"Is that a firefly: Making fire resistant and environmental friendly concrete

that can be used as main material for Infrastructures projects and

residential houses to avoid fire Accidents"

CAPSTONE PROJECT

In Partial Fulfilment

Of the Requirements for the Subject

Work immersion/ Research/ Culminating Activity

Submitted by:

BACOLOD, KRISTLE R.

BONIFACIO, KATE ANN ROSE B.

SAN JOSE, MARK ANTHONY

BERBER, IVAN JULIUS

STEM – C

March 2018
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Chapter 1

INTRODUCTION

This chapter includes the Rationale of the project, Project context, Purpose and

description of the project, Objectives of the project, Scope and limitation of the

project and Definition of terms.

Rationale of the project

This proposal project is all about fire resistant and environmental friendly

concrete. A concrete that can be green alternative for Portland cement because

of its low carbon footprints. The main materials includes to make this product are

materials that contains Alumino-silicates which are industry by products such as

Fly ash that is by-product from burning pulverized coal in electric generation

power plants, Ground Granulated blast furnace slag that is by-product from

the blast-furnaces used to make iron and Rice Husk Ash that is from burning

Rice Husk. Other cementious materials includes Coarse Aggregates (Gravel,

Limestone, Lime rock, Dolomite, Recycled concrete) and Fine Aggregates

(Sand, Fine crushed stone), and Alkaline Activator (Sodium hydroxide and

Sodium Silicate) that will serve as activators to source materials containing

Aluminum-Silicate such as Fly ash, Rice Husk Ash and GGBS. We will also

include some additives which is Polypropylene fibers.

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Our product becomes fire resistant because of the constituents materials

(Cement and aggregates) that is included in the production which, when

chemically combined within concrete, it enables concrete to act as an effective

fire shield.

Project Context

Fire is the one of the most generous disaster that can occur, whether it is

residential or commercial in nature. Fire is adverse events with physical costs to

property and human life. Fire is our greatest fear. When an item was stolen from

you, it can be recovered but when it burns up, it is gone forever.

In addition, fires also inflict adverse consequences on the natural

environment. These include contamination of that air via the fire plume and its

subsequent diffusion, with deposition of particulate and other materials likely to

contaminate soil and water.

The government has been consistent in taking initiatives to raise

awareness through its fire prevention campaign. March is considered as Fire

Prevention Month, but ironically, it is also the month when the worst fire incidents

that went down in Philippine history took place. A factory in Cavite was razed by

fire causing billions of pesos worth damages. Of the 30 workers inside the factory

compound, one died while others sustained critical injuries. Fire insatiably

consumes almost anything it touches, even lives.

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According to Bureau of Fire Protection, there's total of 615 fire events in

Metro Manila in the first 2 months of 2015. In this case, the researchers are

totally determined to give solution to the problem of the people.

Due to the increasing cases of fire disaster not only in the Philippines but

also in other country, some engineers on the past years developed fire-resistant

materials that will decrease the level of spreading of fire during disaster. As

researcher dream to be civil engineers, this is a very helpful for the future

purposes. It will be good to minimize the fire happenings in the Philippines. The

researchers chose this project because of the strong needs of the Philippines

due to being prone to fire incidents.

This project is all about fire resistant concrete, the researchers chose to

propose concrete rather than other construction materials because Concrete

does not burn, it cannot be set on fire and it does not emit any toxic fumes when

affected by fire. Concrete is proven to have a high degree of fire resistance and,

in the majority of applications, can be described as virtually fireproof. This

excellent performance is due, in the main, to concrete’s constituent materials

(cement and aggregates) which, when chemically combined within concrete,

form a material that is essentially inert and, importantly for fire safety design, has

relatively poor thermal conductivity. It is this slow rate of conductivity (heat

transfer) that enables concrete to act as an effective fire shield not only between

adjacent spaces, but also to protect itself from fire damage.

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PURPOSE AND DESCRIPTION OF THE PROJECT

This project will create new highly heat resistant concrete that will be

suitable to the present problem of this country. This will prevent the massive

damage and destruction of buildings, residential houses and other properties. As

research make it alright, it will also make the building strong, not about fire but

also in any disaster.

Also, in making this new concrete, there will be no use of harmful

chemicals unlike the process of other concrete that the main process is relies on

a high-energy manufacturing process that imparts high potential energy to the

material via calcination. This means the activated material will react readily with a

low energy material such as water. On the other hand, our propose concrete

product uses very low energy materials, like fly ashes, slags and other industrial

wastes and a small amount of high chemical energy materials (alkali hydroxides)

to bring about reaction only at the surfaces of particles to act as a glue. By

means of this, we can lessen the harmful effects of chemicals to our environment

due to modern innovation.

