Beruflich Dokumente
Kultur Dokumente
College of Engineering
Materials Engineering Department
Table of Contents
Chapter I
Introduction -------------------------------------------------------------------------------------------- 1
1. Objectives ------------------------------------------------------------------------------------------- 2
2. Significance of the Study -------------------------------------------------------------------------- 3
3. Definition of Terms ---------------------------------------------------------------------------------4
4. Scope and Limitation ------------------------------------------------------------------------------- 5
Chapter II
Review of Related Literature
1. Kapok Fiber ------------------------------------------------------------------------------------------ 6
1.1 Kapok Fiber as Reinforcement
2. Composite Materials -------------------------------------------------------------------------------- 7
3. Fiber Composite ------------------------------------------------------------------------------------- 8
4. Cement Bonded Board ------------------------------------------------------------------------------ 9
5. Synthesis ---------------------------------------------------------------------------------------------- 9
Chapter III
Methodology -------------------------------------------------------------------------------------------- 10
Process Flow -------------------------------------------------------------------------------------------- 11
1. Make Pure Cement Board -------------------------------------------------------------------------- 12
1.1 Mixing Procedures
1.2 Forming
1.3 Curing of Cement Board
2. Make Fiber-reinforced Cement Board ------------------------------------------------------------ 13
2.1 Mixing Procedures
2.2 Forming
Chapter I
Introduction
There are several abundant fibers that can be found in Philippines and has a potential to
be used as reinforcement in the development of cement fiber composites, and one these fibers is
the Ceiba Pentandra or also known as kapok fiber.
Fiber cement boards are common and widely used in construction of buildings and
houses. This is due to the properties these materials exhibit; they are very durable, flexible and
have a variety of uses. However, fiber cement boards have problems; one example of this is the
toxicity of some of the composition of asbestos-based fiber cement boards. Asbestos is highly
toxic and can cause deterioration of health; it mainly affects the lungs contributing to a severe
lung cancer. Another problem in fiber cement board is that it degrades when exposed to moisture
over a long period of time, one example of this the non-asbestos fiber cement board like
HardiFlex.
To resolve these problems in the properties of fiber cement boards, fiber compositions
should be replaced with a more resilient, non-toxic, moisture-resistant and pest resistant natural
fiber. Kapok fiber exhibits these good characteristics. Kapok (Ceibapentandra) fiber is a silky,
cotton-like substance that surrounds the seeds in the pods of the Ceiba tree. They are buoyant,
resilient, moisture resistant, pest resistant and smooth, kapok possess powerful performances in a
lightweight package. It is said that kapok fiber repels water like rain on a ducks back. When a
substance does this we call it, hydrophobic. This hydrophobic quality results in the quick-drying,
buoyant and moisture-resistant properties, which makes kapok fiber remarkable among natural
fibers. When kapok fibers are put under tension they completely return to their original length
when the tension is removed. Kapok fiber is empty of nutritional content thus kapok fiber is pest
resistant so it wont mat or felt easily (Chaput, 2012).
Using kapok fiber as a reinforcement matrix, the cement-bonded board will going to be
moisture resistant because kapok fiber is hydrophobic making the cement board reinforced with
kapok enhance its moisture-resistant properties compared to other cement-bonded board like
HardiFlex. The advantage of moisture resistant cement boards is that it will withstand
degradations because of exposure in wet environments.
This study aimed to find out whether kapok fiber could be a good reinforcement in the
production of fiber cement boards.
1. Objectives
The main objective of the study is to produce Kapok-reinforced cement board.
2.2. Community:
The study will benefit the community by producing such quality composite board
that can be used as claddings, fire proofing walls, thermally insulative ceilings and
exterior cover for building walls.
2.3. Fiber Industries:
The study will benefit by initiating new ideas on the other uses of kapok fiber by
converting it for structural purposes.
2.4. Future Researchers:
The study will exhibit new knowledge and it will open the new ideas for
innovative and useful composite materials.
3. Definition of Terms
For better knowledge and understanding, the following words with their meanings are listed
below:
Fiber Cement Board is a composite building material made of sand, cement and cellulose
fibers.
