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Prime Mortar menuju Arsitektur Hijau dan Pembangunan yang Berkelanjutan

By: Elisa Haryonugroho

Impact of Building Material Industry

When cement becoming known in the era of the Roman empire, the performance of cement known unique and durable because of mineral binders and at low prices, the cement is still the dominating trend of modern construction to the present. However, we are faced with the contradiction when we must reduce pollution resulting from the use of cement. In practical terms, what we can do to save the environment is to increase efficiency and reduce the use of cement with cement but without reducing the performance outcome. Cement production is the process produces CO2, whereas during the cement hydration and experience hardening, is actually a process that requires changes in CO2, some CO2 from the air is need in processing mortar/concrete to harden, as shown in diagram 1.1

Semen+H2O –> Semen Hidrat+

Ca(OH)2+CO2

(pengerasan mortar/beton)

Apakah Arsitektur Hijau

Green architecture, or environmentally friendly building design, is an approach to build with minimal harmful effects on human health and the environment. Architect or green-designer is attaining to maintain air, water and earth by choosing building materials and environmentally friendly construction practices. Green architectural characteristics one is reducing CO2 emissions through the use of building materials and environmentally friendly system structures, especially the consumption of cement absorbing CO2 and producing great energy in its production process. Although, the CO2 in the drying process of concrete is required, but the absorption of CO2 for the drying process of concrete can not fully replace the CO2 emissions generated from the production process. Therefore, reducing the use of cement has strategic significance. Furthermore, the impact of industrial emissions contribute the most CO2 is as follows:

1. The heavy industry such as cement and steel, consumes more than half energy to industry.
2. cement production process not only produces CO2 but also consumes a large energy.
3. Each ton of clinker produced 600kg of CO2 production and consumption of energy equivalent to 400kg of CO2.
4. For the 3 billion tons / year cement
5. production world, there are at least 1.8 billion of CO2 into the atmosphere evaporates.
6. The biggest contributor to global warming is CO2 emissions from industry.

Figure 2. CO2 Emissions from Cement Manufacture

Dry-Mixed is environmentally friendly solutions which play a very effective way to reduce cement usage while maintaining quality and even improve the performance of the cement itself, which includes:

1. Fulfilling requirement
2. Application of thin bed
3. Less waste-material
4. High efficiency

What is Dry-Mixed

Dry-mixed is a mixture consisting of PC (Portland cement), sand with the appropriate grading, lime, as well as certain additives that function in accordance with the requirements that must be met. Dry-mixed known in the market today, the types are very various, there are bricks or blocks layers, plaster mortar, adhesive for marble and ceramic on various media, to the ‘waterproofing’. Dry-mixed which is designed to the specific function, of course, improves efficiency and effectiveness at project site.Efficiency of cement usage, means the cement consumption per square meter obuildings decreases. With the decline in cement consumption, the CO2 emissionsresulting from cement production processalso declined.When the efficiency of cement usage becomes the main requirement in construction, it needs to cope with the demands of dry-mixed into the basic needs of the environment in the construction. The direct impact when we are using dry-mixed collectively are as follows:

1. Reduce CO2 concentration.
2. Conserve energy required during the
   construction.
3. Reduce waste material.
4. Durable building that increase life and minimize repair works.

A Dry mixed Solution

In delivering a sustainable development there are three things that interest;

1. Use materials with pollution of soil, water and air are minimal.
2. Construction is a minimal impact on the environment.
3. Use more energy efficient equipment such as oil, gas, and electricity.
4. Durable structures that are sturdy and
   able to withstand the elements for longer buildings

Figure 3. Production Process in Dry-Mixed

Refers to the demands of an environmentally friendly product above, then the use of dry-mixed on the construction process shall constitute the energy savings during construction, reduction of waste materials including bags of cement and the amount of waste material, and increasing the age of the building as the impact of the use of good materials that minimize the repair work during operational period.

Mortar Usage in Indonesia

Volume of development is estimated at Rp. 200.000.000.000.000 (Two hundred billion rupiah) to the development of infrastructure around Rp. 350.000.000.000.000 (Three hundred and fifty billion rupiah). Those building is categorized as ‘engineer-building’ and ‘non-engineer building’ in the ratio 30: 70.2

The development is divided into infrastructure development, property development, and development by the community. This kind of development is various; some requires high technology development complexity and risk that may arise, to the simple construction. Buildings ‘non-engineer’ organized by the community that require a standard, quality, safety and ease of implementation.Therefore, education, guidance standardization of quality are needed by the non skill resources. Construction, besides producing foreign exchange, related withglobal competitions where innovations are highly needed.