Objectives of the Project

General Objectives:

To propose new fire resistant and environmental friendly concrete that can
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be used as main material for Infrastructures projects.

Specific Objectives:

 To prevent fire damage

 To used fly ashes, slags and other industrial wastes to become useful

and not just treated as wastes.  

 To create a highly cost effective fire resistant concrete.

 To make a product that is beneficial to the people.

 To make a product that is environmental friendly.

 To enhance the quality of concrete used in buildings

 To become fully equipped and prepared for fire disaster

 To ensure the safeties of properties such as houses, buildings and other

infrastructures.

Scope and Limitation of the Project

The project was done to make fire resistant and environmental friendly

concrete that can be used as main material for Infrastructures projects and

residential houses to avoid fire accidents not just in the Philippines but also to the

other country. The project will only focus on creating a new highly fire resistant
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concrete with the use of industrial waste as main materials in creating the

product.

This project will took place in Teresa Rizal which will be the location in

creating this product before it release and sell. The estimated time to make and

produce the materials is 2 to 3 months due to the things that are needed to

produce them.

Definition of Terms.

The following are define in terms of Conceptual and Operational used.

Additives. Are the ingredients in concrete other than cement, water,

and aggregate that are added to the mix immediately before or during mixing.

Alkaline Activation. Is a chemical process in which a powdery aluminosilicate is

mixed with an alkaline activator to produce a paste capable of setting and

hardening within a reasonably short period of time.

Coarse Aggregates. Generally range between 9.5mm to 37.5mm in diameter.

Concrete. is a major building material which is formed by homogeneous mixing

of aggregate (fine and course), cement, and water and with or without chemical-

mineral additives in the conformity with the production technology, initially it is in

plastic form and later it hardens and gain strength.

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Curing. Is the maintaining of an adequate moisture content and temperature

in concrete at early ages so that it can develop properties the mixture was

designed to achieve.

Fly Ash. Is a by-product from coal-fired power plants that is frequently used as

an admixture in concrete to replace a portion of the Portland cement.

Fine Aggregates. Generally consist of natural sand or crushed stone with most

particles passing through a 9.5mm sieve.

Fire Resistant. Is one that is designed to resist burning and withstand heat.

GGBS. Is a by-product of iron manufacturing which when added to concrete

improves its properties such as workability, strength and durability.

Portland cement. Is the most common type of cement in general use around the

world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout.

Rice Husk Ash.

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Chapter 2

REVIEW OF RELATED LITERATURES AND PROJECTS

This chapter represents the various literature and projects of foreign and local

settings which are pertinent of the studies.

Foreign Literature and project

Hao-wen Ye et. al. (2013) Ultra-high-performance concrete is an artificially

synthesized material low in water-cement ratio and high in strength, density,

impermeability, and brittleness. These traits make it easy to crack in case of fire,

which results in reduction in strength. Adding polypropylene fibers not only helps

enhance concrete’s strength and elasticity, but also provides ventilating vessels

when the surrounding temperature rises. With these merits, ultra-high-

performance concrete with fibers is able to tolerate heat and pressure for a

relatively long time without getting seriously damaged, thus making time for fire

fighters to save people’s lives and their properties.

In relation to the project, polypropylene fibers will add to the concrete to

resist to shrink & crack, Increase seepage resistance, Increase friction

resistance, Increase freezing and thawing resistance that will give fully enhance

to our proposed product which is the fire resistant concrete.

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Local Literature and project

Aquino J.F. et. al. (2014) States on their research entitled “Concrete

Strength Analysis: Replacement of Parts of Sand with Sawdust and Parts of

Cement with Fly Ash for Slab on Grade “ that Fly ash particles provide greater

workability of the powder portion of the concrete mixture also lowering of water

requirement for the concrete of same consistency. Pump ability is greatly

enhanced. Also, fly ash generally exhibits less bleeding and segregation than

plain concretes. This makes the use of fly ash particularly valuable in concrete

mixtures made with aggregates deficient in fines; it has lower heat of hydration.

This is related to the present project since fly ash is one of the main

material in producing our product which is fire resistant concrete because Fly ash

is a solid material that serves as a waste by product produced by thermal power

plants which is composed of free lime that give a self-hardening characteristic

that is made to have a good compressive strength. This is also the reason why

our product becomes environmental friendly.

