Post on 20-Jun-2015
description
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sPAPERCRETE-Towards a new beginning
• Name of the authors: Jil Sheth
Saransh Joshi• Faculty of Technology, CEPT
University
• Name of the adviser: Mrs. Anal Sheth
Category: UG
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Motivation
• With the ever increasing pace of industrialization, the carbon footprint has increased considerably at an alarming rate. Cement manufacturing itself contributes to about 5% of the total emission of greenhouse gases. As a result, it has became imperatively necessary to evolve such practices and techniques that considerably reduce the carbon footprint and are environmental friendly in nature. A huge amount of resources and a lot of carbon footprint is consumed in the manufacture of materials used in construction industries especially cement. Cement manufacturing consumes large quantum of energy and requires the extensive use of various resources.
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Motivation
• But, it is an integral ingredient in the manufacturing of Concrete, which is the most commonly used building material all over the world. So, a systematic effort to replace or at least reduce the amount of cement in concrete can have a huge impact on Carbon footprint reduction and can drastically change the entire scenario. This was precisely the central idea behind this research.
• Also need to develop of low cost housing for less fortunate people was motivation.
• Need for sustainable eco-friendly building material.
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sProblem statement
The real problem laid in the fact that there are no specific guidelines and standards for manufacturing ‘Papercrete’
Specific objectives:
Understanding the material, its properties and its workability by casting various forms and building various small elements.
To observe, record ,analyze and compare the properties of papercrete based on empirical evidences obtained by testing the material.
To gain an insight about its overall feasibility and its appearance.
To gain an idea about the approximate quantity of various ingredients needed for producing a certain standard amount of papercrete.
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Methodology
Papercrete moulds were prepared before hand and ideally wood is suited for this.The main materials used for papercrete mix preparation were waste paper (newspaper), Portland cement OPC-53 grade, Sand, Potable water and Soil.Four types of mixes were prepared for the experiment. Mix proportions by volume in percentages are indicated below:1) 50% wet paper pulp/ 30% damp earth/ 10% dry sand/ 10% Portland cement2) 60% wet paper pulp/ 20% damp earth/ 15% dry sand/ 15% Portland cement3) 65% wet paper pulp/ 25% damp earth/ 10% Portland cement4) 70% wet paper pulp/ 15% damp earth/ 15% Portland cement
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Methodology (continued)
There is a lack of any statistical data recorded regarding the physical characteristics of papercrete in regions like Ahmedabad which have relatively hotter climate.
So, we conducted our tests during the month of June, when the temperature was round about 42-47 degree centigrade.
Various elements of different sizes were cast, predominantly a wall and an arch (compression member).
The units were bound together with mortar in case of a wall, and using lock and fit mechanism in case of arch (without mortar).
Three types of mortar mixes were prepared for binding the papercrete blocks in the wall
1)Cement , Sand and Water (C-S -1:4)
2)Cement, Sand, Water and Paper Pulp (C-S-P -1:4:6)
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Methodology (continued)
c)And,lastly,Cement, paper pulp and water (C:P:W-2:4:1).
The last one was found to be most appropriate and it was used for providing proper strength and bonding in the papercrete masonry.
The major steps for preparation of blocks and related equipment used are described below:
• IS sieve 4.75mm was used to remove all coarse aggregate from the sand and soil by temping.
• Shredded newspaper was wetted in water in the curing tank and a motor run machine called the pulp beater machine was used to obtain wet paper pulp.
• Next, the soil, sand, pulp and cement were mixed into a more uniform and consistent mass with help of a cement mixer. The mixer machine was allowed to work for around 3 to 4 minutes to obtain papercrete.
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Methodology (continued)
• Wooden moulds were prepared in the experiment but acrylic or plastic sheets can also be used for mould. The moulds were then greased with burnt oil or taping was done on the moulds which may help in releasing the blocks quickly and easily.
• The papercrete mix was then poured into moulds and compacted on a vibrating to remove voids and achieve more density, resulting in stronger and more durable product. Temping bar was also used for the same purpose.
• The mix was then leveled to achieve satisfactory dimensions and finish.
• After 40 hours, papercrete seemed to attain sufficient amount of strength after which the moulds were released and casted blocks were allowed to sundry for further strength gain and development of load carrying capacity.
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Water absorption tests
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Compressive strength test
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Results
• The above lab scale manufactured papercrete blocks were tested for key properties and following values were obtained.
• Compressive Strength• Compressive strength tests on 15 cm x 15 cm x 15 cm papercrete
cubes revealed an average compressive strength of 0.57 N/mm2
after 3 days of cube preparation. Other research also suggests similar results. [1, 5]. For more strength, higher grade of cement can be used.
• Weight and Density• Density of the material increased with increase in the percentage
of cement in the mixture and reduced with increase in the amount of the paper in the mixture. Average weight of 8 cubes casted was observed to be 3.624 kg, thus block density was about 1.07 gm /cc. This is therefore lightweight in comparison to standard concrete or brick masonry units.
• Shrinkage• Shrinkage measured was between 8-9% in each block.
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Results (continued)
• Water absorption
• Water absorption of the blocks was about 30% in all cases.
• Drying time
• 40 hours at least are needed for drying of papercrete before it can be demoulded. After this it should be sundried for 4 days before usage for better strength. Or it can be placed in oven at nearly 70 °C for 40 hours after casting. Putting it at higher temperature than this can result into segregation of material.
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Pulp beater
Beater machine is a motor run machine which can be made by attaching blade to axle of a vehicle or old car. It helps in making consistent pup out of pieces of wet newspaper.
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Other equipment needed
• Cement mixer• Trowel• Temping rods• IS sieves -4.75 mm• Scooper• Leveler• Pan• Vibrating machine
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Designing of module
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Mold making
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Soaking of paper
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Making of paper pulp
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Temping of soil
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Volumetric batching
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Compaction
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Sundry
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Assembly
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Main points
• Lack of official guidelines and standard procedure describing the method of producing papercrete.
• Solution: By initially casting elements and smaller blocks and elements by varying proportions of constituent elements and checking their strength by experimentation before casting the final elements.
• Papercrete is far lighter a material than concrete or wood has good water absorption and insulation capacity, less shrinkage and is environment friendly, has high strength to weight ratio.
Although this area requires significant amount of research, but papercrete can ideally be used for reduction in dead weight of structural elements in cases where there are no special loads acting on the element. Also, about 55% of paper waste around the globe still doesn’t get recycled and is directly disposed and a considerable portion of it can be used for manufacturing papercrete. Future research on improving it’s tensile strength can widen up the possibilities of papercrete using it as a construction worldwide.
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Acknowledgments
• We are thankful to our faculties, Mr. Nikunj Vakani and Mr. Pranav Gajjar for guiding us through the papercrete workshop. We also thank the lab assistants at the University for their support. We acknowledge the efforts of our team members in this workshop. We are grateful to Prof. Anal Sheth for her valuable inputs and motivation throughout this work.
Thank you. Any questions?