RED – MUD POLYMER

-DOORS AND PANELS

S.KAVITASREE
15AR032
FINAL YEAR
DEPT. OF ARCHITECTURE
 RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• SOURCES OF RED MUD:
• During aluminium
production, bauxite ore is
digested with caustic
soda, when most of the
aluminium passes into
solution as aluminate.
• The muddy red residue
consists of alumina, iron
oxide, titanium oxide and
Various kinds Of red mud small quantities of silica,
Polymer composite tiles and calcium oxide and alkali.
Corrugated Sheets
 RED MUD – A RESOURCE FOR
BUILDING COMPONENTS

Dry Red Mud – the basic raw-material

• India generates over 4 million tonnes of this

by-product annually which is not otherwise put to
any use.
RED – MUD
COLLECTION
IN LARGE-
SCALE
RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• NATURE OF
POLLUTION :
• Red mud is usually
disposed off in ponds.
During monsoons, the
waste may carry by
run-off to surface
water courses and
cause ground water
contamination due to
leaching.
RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• RECYCLING OF RED MUD:
• Red mud can be used for making high
quality exposable bricks, tiles,
corrugated roofing sheets, and as
binder for several useful products
including composite doors, panels, etc..,
DOOR PANELS MADE OUT OF
RED-MUD POLYMER :
 RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• BMTPC has produced a composite from
red mud, polymer and natural fibres,
called Red Mud Jute Fibre Polymer
Composite (RFPC), to replace wood in the
wood based panel products in the
building industry.
• This product uses zero energy aided raw
materials and conserves energy by room-
temperature processing.
RED MUD – A RESOURCE FOR
BUILDING COMPONENTS

• Known as Red Mud Jute Polymer

Composite (RFPC), this composite
contains ferric oxide, alumina and
titanium oxide from red-mud, 82.5%
cellulose and 11.3% lignin from its
jute component. ( jute is 15% of the
total volume of the shutter).
 RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• This newly developed material is
particularly suitable for door shutters,
ensuring significant savings in initial as
well as manufacturing costs.
• There is a huge market for composite
doors and panels, with the potential
waiting to be tapped both in developing
and developed countries.
 RED MUD – A RESOURCE FOR
BUILDING COMPONENTS
• RFPC can also be
used for
furniture,
flooring and
panelling work,
electrical switch
boxes and
insulating sheets
for housing.
DOOR PANELS AND FIBRES
Flow diagram of
how composite
door panels are
made
Press for making RFPC sheets

Manual application of binder

Testing apparatus at RRL, Bhopal
Compnents of RFPC:
Red morrum, Jute
fibre cloth, lime, rice
husk, laddoos,
Cementitious binder
and mixing of binder
INDUSTRIAL WASTE UTILIZATION
• Red Mud Generation – 5.5 millions tons
per year
• High temperature solid state reaction
along with additives generates phases for
radiation shielding from X-Rays and
Gamma rays
( BRNS Program, testing at BARC and
certified by AERB )
RED MUD - FLYASH COMBINATION

• Pavement blocks developed and tested

for several years.
• Bricks/ Prefab under development
• Red-mud & Flyash – Polymer
Composite door panels developed
 FLYASH/REDMUD POLYMER
DOOR SHUTTER
• BMPTC in association with the Regional
Research Laboratory, Bhopal has developed
a technology for the manufacture of
flyash/red mud polymer door shutters,
panels,etc..,
• This technology has been licensed to
M/s Dual Build Tech Ltd., Chennai for
large scale commercial production of door
shutters and panels has been set up at
Pondicherry.
A VIEW OF PLANT FOR PRODUCTION OF
FLYASH/ RED-MUD DOOR SHUTTERS
• MAIN – EQUIPMENT :
• Hydraulic press • LAND –
• Calendaring machine REQUIREMENT:
• Mixing plant – Open – areas :
3,000 sq.m
• Moulds
– Covered areas :
• Sander
500 sq.m
• Grinder
• RAW – MATERIAL:
• Shearing machine
• Red – mud/ flyash
• Oven polymer
• Resin cattle • Additives
• Curing chamber • Woven jute mats
• Cutter
• POWER : • MAN-POWER :
• KW : 40 • Skilled ( No.s ) : 4
• Three phase • Unskilled ( No.s ) : 24
• Voltage : 440V, 50 Hz

