Development of Concrete Roof Tile using Coir Fiber as Reinforcement and Bamboo Charcoal as Thermal Insulator

Development of Concrete Roof Tile using Coir

Fiber as Reinforcement and Bamboo Charcoal
as Thermal Insulator (March 2019)
Advisers: Engr. Edgardo S. Legaspi & Engr. Juan Paulo L. Bersamina
Authors: Roxete S. Alonzo, Ellaine Joyce M. Beljot, Rozalliene C. Homigop, Angelica P. Macaspac,
Arvin L. Nicolas, Angelo Paul O. Torreno

sheet that is lightweight but they give a poor indoor climate

Abstract— This project study is concerned in evaluating the
effects of bamboo charcoal as thermal insulator and coir fiber as
reinforcement in concrete roof tile. Properties of concrete roof
tile was evaluated such as water absorption, permeability,
transverse breaking strength and by thermal experimental setup.
Chemical composition of bamboo charcoal was done. 4 design
mixes with controlled value of coir fiber, cement, sand, water and
varying amount of bamboo charcoal were prepared and tested.
Three trials of physical properties of the concrete roof tile has been
done while the transverse breaking strength of the concrete roof
tile had been verified after 7, 14 and 28 days. The specimens were
also subjected to a thermal experimental setup to determine the
effects and role of bamboo charcoal to the temperature of the
concrete roof tile. It was observed that the water absorption
increases and the concrete roof tile becomes permeable as the
amount of bamboo charcoal increases and this is due to its porous
structure. Addition of bamboo charcoal to the concrete roof tile
reduces the transverse breaking strength of the concrete roof tile.
The thermal experimental setup shows that the addition of
bamboo charcoal reduces the temperature beneath the tile. From
the results, it can be concluded that the concrete roof tile with coir
fiber as reinforcement and bamboo charcoal as thermal insulator
has a significant effect to the mechanical, permeability and
thermal properties of the concrete roof tile.
Index Terms—concrete roof tile, thermal experimental setup,
coir fiber, bamboo charcoal
I. INTRODUCTION
T HE Philippines, being a tropical country, is known to have
only two weathers: the dry and the rainy season. According
to PAGASA, temperatures are continuing to rise across the
country. An example of this would be the heat index felt by the
Filipino people last summer. The heat index data recorded by
PAGASA within those months ranges from 32 – 41 degrees,
which are classified as dangerous as it could cause various
health hazards such as heat cramps, heat exhaustion and maybe
even a stroke. They also defined this range as the “human
discomfort index” (Vera-Ruiz, 2018).
Extreme temperatures like these can be felt inside or outside
our home, pushing the construction industry to innovate
existing materials that can help to lessen the heat induced.
Roofing and walls, as the primary protection against weather
elements, must have a good resistance and durability like
concrete roof tile, in contrast to the use of the conventional GI
(Darsana et al., 2016).
Concrete roof tiles can be a great option of materials for
roofing system however, there are number of drawbacks
encountered while in the process of installation and even while
in the time of its use.
The primary downside of using concrete roof tiles is its
difficulty in installation. It is heavy so the roofing system will
require to be well reinforced prior to the tile being laid. Along
to the fact that it is too heavy, the concrete roof tile being
breakable, although hard and compact, they are also brittle that
they will likely break if a person should stand on them in times
of repair and maintenance.
One of the components of the concrete roof tile is the
Portland cement concrete. Portland cement is a brittle material
and possess a very low tensile strength, limited ductility and
little resistance to cracking. For this reason, a solution would be
the addition of small, closely spaced and uniformly dispersed
fibers to concrete. This is known as fiber reinforced concrete.
Natural fibers are cheap and locally available in many
countries and as a construction material, costs very little since
they are renewable, eco-friendly, economical and production
cost is also low (Vajje et al., 2013). Natural fibers have been
recommended to be used in concrete to improve the strength
and durability of brittle materials due to its lignocellulosic
properties. This certain property will give more strength to the
concrete roof tile due to the crack control capability of the fiber
(Sethunarayanan et al., n.d.).