Innovation in question is a set of regulations covering SNI (Standar Nasional Indonesia), methodologies, and innovations made by their respective companies, innovation of materials, and innovative working methodsfor achieving productivity and higher labor standards. Today, the industrial development of mortar in Indonesia was encouraging, although not able to meet the needs of the construction inIndonesia, especially in the ‘non-engineer’building.

As we have known that the use of cement and dry-mixed in Indonesia was still under Japanese, Korean, Thailand, Malaysia andthe Philippines. We must learn from countriewhere innovation has expanded the use of dry-mixed and widely known.

Figure 4 Cement Usage3

Economically, the impact of production processes and efficient use can be seen in some comparisons below. Some of these price comparisons are a little description of some application of Prime Mortar for the Greater Jakarta area. Reference prices use the Jakarta minimum wage (UMR) and material price retailer-shops at jakarta area.

Figure 5. Comparisons of PM-100 vs Thick Bed

Thick Bed for block layers, is the adhesive
with a thickness of 1 cm who casted usingtrowel. While Thin Bed Mortar PM-100 is the adhesive that laid the dough using toothedtrowel with 3-4 mm of thickness. With a thick adhesive does not allow blocks were prepared to a height ≥ 2.5 m because the wall will tend to tilt due to self weight of theheavy burden had gluten. (See Figure 5).

Figure 6. Comparison of Wage of Block vs Brick Work.

Similarly, the applications of dry-mixed for plastering on wall surfaces, does not require the screening process and scaling sand. Thus, the number of people working in a group also reduced from three people totwo people only, as described in Figure 6. In terms of wages, wage expenditures for thin bed mortar compared to conventional masonry adhesive showed cost savings up to 42.86%. Certainly the consumption of cement for Thin Bed Mortar PM-100 is compared with a thickness of 3mm masonry than 2 cm, is different significantly. (Figure 6)

Figure 7. Comparison of Wage of PM 200 vs Conventional Plaster

Wages are also more efficienct plastering up to 36%. It’s a
significant value when consumption in large volume. Studies mixed prices for some products, also pointedto savings. Just mention the use of cement-based-waterproofing PM-900 compared with brand "AP" rubber-based-waterproofing, it costs Rp 635 000, - per 40 kg can cover an area of 20 m². Especially ‘waterproofing’ of this rubber-based has maximum life-time of only two years because no ultraviolet resistant. (See Figure 8).

Figure 8. Cost Comparison of PM-900 vs Rubber-based-waterproofing

Figure 7. Cost Comparison of PM-300 vs Conventional Skim Coat

Dry-mixed for fine coat, not onlyare more
efficient, but improving the performance of building surfaces that are resistant to alkali. Figure 7 refers to the retail price of paint anti-alkali products brand "M" worth Rp 639 000, - per 20 liters for the use of broad areas of 80 m². Application of fine coat PM-300 also aimed at saving the consumption of paint because the density of pores. Second performance refers to the eco-friendly products that can extend the life of the building.

Toll for Controlling the good products

The survival of mankind, the quality of life and human health and environmental quality, can be achieved through sustainable development. Being a sustainable development can be realized. When in the construction process there is a mechanism of quality control-oriented environment. A project manager can makea practical assessment of every material and system to be used on the project. Therefore, the project manager can ensure that the projects they manage are environmentally friendly construction and green architecture refers. The parameters of environmentally friendly products4 include the following:

1. ‘Carbon foot print’; track record of carbon emissions generated’
2. ‘Product’s biography’; history of the production process of a building
   material

This parameter is known as the Life Cycle Assessment, LCA. Assessment for feasibility tool for material, including assessment to;

1. The planning process
2. Manufacturing process
3. Material selection process
4. The recommended application
5. The correct disposal the product

LCA is a tool to keep track of carbon emissions generated throught the search of raw materials to production processes from carbon emissions generated number to the number of fuel used for this production process.

In the process of LCA, there are two phases to be done, namely:

1. Emissions describing what will happenand what materials are used in producing the product in question. This phase is called inventory phase.
2. phaAssessing the impact of what and depletion of raw materials what will
   happen. This phase is referred to asthe impact assessment phase.

By applying LCA, every process of construction can be ascertained whether the reference to sustainable development.