DEBREMARKOS UNIVERSITY

INSTITIUTE OF TECHNOLOGY
SCHOOL OF CIVIL AND WATER RESOURCE ENGINEERING
ACADAMIC PROGRAM OF CONSTRUCTION TECHNOLOGY AND
MANGEMENT
COST EFFICENT CONSTRUCTION
AGROSTONE CONSTRUCTION
SECTION A

GROUP MEMBERS ID NO.

1. KALKIDAN GIRMA TER 0471/10

2. BIRKU GENET TER 0452/10
3. GETU ADANE TER 0059/10
4. NETSANET YEZBALEM TER 0235/10
5. GETASEW EBABU TER 0898/10

SUBMITTED TO: INS. TESFAHUN

SUBMISSION DATE: 19/07/2015 E.C
 AGROSTONE CONSTRUCTION

Table of Contents
LIST OF FIGURE........................................................................................................................... 2
LIST OF TABLE ............................................................................................................................ 2
LIST OF SYMBOLS, NOTATIONS AND ABBREVATIONS .................................................... 3
1. INTRODUCTION ................................................................................................................... 4
1.1. Agrostone Construction.................................................................................................... 4
1.1.1. Agro stone panel ....................................................................................................... 6
1.2. Advantages of Agrostone ................................................................................................. 8
1.3. Limitations of agrostone................................................................................................... 9
1.4. Production Technology .................................................................................................. 10
1.4.1. Agrostone production in Ethiopia ........................................................................... 11
2. CONCLUSIONS AND RECOMMENDATIONS ................................................................ 16
2.1. Conclusions .................................................................................................................... 16
2.2. Recommendations .......................................................................................................... 17
References ..................................................................................................................................... 18

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LIST OF FIGURE

Figure 1.1 Agrostone ……………………………………………………..……………………..10

Figure 1.2 flow diagram for agrostone ………………………………………………………..13

LIST OF TABLE
Table 1.1 Basic Raw Materials inputs for the production of Agrostone board………..…12

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LIST OF SYMBOLS, NOTATIONS AND ABBREVATIONS

Abbreviations Description

UF/PF resin for panels & blocks

PVC poly vinyl chloride

HDPE high density polyethylene

CPE chlorinated polyethylene

LDPE low density polyethylene

PP polypropylene

PS normal polystyrene

LLDPE linear low density polyethylene

PH potential of Hydrogen

Nomenclature

CO2 Carbon di oxide

MOC Magnesium Oxychloride Cement

SiO2 Silicon di oxide

MgO Magnesium Oxide

MgCl2 Magnesium Chloride

MgCO3 Calcining magnesite

3Mg (OH) 2 magnesium hydroxide

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1. INTRODUCTION
1.1. Agrostone Construction
The construction industry is in a quest for low-cost eco-friendly materials with very good
properties required for building construction The construction sector is facing a severe shortage of
conventional building materials due to environmental issues. Construction requires wide range of
energy- consuming materials that emit CO2 creating negative impact on environment. In order to
support the increasing demand for energy consuming building materials, there is solution to
develop cost-effective eco-friendly materials utilizing agricultural waste and other solid materials
from local areas to solve disposal problems. A low-cost, lightweight eco-friendly construction
material.

Composite is a materials made from two or more constituents with significantly different physical
or chemical properties from each other. One of the composite groups is bio-composite which is
defined as a material that composed of one of its constituent is bio-sources or biodegradable bio-
fibers as reinforcement and biodegradable or non-biodegradable polymers as matrix.

According to ((BMTPC), (2009-2010)) calendar report bio-composites provide environmental

friendly and sustainable alternatives to traditional/conventional composite materials. Bio-
composites have applications in Automobiles, Aerospace, Marine, Chemical Industry, Electrical
and Electronics and Construction etc. Different bio-composites have different applications in
construction ((BMTPC), (2009-2010)) such as wood with polymer for making door shutters, Doors
& window frames; Vegetable fiber/red mud & polyester are also common for flat & corrugated
roofing sheets, shutters & tiles; Jute fiber polyester/epoxy with red mud are applied for panels &
sheets, wall cladding, partitions & door shutters; Bagasse & UF/PF resin for panels & blocks; Red
mud plastic (PVC, polyester) reinforced with sisal fiber are used for producing paneling, roofing,
partitions and door panel