Among the natural fibers, it has been studied that coir fibers
is reported to be most compatible with concrete. Coconut fiber
or coir fiber, is one of the natural fibers that are abundantly
available in tropical regions and is extracted from the husk of
the coconut fruit. It has many advantages, like for example, they
are moth-proof, resistant to fungi and rot, unaffected by
moisture and dampness, tough and durable, resilient, springs
back to shape even after constant use, totally static free and easy
to clean (Darsana et al., 2016).
In a research study, bamboo has been widely acknowledged
and appreciated as an environmental building material for its
growing speed and mechanical properties (Huang, et al., 2013).
In terms of energy saving, charcoal has been given attention in
the recent years because of its special microporous and
 R. Alonzo, E.J. Beljot, R. Homigop, A. Macaspac, A. Nicolas, A.P. Torreno
biological characteristics (Zhao et al., 2008). According to
Zhao, the surface area of bamboo charcoal is ten times more
than wood charcoal. Also, the pores in the bamboo charcoal has
about four times more cavities which traps the air, keeping it
still and making it a good insulator.
Due to coir fiber’s excellent resistance to cracking and
bamboo charcoal’s extremely large surface area and its unique
microporous structure, combining these would be a promising
composite material in making concrete roof tiles which are less
brittle and more effective in reducing heat in structures. This
research will develop the concrete roof tile in three different
ways: (i) to improve its design (ii) to improve its thermal
properties by using bamboo charcoal and lastly, (iii) to develop
the roofing material by adding fiber coir that will serve as a
reinforcement to the concrete roof tile to prevent it from easily
breaking.
II. SCOPE AND LIMITATIONS OF THE STUDY
The study involve producing a concrete roof tile, made from
cement, sand, bamboo charcoal and coconut coir fiber wherein
the properties are required to be determined as per ASTM. The
volume percentage for cement, fine aggregates and coir fiber
will be constant but the amount of bamboo charcoal varies
which gives different mix designs.
The study will also focus on the contribution of bamboo
charcoal and coir fiber in thermal properties, strength and
durability of the designed concrete roof tile, respectively.
To observe the response of concrete roof tile when exposed
to the weather, it will be investigated from an experimental
setup developed in previous studies done by Halwatura et al.
and Silva et al.
The bamboo to be used was limited to waste bamboo that will
be collected in furniture shops in Cavite. Bamboos used was
cleaned removing dirt from it by brushing.
The coir fiber to be used was bought in Pilipinas Ecofiber in
San Pablo, Laguna. The coir was used in the condition received
from the manufacturers. It was cut to a certain length. Dirt and
other materials were removed from it manually. No chemical
treatment was done to the coir fiber used.
The cement to used was Ordinary Portland Cement without
any other additive and/or mixture.
The properties of the developed product includes water
absorption, permeability, transverse breaking strength and an
experimental setup for temperature observation. The
comparison of various mix design is presented through a
graphical analysis for variation of temperature beneath the tile
specimens done by experimental setup and a 7, 14 and 28-day
basis for water absorption and transverse breaking strength and
lastly, an acceptance criteria will be the basis for permeability
test.
III. METHODOLOGY
The bamboo was obtained from Imus, Cavite, The
Department of Science and Technology – Forest Products
Research and Development Institute (DOST-FPRDI) provided
technical assistance in burning the bamboo into charcoal. The
charcoal was then cooled and crushed. The sand that was used
in the research was bought from construction supply store The
cement used was a Type – IP (Ordinary Portland Cement) and
was bought on the construction supply store. The supply for the
coir fiber was obtained from Philippine Eco Fiber in San Pablo,
Laguna. The fiber was cleaned and was cut into 37.5 mm length.
A. Chemical Composition Analysis
The chemical composition testing was done at DOST FPRDI
in Los Banos, Laguna. The research institute assessed the
structural components of the bamboo charcoal such as fixed
carbon, volatile combustible matter, ash and moisture content.
Fixed carbon determines the amount of non-volatile carbon
that remaining in a coal sample after combustion. Volatile
combustible matter determines the amount of non-water gases
released by combustion of a sample. Ash content determines the
amount of non-combustible material. Moisture content
determines the amount of water that exists in the coal.
