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Manufacturer
Domtec Company Limited
1005/29 Soi
Prachachuen 30
Bangsue, Bangkok 10800, Thailand
Tel: 910-1463,910-1465
Fax. (66-2) 910-1465
WHAT IS MCR?
The Micro Concrete Roofing (MCR) technology is a relatively new technology that can be used to produce inexpensive and reliable concrete tiles for roof cover. The tiles are light, durable and can be made by using locally available raw materials: cement, sand and stone-dust.
Figure
ROOF STRUCTURE:
A roof constitutes the most important part of the building. Hence it is inevitable to take special care during the preparation of the roof and its elements. In order to construct a durable roof, not only the covering material must be of a good quality, but also the entire root structure and cover must function as a coherent system adapted to local conditions such as climate, available skill and structural materials. Roof structures are affected by the following factors:
Load: Conventional concrete and clay tiles weigh 50 to 80 kg per square meter whereas the MCR tiles weigh much less. The load of the MCR tiles on the roof structure depends on its thickness. The following Table shows weight factor for specific thickness grades of tiles:
|
Tile |
Weight / |
Unit / |
Weight / |
|
Thickness |
Unit |
sq.m. |
sq.m. |
|
6 mm. |
1.6 kg |
12.5 |
20.0 kg |
|
8 mm. |
2.2 kg |
12.5 |
27.5 kg |
|
10 mm |
3.0 kg |
12.5 |
37.5 kg |
Figure
In addition to the load from the tiles themselves, it is necessary to consider the wind and repair loads, and in some cases the snow load as well, depending on local weather conditions. The most crucial load in most locations is the wind load. Strong winds or storm can cause great damage to a roof if it is not well made and securely fixed to the building. In general a maximum wind speed of 150 km/h is taken into account which is equivalent to a storm capable of uprooting trees. This results in suction forces on the roof of up to 70 kg/ sq.m. The wind can also create pressure of up to 30 kg/sq.m. on the roof.
Slope: The minimum slope required for the MCR tile roofs is 22° in areas with moderate climate and 30 to 40° in areas with severe driving rains. The slope of the roof is also determined by additional criteria such as aesthetic, form and function.
|
MCR Tile Characteristics: | |
|
Use for: |
Roof covering |
|
Materials Used: |
Concrete (cement, sand, fine aggregate and water) rectangular with broken wedges (special tiles arc manufactured for ridges and edges) |
|
Profile: |
Corrugated |
|
Standard Size: |
25 cm. x 50 cm. |
|
Effective cover: |
20 cm. x 40 cm. (1 2.5 tiles per sq.m. area) |
|
Thickness: |
6 mm, 8 mm. and 10 mm. |
|
Weight: |
1.6 kg., 2.2 kg and 2.8 kg. |
|
Bearing Capacity: |
30 kg, 50 kg, and 80 kg. |
|
Production Capacity: |
200 tiles per day per workstation |
Battens: The setting of battens is the most important part of MCR roofing on which the proper laying of the tiles and water-tightness depend. The spacing of the battens is 40 cm. The battens can be of wood or steel sections which should be able to bear the weight of the tiles and a man (about 80 kg.) for the safety of the workers during construction and maintenance.
Structure: The section and spacing of the purlins and rafters are calculated according to the slope, climate conditions, and weight of the tile. The roof structure needed for MCR roofing is simple and uses light triangular roof trusses. The trusses may be made of wood or metal. But with the increasing scarcity of good quality timber, metal structures are becoming more and more a competitive alternative in roof construction. The main advantage of the metal structure is that it is highly accurate and constitutes an even and stable under-structure for the tiles.
TILE INSTALLATION
To ensure watertightness, a proper installation of the MCR tiles is required, specially in the most exposed areas, that is, the installation of the side and wall plates. The battens supporting the tiles should be fixed by a skilled roofer.
Laying: For the better interlocking of the MCR tiles, they should be first laid from the lower left-hand corner of the slope with the next one overlapping on the top part and then on to form a first vertical row. Then the roofer proceeds with the second and succeeding vertical rows in the same manner. In order to obtain a good interlocking of tiles, it is recommended to install first a complete horizontal row from edge to edge. To align perfectly the columns, it is possible to trace vertical lines with a rope maintained at the top and bottom.
Figure
When the first slope is completed, the second slope is also laid in the same way. The ridge tiles should be installed gradually as soon as enough columns are completed on the second slope. This avoids the need of climbing on the finished part of the roof.
Fastening: For the wind-prone areas, it is very necessary for the tiles to be fastened. In general, all the tiles are fastened by tying the batten with the wire passed through the nib's wire of the tile.
Ridge: The ridge line is covered with specially designed tiles and finally bedded in mortar or pre-casted concrete ridge blocks are glued to allow dry fixing of ridge tiles. Ridge tiles overlap by 50 mm. minimum or may be laid with a double row of ridges.
Figure
Edge: Lateral edges can be made with specially designed tiles; the joint between wall and tiles can be made with a carefully prepared mortar. If there is a roof overhang, a good solution consists in using a fascia board.
Hip and Valley: Hip tiles are specially-designed tiles binded with mortar; valley gutters are most often made of galvanized iron sheet under the cut edge of the tile.
Figure
TRAINING:
Training in the MCR tile production as well as training in installation with the tiles can be provided by the manufacturer. Group training may carried out either at the manufacturer's own training center or at a project site with the equipment provided.
The training costs are established on a case by case basis. For more information and details, please write to the manufacturer.
Manufacturer
Domtec Company Limited
1005/29 Soi
Prachachuen 30
Bangsue, Bangkok 10800, Thailand
Tel: (66-2) 910-1463
Fax. (66-2) 910-1465
Description:
A complete workstations for producing Micro Concrete Roofing (MCR) tiles consists of a vibrating table, an electric motor, 200 plastic moulds and interface sheets, an admixture container and testing equipment for quality control.