According to ((BMTPC), (2009-2010)) www.compositebuilding.com) nowadays, engineers and

researchers are searching and developing new composites for different advantages that include,
light weight, high specific stiffness and strength, easy molding property to complex forms ,easy
bonding capacity, good dumping properties ,low electrical conductivity and thermal expansion,

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good fatigue resistivity and low cost. such as Agrostone. It is made of magnesium oxychloride
cement and fillers for reinforcement.Agro stone technology has introduced in Ethiopia since 2005
for housing projects. Magnesium oxychloride (MOC) is non-hydraulic cement used to produce
magnesium oxide boards and Agro stone panels. The production of eco-friendly Agro stone
material is simple, energy-efficient and generates low “greenhouse” gases compared to the
conventional construction materials.

Agrostone panel is composed of agricultural/industrial wastes and/or lightweight natural minerals

as fillers, most Agrostone production center has adopted this technology based on locally available
raw materials which are presented below.

 Filler: - Fillers for Agrostone panel production can be agricultural products and/or lightweight
natural minerals like pumice and diatomite. Agrostone production center uses an agricultural
product, bagasse which is available from a number of inland sugar factories. Bagasse has two
main advantages. One of the advantages is its high tensile strength and elasticity modulus
properties. Besides being filler material, these properties make the bagasse to provide
reinforcement. The second advantage is its high resistance against solvent and chemical attacks
since it has high proportion of cellulose in its structure. The cellulose fiber makes the bagasse
to be highly crystalline and stable polymer as cellulose is a linear polyglucose and is highly
hydrogen bonded component. Moreover, as bagasse is largely available agro waste material;
the production of Agrostone panels is sustainable and ecofriendly, contributing to the socio-
economic and environmental well-being of the Country.
 Binder: - Agrostone panel uses Magnesium Oxychloride Cement (MOC), also known as Sorel
cement as a binder. MOC is non-hydraulic cement which is formed by mixing powdered
Magnesium Oxide, MgO with concentrated solution of Magnesium Chloride, MgCl2. There
are two methods to produce Magnesium Oxide. One is by calcining magnesite (MgCO3) to a
temperature range of 700 – 2000°C, and then they release CO2 and form MgO. In different
range of temperature different types of MgO is produced. The second method is by processing
seawater and underground deposits of brine which contains magnesium chloride. Like MgO,
Magnesium Chloride, MgCl2 can be also produced locally from different sources including
evaporation of seawaters or brines, but imported MgCl2 is used for the production of the
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Agrostone panel. MOC was discovered by Sorel in 1867 just few years after the ordinary
Portland cement discovered. MOC have better qualities than Portland cement. It has high early
strength as well as it creates a good bond with various inorganic and organic fillers such as
sand, gravel, marble flour, wood flour, sawdust, pumice, and red ash. Its high fire and abrasion
resistance, low thermal conductivity, and high compressive and flexural strength are other
superior engineering properties of MOC. Moreover, MOC is suitable to use with fiberglass
without aging problems since it has lower PH value of 10 – 11 compared to Portland cement
with PH value of 12 –13. These all properties make MOC an appropriate binder for the
production of Agrostone panels.

1.1.1. Agro stone panel

Agro stone panel is composed of agricultural/industrial wastes and/or lightweight natural minerals
as fillers, magnesium-based chemicals as a binder and fiberglass as reinforcement. It’s an
alternative low -cost eco-friendly building material that reduces the cost of wall construction
significantly while attaining the desired physical and mechanical properties. (Taffese.W, 2012).
It is a construction material that can be used as an exterior wall.it is composed of magnesium oxide,
magnesium chloride, iron sulphate heptahydrate, foaming agent etc..
Ago stone panels do not require cement plastering for finishing work, which requires a significant
amount of cement, unlike traditional building materials. During construction, it does not consume
much water at all. Furthermore, its manufacturing uses energy-efficient and uncomplicated
machinery that could be executed by unskilled workers. All of these makes the panel more cost-
effective than the conventional materials. In another way, its lightweight feature enables the cost
of construction to be low. In short periods of time, the Agrostone plane is also quite easy to
assemble and cover large wall area, which in turn reduces construction time.
Its environmental friendly processing and the physical characteristics of the Agrostone panel
described above make it ideal for building materials than conventional materials. Agrostone for
the use of internal partitions and non- loading walls was patented. However, in various housing
projects in Addis Ababa, it has been used for exterior walls by treating different finishing materials
to protect from moisture attacks. As the water absorption test carried out at Materials Research