B. Cement and Sand
The density of cement in connection with the design of
Portland cement concrete mixtures was conducted according to
the standard procedure of ASTM C 188-95. Le Chatelier Flask
was filled with kerosene a little over 1 cc mark and then
immersed in a water bath with temperature remain at 20 degree
Celsius for about 40 minutes. The kerosene level after
immersion was recorded as the initial reading. The cement
sample was added in the flask and then immersed in the bath
for 40 minutes and the level of kerosene after the immersion
was recorded as the final reading.
Specific gravity test was done using the standards procedure
of ASTM C128-01. The fine aggregates were set into its SSD
condition. SSD condition was confirmed when the sand was put
in the cone mold and tampered for 10 times and the slump of
the aggregate was observed. The sample weighing 500 grams
were poured into the Chapman’s flask and was immersed in
water bath at a temperature of 20 degrees Celsius for three
hours. Datas were then collected and used for calculating the
specific gravity of sand. IEEE will do the final formatting of
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C. Mix Design
3.4. Mix Design
Table 1 shows the four mix designs used which varies in
bamboo charcoal. Water, cement, sand and coir fiber are
constant. The mixed design was based on a study done by
Ghana et al. in 2016, a concrete roof tile manual written by Bo
Johannson and for the fiber length would be based from the
study done by Cook et al.
D. Concrete Roof Tile
Proper mixing of raw materials such as water, cement and
aggregates was done to attain uniformity. Then, the mixture was
placed in a mold to produce a concrete roof tile. The principle
for making concrete roof tiles are based on simple technology
and equipment. After the right quantities of the raw materials
 Development of Concrete Roof Tile using Coir Fiber as Reinforcement and Bamboo Charcoal as Thermal Insulator

was chosen and mix, the concrete roof tile mortar was put on coarser wire mesh, removing visible surface water with a damp
the mold until it is completely filled. The excess concrete roof cloth; weigh and record as Ws (saturated weight). For drying,
tile mortar was scraped off until a smooth surface is achieved. subsequent to saturation, all specimens were dried in a
Specimens were stored immediately after finishing until the ventilated oven at 212 to 239°F (100 to 115°C) for not less than
removal of the molds to prevent loss of moisture from the 24h. The weight of dried specimens were recorded as Wd
specimens. It was stored on a cool place and was kept damp. (oven-dry weight). Absorption will be calculated as follows:
𝑊𝑠 − 𝑊𝑑
TABLE I 𝐴𝑏𝑠𝑜𝑟𝑝𝑡𝑖𝑜𝑛, % = [ ] 𝑥 100 (1)
𝑊𝑑
DESIGN MIX PROPORTIONS
F. Permeability Test
CONCRETE MIXTURE ADDITIVE
The permeability test was used to determine whether the
MIXTURE C:S W/C Ratio Coir Fiber Coir Fiber BAMBOO water can pass through the concrete roof tile in given span of
SET 1:2.5 0.55 37.5 mm Length CHARCOAL time. The frame was constructed 3 ft (1 m) by 3 ft (1 m) at a
pitch not to exceed 30° without nails or roofing felt.
(g) (g) (g) (mm) (g)
The tiles were installed as would be installed during field
MIX A 563 1408 253 37.5 0 application for tile headlap without the use of nails. A 1⁄2 in.
MIX B 563 1408 253 37.5 5
diluge pipe (12 mm) inside diameter with 1⁄16 in. (2 mm) holes
on 11⁄2 in. (38 mm) was placed over the top course of the roof
MIX C 563 1408 253 37.5 10
to simulate run down from the higher course. A spray nozzle
MIX D 563 1408 253 37.5 15 was placed over the center of the tile to simulate direct rainfall
and such that every tile on the roof received an equal volume of
water. The acceptable criteria for the concrete roof tile to pass
will be: (i) when the free water has not formed on the underside
of the tile and (ii) not more than 25% of the visible underside of
any one tile shall show dampness.
G. Transverse Breaking Strength
The transverse breaking strength of tiles was determined as
described in the Modulus of Rupture Test in ASTM C 67-03.