Figure
The vibrating table consists of a screeding table and a steel chassis. An electric motor is bolted to the machine in order to vibrate the mixture for compaction.
A container is used to keep fresh concrete mixture to produce tiles. It is made of a steel box (60 cm x 65 cm x 20 cm) fixed on a steel chassis. The box has a sloped front in order to take out the mixture easily.
Moulds are of two types: the moulds for regular tiles are made of ABS plastic and are rectangular in shape with broken wedges. The profile of the tiles is corrugated. The moulds for the ridge tiles are made of wood and steel and have a V-shaped profile.
Figure
Interface sheets are used to transfer fresh mixture from the vibrating table to the moulds. They are placed on the vibrating table under the screeding frame before the mixture is scooped onto it.
The testing equipment used for Bending and Nib Tensile tests consists of a steel frame with two angular sections fixed at a distance of 400 mm.
Figure
|
MCR Tile Characteristics: | |
|
Used for: |
Covering the roof of different types of buildings |
|
Materials Used: |
Concrete mixture of cement, sand and aggregates. |
|
Shape: |
Rectangular with broken wedges (special tiles can be produced for ridges and edges) |
|
Profile: |
Corrugated |
|
Standard Size: |
25 cm. x 50 cm. |
|
Effective cover: |
20 cm. x 40 cm. (12.5 tiles per sq.m. area) |
|
Thickness: |
6 mm, 8 mm. and 10 mm. |
|
Weight: |
1.6 kg., 2.2 kg and 2.8 kg. |
|
Bearing Capacity: |
30 kg, 50 kg. and 80 kg. |
|
Production Capacity: |
200 tiles per day per workstation |
MICRO CONCRETE
The Micro Concrete Roofing technology is a relatively new technology that can be used to produce inexpensive and reliable concrete tiles for roof cover. The tiles are light, durable and can be made using locally available raw materials: cement, sand and stone-dust.
Figure
RAW MATERIALS:
Cement: Portland cement needs to be used in the production of MCR tiles. The cement should be of the standard required for normal concretework. The amount of the cement required for a tile of 8 mm. thickness is 0.45 kg.
Sand: The sand should be well graded, clean and free of organic materials. The clay and silt content of the sand should not exceed 4%. Sand should be seived with a mesh size of 2 mm.
Stone-dust: It should have the same characteristics and properties as sand. The maximum size of the aggregate should not exceed two-thirds of the tile thickness. They should be as clean and free from clay as the sand.
Water: The water should be clean and fresh, and free of salt. If the water quality is doubtful, it can be tested in laboratory for salt content and other chemical contamination.
Colourant: The MCR tiles are naturally light grey in colour. To achieve a more attractive product they may be coloured by using additives to the admixture such as iron oxides or carbon black (darker grey tiles) or, they can be painted using a spray gun or brushes.
Placement: Metal wire is used for fixing the tiles to the roof structure. Galvanized steel wire of 2 mm. diameter should be used for this purpose as it will not corrode. These wires are placed in the nibs when the tiles are fabricated.
PRODUCTION PROCESS:
The general steps are the following:
- Mortar Preparation
- Vibrating and moulding
- 24 hrs mould curing
- Demoulding
- Curing / storage
- Quality control
Figure
ROOF STRUCTURE:
In order to construct a reliable roof, not only the roofing material must be of good quality, but also the entire roof must function as a coherent system adapted to local conditions such as the climate, the available skills and structural materials. Roof structures are affected by the following factors:
Load: Conventional concrete and clay tiles weigh 50 to 80 kg per square meter whereas MCR tiles on the roof structure varies from 20 to 37.5 kg per sq.m. depending on thickness. Consideration should be given to live loads such as wind and rain depending on local conditions.
Slope: The minimum slope required for the MCR tile roofs is 22° in areas with moderate climate and 30 to 40° in areas with severe driving rains.
Battens: The spacing of the battens for MCR tiles is 40 cm. The battens can be of wood or steel sections.
Structure: The section and spacing of the purlins and rafters arc calculated according to the type of materials, slope, climatic conditions, and weight of the tiles.
TRAINING:
Training in production of MCR tiles and in managing production units can be provided by Habitech Center at its typical production facilities on AIT campus. Follow-ups and testing for quality control of the production are provided as an integral part of the training.
The training cost is established on a case by case basis. For information and details, please contact:
Habitech Center
Asian Institute of Technology
G.P.O. Box
2754, Bangkok 10501
Tel: (66-2)524-5611
Fax: (66-2)
516-2128
|
Equipment Characteristics: |
| |
|
Size and Weight of Vibrating Table |
60 cm x 64 cm x 92 cm |
78 kg |
|
Size and weight of Container |
60 cm x 70 cm x 91 cm |
28 kg |
|
Size and Weight of 200 Plastic Mould |
36 cm x 6 1 cm x 120 cm |
120 kg |
|
Size and Weight of 200 Interlace Sheets |
31 cm x 50 cm x 30 cm |
14 kg |
|
Weight of Tools |
39 kg | |
|
Total Weight of Equipment |
279 kg | |
|
Shipment of equipment |
arranged by manufacturer | |
|
Cost of the Equipment (ex - work) |
US$ | |
APPRO-TECHNO
S.A.
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1. Dosage et mlange du sable,
ciment, colorant et fibres. Dosage and mixing of sand, cement, colourant and
fibres.
2. Etalement grossier du mlange.
Rough spreading of the mix.
3. Vibration et lissage final du
mlange. Vibration and final smoothing of the mix.