TENTATIVE PROJECT COST :

FLYASH/ RED-MUD DOOR SHUTTERS
• PRODUCTION
CAPACITY:
• The pilot plant has a • LABOUR:
capacity to produce • At 100% utilization,
12 to 15 door labour component
shutters of standard requirement is 8
size per day. skilled and 12
• 12,000 sq.m door unskilled workers.
panels per annum
( 8hrs shift )
• SIZE OF PRODUCT :
• DOOR : 2100 x 900 x 25-30 mm or any other
size
• Panel : 1800 X 900 X (3-25 mm)

• PROPERTIES OF PRODUCT:
• Density : 1.65 to 1.70 gm/cc
• Modulus of rupture : 85-95 N/sq.m
• Tensile strength : 22 – 24 N/ sq.m
• Moisture content : 0.2 – 0.38%
• PROPERTIES OF PRODUCT:
• Compression perpendicular
to surface : 78 – 101 N/sq.m
• Compression parallel
to surface : 44 – 51 N/ sq.m
• Swelling in water :
• Length : 0 – 0.36%
• Width : 0 – 0.47%
• Thickness : 0 – 1.38%
• Water absorption :
• 2 hours : 0.15 – 0.4%
• 24 hours : 1.1 – 1.5%
• Fire – retardancy :
• Self – extinguishing in 15 seconds
 PILOT RESIN
MANUFACTURING PLANT:
• Inorder to produce the specific type and
quality of polyster resin required to
manufacture red mud/flyash polymer door
shutters, panels,e tc..,a pilot plant to
manufacture polyster resin has been set up
at the door manufacturing unit itself.

• The capacity of this resin plant is 250kg

(batchsize) per day.
• The resin so produced will be used in the
pilot plant for the manufacture of red
mud/flyash polymer door shutters.

• This has helped in reducing costs and

improving the quality and surface finish
of red mud/flyash polymer door shutters
and panels.
 According to the research institute’s official
investigation, reference https://www.csir.res.in

WOOD SUBSTITUTES FROM

RED MUD
• Product: Manufacture of R-wood - a composite
material from red mud (aluminium industry
waste), fibre and polymer.
• Application: As wood substitute for making door
panels and building components
• Feature: R-wood is nearly 3 times stronger than
wood; weather resistant; non-corrosive;
resistant to termite, fungus, rot & rodents and is
fire-resistant.
• It has bulk density: 1.7 kg/cm2,
• tensile strength: 25 MPa,
• flexural strength: 75 MPa and
• screw withdrawal: 135-225 kg.
• For manufacture, the red mud and polymer are
mixed with additives and poured in moulds of
appropriate size and conditioned.
• The door shutter/panel, thus fabricated,
does not require painting.
• The flush door shutters are fabricated
out of the panels and strips made.
• The entire processing for the panelled
door shutters is done in a single
operation.
• Commercialisation: Commercialised.
• Equipment: Hydraulic press, moulds &
fixtures, mixer, grinder, sander, drill
machine, welding machine, pulveriser, oven,
kettle, cutter.
• Raw materials: Red mud, fibre, polymer,
additives.
• Institute: Regional Research Laboratory,
Bhopal
 PRODUCT DETAILS ON
MANUFACTURE & MARKET
 SALIENT FEATURES
• A very good wood substitute for doors,
windows, ceilings, partitions, furnitures,
etc..,
• Environment friendly technology
• Utilization of industrial waste such as
flyash, red mud
• Energy efficient production technology
• Products stronger than wood
• Weather resistant and durable
• Termite, fungus, rot and rodent
resistant
• Fire – resistant
• Cheaper than natural wood
• Less maintenance cost
 REFERENCE

• BMTPC – Building Materials &

Technology Promotion Council.
Ministry of Urban Development
and Poverty Alleviation, Government
of India