Ceramic Roof Research Articles

Optimizing industrial tunnel kiln operations for ceramic roof tile production: A bi-objective approach

The ceramic firing process constitutes a highly energy-intensive production step that significantly affects the quality and final properties of the ceramic product. This work presents a model-based, bi-objective optimization approach for an industrial-scale tunnel kiln used in ceramic roof tile production, focusing on the exploration of trade-offs between productivity and thermal energy consumption. Initially, sintering kinetics are established based on lab experiments and integrated within a novel physics-based tunnel kiln model, thus allowing sintering evolution to be considered for the derivation of the optimal kiln operation. Two bi-objective optimization studies are then conducted to explore trade-offs under steady-state and transient-state kiln operations, thus generating a set of non-dominated operating policies. The attained Pareto optimal solutions are then evaluated with respect to the values of Specific Energy Consumption (SEC), which is distinctly minimized. This results in optimal SEC values of 0.283 for the steady state and 0.277 kWh/kg for the transient state kiln operation.

Influence of Luffa fibers thermomechanical treatment and ceramic roof tile waste on performance of cementitious composites

The performance of vegetable fibers and the insertion use of different residues in as substitution for cement are important crucial factors to be evaluated to assess in composites. Therefore, this research aims to evaluate the efficiency of thermomechanically treated vegetable fibers and the replacement of 40% of the cement mass with ceramic roof tile waste (CRW) in fiber-cement composites. Thermomechanical treatment of Luffa cylindrical fibers (LC) at 160 °C resulted in reduced absorption in composites with added ceramic roof tile waste (CRW-160) after 1 year of aging. This indicated improved mechanical performance and durability compared to composites with natural fibers. In the CRW-160 matrix, no cracks were observed, and the fibers exhibited greater pullout. The results of aged composites (CRW-160) demonstrated superior performance compared to matrices with only cement and LC fibers, as well as composites with a 40% cement replacement by CRW. This suggests that the combined use of thermomechanically treated LC fibers and partial cement replacement with CRW can enhance composite durability, reduce cement usage, and increase the utilization of discarded waste.

Undecorated Roman-Period Roof Tiles – An Old Material Providing New Results

Abstract Undecorated ceramic roof tiles and their fragments are one of the most enduring and numerous remains of the earthen architecture of the Roman period to survive to us from many parts of the Roman world, especially from the Mediterranean region. Despite this, we have huge gaps in our knowledge regarding this material due to the sparsity in specialist studies and published excavation or survey records. The most detrimental gap is a lack of sufficiently fine-grained tile typology to easily situate and compare any tile material found. This work will outline the methodology used in the author’s recent research concerning Roman-period ceramic roof tiles in the Eastern Mediterranean and discuss the different ways we can approach undecorated roof tiles as material to gain valuable data. The work will also touch on the current limitation we have for further research in using this material as a dataset based on the status of research (limited and biased), the methodologies that would be most valid for research (e.g. is typology still a valid tool?), and the means we have in increasing the value of this material as a source for knowledge (better documentation). Such research allows us to gain meaningful and interesting new information on style, production, and transfer of knowledge and technology, which ultimately will help us to better understand how past societies functioned and interacted.

Optimal Tunnel Dryer Operating Strategies for the Production of Ceramic Roof Tiles under Tight Quality Considerations

Optimal Tunnel Dryer Operating Strategies for the Production of Ceramic Roof Tiles under Tight Quality Considerations

Evaluation of the possibility of improving the durability of tools made of X153CrMoV12 steel used in the extrusion of a clay band in ceramic roof tile production

Abstract The article presents the results of a complex comparative analysis of the abrasive wear resistance of tools made of X153CrMoV12 steel after different heat treatment variants. These investigations aimed to select the most durable material for application in tools forming a mass band in the production of ceramic roof tiles. The tests included the determination of resistance to abrasive wear in ball-on-disc tests, hardness measurements, and microstructure analysis, including the assessment of changes occurring in the subsurface area, as well as impact tests (at a working temperature for the tools of 50°C). The comprehensive test results showed that the best effects of increasing the resistance to abrasive wear can be obtained through a heat treatment that consists of hardening at 1020°C and then tempering at 200°C for about 2 hours. The next stage of research will be to compare the results obtained with another popular material for tools for the production of roof tiles - Hardox steel, which is characterized by high resistance to abrasive wear.