4. Ouverture automatique du cadre
Automatic opening of the frame.
5. Mise en forme avec l'interface sur
le support double. Giving the final shape with the interface on to the double
support.
6. Empilage des supports pour la
premire cure de 24 heures. Stacking of the supports for the first 24 hour
cure.
7. Dmoulage de la tuile et bavurage
Demoulding of the rite and removal of the excess flashes.
8. Bassins de cure (5 6 jours).
Curing tanks (5 to 6 days).
1.1. What are fibro concrete roofing tiles or micro concrete roofing tiles ?
Fibre concrete or micro concrete roofing tiles are an excellent covering material with very high insulating (thermal and accoustic) qualities; their durability and resistance are also worth mentioning especially in comparison with galvanized roofing sheets. These qualities, together with other macro and micro economic aspects of the so called «locally productible building materials» make this type of roofing particularly appropriate to the realities of developping countries.
The raw materials consist of sand (average granulometry or «well graded» i.e. 0,06 to 0,2 mm), Portland Cement (CPA 35), organic or synthetic fibres (or aggregates) and possibly colourants (chemical pigments).
The tiles can be 8 or 10 mm tiles. We strongly advice against the production of 6 mm thick thiles due to their brittleness, bad resistence to violent winds (hurricanes) and to the problems encountered during their implementation. The money saved in terms of raw material does not compensate these disadvantages.
The manufacturing process is relatively easy. However, one should keep in mind that the productivity and the products quality are directly related to a good knowledge of the material and of the equipment as well as to a rational organisation of the work stations; this is the reason why APPRO-TECHNO offers and strongly advices a complete and professional training (see 2.9.).
The technological process can be summed up as follows *:
- cement and sand (ratio varying between 1:2 and 1:3) are drymixed into a mortar in a concrete mixer. Organic (15 mm long chopped pieces) or synthetic fibres are then added (so called «Fibre Concrete Roofing tiles» or F.C.R.).If, for one or another reason, it is not possible or preferable to use vegetal or synthetic fibres, they can be replaced by aggregates (granulometry not bigger than 2/3 of the final roofing tile thickness). In that case, the final product is referred to as «Micro Concrete Roofing tile» (M.C.R.).
- the mortar is then laid on a plastic interface (already on the vibrating table) inside the screeding frame thanks to a mortar scoop. The mortar should be vibrated ± 45 seconds. The quality and duration of the vibration play an essential part in the quality of the final product (for instance, too long a vibration prevents the distribution of the various elements from being homogeneous, since the heavier elements tend to sink). The nib is also moulded during that time.
- the vibrated mortar is then gently transferred onto a support, which will give its final shape to the tile.
- at this level, the galvanized iron loop is inserted into the nib (to fix the tile on the roof).
- the tile should then remain on the support for 24 hours for shaping and drying and be covered with a plastic sheet to avoid cracks. The tiles are then put in a curing tank for 5 days (the humidity rate being 100 %) and stocked 15/20 days in a shed for final curing. From then on, they can be used or sold.
* a thorough description can also be found in the book by G. Brys, Tuiles en Fibro mortier, procd de production et pose en toiture, Genve, B.I.T., 1988.
1.2. Advantages.
FCR/MCR have many advantages which often make them the ideal solution as far as the roofing issue is concerned in developping countries. These advantages can be identified on severals levels:
Qualities of the roofing material as such:
For the man in street, one of the essential things in every day's life is to have an irreproachable weatherproof roofing material above his head. In this respect, FCR/MCR meet this expectation. But, once again, as for any industrial product, a strict, permanent and intransigent quality control has to be set up. The first function of a roof is to protect its inhabitants from outside elements such as rain and sun.
As far as rain is concerned, FCR/MCR are perfectly waterproof. Moreover, their accoustic insulating qualities are such that no comparison can be made between a FCR/MCR roof and a roof covered with galvanized iron sheets when it rains.
Furthermore, it has been possible to verify the excellent resistance of the FCR/MCR roofs to violent winds in comparison to galvanized iron sheets on the occasion of the «Hugo» hurricane in 1989: most FCR/MCR roofs have not been affected by the hurricane whereas most other roofs have been blown away. In some «risky» areas, it is even advisable to use «hurricane tiles» (with a double fixing device) or thicker tiles (10 mm).
As far as thermic insulation is concerned, they can simply not be compared with galvanized iron sheets, which actually heat houses rather than cool them. This advantage is decisive in areas where coolness is so much looked for and so expensive.
Their mechanical resistance and resistance to shocks are also worth mentioning (a 8 mm tile should resist to a hanging weight of 50 kg). This is important since many galvanized iron sheets roofs are damaged by stones or fruits.
Their life expectancy can be estimated to 15 years at least, which makes their purchase by the final customer very profitable.
Last but not least, a look at the front cover picture will convince you of the esthetic qualities of this roofing material (available in various colours).
Economic advantages:
Beside the quality of the covering material itself, the price at which it can be produced or sold plays an essential part. This price logically varries according to local conditions (raw material, workforce, competitors,...) but, generally speaking, it can be claimed without much risk of error that the cost price of a FCR/MCR roof is cheaper than for other types of roofing (e.g. galvanized iron sheets or fired roofing tiles). It is important to make this comparison in terms of «roof» and not of «product» (i.e. tiles). It is obvious that the roof substructure is different for FCR/MCR and for galvanized iron sheets. For instance, the substructure for FCR/MCR roofing is much lighter (1 m2 = 26,6 kg) and consequently cheaper than for fired tiles roofing.
Many casestudies have shown that 30 to 60 % of the cost price of a roof can be saved with a FCR/MCR roofing in comparison with other types of roofing. In one word, the biggest trump of FCR/MCR is its cost price.
