On the use of historical material data

Karlsruhe Institute of Technology [KIT]

Prof. i.R. Dr. Niklaus Kohler

On the use of historical material data

International Workshop on Technosperic Mining 2015


Prof. i.R. Dr.Niklaus Kohler, arch. EPFL-SIA


Some of the present data have ben published in :

Kohler, N. (2004) Wieviel Beton ist in einem Haus? in Hassler U. and Schmidt H. “Häuser aus Beton”

Wasmuth Verlag, Tübingen





Overview

1. Why historical data ?

2. Historic diffusion of concrete in the building stock

3. Closed-loop economy and resilience, a historic example

4. „Historic“ perspectives of concrete





Questions 1

- How much concrete in a building ?

- In which part of the stock is it ?

- How did concrete diffuse historically in the stock

- Importance of substitution process (binder, aggregates)

- Bottom-up and top-down process





Cement production in Germany since 1882

Quelle: Statistisches Bundesamt





Binder substitutes

Quelle: Kleinkogel, Einflüsse auf

Beton, 1950

Nutzungszeitraum unbekannt

Nutzungszeitraum

Ende der Nutzung unbekannt

Ersatzstoffe für Portlandzement

1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000

Anhydrit

Molererde (n. Puzz.)

Müllschlacke (k. Puzz.)

Filteraschen

Thurament

Kalk/Dolomitkalk

Si-Stoff

Sparzement 225

Schwelkoks (Ölschiefer)

Material substitutes for Portland Cement

Oil shale , low temp coke

Spare cement 225

Si materials

Lime stone

Thurament

Fly ash

Waste slag (puzz)

Moler earth

Anhydrid

Use period unknown

Use period

End use period unknown





Aggregat substitutes

Quelle: Kleinkogel, Einflüsse auf

Beton, 1950

Use period unknown

Use period

End use period unknown

1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000

Treibmittel (Aerokret, Iporit, Betocel)

Natürlicher Bimbs

Hüttenbimbs/Kunstbimbs

Blähschiefer (Dachschieferabfälle)

Blähton

Trümmersplitter (Ziegel,Ton, KS)

Seetang

Eisstücke, Schnee/Gipsgemisch

Asbest

Holzfasern/ Späne

Faserstoffe (Jute, Sisal)

Glasfasern

Glas

Ersatzstoffe für natürliche Füllstoffe

Glas

Glasfibres

Organic fibres

Wood fibres

Asbestos

Ice snow-gipsum

Kelp

Debris (brick)

Expanded clay

Shale

Bimps (debris)

Slag

Natural bimps

Propellant

Substitutes for mineral aggregats





Materials in an urban 19th century building

Materialien im Haus

Dachziegel 13,6 m³

Leichtwände 91,5 m³

Fensterglas 0,9 m³

Keramik (Öfen, WC, Becken) 35,0 m³

Innenputz 116,0 m³

Außenputz 47,8 m³

Deckenputz 43,7 m³

Estrich 2,7 m³

Terrazzo 2,7 m³

Koksasche (Deckenschüttung) 10,9 m³

Dachpappe 2,0 m³

Rohrleitungen 14.744,0 kg

Kleineisen/Beschläge 3.950,0 kg

Gusseisen (Wanne, Herde) 3.950,0 kg

Zinkbleche (Dach, Fenster) 11.803,0 kg

Messing (Türen, Fenster) 63,9 kg

Quelle: Groß, Erhard, Skalitzer Strasse 99 - Biographie eines Hauses, Katalog zur Ausstellung, Berlin, 1988





Materials in an urban 19th century building

Materialien im Haus

Dachziegel 13,6 m³

Leichtwände 91,5 m³

Fensterglas 0,9 m³

Keramik (Öfen, WC, Becken) 35,0 m³

Innenputz 116,0 m³

Außenputz 47,8 m³

Deckenputz 43,7 m³

Estrich 2,7 m³

Terrazzo 2,7 m³

Koksasche (Deckenschüttung) 10,9 m³

Dachpappe 2,0 m³

Rohrleitungen 14.744,0 kg

Kleineisen/Beschläge 3.950,0 kg

Gusseisen (Wanne, Herde) 3.950,0 kg

Zinkbleche (Dach, Fenster) 11.803,0 kg

Messing (Türen, Fenster) 63,9 kg

Quelle: Groß, Erhard, Skalitzer Strasse 99 - Biographie eines Hauses, Katalog zur Ausstellung, Berlin, 1988





Diffusion of concrete in the stock





Concrete share by age and element





Construction Elements

Quelle: Ahnert, Krause, Baukonstruktionen von 1860

bis 1960, Verlag für Bauwesen, Berlin, München, 1993





Construction elements- foundations / floorplate



Stampfbetonfundamente vor 1908, Druckerei:

„Stampfbetonfundamente mit bis zu 6 Absätzen. Um Zement zu sparen,

wurde jeder Absatz in einem anderen Mischungsverhältnis hergestellt.“ Zementgehalt: 1:4 bis 1:12





Construction elements : Foundations



Streifenfundament, 1908, Wohngebäude







Plattengründung, 1907, Wohngebäude

Construction elements : Foundations





Construction elements : slabs



Preußische Kappe, 1890, Betonanteil: ~ 0,07m³/m²





Construction elements : basement slabs



Kleinesche Decke (Stahlsteindecke), 1892

Betonanteil: ~ 0,05m³/m² „Aufbeton zwischen 30mm und 50mm“

"In Berlin besteht z.b. der überweigend größere Teil aller massiven Decken

aus Steineisenkonstruktionen"





Construction elements : slabs



Koenensche Voutenplatte, 1897, Betonanteil: ~ 0,18m³/m²

1909: „Die erste Probeplatte der Koenenschen Voutenplatte wurde am 25.