백제 사비기 왕궁과 사원의 기와 수급 방식과 와공의 동향

The purpose of this study is to shed light on the differences in the production and distribution of ceramic roof tiles used in the construction of the royal palaces and Buddhist temples of Baekje in the Sabi period (538-660) and the changes that occurred in the activities of the tile makers.The discussion in Chapter 2 is focused on the differing ways in which ceramic roof tiles were used in the construction of royal palaces and temples during the Sabi Baekje period. The convex roof-end tiles excavated at the sites of Baekje’s royal palaces, including those at Busosanseong Fortress, Archaeological Site in Gwanbuk-ri, Gua-ri and Ssangbuk-ri Buyeo, shared similar decorative motifs such as circular and triangular dots and waves for a long period of time. Conversely, the convex roof-end tiles discovered at temple sites dating back to the Sabi Baekje period, such as Temple Sites in Neungsa-ri and Gunsu-ri, and Wangheungsa Temple Sie in Buyeo, and Jeseoksa and Mireuksa Temples in Iksan, show that more than two new motifs were introduced at that time. The difference can be explained by the fact that new buildings continued to be added to the royal palaces, making necessary stricter management and control of the tile manufacturing facilities and equipment.In Chapter 3, the discussion deals with the ways in which roof tiles were produced and distributed for the construction of royal palaces and temples and the tendencies of tile makers. The roof tiles of new Buddhist temples built during the Sabi period were supplied by both state-run kilns and private kilns specializing in the production of roof tiles for Buddhist temples. The construction of palace buildings in the Sabi period led to continuous growth inthe size and number of tile kilns, as can be seen in the kiln sites at Geumdeok-ri, Jeongam-ri, Jeongdong-ri, Wangjin-ri and Hyeonbuk-ri. The discoveries made at the Yeondong-ri kiln site in Iksan suggest that the tile makers hired by the government-run workshops in Buyeo produced the roof tiles required for construction projects in the Iksan area. The excavation of the Wangheungsa Temple kiln site has revealed that the operator of the kiln organized temporary teams of tile makers from among workers at other kilns, suggesting a turning point in the history of tile production in Baekje. Analysis of the archaeological features has also revealed that the tile kilns of Wangjin-ri, Gwanhyeon- ri and Bonui-ri in Cheongyang were created by tile makers who had previously worked at the larger, government-financed kilns in Jangam-ri and Geumdeok-ri in Seocheon. The appearance of the convex roof-end tiles discovered at the kiln sites in Sinsan-ri of Seosan, Bunhyang-ri of Cheongyang, Sudeoksa Temple in Yesan, and Cheonho-ri of Nonsan suggests that they were produced by tile makers sent from the government-run kilns in the capital of Baekje for short-term local projects. Such changes in Baekje’s tile production system resulted from the effort to meet the need for a new system to ensure the mass production of roof tiles, effectively meeting the rapidly growing demand related with the construction of the fortified capital of Sabi in the late sixth century.

Comparative Analysis of the Wear of NC11LV and Hardox 600 Steel Used in Tools for Extrusion of Clay Strands in the Process of Producing Ceramic Roof Tiles.

This article presents the results of a comparative analysis performed with respect to the wear of tools used for the extrusion of a clay strand (for ceramic roof tile) made from two materials: steel NC11LV and steel Hardox 600. The aim of the studies was to determine the causes and mechanisms of wear as well as to evaluate the possibility of choosing the optimal material, mostly in respect to its resistance to intensive wear as well as an increase in the operation time. The results of the conducted investigations included: an analysis of the technology, thermovision measurements of the forming process, a macroscopic analysis combined with 3D scanning of the worn tools, ball-on-disc tests of the sliding wear resistance and hardness measurements. The obtained results demonstrated that the tools made of steel NC11LV were much less worn than those made of steel Hardox 600, as the operation time for the NC11LV steel tools was almost three times longer. The results of the ball-on-disc tests showed a similar manner of wear for both materials (with the working temperature of about 50 °C). The higher durability of the tools made from steel NC11LV can be an effect of a slightly lower coefficient of friction in the initial period of operation as well as the presence of hard carbides, which means increased hardness and thus also higher wear resistance at working temperatures.