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and Testing Center (MRTC) showed, the water proofing of the Agrostone panel is low. Therefore,
in order to use it as an exterior wall, it needs proper surface water resistance treatment.
Agro stone panel is used in housing projects in Ethiopia. This technology composed of
agricultural/industrial wastes and/or lightweight natural minerals as fillers,
magnesium- based chemicals as a binder and fiberglass as reinforcement. Addis Ababa Agro sto
ne production center has adopted this technology based on locally available raw materials. It uses
an agricultural product, bagasse and also partly uses lightweight natural minerals such as pumice
and diatomite as fillers. (Taffese, 2012)

In the country bagasse is largely available agro waste material; which is an increase significantly
as the country plans to boost the sugar production by sevenfold (2.25 million tons per year) by
mid 2015. Agro stone panel has several benefits compared to conventional building materials. One
of the major benefits of the product is its low-cost production. This in turn contributes towards
reducing housing construction costs. Agro stone panel nearly reduces the cost of the wall
construction by half compared with the conventional hollow concrete block walls. Unlike the
traditional building materials, Agro stone panel do not require cement plastering for finishing work
which demands considerable amount of cement. It does not also consume much water during
construction. In addition, its production utilizes energy efficient and uncomplicated machinery
which can be operated by unskilled workers. In another perspective, its lightweight property
enables reduction of costs of building structures and also quite easy to assemble and cover large
area of wall within short period of time, which in turn reduces the construction time. Agro stone
panels had been patented for internal partition and non-loading walls use. However, it has been
used for external walls in number housing projects in Addis Ababa by treating with
different finishing materials to protect from moisture attack.

Generally agro stone panel is cost effective, time efficient, environmental

friendly production as well as the above-mentioned physical properties of the Agrostone panel
makes it better building materials than the conventional materials. Advantage ago stone is very
cheap and it in weight and as well as very easy to construction and assembly.

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Agrostone is an eco-friendly construction material made from plant fibers and natural, mineral-
based binder. It is light weight, fire retardant and non-toxic, making it an ideal construction
material in many scenarios.

Agrostone is also very strong and can be used in walls, floors and roofs with excellent performance
results. Its ability to retain water also makes it useful for sound and thermal insulation. The use of
agrostone not only helps reduce the amount of traditional construction materials in use, but also
provides a more sustainable choice that limits the negative impacts on the environment caused by
their production process.

Agrostone is a type of construction material that combines crushed stone, an aggregate material
similar to gravel, with specially formulated polyurethane or other polymer-based binders.
Agrostone is usually made from an evenly blended mix of coarse and fine aggregate materials such
as sand, gravel, limestone or granite along with polyurethane or other polymer-based binders. The
final product results in a hard wearing surface that is highly resilient and resistant to abrasion.
Agrostone is most commonly used in high traffic areas such as commercial buildings and public
spaces as it provides a durable surface that withstands weathering and wear caused by everyday
use. It can also be used in residential settings for patios, driveways, walkways, paths and pool
decks for a long lasting solution that still looks great.

1.2. Advantages of Agrostone

 It reduces the construction cost and save time.

 It increases the strength of the building and beauty of the house.
 It comprises five important properties in a single product.
 It is possible to produce it at different size, shape and at different forms.
 It utilizes large labor forces and is convenient for developing countries.
 It is manufactured from waste material as well as light and cheap mineral products.
 It goes inline with our mineral resource potential.

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1.3. Limitations of agrostone

1. Cost: Agro stones are often expensive to purchase and install, making them much more
expensive than other building materials like brick, concrete, or wood.