Flexural Strength is the ability of the material to resist deformation under load.
G. I. (Galvanized Iron) Sheet is an Iron that is coated with zinc to protect it from rust.
Impact Resistance is the resistance of a material (as metal or ceramic ware) to fracture by
a blow, expressed in terms of the amount of energy absorbed before fracture.
Kapok Fiber is a fine, silkily lustrous fruit fibers from the fruit walls of the capsules, 10 20 cm in length and 3 cm in thickness, of the kapok tree (Ceiba pentandra).
Portland cement is a hydraulic cement (cement that not only hardens by reacting with
water but also forms a water-resistant product) produced by pulverizing clinkers
consisting essentially of hydraulic calcium silicates, usually containing one or more of
the forms of calcium sulfate as an inter ground addition.
A Vernier Caliper is a measuring device that consists of a main scale with a fixed jaw and
a sliding jaw with an attached Vernier scale. In this study, it was used as a measuring
device for the thickness of the fiber cement board.
Water Absorption is a test method used to determine the percent absorbency of water to
the specimen in specified duration of immersion.
The study focuses on the making of cement board reinforced with kapok fiber. The
experiment will be conducted in the 2nd semester of the academic year 2012-2013. The
researchers will Posttest-only as experimental design. The statistical methods of analysis will be
used to the results of the experiment using Mean and One Way analysis of variance to determine
if the results of the experiments on composite board will meet the desired properties.
The fiber cement board will be tested accordingly by means of flexural strength, water
absorption and impact resistance while the cost of materials and the labor will not be included in
the data of the results and the equipment for testing will be all improvised. The standards of
ASTM in test methods will be followed in the materials testing procedures with corresponding
dimensions of 12in. x 6in. x 16mm (305mm x 152mm x 16mm) for flexural strength test and 4in.
x 4in. x 16mm (100mm x 100mm x 16mm) for water absorption test. The kapok fiber cement
board will be tested to compare its properties with pure cement board to know if there is
significant difference in its mechanical properties.
Chapter II
This chapter consists of several topics that support the foundation of the study of kapok
fiber cement board. In this chapter kapok fiber, composite materials, fiber composite and cement
bonded board are discussed to condense the idea of creating the kapok fiber cement board.
Related Studies
Kapok Characteristics
Average Density
0.29 g/cm3
0.064 tex
Average Diameter
20.5m
Average Length
20mm
Moisture Regain
10%
2. Composite Materials
Composite materials for construction, engineering, and other similar applications are
formed by combining two or more materials in such a way that the constituents of the composite
materials are still distinguishable, and not fully blended. One example of composite material is
concrete, which uses cement as a binding material in combination with gravel as a reinforcement.
In many cases, concrete uses rebar as a second reinforcement, making it a three-phase composite,
because of the three elements involved. Generally, composite materials have excellent
compressibility combined with good tensile strength, making them versatile in a wide range of
situations (Grosz, 2010).
3. Fiber Composite
Fiber Reinforced cement (FRC) composites have been classified according to many
criteria, such as the fiber material ( steel, synthetic, natural organic) or the level of performance,
a general, simple and convenient classification has been recently suggested. Such a classification
suggests a level of performance irrespective of the fiber type, fiber content, or matrix
composition. FRC composites are particularly suitable for structural applications. These include
stand-alone applications, for example, pipes or thin sheets, applications in parts of structures
such as those in impact resistant and protective structures (Naaman, 1996).
The behavior of the fiber reinforced cement composites (FRCC) can be described and
quantified by a variety of parameters, such as strength and strain capacity, toughness index, and
fracture energy, obtained from tests in tension or bending in large number different
configurations including varying specimens geometries and test setups. Depending on the details
of the individual testing procedures, a particular composite may be characterized and classified
inconsistently. To enable the evaluation of FRCC performance, a common basis for comparison
is required, which will reflect the relevant material characteristics (Fischer, 2004).
4. Cement Bonded Board
A typical formulation would be about 5- 10% asbestos fibers, 30-50% cement, and about
40-60% silica. The second development was to replace some of the asbestos reinforcing fibers
with cellulose fibers from wood. This was not widely adopted except for siding products and
wet-area lining sheets. The great advantage of this development was that cellulose fibers are
hollow and soft, and the resultant products could be nailed rather than by fixing through predrilled holes (Welly, 2010).