Test specimen were supported flatwise unless specified and
reported otherwise (that is, apply the load in the direction of the
(a) (b) depth of the unit) on a span approximately 1 in. (25.4 mm) less
than the basic unit length and loaded at midspan. If the
Fig. 1. From left (a) Production Process, (b) Concrete roof output specimens will have recesses (panels or depressions) place
them so that such recesses are on the compression side. The load
was applied to the upper surface of the specimen through a steel
bearing plate ¼ in. (6.35 mm) in thickness and ½ in. (38.10 mm)
in width and of a length at least equal to the width of the
specimen. The supports for the test specimen were free to rotate
in the longitudinal and transverse directions of the test specimen
and will be adjusted so that they will exert no force in the
directions. For the speed of testing, the rate of loading shall not
exceed 2000 lbf (8896 N)/min. But this requirement will be
considered as being met if the speed of the moving head of the
testing machine immediately prior to application of the load is
not more than 0.05 in. (1.27 mm)/min. Modulus of rupture of
Fig. 2. Concrete roof tile specimens each specimen was calculated and reported to the nearest 1 psi
(0.01 MPa) as follows:
E. Water Absorption Test 𝑙
( − 𝑥)
This test is used to determine the capacity of concrete roof 𝑆 = 3𝑊 2 2 (2)
tile to absorb water when it is subjected to heavy rain. For 𝑏𝑑
saturation, the test specimens were immersed in water at a
temperature of 60 to 80°F (15.6 to 26.7°C) for 24 h. The Where S is the modulus of rupture of the specimen at the
specimens were weighed while suspended by a metal wire and plane of failure, lb/in2 (Pa), W is the maximum load indicated
completely submerged in water and record Wi (immersed by the testing machine, lbf (N), l is the distance between the
weight). The specimens were remove from the water and allow supports, in (mm), b is the depth of the specimen at the plane of
to drain for 1 min by placing them on a 3⁄8-in. (9.5-mm) or v, failure, in mm and x is the average distance from the midspan
of the specimen at the plane of failure measure in the direction
 R. Alonzo, E.J. Beljot, R. Homigop, A. Macaspac, A. Nicolas, A.P. Torreno
of the span along the centerline of the bed surface subjected to
tension, in mm.
H. Thermal Experimental Setup
The thermal properties of the roof tiles were investigated
from an experimental setup, similar to the set ups developed in
previous studies. Roof tiles were covered with an insulating
material in all surfaces except the top surface. Space between
the insulating material and the tile was filled with Styrofoam to
avoid heat transferring from other surfaces except the top
surface. Two Temperature MAX 6675 thermocouple amplifier
module with Type K thermocouple were placed on the top and
the bottom surfaces at the middle of the tile. The temperature
was measured in every 30 mins from 8:00 am to 5:00 pm. The
amplifier measured the output of the K thermocouple and
provided the results to Arduino via SPI.
(c)
(a)
(b)
(d)
Fig. 3. From left (a) and (b) water absorption, (c) permeability test, (d)
transverse breaking strength, (e) thermal experimental setup
IV. RESULTS AND DISCUSSION
A. Cement and Sand
In accordance to ASTM procedures, the cement has a
specific gravity of 2.936 while sand has a specific gravity of
2.513. The density of coir fiber was determined by volume
displacement method and was recorded as 0.9 g/mL.
(1)
B. Chemical Analysis of Bamboo Charcoal
The chemical analysis of bamboo charcoal was included in
the study to further understand the effects of bamboo charcoal
to the concrete roof tile and to also know what the coal ranking
of the sample would be. The analysis done was the proximate
chemical analysis which includes determining the fixed carbon,
volatile combustible matter, ash and moisture content.
TABLE I
PROXIMATE ANALYSIS RESULTS
TEST RESULTS (%)
Fixed Carbon 63.37 ± 0.33
Volatile Combustible Matter 22.47 ± 0. 83
Ash 14.15 ± 0.17
Moisture Content 2.50 ± 0.31
Based on the results, the bamboo charcoal used can be ranked
as a medium rank coal, specifically, a bituminous coal.
The moisture content together with the ash content are
important charcoal’s chemical properties that define its quality.
Moisture lowers the calorific value of charcoal. The ash content
determines the amount of non-combustible matter. Based from
the results shows, the ash content and moisture content is low
which shows that the bamboo charcoal’s carbonization has been
done properly.