On a macroeconomic level, it is worth noting some advantages likely to encourage the dissimination of this technology and the official support of the local authorities.
First of all, the type of industrial unit that is proposed (see 2.5.) allows to some extend a decentralisation of the industry of building materials. On its scale of course, it enables the authorities to struggle against the process of rural exodus and wild urbanization which affect most developping countries by using local workforce in several production units situated in rural or peri-urban areas.
Beside the creation of jobs in different areas, the part of value added locally is much more important than for imported materials.
Little initial investment and little energy input in production being required, FCR/MCR also means substential savings in terms of foreign exchange.
Several studies have shown (e.g. in Kenya*) that the part of foreign exchange used for FCR/MCR is by far lower than for galvanized iron sheet:
- 66 to 75 % of the cost price of the galvanized iron sheets.
- 17 % of the cost price of FCR/MCR.
* P. Coughlin: «Steel vs tile roofing. What's appropriate for Kenya», Nairobi, Kenya, Economic Department, University of Nairobi, 1985.
Environemental advantages:
the main advantage on this level is that, little energy input being required, no firewood (fired roofing tiles) or other combustible (as for the manufacture of iron sheets) will be necessary. This may be a major asset in the struggle against desertification.
Technological simplicity:
A last major advantage is the technological simplicity of the production process of FCR/MCR. As a matter of fact, building and running a kiln (even a simple one) is not very easy. Manufacturing galvanized iron sheet requires a heavy industry. Producing FCR/MCR is relatively simple. But one must keep in mind that the production of good quality FCR/MCR can only be reached by respecting all the production parameters very carefully. This is the reason why we insist (see also 2.9.) very much on a professional training.
2. Description of the TEGULAMATIC unit.
2.1. Brief description of the double vibrating table.
Thanks to its robustness and its conception, the TEGULAMATIC can conply with an intensive use by unskilled workforce.
The frame of the table consists of sectional steel sheets which give the necessary robustness for ideal vibration.
The basic vibrator is made in one piece and has the following characteristics: 3000 r/m, 0,095 kw, 220 V monophase. 220/380 V triphase, 50/60 Herz (tropicalization also on request), 24 or 12 V in continuous and alternating current are also available on request. This is very important since the quality of the final product greatly depends on the ratio quality of vibration / time of vibration.
This type of vibration makes it also possible to produce vibrated concrete tiles.
Its output capacity can reach 700 tiles/day; it depends on the quantity of double supports available.
2.2. Simplification of the work.
The conception of the vibrating table is such that the operator's work is simplified to a maximum: in this way, he can exclusively concentrate on the quality of the final product thanks to the following devices:
1) Placing to the operator's disposal of:
- the 200 micron plastic interface sheet
- the rubber mortar box (52 x 32 x 22 cm)
- the metallic screeding trowel.
2) 2 adjustable and retractable stringers allowing a soft «gliding» of whatever type of tile on its support.3) The sectional sheet of the vibrating surface allows a simultaneous blocking of the frame in 3 different places by a simple pressure by the operator's foot or hand (double control).
4) Each blocking point is individually adjustable, which avoids the use of a waterproofness joint between the frame and the vibrating table.
5) The change of frame (to manufacture other types of tiles) is facilitated by the use of 3 standardized hinges.
6) An automatic opening system of the frame enables the operator to hold the 2 nibs with his thumbs.
7) The vibrator is also controlled by a pedal on the same axis as the pedal used for the blocking of the frame.
8) The level of the table can be adjusted by 4 bolts; checking is permanent thanks to 2 water-gauges fixed on visible places.
2.3. Basic equipment accompanying each Tegulamatic unit.
- 1 Frame for 2 overlapping pantiles 490 x 235 (12,5 tiles/m2)- 1 Frame
for 1 overlapping under-ridge (same dimensions)
for 1 overlapping edgetiles (same dimensions)
- 1 Frame for two 490 mm long ridges (overlapping: 70 to 80 mm)- 1 Concrete-mixer (140 I)
- 1 Roll of 300 mm wide and 200 micron thick plastic sheet to be locally cut into 1000 interface sheets (500 mm long)
- 1 Mortar scoop for 8 mm pantiles (1 scoop = 1 tile)
- 1 Mortar box 52 x 32 x 22 cm (30 I)
- 1 metallic screeding trowel
- 1 balance (4 kgs)
- 1 ten liter (graduated) rubber bucket
- 1 hand-drill for the twisting of the loop
- 1 quality control material (resistence to shocks)
- 1 quality control material (resistence to flexion)
- 1 sample of synthetic fibres
- 1 sample of red colourant
2.4. Double supports
These galvanized steel double supports are 8 mm thick. This provides a better solidity and a longer life expectancy to the supports, which are, eventually, the most expensive part of the production unit. Moreover, the fact that the supports are made out of galvanized steel allows the operator to clean them in an easier way and to remove the cement sticking to their surface than if they were made out of plastic.
They are 1080 mm long so that 2 tiles can be laid on each support. 1 complete double support for pantiles weights 4,03 kg (not packed); 1 complete double support for ridges weights 4,8 kgs (not packed).
2 galvanized steel lateral distance-pieces provided with each support are screwed and allow to stack the supports with 40 mm space between each support.
Due to the cost of the supports, we offer 7 types of TEGULAMATIC units AP, as detained in the following table.
For an optimal use of the vibrating table and for a double pitch roof, we advice the following:
- 375 supports for 650 pantiles
- 25 supports for 50 ridges
This quantity enables the operator to start the day with a reserve of 50 supports (not used the day before).