Porous Ceramic Roof Insulation in Malaysia’s Construction Industry: A Review

Nowadays, Malaysia's construction industry has risen to become one of the country's fastest-growing industries. The application of green building is becoming more popular towards increasing the use of sustainable products in the construction industry. Nevertheless, due to rapid construction and low sustainable products for buildings, problems related to thermal comfort could indeed arise which may cause people stress and irritation. As a result, the objectives of this paper are to identify the issues, problems, concepts, and needs of Porous Ceramic Roof Insulation. In order to do so, extensive literature reviews conducted via various databases (i.e., Scopus, Web of Science, and Scopus) were explored. The findings have revealed that Porous Ceramic Roof Insulation has the potential to be marketed due to its great benefits (i.e., roof cooling, water absorption, solar absorption, and heat absorption within the building). Thus, it is anticipated that the study of Porous Ceramic Roof Insulation would improve the building's well-being while increasing thermal comfort.

Characteristic Analysis of Solar Panels on Clay and Ceramic Roof Tiles

Wydawnictwo SIGMA-NOT wydaje czasopisma fachowe informujące swoich czytelników o najnowszych osiągnięciach naukowych i nowoczesnych rozwiązaniach technicznych w Polsce i na świecie, popularyzuje problemy techniczne oraz poszerza wiedzę i kulturę techniczną.

Recycling of Iron Slag Waste in the Production of Ceramic Roof Tiles

The merit of this study is manufacturing cheaper roof tiles using fluxed waste material such as granulated iron slag, in addition to the environmental benefit of decreasing the cost and negative impact of their disposal and landfilling. Waste water-cooled granulated iron slag was ground and added in proportions ranging from 0 to 30 wt.% to kaolin clay to prepare roof tiles for the economic purpose of decreasing the production cost by incorporating cheap waste and to serve sustainability. The raw materials were characterized by XRD, XRF, and particle size analysis. The specimens were shaped using a rectangular mould with dimensions of 150 × 30 × 30 mm3 under an axial pressure of 10 MPa and then dried in a dryer at 110°C. The firing of the dried specimens was carried out at 900, 1000, and 1100°C. The characteristics of fired specimens were determined by their linear firing shrinkage, water absorption, compressive strength, and freezing-thawing resistance. Results showed that samples containing 20% slag waste and fired at 1000°C displayed a cold water absorption of 12% and a saturation coefficient of 0.82, both values being lower than the maximum value recommended by standards. Also, the recorded breaking strength of 5040 N was much higher than the minimum standard value. These samples were also subjected to 50 freeze-thawing cycles, which they passed without the appearance of any cracks. It was concluded that samples containing 20% slag waste and fired to 1000°C or 1100°C fulfilled the requisites of ASTM C1167 for grade 3 normal duty roof tiles.

Characteristic Analysis of Solar Panels on Clay and Ceramic Roof Tiles

Characteristic Analysis of Solar Panels on Clay and Ceramic Roof Tiles

Life cycle assessment of ceramic roof tiles: A temporal perspective

The production of ceramic roof tiles is energy intensive, leading to high carbon dioxide emissions intensity. The aim of this study is to conduct a life cycle assessment study to evaluate the environmental profile of ceramic roof tiles produced in two Portuguese ceramic plants (T1 and T2) that use different technologies. This assessment is performed on a temporal basis (over a 10-year period) to evaluate the effect that ceramic processual changes have on environmental impacts. System boundaries include the whole life cycle—from extraction and acquisition of raw materials up to tile end of life. Environmental impacts were calculated for eight impact categories. The impact results show an overall improvement in the environmental performance of roof tiles produced in T1 and T2 for all impact categories over the 10-year period as a result of the continued introduction of technical and energy saving measures during the tile manufacturing. Overall, roof tile 2 shows the worst environmental profile for all impact categories, with the exceptions of acidification and photochemical oxidant formation, due to the use of refractory material in the firing process. These exceptions can be explained by the existence of a dry flue gas cleaning adsorber with a filter coupled at kilns in T2. • Ceramic roof tile LCA study with inventory data over a 10-year period enables an integrated timeframe perspective of roof tiles environmental burdens. • Overall, improvement in the environmental performance of the T1 and T2 plants for all impact categories over the 10-year period was observed. • Changes to production technology affect the potential environmental impacts of ceramic roof tiles. • Overall, the production stage (modules A1–A3) is the hotspot for all impact categories.