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Chapter 3

TECHNICAL BACKGROUND

Things that needs to consider in producing fire resistant and environmental

friendly concrete

Description of the Project

This project is all about fire resistant concrete, the researchers chose to

propose concrete rather than other construction materials because Concrete

does not burn, it cannot be set on fire and it does not emit any toxic fumes when

affected by fire. This project will create new highly heat resistant and eco-friendly

concrete and will use the following materials such as Fly ash, Granulated Glass

Blast Slag (GGBS), Rice Husk Ash, Fine aggregates and coarse aggregates,

polypropylene fibers and Catalytic liquid system (CLS) to activate the source

materials (containing Si and Al) such as fly ash and GGBS.

Production Process

Ultimately, the objective of the production process is to create goods or

product that will be beneficial to the people.

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The production process of creating a fire resistant concrete involves Raw

materials and Preparation, Mixing Process, Molding and compressing, Curing

and handling.

The following steps is how to create Fire resistant concrete using small equipment.

1) Preparation of the materials

Prepare the raw materials including: Fly ash, GGBS, Fine and Coarse

aggregates, admixtures and Alkali Activators.

2) Combine the solid materials

Combine the materials with appropriate amount of ratio

3) Mix using mechanical Mixer

Mix the raw materials using mechanical mixer

4) Add the Catalyst liquid (activator)

Add the Sodium hydroxide and sodium silicate in the raw materials

5) Mix using mechanical mixer

Mix the raw materials and catalyst liquid using mechanical mixer

6) Put in a square container (molding)

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After the mixing process, put the cement in a square container and flat

7) Place on top of vibrating table for 2 minutes

The square container will place in a vibrating table and wait until 2 minutes

8) Remove the concrete on the container after 8 hours

After two minutes, remove the container in a table and live it for 8 hours

9) Place it on the large oven for 3 days

After 8 hours, remove the concrete in the container and place it in curing

conveyor oven for 3 days

10) Handling

After 3 days the concrete is ready to sell.

START HANDLING
MIXING
PROCESS CURING

RAW MOULDING AND END

MATERIALS COMPRESSING
AND
PREPARATION

FIGURE 1
Production Flowchart
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1) Raw Materials and Preparation

The researchers will prepare the safe working place and at the

same time the materials needed to create a fire resistant materials. The

raw materials includes are fly ash which is by-product from burning

pulverized coal in electric power generating plants, Granulated Blast

furnace slag which is by-product of steel manufacturing process, Rice

Husk ash which are made from burning Rice Husk, Fine aggregates which

are crushed stones and sand etc., coarse aggregates which are gravel,

limestone, dolomite, limerock and recycled concrete etc., Alkaline

Activator such as, Sodium Hydroxide (NaOH) and Sodium silicate

(Na2SiO3), and polypropylene fibers.

2) The Mixing Process

The materials that had been prepared before should be weighed

accordingly based on the design ratio. Then the materials need to be put

into the mixer by following the sequence which is waste material before

sand and lastly alkaline activator accordance to the standard. The

sequence is important due to different properties in each material that

affect the mixing process. Before mixing it, the sand should be prepared in

a right condition that is surface saturated dry. This condition is important to

make sure that the sand does not add or absorb any solution in the mix.

The source of material need to mix first before the alkaline activator was
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added to the mix. After all the material already being put into the mixer

then press mixer button on. The duration of mixing process is depending

on the design ratio and material used. Usually the mixing process does

not take more than 20 minutes for each batch

3) Moulding and compressing

After the mixing already is mixed, on mixer moving switch then

open the nozzle by switching on the nozzle switch. Then switch on upper

cylinder button. After an accordance suitable time, switch off upper

cylinder and switch on lower cylinder. To move the brick, switch on the

mixer moving switch again. Then the brick will be move into the curing

oven thru the extension conveyor.

4) Curing

For curing operation, the brick will be automatically moved in and

out of the oven by the stainless still belt at the curing conveyor oven. The

temperature need to be set to required temperature before the brick being

pulled into the oven by using oven temperature control at the control

board. After the brick finish going thru the curing conveyor oven, the brick

end product will go to end gravity conveyor and ready to be use.

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5) Handling

After the product is test, it is now ready to distribute and sold.

Production Capability and Schedule

The table below is the schedule for the production of the fire resistant and

environmental friendly concrete.

Raw material and Preparation 1 month

Mixing process 15 minutes – 20 minutes
Moulding and Compressing 3 minutes – 5 minutes
Curing 24 hours

Table 1

Production Schedule

Physical Facilities

This are large piece of equipment that is built specific for purpose.