2.5. 7 types of unit
|
Type |
Qty sup. pantiles |
Qty sup. ridges |
Daily production |
M2 / roof daily |
|
AP 100 |
95 |
5 |
190 tuiles |
15m2 |
|
AP 150 |
145 |
5 |
290 tuiles |
23m2 |
|
AP 200 |
190 |
10 |
380 tuiles |
30m2 |
|
AP 250 |
235 |
15 |
470 tuiles |
37m2 |
|
AP 300 |
280 |
20 |
560 tuiles |
44m2 |
|
AP 350 |
325 |
25 |
650 tuiles |
52m2 |
|
AP 400 |
375 |
25 |
700 tuiles |
56m2 |
2.6. Raw material for one month production (25 days/690 tiles) for the production of 17 250 tiles (8 mm).
- 22,5 m3 sand- 9,375 T. cement
- 187,5 kg sisal or 18,75 kg synthetic fibre
- 281,250 kg colourant
- 9 kg galvanized wire (1 mm)
It should be noted that fibre can be replaced by aggregates (max. 6 mm);
the quantity is determined by the type of aggregate.
- 4 874 l water
2.7. 30 daily mixing operations for 690 tiles in a 140 l concrete-mixer (real capacity = 110 L)
(1 mix = 23 tiles (8 mm))
- 30 liters sand = 3 buckets of 10 liters
- 10 liters cement = 1 buckets of 10 liters
- 250 gr sisal (natural fibre) or 25 gr synthetic fibre (for aggregate see ratio density/volume)
- 375 gr of colourant
- 6,5 l water
2.8. Cost price of 1 tile or 1 m2 of roof.
On your request, we can provide with you with a complete feasibility study free of charge for financing purposes.
Therefore, on your request, we can send you a questionary enabling us to calculate the cost price of 1 m2 of roof according to local parameters; the reliability of your study will mainly depend on the correctness of your answers.
The above-mentioned quantities will already give you a rough idea for the comparison with the existing materials in your area.
Moreover, we remind you that 12,5 tiles are necessary to cover 1 m2 of roof, which means a lighter framework (26,6 kg (8 mm tiles)/m2).
2.9. Training.
Training (be it from APPRO-TECHNO or from a training center known for the quality of its transfer of technology) is essential and can be considered as an investment at the same level as equipment. The optimal production of good quality FCR/MCR and the correct dissimination of the technology are greatly bound to a theoretical but also practical training (technology and management).
This is the reason why APPRO-TECHNO offers a training on the site or in Abidjan (Ivory Coast). For further information on this subject, please contact us.
2.10. Packing details.
|
AP 100: |
1.225 kg (total gross weight) | |
| |
3,53 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 300 kg / GW 450 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 0,60 m., NW 680 kg / GW 750 kg |
|
AP 150: |
1.625 kg (total gross weight) | |
| |
3,82 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 360 kg / GW 475 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 0,80 m., NW 1.000 kg / GW 1.150 kg |
|
AP 200: |
2.050 kg (total gross weight) | |
| |
4,03 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 475 kg / GW 600 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 0,95 m., NW 1.300 kg / GW 1.450 kg |
|
AP 250: |
2.430 kg (total gross weight) | |
| |
4,28 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 450 kg / GW 600 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 1,12 m., NW 1.720 kg / GW 1.830 kg |
|
AP 300: |
2.810 kg (total gross weight) | |
| |
4,57 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 450 kg / GW 600 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 1,32 m., NW 2.100 kg/GW 2.210 kg |
|
AP 350: |
3.075 kg (total gross weight) | |
| |
5,57 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 550 kg / GW 690 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 2,02 m., NW 2.200 kg / GW 2.385 kg |
|
AP 400: |
3.345 kg (total gross weight) | |
| |
4,83 m3: |
- 1 seaworthy case 1,77 X 1,35 X 1,12 m, NW 1.205 kg / GW 1.365 kg |
| |
|
- 1 reinforced seaworthy case (supports) 1,20 X 1,20 X 1,50 m., NW 1.780 kg / GW 1.980 kg |
TEXTE FRANAIS
1.1. Qu'est-ce que la tuile en fibro-mortier ou en micro-mortier ?
La tuile en fibro-mortier est un matriau de couverture dont les qualits d'isolation (thermique et accoustique), la durabilit et la rsistance mcanique et aux impacts sont remarquables; ces caractristiques lies aux aspects micro et macro-conomiques des matriaux de construction localement productibles rendent ce type de couverture particulirement adapte aux ralits des pays en voie de dveloppement.
Les matires premires utilises sont du sable de granulomtrie moyenne (granulomtrie de 0,06 2 mm homogne), du ciment Portland CPA 45 ou CPA 35 (ou quivalent), des fibres vgtales (ou des graveleux latritiques) ou ventuellement du colorant.
Les tuiles peuvent tre produites en paisseur de 8 ou 10 mm. Nous dconseillons fortement la fabrication de tuiles de 6 mm d'paisseur vu les problmes de fragilit, mise en œuvre et mauvaise tenue aux vents violents. L'conomie ralise au niveau des matires premires est donc une fausse conomie.
Le processus technologique de fabrication est relativement simple (et certainement adapte la main d'oeuvre locale). Toutefois, il faut bien garder l'esprit organisation rationnelle de tous les postes de travail. C'est la raison pour laquelle APPRO-TECHNO propose et conseille vivement une formation (voir 2.9.). Le processus technologique peut se rsumer comme suit:
- un mortier de ciment-sable (ratio variant de 1:2 1:3) est prpar dans un mlangeur. On y ajoute ensuite les fibres vgtales trononnes au pralable en morceau de 15 mm ou synthtiques (appel le fibro-mortier).Si pour une raison ou une autre, il n'est pas possible ou prfrable d'utiliser des fibres, on peut les remplacer par du graveleux latritique (dont la granulomtrie ne dpasse pas 2/3 de l'paisseur du produit final) appel le micro-mortier).