Real-time sensing and low-cost experimental setup for water quantity investigation in Nature-based Solutions

Abstract Nature-based Solutions (NbS) Regulatory Ecosystem Services are less tangible and more complex to quantify. Among these, research to quantify water regulation services provided by Blue-Green Infrastructure is especially relevant for a range of different applications. However, to reach this quantification, experimentalists usually need to measure the flow rate, which can be costly if using high-end industry standard sensors. The present article brings, thus, a low-cost experimental setup for real-time data capture and logging using the US-025 ultrasonic sensor. The proposed setup measures a weir tanks’ water level in order to indirectly estimate the flow rate. A successful pilot experiment is described, estimating the water quantity performance of a vegetated roof in comparison to a ceramic tiled roof. For a same event, flow rate measures taken by the proposed setup are compared to readings from a rain gauge and results show a close trend. The performance of the vegetated roof has shown substantial rainfall retention and detention when compared to the ceramic roof. It is concluded that the setup is a cost-effective tool that can be attached to inlets and outlets of different NbS for characterising a range of water flow rates capable of supporting laboratory and field data capture.

Desempenho térmico de aviário localizado no semiárido pernambucano a partir de simulação computacional

ABSTRACT For studies of thermal performance, computational modeling has been presented as an important decision-making tool to solve complex and everyday problems in poultry production and research. Thus, the present study aimed to validate computational models developed using the EnergyPlus software package and, based on these, evaluate the thermal performance of a poultry house with different types of tiles (thermoacoustic, ceramic, fiber-cement, and metal). The research consisted of two stages: an experimental phase and another phase in which the climatic conditions in four aviary models are numerically simulated, considering different types of tiles. The experimental phase was conducted in two climate seasons, winter (2019) and summer (2020), where air temperature and relative air humidity data were measured and recorded using six HOBO model H12 data loggers distributed inside an aviary located in the semiarid region of Pernambuco state, Brazil. For the computer simulation, a virtual model of the house was developed using the OpenStudio graphical user interface in Sketchup, and the thermal performance was calculated using the EnergyPlus software package. The models were validated, showing a strong correlation between the experimental and simulated data, with Pearson’s correlation coefficient (r) values greater than 0.95. The simulations demonstrated the influence of the roof tiles on the thermal performance of the evaluated building. For the climatic conditions of the semiarid region of the Pernambuco state, thermoacoustic roof tiles presented the best thermal performance, followed by ceramic, fiber-cement, and metal roof tiles.

Characteristic Analysis of Solar Panels on Clay and Ceramic Roof Tiles

In general, the Rooftop PV Panel installation only considers the power capacity to be installed and the available roof area. It does not consider the type of roof material where it is installed. Meanwhile, the roof of the house has the absorption of sunlight and different thermal properties depending on the type of roofing material. In this study, the objective of this research is to observe the temperature characteristics between solar panels and roofs from 2 types of materials, namely clay tile and ceramic tile, the influence of the height between the solar panel and the ceiling on the temperature and its effect on the efficiency of the solar panel. Based on the results of this study, the temperature characteristics between the solar panel of various types of material have an influence on the efficiency value of the solar panel, where the maximum efficiency value obtained for clay tile material is 4.22% and ceramic tile is 5.69%.

ANALYSIS OF SURFACE THERMAL BEHAVIOR FOR THE STUDY OF URBAN HEAT ISLANDS: AN EXPERIMENT USING UNMANNED AERIAL VEHICLE (UAV)

The objective of this study was to analyze the variation of horizontal superficial temperature of different typologies of surfaces through thermographies using a thermal camera embedded in an unmanned aerial vehicle (UAV). The temperature data of some typologies of ground cover (asphalt, cement sidewalk, lawn and trees) and buildings cover (ceramic roof and cement tile) were analyzed. The results showed that there was a greater retention of heat by the asphalt covering, followed by the cement sidewalk. The temperature of the lawn was high during the day, but at night it was the surface with the lowest temperature among all analyzed. The top of the tree accumulated less heat during the day and it took longer to lose it during the night, getting the lowest thermal amplitude. At the building covering surfaces, while the temperature of the ceramic roof suffered little variation during the day, the cement tile suffered a high variation, showing that it is not a good thermal insulator. The use of UAV allowed a quick acquisition of the thermographies of the selected targets. The weather analysis was a determining factor to carry out the UAV missions.

