Chapter III: Methodology

This chapter discusses the methods used throughout the study. This includes the test
variables, the test specimens, the preparation of materials, the determination of physical properties of
materials, the design mix proportions, the preparation of specimens, the test procedures conducted on
obtaining the performance characteristics of fiber cement board.

Project Development Plan

Determination of
Preparation of Chemical Content of Determination of
Raw Materials Bagasse Ash Bagasse Ash Physical and
Mechanical
Properties of Raw
Materials
Portland Cement Elephant Grass Bagasse Fiber
Fiber

Curing and Pouring and Assembly of

Batching and Mixing
Conditioning Compressing Molds

Trimming of
Specimens
Density

Physical Water Absorption

Determination of
Properties and Thickness
Physical and Choose the Optimum Mix
Mechanical Properties Swelling Design of Elephant Grass
of Elephant Grass and and Bagasse Fiber Cement
Bagasse Fiber Cement Flexural Strength Board based on the test
Mechanical
Board Test results
Properties

Thermal
Conductivity

Nail Head Pull-

Through Test
 The figure shows the project development of this study. The materials used will be initially
investigated, and will be prepared for the fabrication of fiber cement board. Specimens with four varying
bagasse ash composition and three varying fiber percent ratio will be used to analyse its effect on the
produced board. Samples will be trimmed from the fabricated boards in accordance to ASTM standards
and will be subjected to each type of testing to determine the physical and mechanical properties of the
board.

Preparation of Materials

a. Elephant Grass and Bagasse Fiber

Elephant Grass will be obtained at GSMB Agrifarms at Tanay, Rizal and the bagasse will be
supplied by Bernado Planting and Cutting Sugarcane Services (Barangay Bantog, Tarlac City).
The Elephant Grass Fiber and Bagasse Fiber will be soaked in 10% and 1% Sodium
Hydroxide solution accordingly (4 grams of NaOH crystals per one liter of water), for a period of
72 hours. After that it will be sun dried for one week. Elephant Grass and Bagasse Fiber will be
extracted manually, by beating the treated stalks gently with a mallet to loosen and separate
the fiber. The resulting fiber bundle will be scrapped with sharp knife and combed until
individual fibers were obtain. Extracted elephant grass and bagasse fibers will be cut into 5mm
length .
b. Bagasse Ash
Bagasse ash will be obtained at Central Azucarera de Tarlac Powerplant (San Miguel, Tarlac )
c. Water
For both mixing and curing, ordinary potable water will be used.
d. Binder
Ordinary Portland Cement (Type 1 Eagle Cement) will be used as the binder.)

Determination of Physical Properties of the Materials

a. Determination of Specific Gravity of Cement – ASTM C188

Procedure described in ASTM C188 – Density of Hydraulic Cement will be used. A Le

Chatelier’s Flask will be filled with kerosene to a point between the stem between zero and 1 mL .
Weight to the nearest 0.05 g and record the mass, Ma, of the flask with liquid. Record the first
reading of the liquid height after the flask has been immersed in a constant-temperature water bath
for sufficient periods of time. Introduce 64 g of Portland Cement at the same temperature, take care
to avoid splashing and see that the cement does not adhere to the inside of the flask above the
liquid. After all the cements has been introduced, weight the flask again to the nearest 0.05 g and
record the mass, Mt. Then, put a stopper in the flask to remove the entrapped air by rolling it in an
inclined position until no further air bubbles rise to the surface of the liquid. Take the final reading
after the flask has been immersed in the water bath in accordance with the previous procedure.
 𝑀𝑐 = 𝑀𝑡−𝑀𝑎 (Equation 3.1)
M
𝜌𝐶 = C (Equation 3.2)
V
ρC
𝑆G = (Equation 3.3)
ρW

where:
𝑀𝑎 = Mass of the flask, g, with the liquid to the first set of graduation
𝑀𝑡 = Mass of the flask, g, containing the liquid and the cement
𝑀𝑐 = Mass of cement used, g
V = displaced volume of liquid, cm3
ρC = density of cement, g/cm3
ρW = density of water, g/cm3
SG = cement density/water density at 4°C