- Le mortier est ensuite dpos l'aide d'une pelle doseuse sur un interface en plastique pos sur la table vibrante, l'intrieur du cadre de vibration. Le mortier doit tre vibr pendant environ 45 secondes. La qualit et la dure de vibration jouent un rle trs important dans la qualit du produit final (par exemple, une vibration trop longue rend la rpartition des diffrents lments peu homogne car les lments plus lourds ont tendance redescendre). On moule galement pendant ce temps le talon d'accrochage.
- ensuite, le mortier vibr est transfr en douceur sur un support de mise en forme qui a la mme forme que la tuile finale.
- ce stade, on noie un fil de fer galvanis dans le talon de la tuile (pour l'accrochage la charpente).
- ensuite, on laisse la tuile sur un support pendant 24 heures pour la mise en forme et le schage; elle doit tre recouverte d'un plastique pour viter les fissures.
- Le lendemain, les tuiles de la veille sont retires dlicatement de leurs supports et sont bavures avec un couteau. Les tuiles sont ensuite mises curer pendant 5 jours en milieu humide (100% d'humidit) et 15 20 jours sous abri. A partir de ce moment, elles peuvent tre mises en œuvre ou vendues.
1.2. Avantages.
La tuile fibro ou micro-mortier prsente de nombreux avantages qui en font dans de nombreux cas la solution idale au problme de la couverture dans les pays en voie de dveloppement. Ces avantages se situent plusieurs niveaux.
Qualits du matriau en tant que tel.
L'avantage le plus important au niveau de la vie quotidienne est de pouvoir disposer d'un matriau de couverture d'une qualit irrprochable. A cet gard, plusieurs aspects peuvent tre souligns tout en gardant bien l'esprit que comme pour tout produit industriel un contrle de qualit strict, permanent et intransigeant doit tre mis en place.
La fonction premire d'une toiture est de protger les habitants contre des lments extrieurs tels que la pluie et le soleil.
A ce propos, les tuiles fibro ou micro-mortier offrent dans le premier cas (la pluie) une protection absolue puisqu'elles sont parfaitement impermables. De plus, leurs qualits d'isolation accoustique les rendent incomparables par rapport aux tles lorsqu'il pleut.
Par ailleurs, le cyclone «Hugo» de 1989 dans les Antilles a permis de vrifier la bonne tenue des toitures en fibro-mortier aux vents violents par rapport aux tles ondules. De plus, dans les zones risques, il est possible et mme recommand d'utiliser des tuiles «ouragan» double accrochage ou des tuiles plus paisses (10 mm).
De plus, leur isolation thermique est incomparable par rapport la tle ondule traditionnelle qui rchauffe plutt qu'elle ne rafrachit les maisons dans des pays o la fracheur des maisons constitue l'aspiration de chacun malgr son cot lev.
Ensuite, la tuile fibro-mortier a une excellente rsistance mcanique (une tuile de ce type d'une paisseur de 8 mm doit pouvoir rsister au minimum une charge suspendue de 50 kg) et surtout une trs bonne rsistance aux impacts. L o, par exemple, les impacts de pierres ou de fruits abment les tles ondules de faon irrmdiable, les tuiles fibro-mortier font preuve d'une excellente rsistance ce genre de choc.
Leur esprance de vie est d'au moins quinze ans, ce qui rend leur achat trs rentable pour le client final.
Enfin, elles redonnent naissance un style traditionnel disparu au profit d'un non-style. Un simple coup d'œil aux photos vous en convaincra. De plus, la tuile est ralisable en plusieurs couleurs.
Avantages d'ordre conomique.
Outre la qualit du matriau de couverture lui-mme, le prix auquel il peut tre produit ou vendu joue un rle essentiel. Il est certain que ces prix sont en fonction des conditions locales (prix des matires premires, de la main d'oeuvre, concurence, etc...) mais, de faon gnrale, on peut affirmer que le prix de revient des toitures en tuiles fibro ou micro-mortier est nettement moins lev que celui des autres types de couverture (tles galvanises et tuiles en terre cuite pour ne citer que les principales). Nous parlons bien ici de «toiture». En effet, il ne faut pas se limiter au seul produit (la tuile) mais bien s'tendre la toiture dans sa globalit. Sans entrer dans les dtails, il est vident que les tuiles en terre cuite (trs lourdes), les tuiles en fibro-mortier ou les tles galvanises ne requirent pas le mme type de charpente. A titre d'exemple, les tuiles en fibro-mortier demandent une toiture beaucoup plus lgre et donc beaucoup moins coteuse que la terre cuite (les tuiles en fibro-mortier de 8 mm d'paisseur ne psent que 26,6 kg/m2).
De nombreuses tudes ont montr que l'conomie ralise grce une couverture en fibro ou micro-mortier va de 30 60 % par rapport aux autres variantes (terre cuite, tle galvanise). Il faut donc reconnatre que, la tuile fibro-mortier a un norme atout pour elle: son prix !
Au niveau macro-conomique, les avantages sont considrables pour les pays en vole de dveloppement. Ceci devrait encourager la dissimination de la technologie et l'aide officielle des autorits locales.
En premier lieu, le petit type d'unit industrielle (voir 2.5.) propose (qui sont par ailleurs modulables en fonction du nombre de supports) permet une certaine dcentralisation de l'industrie. Elle permet, son chelle bien entendu, d'enrayer le processus d'exode rural et d'urbanisation galoppante qui frappe de faon cruelle la plupart des pays en voie de dveloppement en employant la main d'oeuvre en de nombreux points de production (zone urbaine, zone pri-urbaine et zone rurale). A ct de cette cration d'emploi, aspect non-ngligeable, une plus value locale relativement (certainement par rapport aux matriaux imports) importante est cre.
