustainability. One important objective is to optimise its properties and its production costs.
In the first half of the project the 5 systems were developed first in the laboratory and then for the scale-up step, focussing on the replicability and the workability. The project sets also a major focus on the â€œgo to marketâ€ validation of the products. Business planning and performance assessments are already started.

Work performed

ENERSENS set-up the most important characteristics of silica aerogel (especially particle size distribution) for a production with best possible properties for industrial partners. More than 3000 Liters of KWARKÂ® silica aerogel were delivered to the partners.
VIMARK developed the first prototypes of internal plaster. Thermal performances were investigated and evaluated by POLITO and USTUTT. The formulations of the coating-finishing that stand out for mechanical performance were assessed by POLITO for defining thermal properties. Encouraging results were shown.
TOUPRET tested several formulations of the interior patching filler. Results led to the definition of the suitable aerogel PSD together with other insulating aggregates with good insulating performances.
A technical-economic evaluation of the raw material used in the final products was done. The most relevant competitor products were also compared.

A mineral sprayable external render with good workability and insulation property was developed. The charge mortar matches well to defined target for the thermal conductivity and shows excellent workability properties for an automatic industrial filling.
Bricks with a combination of large sized holes with sufficiently dimensioned bridges to provide a high filling capacity combined with high static strength have been designed and produced.
Thermal conductivity of exterior render and charge mortar and of wall brick was measured by USTUTT. Numerical simulations were conducted to estimate optimisation of thermal conductivity due to adding of aerogel-based charge mortar as brick filling. A measurement methodology was developed to perform dynamic test on empty bricks and bricks with charging mortar by POLITO.

Regarding demonstration phase, first installation had been finished in an ATC building, monitoring is fully installed and had started successfully. Other buildings are identified and preparatory works started.
Numerical toolsâ€™ development led to the first version of the new type unit dedicated to TRNSyS by Effinâ€™Art. USTUTT and POLITO progressed with modeling, first validation of numerical model on experimental results gave good concordance. BRE and CEA worked on preliminary numerical simulations to include products in already existing tools. First results emphasised possible energy savings by improving comfort and increase wall temperatures inside.

The scope of Life Cycle Analysis is defined. For life cycle inventory, data sheets were created and circulated by USTUTT for collecting all relevant data of product and installation stages, and information about use and end-of life.

We established prior art, initiated a patent monitoring process in order to ensure the definition of an IP strategy for Wall-ACE and assess capacity of recording patent for our innovative solution.

A Wall-ACE promotional video, poster and logo were created. The partners have participated to different events to promote widely Wall-ACE, and have delivered the first exploitation and dissemination plan.

Final results

With regards to progress beyond the state of the art,
The existing process and production equipment of aerogel powder has been improved; this will allow the manufacturing aerogel in a quicker and more cost-effective way.

Wall-ACE aims at developing an interior thermal coating-finishing with low-emissivity being at least 25% more energy performant than the state-of-the-art ones, with improved thermal comfort.
In laboratory we achieved good results with the developed formulations in view of thermal conductivity. We started already the first installation of the coating finish at demo site in Torino.

The partners aim also at developing internal high performance insulating plaster and external high performance insulating render that are at least 30-40% more energy performant than the best traditional insulating plaster.
The developed formulation of internal insulating plaster can be sprayed on the wall and showed encouraging thermal insulation properties, a good adhesion between binders and the light nanomaterials, and a good workability.
The external insulating render showed also very good workability. Thermal conductivity tests showed very good insulating properties of the render, beyond conventional expanded polystyrene plates.

The insulating interior patching filler is expected to decrease up to 80% the thermal conductivity relative to standard ones.
Results of the tested formulations led to the definition of the suitable aerogel particle size distribution together with other insulating aggregates.

The energy efficiency of the masonry brick units is expected to be increased by about 15% compared to the best performant bricks in the market.
We have determined the thermal conductivity of developed hollow brick with various fillings experimentally and numerically. The brick with aerogel-based filling showed a high performance beyond state of the art with Î» < 0.07 W/(mâˆ™K).

Wall-ACE aims also at increasing the durability of silica aerogel-based materials.
The analysis of life cycle (LCA) and life cycle costs (LCCA) for all the products developed have started.

The products developed are a complete solution for a building wall with outstanding insulation properties and reduced costs. The high thermal insulation of the materials used helps to save energy consumption. The insulating layer can be applied significantly thinner: this is a great advantage, especially when renovating historical listed buildings. Wall-ACE products could help reduce CO2 emissions. The developments are based on silica-aerogel and are almost completely mineral and thus especially fire-resistant and sustainable. The Wall-ACE products have a high replication potential in both new construction and renovation in Europe.