2. Weight: Agro stone is generally heavier than other types of construction materials, making it
difficult to transport and install in some situations. Agrostone is heavier than many other
construction materials and can require a sound foundation or extra bracing or beam requirements
to support it.

3. Susceptibility To Damage/Wear: Agro stone is susceptible to damage caused by weathering,

erosion, and termite infestations if not treated properly with protective sealers and coatings before
installation or periodically thereafter.

4. Limited Color Options: Because agro stones are a natural material with limited color options, it
can be difficult to match house exterior colors or landscaping features when using the product for
exterior applications.

5. Moisture resistance: Because stone is a natural material, it has the potential to absorb moisture
which can eventually cause cracking and spalling in the stonework if there are not adequate
drainage measures taken. Agrostone is porous, which allows for the absorption of moisture and
creates an environment for the growth of mold, mildew, and other undesirable organisms.

6. Agrostone must be sealed with a waterproof sealer if used in areas where it will be exposed to
moisture or extreme weather conditions.

7. Agrostone is not as durable as other more traditional building materials like wood or brick, and
may deteriorate much faster when exposed to extreme weather conditions.

8. Agrostone can be difficult to cut and shape due to its lightweight composition and its lack of
dimensional stability.

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1.4. Production Technology

The Chinese Agrostone technology utilizes agricultural wastes as filler , chemical raw materials
as binder and fiber glass as reinforcement.

The agricultural raw materials can be from different sources as long as it is not chemically reactive
and reduces workability. Preferably, raw materials with high tensile strength such as bagasse are
important.

We have partly reduced the agricultural materials by light weight mineral fillers and the selected
materials are cheap, light and easily available in the country. (W.Z. & Taffese and K.A, 2019)

Agro stone production and processing takes place in many countries, including India, China and
Brazil. Agro stones are often used for building construction, road and bridge construction,
landscaping and aquariums. Agro-stone is a type of construction material made from plant-based
agricultural byproducts such as wheat, rice, corn and sunflower husks. This product is used for
making building blocks and other masonry structures. The main advantages of agro-stone are that
it offers a sustainable and environmentally friendly solution compared to traditional masonry
materials. It also helps reduce landfill waste and can be safely recycled or composted after use. It
is a light yet strong material with good insulating properties, resulting in significant energy savings
when used in walls or roofs. Additionally, agro-stone can be produced in different sizes and shapes
allowing increased flexibility when constructing buildings.

Figure 1.1 Agrostone

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1.4.1. Agrostone production in Ethiopia

Agrostone production is an incredibly important industry in Ethiopia. It provides a vital link

between the rural communities and their urban counterparts, supplying building materials for
various construction projects. Ethiopian Agrostone mainly comes from natural stones found in the
volcanic regions of the country's Central Plateau, including Tigray and Amhara. In addition to
providing building materials for construction projects, agrostone is also widely used for decorative
purposes in homes and offices.

The process of producing agrostone typically involves cutting natural stone blocks into slabs or
“shells” that are then mechanically cut, trimmed and sized to desired shape and thickness. The
resulting slim stone pieces are then laid on a string bed before being placed on concrete molds for
curing.

This curing process can take place under the sun or under UV lamps, depending on what type of
product is desired. After curing and drying, the cured stones are sent off to a polishing unit
equipped with grinding machines which give it its finishing touch that enhances its color and
appeal as decorative stone material.

The unique characteristics such as strength, longevity and beauty make agrostone products very
popular in both residential and commercial construction applications across Ethiopia. Agrostone
not only increases the visual aesthetic value but also adds strength to infrastructure by visually
reinforcing construction elements like walls, arches or columns. Its porous nature acts as an
insulation to walls thus minimizing energy consumption in buildings built with this valuable
material. (Taffese, 2012)

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Table 1.1 Basic Raw Materials inputs for the production of Agrostone board

S/N Description Standard consumption Quantity/board(Kg) Weight (%)

1 Magnesium Oxide (MgO) 18.00 41.75
2 Magnesium Chloride (MgC12) 12.51 29.01
3 Fiberglass 1.01 2.34
4 Red ash/pumice 8.33 19.32
5 Bagasse 3.03 7.02
6 Steel bar (4mm) 0.11 0.25
7 Admixtures 0.12 0.27
Total 43.11 100.00
(Mulugeta, 2017)

1.4.2. Production process

The process of agro stone production usually involves quarrying the materials from a particular
area, crushing them into agro stones of various sizes, then transporting them to another facility to
further refine and package for sale. Depending on the purpose for which the stone is purchased,
there may be additional stages of production required such as heat-treating or grinding.