Januar 1897 baupolizeilich geprüft; nach Angaben der Aktiengesellschaft für

Beton- und Monierbau sind seit dieser Zeit über 5 Millionen m² dieser Decke

ausgeführt“.





Construction elements : exterior walls



Betonformstein „Wayss

und Freitag“, 1919

„Brennstoffmangel, ve-

rminderte Konstruktions-

dicke und Sparbauweisen

führten nach 1919 dazu,

daß eine große Zahl von

Betonsteinen entwickelt

wurde.“








System Hartmann und Schlenzig, 1919

„Hochkantmauerwerk [wurde] nach 1919 mit Bindersteinen aus Beton

versteift“.








Betonsteine, 1937





Exterior wall materials

Produktion von Wandbaustoffen im Bundesgebiet von 1950 - 1989

0,0

2,0

4,0

6,0

8,0

10,0

12,0

14,0

16,0

1950 1960 1970 1972 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989

Jahr [-]

Ma

uerw

erk

[M

ill.

cb

m]

Kalksandstein

Ziegel

Leichtbeton (Bims)

Gasbeton (Blscke)

Schlackensteine

Normal- und Schwerbeton (Betonsteine)

Nach: Rahlw es, K., Wiederverw ertung von Baustof f en im Hochbau, 32. DarmstSdter Seminar

A bf alltechnik: "Kreislauf technik Bau - Stand und Perspektiven beim Recycling von Baurestmassen",

WA R Schrif tenreihe Band 67, Seite 120 -141, Darmstadt, 1993





Future needs of mineral raw materials

Quelle: Fleckenstein, Kurt, Prognose der mittel- und langfristigen Nachfrage nach mineralischen Baurohstoffen,

Forschungsberichte des BBR, Heft 85, Bonn, 1998





Cement production Germany





Conclusions

- The cement production follows a logistic function since 1880

- Concrete becomes the dominating material since 1920

- The diffusion of concrete in buildings starts at the foundation and

moves to the (flat) roof

- Substitution process are important 1920-1960

- At present concrete demand is constant, maintenance needs lower

quantities than new construction

- Importance of patents and firm know how

- Combination of distributed (local aggregates) and concentrated

(cement production) process





Closed loop and resilience:

a historic example





Berlin 1945









Destroyed buildings and

population (women) in Berlin 1945





„Trümmerverwertung“

- Composition and quantities of materials and debris per building type

- Handling of the debris (level off, transport)

Selection of debris

Transformation of debris into split

- Equipment for handling and preparing of split

- Needs of brick split and other materials for the reconstruction

- Transport and handling plants for split

- Economic aspects (work force, investment)

- Repair of damaged buildings

- Intermediate repair and replacement

- Concrete with brick aggregate

binders and use of pouzzolane

application conditions for recycled concrete

floor plates with brick-based mortars

-Standards and work sheets

Inventory form for the diagnosis of war damage

List of relevant standards for recovered materials





„Gründerzeit“ Building (before 1914)





Quantity and composition of debris in Berlin 1945





Debris per m3 built volume





Distribution of debris in building plinth





Substitutes : brick-sand and brick filler





Test of concrete with brick debris





Need of materials for the reconstruction





Debris preparation





Debris Logistics





Energy for transport and handling





Embodied energy





Material needs for the reconstruction





„Debris-women“





Conclusion : an example of resilience

• The reconstruction of Berlin after

1945 is an example for resilience

• Technosperic mining under dramatic

circumstances

• It shows the importance of material

properties and basic standards

• Logistics are constantly reinvented

• The management of knowledge and

the fast learning are crucial

• Social and technical aspects cannot

be separated





The future of cement and concrete





Raw material consumption





Cement production estimation 1990-2050





Cement production per capita 1990 - 2015





Global cement production 1990 - 2015





„Historic“ Perspectives of Concrete

How to increase the cement production by factor 3 (until 2050) and

reduce the environmental impact (CO2 emissions) by a factor 3 (base

1990) ?

Increase

efficiency

Increase

Residence time

Close loops

Carbon capture





A blue print for the future of cement

Müller, N. and Harnisch, J. (2008). A blueprint for a

climate friendly cement industry. Report for the WWF–

Lafarge Conservation Partnership. Gland, Switzerland,

WWF.





Some general Conclusion

• Concrete has become the dominating building material in Europe in the last 100 years

• This process is also taking place world wide

• The growth curves seem to be logistic

• The concrete technology is relatively simple

• The production combines local and centralised components

• The production chain is highly integrated and concentrated,

• The end-of-the life phase is not (yet) part of his chain

• There is no alternative material in sight

• A blueprint – back casting over 50 years is the necessary historic time scale-

• Understanding the built environment as a social ecological system draws the attention

to the relations between the natural, material, social and cultural values of the building

stock

• The goal of technophere mining could be either to maximise the loop closing or to slow

down the system transformation (increase the duration)

• The knowledge of the technosphere and its dynamic can be crucial when dealing with

a combination of known and unknown risks. It is a form of resilience

Documents

On the use of historical material data