C. Water Absorption
Fig. 4 Water absorption
The required maximum water absorption values for
lightweight concrete roof tile to 18%. The maximum average
water absorption recorded was 12.28% which is mix D.
As shown from Fig. 4, it can be observed that the water
absorption is directly proportional to the increase in bamboo
charcoal due to charcoal’s porous structure.
Water absorption is used as an indicator for assessing the
durability of concrete it also determines the capacity of concrete
roof tile to absorb water when it is subjected to heavy rain.
Bamboo charcoal has an effect on the water absorption due to
its porous structure. The void spaces were filled with water
when submerged.
D. Permeability
Fig. 4 Water absorption
On 7th day, Mix A (0% bamboo charcoal) and Mix B (2.5%
 Development of Concrete Roof Tile using Coir Fiber as Reinforcement and Bamboo Charcoal as Thermal Insulator
bamboo charcoal) have passed the permeability test as water did
not penetrate beneath the tile and showed no dampness. Mix C
(5% bamboo charcoal) and Mix D (7.5% bamboo charcoal)
have become more permeable because adding bamboo charcoal
increased the porosity of the roof tile showing gradual
dampness on the underside of the tile but on the 14th day and
28th day, all roof tile have shown no freewater formed and less
dampness were found on it.
E. Transverse Breaking Strength
Fig. 5 Modulus of Rupture
Fig 5 shows that incorporating bamboo charcoal in concrete
roof tile has an effect in the early flexural strength. Strength of
the roof tile increases as time progresses. Bamboo charcoal
decreases the strength of the roof tile. Mix A was able to reach
its strength faster than Mix B, C and D, which shows that the
charcoal retards the cement hydration and prolonging the
setting time of the cement.
F. Thermal Experimental Setup
Fig. 6 Modulus of Rupture
The addition of bamboo charcoal to the concrete roof tile
shows a significant effect on the thermal performance of the
tiles. Mix A (0% bamboo charcoal) shows the highest
temperature value beneath the tile, while Mix D (7.5%) which
has the highest content of bamboo charcoal shows the lowest
temperature beneath the tile. On average, mix A, mix B, mix C
and mix D has reduced the temperature beneath the tile by about
1.62°C, 2.35°C, 3.15°C and 4.78°C, respectively. The reduction
in the temperature beneath the tile is due to the improved porous
nature of the tile that is caused by the mixing of bamboo
charcoal
V. CONCLUSIONS AND RECOMMENDATIONS
Based on the results of the experiments, the following
conclusions were derived: (1) Water absorption is directly
proportional to the amount of the bamboo charcoal that was
being added in the concrete roof tile mixture. As the amount of
concrete roof tile increases, the water absorption also increases.
The maximum average water absorption was 12.28 % of the
mix D which contains 7.5% bamboo charcoal content. (2)
Permeability was also found to be directly proportional to the
amount of bamboo charcoal content. As the amount of bamboo
charcoal increase, the roof tile becomes permeable. (3)
Addition of bamboo charcoal to the concrete roof tile affects the
early strength of the concrete roof tile as it retards the cement
hydration and prolonging the setting time of the cement. (4) The
thermal experimental shows that the addition of bamboo
charcoal reduces the temperature beneath the tile which causes
the indoor environment cooler. When the humidity or the
moisture level of the surrounding is higher than of the bamboo
charcoal, the bamboo charcoal adsorbs the mass of moisture in
the air, vice versa. (5) The specimen with 2.5% bamboo
charcoal content is the governing mix having a modulus of
rupture of 4.25 MPa ,water absorption of 9.08%, passing the
permeability test and lowers the temperature indoors by 2.35°C.
The proponents would like to present the following
recommendations for further development of the study.
Addition of admixtures is recommended to improve the flexural
strength of the tile. Further study of the effect of fineness of
bamboo charcoal to the strength of the roof tile by scanning
electron microscope. For an increase in the amount of bamboo
charcoal in order to attain a cooler indoor environment, the use
of water proofing agent is highly recommended. When it comes
to production, it is better that the water, sand and cement will
be mixed first and bamboo charcoal will be added after because
bamboo charcoal has an effect on the workability of the
concrete roof tile. A suitable mold is recommended other than
the use of GI sheet to better control the thickness of the
specimen.
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