1) Quarrying: This is the first step in agro stone production where natural deposits of sandstone
are located and quarrying begins to break down large rocks into smaller pieces that can be used
for various purposes.

2) Crushing: After quarrying has taken place, machines such as jaw crushers or hammer mills are
then used to break the stones down into smaller pieces that can pass through sieves with specific
mesh sizes.

3) Transporting: Once all the pieces have been sized correctly they must then be transported to a
separate facility where further treatment can occur depending on their intended use.

4) Refining/Packaging: In this final step of the processs, any additional refinement or re-shaping
is done if required before packaging for delivery orders. (Dr. Eng Abebe, 2017)

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FLOW DIAGRAM FOR AGROSTONE

PRODUCTION
FILER RAW MATERIAL BINDING MATERIALS REINFORCING MATERIAL

FILLERS CHEMICALS CHEMICAL

SOLUTIONS

Agricultural and/or MgO MgCl2 Fiber glass

minerals

CRUSHING Mixing (MgCl2 + water +

Additive)

STORAGE

PUMPING

WEIGHING WEIGHING

MIXING

MOULDING

Figure 1.2 flow diagram for agrostone

(Dr. Eng Abebe, 2017)

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Experimental studies made on compressive strength of Agrostone

In the present work, experimental studies are made on compressive strength of Agrostone made of
different bio-fillers like water hyacinth, bagasse and grass to identify a low-cost bio-filler that
gives the required properties. It is also aimed to replace the presently used fillers with water
hyacinth refuse from Lake Tana, Ethiopia to reduce cost and disposal problems. The specimens
are casted as per ASTM C109 standard of 50 mm cube from the three bio-fillers. Twenty-four
specimens are prepared for each type and six specimens are selected randomly from each of the
three groups with a curing time of 7, 14, 21, and 28 days. The compressive strength of specimens
is tested as per ASTM C90 based on the peak load. The average values of compressive strength
for water hyacinth Agrostone are 5.26 MPa, 5.34 MPa, 5.52 MPa, and 6.4 MPa at 7, 14, 21, and
28 days of curing, respectively. Agrostone made of bagasse and grass bio-fillers have higher
compressive strength compared to that of water hyacinth. The water hyacinth Agrostone specimens
after 28 days of curing have comparable strength of class AAA hollow concrete block (5 MPa) of
Ethiopian material code. The strength to mass ratio of water hyacinth Agrostone is superior to
those of bagasse and grass. (Yonas, 2021)

The use of Agrostone material has been already there in several parts of Latin American, Far East,
North America and Middle East countries for construction of partition and fire walls. The MOC is
also known as Sorel cement or eco-cement, which is formed by mixing the powdered magnesium
oxide with concentrated solution of magnesium chloride. Presently, the Agrostone panels are being
prepared using agricultural and industrial wastes along with lightweight natural minerals and
magnesium oxychloride cement. A suitable proportion of fiberglass is also used for reinforcement.
The resulting cement composition has a chemical formula of either 3MgO.MgCl2.11H2O or
5MgO.MgCl2.13H2O or a combination thereof. Agrostone materials have sufficient strength and
better fire resistance characteristics compared to the conventional hollow concrete blocks.

The Agrostone factory in Bahir Dar, Ethiopia, utilizes bagasse bio-filler brought from Fincha
Sugar Factory located far from Bahir Dar. The Agrostone panels are available in 3.5 m length and
0.60 m width with thickness of 0.10 m or 0.15 m. (Yonas, 2021)

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The most important factor that motivates the stakeholders in construction sector is to use a new
material like Agrostone for cost reduction. The cost analysis for hollow concrete block class A and
Agrostone made of different bio-fillers are compared by the cumulative cost of raw material and
labour cost per meter square. The cost of materials for the analysis are taken from 2019 Bahir Dar
town conventional and alternative building material cost break down document.