Ensuite, la dpendance par rapport aux devises est nettement moins importante que dans le cas de tles importes vu l'investissement de dpart rduit et l'emploi restreint d'nergie. A ce propos, plusieurs tudes ont montr (notamment au Kenya *) que la part des devises utilise pour les tles ondules:
- 66 75 % du prix de vente de la tle ondule.
- 17% du prix de vente des tuiles fibro-mortier.* P. Coughlin: «Steel vs tile roofing, What's appropriate for Kenya», Nairobi, Kenya, Economic Department, University of Nairobi, 1985.
Avantages pour l'environnement:
A ce niveau, le principal avantage est constitu par l'emploi restreint d'nergie: ni le bois de chauffe (tuiles cuites), ni quelqu'autre combustible n'est ncessaire. Ceci constitue certainement un argument de poids dans la lutte actuelle contre la dsertification.
Simplicit technologique
Un dernier avantage important dont nous avons dj touch un mot est la simplicit technologique du processus de production de tuiles fibro-mortier En effet, construire un four (mme relativement simple) et le faire fonctionner correctement n'est pas simple. Fabriquer des tles ondules ncessite une industrie lourde. Produire des tuiles fibro-mortier est relativement simple. Encore faut-il qu'elles soient de bonne qualit! Seul le respect de tous les paramtres de fabrication garantit cette qualit. C'est la raison pour laquelle, nous tenons insister qu'une formation professionnelle (voir galement 2.9.) est souvent souhaitable.
2. Description de l'unit TEGULAMATIC.
2.1. Description sommaire de la table vibrante double.
Sa robustesse et sa conception lui permettent de rpondre un usage intensif et une utilisation par une main d'œuvre peu qualifie.
Le bti de la table est constitu de tles profiles qui lui confrent la robustesse ncessaire pour une vibration idale.
Le vibrateur de base est de conception monobloc - 3000 T/M - 0,095 KW/ 220 V MONO. Sur demande 220/380 V triphas, 50 ou 60 priodes (la protection tropicalise peut tre obtenue sur demande) ou 24 V et 12 V en courant continu et alternatif peuvent tre obtenus. Cet lment est extrmement important puisque la qualit du produit final dpend en bonne partie du rapport qualit de la vibration / temps de vibration.
Le type de vibration permet de raliser galement des tuiles en bton vibr (sans sisal).
Sa capacit de production peut aller jusqu' 700 tuiles/jour; elle dpend du nombre de supports doubles disponibles.
2.2. Simplification des oprations.
Sa conception est telle que le travail de l'oprateur est simplifi au maximum; il peut ainsi se concentrer uniquement sur la qualit du produit final notamment grce aux diffrents dtails repris ci-dessous:
1) Mise disposition porte de main de l'oprateur de:
- La feuille de PVC appele interface de 200 MICRONS.
- Un bac mortier en caoutchouc de 52 X 32 X 22 cm (30 L)
- Un emplacement pour la taloche mtallique.
2) 2 longerons rglables en hauteur et rtractables permettant un glissement en douceur de la tuile quel que soit le modle.3) Le profil de la surface vibrante permet un blocage du cadre de la tuile trois endroits simultans par une simple manœuvre commande au pied ou la main (commande double).
4) Chaque point de blocage est rglable individuellement, ce qui vite l'emploi d'un joint d'tanchit entre le cadre et la surface vibrante de la table.
5) La permutation des cadres permettant de raliser les diffrentes tuiles se fait facilement par l'emploi de 3 charnires normalises.
6) Un systme automatique d'ouverture du cadre permet l'oprateur de maintenir avec les 2 pouces les talons des 2 tuiles.
7) La commande du vibrateur se fait galement par une pdale au pied monte sur le mme axe que le blocage du cadre.
8) Le niveau de la table est assur par 4 boulons et le contrle est permanent grce 2 niveaux fixs des endroits visuels,
2.3. Equipement de base.
Avec chaque table vibrante double, nous fournissons:
- 1 cadre pour 2 tuiles recouvrement de 490 X 235 M/M -12,5 tuiles/m2.- 1 cadre pour 1 tuile recouvrement sous faitire (mmes dimensions).
- 1 cadre pour 1 tuile recouvrement de rive (mmes dimensions).
- 1 cadre pour 2 tuiles faitires de 490 M/M (recouvrement de 70 80).
- 1 btonnire de 140 L,
- 1 rouleau de PVC de 300 MM de largeur appel interface de 200 microns dcouper localement en 1000 feuilles de 500 MM de long.
- 1 pelle doseuse pour tuile 8 M/M (1 pelle = 1 tuile).
- 1 bac mortier de 52 X 32 X 22 cm (30 litres).
- 1 taloche mtallique.
- 1 balance 4 kgs (750 gr de colorant et 500 gr de sisal pour 46 tuiles de 8 m/m).
- 1 seau de 10 L gradu en caoutchouc.
- 1 drille pour le torsadage du fil de fer.
- Matriel de contrle de qualit des tuiles (rsistance aux chocs).
- Matriel de contrle de qualit des tuiles (rsistance la flexion).
- 1 chantillon de fibre synthtique.
- 1 chantillon de colorant rouge.
2.4. Supports doubles de mise en forme de schage.
Ces supports doubles en acier galvanis ont 0,8 M d'paisseur. Ceci permet d'assurer une solidit et une esprance de vie beaucoup plus longue des supports (qui constituent en fin de compte une des parties les plus onreuses de toute unit de production de tuiles fibro-mortier). De plus, le fait que la matire premire soit de l'acier galvanis permet de nettoyer les supports plus facilement que ceux conus en plastique et d'liminer notamment tout rsidu de ciment qui viendrait s'y coller.