Roof-mounted photovoltaic generator temperatue modeling based on common brazil roofing materials

This paper examines the performance of solar photovoltaic generators on roofs of residential buildings. The primary focus is the loss of performance due to temperature increase as function of roof material and the distance from the photovoltaic (PV) generator to the roof. A heat transfer model has been developed to predict PV module temperature, and the equations of the model were solved using the Engineering Equation Solver (EES) software. The research modeling correlates the distance of the solar generator to the roof and the roofing material with the temperature variations in the PV generator. There are many models to predict PV module temperature, but this study refines the prediction by the distance from PV module to roof and the roofing material as variables. Optimal combinations of distance and materials that minimize the heating loss in the solar generator leading to increased electrical power generation. Results show an average error of 3%–4% from the temperature predicted by the model to the temperature measured under experimental conditions in Belo Horizonte, Brazil. The minimum roof-module separation required to ensure minimal PV performance loss from heating from the roof is ∼10 cm for red ceramic and cement fiber roofs. For galvanized steel, the optimal distance is between 20 cm and 30 cm. Cement fiber shows the best predicted and measured characteristics for PV-panel roof mounting among the 3-common commercial roofs evaluated in these studies. These investigations were based on roof installations and local materials in Belo Horizonte, Brazil.

Solar energy available and energy generated in photovoltaic systems in different inclinations and orientations of roofs of buildings

This work aimed to determine the solar energy available in different inclinations and orientations of roofs of buildings in the four seasons, using data of Global Solar Irradiation in the horizontal plane, temperatures, and wind speed. The inclined hourly solar irradiation and the energy generated by photovoltaic systems of different capacities installed in Cascavel-PR were simulated, with different orientations and inclinations and types of roofs (ceramic, fiber cement and metal). SWERA (Solar and Wind Energy Resource Assessment) daily global solar irradiation and wind velocity data were used to simulate daily inclined global solar irradiation in PVSyst software. Thus, also with the help of the software, the energy generated by photovoltaic systems of different capacities installed in Cascavel - PR, with different orientations and inclinations of roofs was determined. Consequently, the levels of losses in different seasons of the year were calculated and an analysis of the economic viability of the undertakings was made. Thus, the losses, profits and income of the systems were compared. Solar panels installed in northern oriented ceramic roofs provide better energy production performance throughout the year compared to metallic roofs and fibrocement. However, for the other orientations (South, East and West), the losses for ceramic roofs were twice as high as the metallic and fibrocement roofs in relation to their respective northern orientated slopes. Regarding orientation, roofs oriented to the North receive more Irradiation annually and therefore produce more energy. Then there is East, West and South as the most unfavorable condition.

Production of ceramic construction materials as an environmental management solution for sulfidic mine tailings

Mine tailings (MT) waste valorization in construction materials can be one possible solution because they may allow an alternative for some applications as an important contribution for a more circular economy. The aim of this work was to study the feasibility of using a sulfidic mine tailing in the production of building materials such as ceramic roof tiles. The introduction of 5, 10 and 20% MT in ceramic roof tiles promoted an improvement on the final properties of these materials. The use of 20%MT has decreased the firing temperature from 1150º to 1050 ºC, hence promoting energy savings and lower costs. Properties as density and water absorption were improved. Firing shrinkage, many times responsible for cracking, also decrease with the use of MT and, in this way, improve the production rate. The 20% MT ceramic formulation achieved the highest value of strength with lowest firing temperature. For the effects of sulphates' emission (SO2 and SO3 gases) upon firing, a solution was proposed involving their reaction with water and, through condensation, providing afterwards sulphuric acid as a process by-product. The use of high sulphide MT in ceramic roof tiles processing could be viewed as a potential safe waste management solution for these particular mine tailings.

Thermal and gas emission analysis of ceramic roofing tile pastes containing cigarette butt waste

Thermal and gas emission analysis of ceramic roofing tile pastes containing cigarette butt waste