1. Main Facility

In the production of Fire resistant concrete, there must be an

appropriate work place, a safe and neat place that is relevant to

avoid some hazardous even that might happen during construction.

2. Finished product Storage

After the production process, the finished product should store in

one room

3. Raw material Storage

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The raw materials that is needed for the production will place

separately based on their categories.

4. Recycle Storage

The dumping storage are the storage of waste materials from

concrete that can be use latter on as Coarse aggregates in the

production of new fire resistant concrete.

FIGURE 2

Physical Facilities
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Production Input

INPUT NAME DESCRIPTION QUANTITY COST TOTAL COST

The structure of the mixer

including mixing tank, spindle

shaft, and body of mixer was

Mixer made with mild steel structure 1 8,000 8,000

coated with powder coating. The

motor installed were spindle

motor with 2 horse power helical

gear. The speed of motor for

mixing process was 10 rotations

per minute that can be control

with controlling board. The

capacity of the mixing tank was

40 kg.
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The main component of

compactor is air cylinder pressing

with force capacity of 40 tonne.

The size of the mould is 9” x 4” x

Moulding
and 2.5” accordance with the
Compactor 1 10,000 10,000
standard size based on British

Standard BS 3921: 1985 [10].

There are three plates in the

moulding and compactor. The

first plate is top support plate

made with 12 mm steel plate to

support the air cylinder presser.

Then 12 mm steel pressing plate

that hold the top pressing plate

and bottom base plate connected

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with mould made with 15 mm

steel plate.
The conveyor belt was made with
nylon with aluminium profile
frame. The speed of the
Conveyor
conveyor can be controlled with
Belt
conveyor speed controller at 1 7,000 7,000
maximum speed of 200 mm per
second. The stand levelling is
adjustable and heavy duty.

This can be used for a wide

variety of heat processes
including drying, curing, aging,
Ouring
annealing, stress relieving,
Conveyor
oven bonding, tempering, preheating 1 15,000 15,000
and forming. In either a horizontal
or vertical configuration, the
Conveyor Oven offers the ability
to handle high production rates.
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The purpose of this machine is to

roll the end product of brick

specimen to be use. The whole

End Gravity process of concrete making 1 7,000 7,000

Conveyor
machine is being control either

automatically or manually by

using control panel board.

The whole process of concrete

making machine is being control

Control
Panel either automatically or manually 1 7,000 7,000
Board
by using control panel board
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Is a fine powder which is a by-

product from burning pulverized
1 sack 650.50 650.50
coal in electric generation power
Fly Ash
plants. (25kg)

is a cementitious material whose

GGBS main use is in concrete and is
(Ground 1 sack 723.40 723.40
a by-product from the blast-
granulated
blast slag) furnaces used to make iron (25 kg)

Rice husk ash from burning

of rice husks (RHA) has already
demonstrated that it is one of the
1 sack 150 150
most promising supplementary
Rice Husk
Ash cementing materials (SCM), (50 kg)
given its high specific surface
and great amount of silica soluble
in alkaline conditions.
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Sand is a naturally occurring

granular material composed of

Sand finely divided rock and mineral

(Fine
Aggregate) particles. It is defined by size, 2 Sack 100 200

being finer than gravel and

coarser than silt.

Crushed stone or angular rock is

a form of construction aggregate,

Crushed typically produced by mining a 2 sack 50 100

stone
(Fine suitable rock deposit and
aggregate)
breaking the removed rock down

to the desired size using

crushers.
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Limestone is a sedimentary rock

composed mostly of the mineral
calcite and comprising about
Limestone
(Coarse 15% of the Earth's sedimentary
Aggregate) crust. It is a basic building block 2 sack 150 300
of the construction industry
(dimension stone) and a chief
material from which aggregate,
cement, lime and building stone
are made.

Dolomite, also known as

"dolostone" and "dolomite rock,"
is a sedimentary rock composed

Dolomite primarily of the mineral dolomite,

(Coarse CaMg(CO3)2.
Aggregate) 2 sack 200 400
Dolomite is found in sedimentary
basins worldwide. It is thought to
form by the postdepositional
alteration of lime mud and
limestone by magnesium-rich
groundwater.
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Used as secondary
reinforcement, polypropylene
fibers help reduce shrinkage and
polypropyle
ne fibers  control cracking. To use these 1 kg 54.71 54.71
fibers, concrete mix design does
not have to be altered, and no
special equipment or slump
modifications are required, even
for pumping or shotcreting.