Les supports doubles ont une longueur de 1080 M/M afin de dposer facilement 2 tuiles sur un seul support. 1 support double complet pour tuile recouvrement pse 4,03 kg (non emball); 1 support double complet pour tuile faitire pse 4,8 kg (non emball).
Les 2 entretoises latrales en acier galvanis fournies avec le support sont boulonnes et permettent d'obtenir un empilage parfait en laissant 40 M/M d'espace pour les 2 tuiles.
Vu le cot de ces supports, nous offrons 7 propositions type AP dtailles dans le tableau suivant.
Pour une utilisation optimale de la table vibrante et de la demande normale pour un toit deux versants, nous conseillons la formule suivante:
- 375 supports pour le schage de 650 tuiles recouvrement.
- 25 supports pour le schage de 50 tuiles faitires.
Cette quantit de supports permet de dmarrer la journe de travail avec une rserve de 50 supports non utiliss la veille.
2.5.7 TYPES D'UNIT.
|
Type |
Qty recouvrement |
Qty Faitires |
Production / jour |
M2 / jour |
|
AP 100 |
95 |
5 |
190 tuiles |
15m2 |
|
AP 150 |
145 |
5 |
290 tuiles |
23m2 |
|
AP 200 |
190 |
10 |
380 tuiles |
30m2 |
|
AP 250 |
235 |
15 |
470 tuiles |
37m2 |
|
AP 300 |
280 |
20 |
560 tuiles |
44m2 |
|
AP 350 |
325 |
25 |
650 tuiles |
52m2 |
|
AP 400 |
375 |
25 |
700 tuiles |
56m2 |
2.6. Matire premire prvoir mensuellement (25 jours 690 tuiles) pour la production de 17.250 tuiles de 8 mm.
- 22,5 m3 de sable- 9,375 T de ciment
- 187,5 kg de fibre de sisal ou 18,75 kg de fibre synthtique
- 281,250 kg de colorant
- 9 kg de fil de fer galvanis de 1 mm
Il est noter que la fibre peut tre remplace par du graveleux latrique de 6 mm maximum (quantit dterminer en fonction du type de graveleux).
- 4.874 l d'eau
2.7. 30 mlanges prvoir par journes de 690 tuiles dans un mlangeur de 140 litres (capacit de 110 litres) 1 mlange = 23 tuiles de 8 mm d'paisseur.
- 30 litres de sable = 3 seaux de 10 litres- 10 litres de ciment = 1 seau de 10 litres
- 250 gr de fibre de sisal ou 25 gr de fibermesh (pour le graveleux, cfr le paramtre rapport densit/volume)
- 375 gr de colorant
- 6,5 l d'eau
2.8. Calcul du prix de revient de la tuile ou du m2 de toiture.
A votre demande, nous pouvons vous raliser gratuitement l'tude de faisabilit bancaire.
Un questionnaire nous permettant d'tablir le prix de revient du m2 de toiture en fonction des paramtres locaux vous sera envoy votre simple demande; la fiabilit de notre tude dpendra essentiellement de l'exactitude de vos rponses.
Les quantits des matires premires reprises ci-dessus vous permettent dj de comparer avec les matriaux existants dans votre rgion.
De plus nous vous rappelons qu'il faut 12,5 tuiles au m2 ce qui reprsente un poids de 26,6 kg par m2 pour de la tuile de 8 mm d'paisseur et donc une charpente plus lgre.
2.9. Formation.
Prvoir une formation (qu'elle soit d'APPRO-TECHNO ou de tout autre institut de formation reconnu pour la qualit de son transfert de technologie) est trs important et peut tre considr comme un investissement au mme titre que le matriel. La fabrication optimale de tuiles fibro-mortier de qualit et la russite de la dissmination de la technologie sont largement lies une formation thorique et surtout pratique (technologie et gestion).
C'est pour ces raisons qu'APPRO-TECHNO propose une formation soit sur le site soit Abidjan (Cte d'Ivoire). Pour plus de renseignements ce sujet, veuillez nous contacter.
2.10 Dtails du collissage.
|
AP 100: |
1.225 kg (poids brut total) | |
| |
3,53 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 300 kg / PB 450 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 0,60 m., PN 680 kg / PB 750 kg |
|
AP 150: |
1.625 kg (poids brut total) | |
| |
3,82 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 360 kg / PB 475 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 0,80 m., PN 1.000 kg / PB 1.150 kg |
|
AP 200: |
2.050 kg (poids brut total) | |
| |
4,03 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 475 kg / PB 600 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 0,95 m., PN 1.300 kg / PB 1.450 kg |
|
AP 250: |
2.430 kg (poids brut total) | |
| |
4,28 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 450 kg / PB 600 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 1,12 m., PN 1.720 kg / PB 1.830 kg |
|
AP 300: |
2.810 kg (poids brut total) | |
| |
4,57 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 450 kg / PB 600 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 1,32 m., PN 2.100 kg/ PB 2.210 kg |
|
AP 350: |
3.075 kg (poids brut total) | |
|
|
5,57 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 550 kg / PB 690 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 2,02 m., PN 2.200 kg / PB 2.385 kg |
|
AP 400: |
3.345 kg (poids brut total) | |
| |
4,83 m3: |
- 1 caisse maritime 1,77 X 1,35 X 1,12 m, PN 1.205 kg / PB 1.365 kg |
| |
|
- 1 caisse maritime renforce (supports) 1,20 X 1,20 X 1,50 m., PN 1.780 kg / PB 1.980 kg |
|
DEALER:
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