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MANUFACTURE OF
CEILING BOARD USING LOCAL MATERIALS
ABSTRACT
This project “The Production of Ceiling
Board from Local Raw Materials” was carried out basically using raw materials
which was sourced locally. These raw materials are found to be very much in abundance.
Some are materials sourced from the ground and others are from agricultural
wastes.
Three different types of ceiling boards
were produced, their difference being in the type of fibre that was used. The
fibres used for this different type includes; cellulose fibre obtained from
pulped carton, saw dust and rice husk.
The raw materials used for the
production of the different ceiling boards includes, cement, calcium carbonate
(CaCo3), Kaolin, starch and water.
The first type produced is from pulped carton.
First, the cartons were collected, size reduce, soaked in a large quantity of
water for 24hours, strained to remove the water and the milled by grinding
using a motar and pestle. The quantity to be used was weighed out. The other
raw materials which include starch, powdered kaolin, calcium carbonate and
water were all measured. The pulped carton was poured and thoroughly mixed. The
CaCo3, kaolin and starch and water were all measured. The pulped Carton was
poured into the reactor; next cement was poured and thoroughly mixed. The
CaCo3, kaolin and starch was added one after the other while stirring
continued. Finally, water was added sparingly and gradually until a very smooth
slurry was obtained. This was then poured into a mould and smoothened out using
a roller and was left to dry. It took 7days for it to get dry.
The next produced was
ceiling board from sawdust. The sawdust was first sieved, soaked for a day and
then strained to remove the water. The quantity used was measured as well as
all the other raw materials that was used. The same procedure was repeated as
that of the first method and it was allowed to dry. It took three days to dry.
Finally, ceiling
board using rice husk was produced. The rice husk was sieved, materials to be
used weighed out and procedure repeated again in this case and allowed to dry.
It took 5 days for it to dry. Drying was done with solar energy for all cases.
The three different
types were subjected to different test. This includes; moisture content test
percentage humidity, bursting strength. The weight of the wet samples and dry
samples was obtained as well as the density and volume.
Finally, the different ceiling boards
were coasted. Ceiling board from cellulose fibre (Sample A) costs N186.00
for the production, that of sawdust costs N184.00 while that of rice
husk costs N185.00.
TABLE OF CONTENT
CHAPTER ONE
1.0
INTRODUCTION
1.1
Aims and Objectives of the Project
CHAPTER TWO
LITERATURE REVIEW
2.0
History of Ceiling Board
2.1
Types of Ceiling Board
2.1.1
Asbestos Cement Ceiling Board
2.1.2
Acoustical Ceiling Board
2.1.3
Gypsum Ceiling Board
2.1.4
Gypsum Fibre Celling Board
2.1.5
Cement Fibre Ceiling Board
2.2
Raw Materials Used For The Production Of Ceiling Boards
2.2.1
Cement
2.2.2
Fibre
2.2.3
Starch
2.2.4
Calcium Carbonate
2.2.5
Kaolin
2.2.6
Additives
2.2.7
Pigments
2.2.8
Fludifiers
2.3
The Study Of Thermal Properties Of The Ceiling Boards
2.3.1
Thermal Comfort
2.3.2
The Principles Of Thermal Insulation
2.3.3
Typical Thermal Properties Of Some Ceiling Boards
2.3.4
Conductivity Of Porous Materials
2.3.5
Surfaces Coefficients
2.4
Study Of Acoustic Properties
2.4.1
Acoustic Properties
2.4.2
Sound Absorption
2.4.3
Basic Factors In Acoustic Design
2.4.4
Manufacturing Process
2.5
Manufacturing Process
2.5.1
The manufacture of wood wool cements ceiling board.
2.5.2
Production Of Ceiling From Various Types Of Fibred
2.5.3
Production Of Ceiling Board From Paper
CHAPTER THREE.
3.0
Manufacturing Process
3.1
Apparatus and Equipment Used For the Production
3.2
Chemicals And Materials Used For The Production
3.3
Composition Of Materials Used For The Production
3.4
Preparation Of Raw Materials
3.5
Production Procedure
3.6
Dying
3.7
Trimming
3.8
Analysis Of The Samples
3.8.1
Introduction of the samples
3.8.2
Composition of sample sheet
3.8.3
Test and result of test
3.8.4
Rate of drying
3.8.5
Bursting strength
3.8.6
Moisture strength
CHAPTER FOUR
4.0
Costing
4.1
Cost of Raw Materials
CHAPTER FIVE
5.0
DISCUSSION
CHAPTER SIX
6.0
CNCLUSSION/RECOMMENDATION
Reference
CHAPTER ONE
INTRODUCTION
A ceiling board is a horizontal slab covering
the upper section of a room or internal space. A ceiling board is generally not
structural but is a shell concealing the details of the structure above.
However, the ceiling might be holding up building materials such as heat or
sound insulation.
In modern buildings, electric lights,
smoke detector, security cameras and signage are commonly attached to ceilings.
This project however, is based on the production of ceiling board from local
raw materials. These local raw materials include cement, fibre cellulose, fibre
obtained from ground paper, mainly waste paper, water and some other additives.
There are different types of ceiling boards. These include;
1)
Gypsum ceiling boards;
2)
Acoustical ceiling boards;
3)
Gypsum fibre ceiling boards;
4)
Cement fibre-ceiling boards. Etc
These types of ceiling boards are
grouped in accordance to the raw materials used for the production. Gypsum
ceiling boards are produced from gypsum, Acoustical ceiling boards are obtained
from mineral wool, gypsum and small amount of paper and starch. Gypsum fibre
ceiling boards are produced from gypsum and fibre to reinforce the ceiling
board.
This study however will be based mainly on the production of fibre cement
ceiling boards. This consist essentially of an inorganic binder usually calcium
silicate formed by the chemical reaction of a siliceous material and a
calcareous material. This is reinforced by organic fibres, fillers and pigment
compatible with the fibre reinforced cement to form a ceiling board.
In the past, ceiling boards were
produced using Asbestos a fibre present naturally in rocks. It was used because
of its high tensile strength, poor heat conductivity and high fire resistance.
However, asbestos causes asbestosis, which leads to cancer. As a result of this
problem, manufacturers of ceiling boards went into research to find out
substitutes that can be used in the production of ceiling boards.
This substitute includes shredded wood,
cellulose fibre agricultural waste etc.
Rather than
industrial products (glass-fibre, iron fillings) and man-made
materials, the fibres best suited to
the socio-economic circumstances of developing countries are natural fibres.
This project
therefore, is based on how these natural fibres can be used in the production
of ceiling boards in order to reduce cost and as well comparing the product
with that which has been produced naturally.
1.1
AIMS AND OOBJECTIVES OF THE PROJECT
1.
To
study the possibility of making use of local raw materials for the production
of ceiling board.
2.
To
produce a board with good acoustic and thermal insulating properties.
3.
To
produce a board with reduced cost to discourage importation there by saving
Nigeria her foreign exchange and booting her economic status.
4.
To
reduce environmental pollution caused by indiscriminate litering of papers and
the pollution of the air resulting from burning these waste.
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