5. Synthesis
The researchers conduct research on kapok fiber as reinforcement due to the properties
that kapok fiber exhibits. The reinforcement of kapok fiber in cement board will have good effect
especially in its impact strength, flexural strength, water absorptivity and compressive strength.
Kapok fiber is water resistant, pest resistant and lightweight; these are the significant properties
that kapok fiber has compared to other natural fibers present.
Chapter III
Methodology
The researchers will conduct experiment and testing for different proportions of Portland
cement, sand and kapok fiber to determine the best formulation of components in order to attain
the best properties of fiber-reinforced cement board. The (3) three different proportions of fiberreinforced cement board and the commercial fiber cement board (HardiFlex) will be tested in (3)
three material testing procedures, namely, flexural strength test, water absorption and impact
resistance. The results in the (3) three material testing procedures will give the researchers the
conclusion if there are significant differences between kapok-reinforced cement board and
commercial fiber cement board (HardiFlex) using statistical analysis: One Way ANOVA and to
verify the best proportion of Portland cement, sand and kapok fiber using Criteria Method.
Forming
Curing
Product
Testing
Analysis of
Data
Verification
/ Selection
Figure 3.1. Process Flow Chart for Production of Kapok Fiber Cement Board
The kapok fiber-reinforced cement board will consist of Type 1 Portland cement, kapok
fiber and sand. The sand will be sieved with mesh no. 12 (ASTM C778-02), 1.68mm screen
opening. Basing with the total mass of the board, 840g, the weight proportions are:
Kapok Fiber
Sand
Water/cement ratio
Wt%
weight, g
Wt%
weight, g Wt%
weight, g
0.55 wt./cement
Ratio 1
40%
336g
5%
42g
55%
462g
184.8g
Ratio 2
40%
336g
7%
58.8g
53%
445.2g
184.8g
Ratio 3
40%
336g
10%
84g
50%
420g
184.8g
Ratio 4
40%
336g
15%
126g
45%
378g
184.8g
1.1Mixing Procedures
The researchers will mix first the Portland cement and sand. When the mixture is
thoroughly mixed, water will be slowly added. When the mixture is ready, the researchers
will add the kapok fiber randomly and will be mixed.
1.2 Forming
The dimension of the cement board will be 16mm x 305mm x 152mm for flexural
testing based on ASTM C1185-03 and 16mm x 100mm x 100mm for water absorption
testing based on ASTM C1185-99. The researchers will use an improvised molder made
of G.I. (Galvanized iron) sheets.
f=
The researcher will use Universal Testing Machine (UTM) for this kind of
material testing. The unit that will be used is Mpa (megapascal). The dimension of the
specimen will be 16mm x 305mm x 152mm for Compressive testing based on ASTM
C1185-03.
with kapok fiber the researchers will use One Way ANOVA (Analysis of variance) to analyze the
data.
Table 2: Mechanical test results
Ratio 1
Ratio 1
Ratio 2
Ratio 2
Ratio 3
Ratio 3
Ratio 4
Ratio 4
Hardifle
Hardiflex
x
Trial 1
Trial 2
Trial 3
The researchers will find the value of F and compare it to F,u,v , where is the level of
significance, u is the degree of freedom numerator and v is the degree of freedom denominator. If
F> F,u,v with respect to level of significance, there is a significant difference in the
mechanical properties results.
Ratio 1
wF1
Ratio 2
wF2
Ratio 3
wF3
Ratio 4
wF4
HardiFlex
wF5
Strength
Water
wW1
wW2
wW3
wW4
wW5
Absorption
Impact Strength
Compressive
wI1
WC1
wI2
WC2
wI3
WC3
wI4
WC4
wI5
WC5
Strength
Total
w1
w2
w3
w4
w5
Formula:
meanvalue
w= highest mean
w= [
lowest mean
x 25.00
mean value
(water)
The researchers will select the highest w; the highest score in the w will be the best
proportion.
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