Concentration of sodium
hydroxide is the most important
factor for geopolymer synthesis.
Sodium
Hydroxide The solubility of aluminosilicate 1 gallon 300 300
increases with increase in
hydroxide concentration. The use
of higher concentration of sodium
hydroxide yield higher
compressive strength of
geopolymer concrete.
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Sodium silicate has already

found multiple uses in

cementitious materials. For

example, it is used as an alkali-

activator in alkali-activated
Sodium
Silicate cements. In concrete, it is used
(water 1 gallon 250 250
glass) as a setting accelerator and also

applied in the form of silicate

mineral paint to enhance

waterproofing

And improve durability.

TABLE 2

Production Input
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Waste and Waste Disposal Method

In the production, there is no waste that is produce, that’s because the

materials needed to make a fire resistant materials should be measure at the

proper ratios, all the materials are supposed to be a concrete after the

production. The container, tools and other equipment will not dispose after the

usage.

Utilities

The Utilities needed are electricity and water.

Electricity is needed in able for the machineries to work and without

electricity, it is not possible to attain the compressive strength of our product

because it will only attain by placing the concrete on a high rate of temperature or

in Curing Conveyor oven which needs electricity to work.

On the other hand, Water supply also needed, even though it is not part of

our materials, it is also needed for sanitizing and cleaning the tools, equipment,

machineries and Working area.

Location Map

The location Map of our Working area is located in Teresa, Rizal

Philippines. Teresa is a second class municipality in the province of Rizal,

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Philippines. According to the 2015 census, it has a population of 57,755 people.

The municipality is named after Reyna Teresabanta, the only female datu in

precolonial Philippines.

FIGURE 3

Location

Plant size and Layout

The working area contains different rooms and facilities that will be used in

the production of the product which are the production room, Raw materials

storage or stock room, Finished product storage, Recycle storage, Employer’s

room, the workers room and the comport room.

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FLOOR PLAN
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BIBLIOGRAPHY
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CURRICULUM VITAE
PERSONAL DATA
Name : Kristle R. Bacolod
Date of Birth : July 24, 2000
Place of Birth : Pangasinan
Home Address : 061 Lumang ilog St. Brgy.
Evangelista Baras, Rizal.
Sex : Female
Religion : Catholic
Name of Parents : Tessie A. Rico
Nathaniel B. Bacolod

EDUCATIONAL BACKGROUND

Secondary : Tomas Claudio Colleges

(Senior High School)
Taghangin Morong, Rizal
2016 – 2018

Morong National High School

(Junior High School)
Morong, Rizal
2012-2016

Primary : Baras Elementary School

Baras, Rizal
2006 – 2012
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CURRICULUM VITAE
PERSONAL DATA
Name : Kate Ann Rose B. Bonifacio
Date of Birth : June 29, 1999
Place of Birth : Teresa, Rizal
Home Address : Teresa, Rizal
Sex : Female
Religion : Catholic
Name of Parents : Rose Bonifacio
Andy Bonifacio

EDUCATIONAL BACKGROUND

Secondary : Tomas Claudio Colleges

(Senior High School)
Taghangin Morong, Rizal
2016 – 2018

St. Rose of Lima Montessori School

(Junior High School)
Teresa, Rizal
2012-2016

Primary : Teresa Elementary School

Teresa, Rizal
2006 – 2012
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CURRICULUM VITAE
PERSONAL DATA
Name : Mark Anthony D. San Jose
Date of Birth : August 10, 1999
Place of Birth : Teresa, Rizal
Home Address : Teresa, Rizal
Sex : Male
Religion : Catholic
Name of Parents : Medel San Jose
Analyn San Jose

EDUCATIONAL BACKGROUND

Secondary : Tomas Claudio Colleges

(Senior High School)
Taghangin Morong, Rizal
2016 – 2018

St. Rose of Lima Montessori School

(Junior High School)
Teresa, Rizal
2012-2016

Primary : Bagumbayan Elementary School

Teresa, Rizal
2006 – 2012
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CURRICULUM VITAE
PERSONAL DATA
Name : Ivan Julius Berber
Date of Birth : October 19, 1999
Place of Birth : Teresa, Rizal
Home Address : 268 F. Gonzales St.
Prinza Teresa rizal
Sex : Male
Religion : Catholic
Name of Parents : Jovito D. Berber
Bernadette I. Berber

EDUCATIONAL BACKGROUND

Secondary : Tomas Claudio Colleges

(Senior High School)
Taghangin Morong, Rizal
2016 – 2018

Tomas Claudio Colleges

(Junior High School)
Morong, Rizal
2012-2016

Primary : Prinza Elementary School

Teresa, Rizal
2006 – 2012