Agrostone partition wall made of water hyacinth is slightly lower by 2 % and 0.5% respectively
compared to the control specimens made of bagasse and grass bio-fillers.

1.5. Compare agrostone with block work

Agrostone is an eco-friendly, more durable alternative to traditional block work for construction.
It consists of a mixture of crushed stone and recycled foam packets formed into block form.
Agrostone blocks are lightweight yet strong, insulating better than concrete blocks and offering
higher fire resistance than masonry. They can be used for interior or exterior walls and require
minimal maintenance to keep their good looks. In contrast, block work is made from concrete
blocks, which are heavier and can achieve higher strength ratings but don’t offer the same level of
insulation or resistance to fire damage as agrostone. Blockwork also needs more maintenance to
remain aesthetically pleasing and maintain its integrity over time.

The cost of building partition walls using water hyacinth Agrostone will be reduced by 53 %
compared to plastered and painted hollow concrete block wall of the same thickness.

Agrostone construction saves 50 % compared to conventional hollow concrete block walls, and
even more if used on large-scale. Agrostone and GFRG have the potential to meet the challenges
of mass housing construction at reduced cost.

Agrostone and glass fiber reinforced gypsum (GFRG) plays a vital role in reducing the
construction cost and time compared to conventional materials. A significant reduction in use of
energy intensive materials like steel, cement, sand, and water by utilizing recycled industrial waste
gypsum or natural gypsum and less labor input.

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2. CONCLUSIONS AND RECOMMENDATIONS

2.1. Conclusions

Agrostone is a construction material that can be used as an exterior wall.it is composed of

magnesium oxide, magnesium chloride. Iron sulphate heptahydrate, foaming agent etc. The basic
raw material of Agrostone is agricultural/industrial wastes such as bagasse to provide
reinforcement and natural minerals as a filler, magnesium-based chemicals as a binder and
fiberglass as reinforcement. It uses in Automobiles, Marine, Chemical Industry, Electrical and
Electronics and Construction etc. the Agrostone panel improved damage tolerance, environmental
resistance, fire resistance, recyclability, good strength, light in weight and potential for fast
processing. The use of agrostone construction for home and building purposes is an effective,
economical and sustainable way to build homes. It has been proven to be cost-effective, durable,
aesthetically pleasing and capable of providing a healthy indoor environment. Agrostone
construction also offers several environmental benefits due to its natural material origins, reducing
the overall carbon footprint of the building materials used in construction. Ultimately, agrostone
construction has much to offer in terms of sustainability and performance while delivering lasting
value to homeowners.

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2.2. Recommendations

We recommend on Agrostone construction

 Shall give consideration for larger production rooms.
 For not only production but also storages should be provided.
 Consistent supply of chemical raw materials from suppliers shall be prepared for better
production.
 To be manufactured with different custom sizes for different purposes and ease of
transportation and handling.
 Manufacturers should consider giving training to have skilled manpower and supervisor
for construction purpose.
 Should consider to make non porous in any weather conditions (moisture resistance).

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References
(BMTPC). ((2009-2010)). Building Materials and Technology Promotion Council. calander of events for
the year, 6. New Delhi.

Dr. Eng Abebe, D. P. (2017, October). Agrostone production technology in Ethiopia.

Mulugeta, T. M. (2017, February). Testing and Characterized Mechanical properties of Agrostone.

Taffese, W. (2012). Low-cost eco-freindly building material: case study in Ethiopia. World Academy of
Science, Engineering and Technology, International Journal of Civil and Environmental
Engineering, 183-187.

W.Z., & Taffese and K.A, A. (2019). Embodied Eneregy and CO2 emissions of widely used building
materials: the Ethiopian conext. buildings.

Yonas, D. M. (2021). Effect of curing time on compressive strength of agrostone building material with
water Hyancith, Bagasse and Grass. Jorurnal of Engineering Science and Technology, 16, 792-
806.

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