Determination of Specific Gravity of Bagasse Ash (BA) – ASTM C188

Procedure described in ASTM C188 – Standard Test Method for Density of Hydraulic Cement
will be used. A Le Chatelier’s Flask will be filled with kerosene to a point between the stem between
zero and 1 mL as shown in Figure 3.6. Weight to the nearest 0.05 g and record the mass, Ma, of the
flask with liquid. Record the first reading of the liquid height after the flask has been immersed in a
constant-temperature water bath for sufficient periods of time. Introduce 64 g of Elephant Grass Ash at
the same temperature, take care to avoid splashing and see that the cement does not adhere to the
inside of the flask above the liquid. After all the cements has been introduced, weight the flask again to
the nearest 0.05 g and record the mass, Mt. Then, put a stopper in the flask to remove the entrapped
air by rolling it in an inclined position until no further air bubbles rise to the surface of the liquid. Take
the final reading after the flask has been immersed in the water bath in accordance with the previous
procedure.

𝑀𝑒 = 𝑀𝑡−𝑀𝑎 (Equation 3.4)

MC
𝜌𝑒 = (Equation 3.5)
V
ρe
𝑆G = (Equation 3.6)
ρw

where:
𝑀𝑒 = Mass of Elephant Grass Ash used, g
𝑀𝑎 = Mass of the flask, g, with the liquid to the first set of graduation
𝑀𝑡 = Mass of the flask, g, containing the liquid and the cement
V = displaced volume of liquid, cm3
SG = Elephant Grass Ash density/water density at 4°C
ρe = density of Elephant Grass Ash, g/cm3
ρw = density of water, g/cm3

Determination of Specific Gravity of Elephant Grass and Bagasse Fiber (EGF and BF) – ASTM D 4442-
15
 Yarn Density—Select a suitable representative length of yarn, weighing at least 0.15 g. Wrap
the sample (the end of a small winding cone is suitable) and intertwine the ends of the fiber tow or yarn
to prevent unraveling. Proceed by weighing the suspension wire. Record as M1, g. Raise the laboratory
jack to the immersion point of the suspension wire and record the weight as M2, g. Rinse the wire with
acetone and let air dry. Attach the sample to the wire and weigh. Record as M3, g. Remove the wire
and soak in the liquid and vacuum degas. Reattach the sample and wire to the balance. Again, raise
the jack to the immersion point and weigh. Record as M4, g. Remove wire and standard and rinse with
acetone.

(M 3−M 1) ρ1
ρf= (Equation 3.7)
[ ( M 3−M 1 )− ( M 4−M 2 ) ]

Determination of Mechanical Properties of the Materials

a. Determination of Tensile Strength of Elephant Grass Fiber (EGF) – ASTM D 3822 / D 3822M-
14
The elephant grass fiber will be tested in a Physical Testing Laboratory at Philippine Textile
Research Institute. In accordance with ASTM D3822/D3822M-14, the physical properties of the
fiber will be analyzed using a Zwick/Roell Tensile Strength Tester Z005 (CRE) under a 5 kN full
scale load. The fiber will be carried out for 30 specimens with 25 mm gage length to get a valid
average.
b. Determination of Tensile Strength of Bagasse Fiber (BF) – ASTM D 3822 / D 3822M-14
The bagasse fiber will be tested in a Physical Testing Laboratory at Philippine Textile Research
Institute. In accordance with ASTM D3822/D3822M-14, the physical properties of the fiber will
be analyzed using a Zwick/Roell Tensile Strength Tester Z005 (CRE) under a 5 kN full scale
load. The fiber will be carried out for 30 specimens with 25 mm gage length to get a valid
average.

Determination of Chemical Properties of the Materials

a. Determination of Chemical Content of Bagasse Ash (BA) – ASTM C618 – 12a.
Chemical Content of Bagasse Ash will be analyzed in accordance to the procedure described
in ASTM C618 – 12a.

Mix Design Proportion

The table shows the tabulated mix design proportion of the specimens used in this study. For
this study, twenty-four (24) boards of 300mm x 300mm x 12mm thickness and twelve (12) boards
100mm x 200mm x 12mm thickness will be fabricated. All mix design was based on weight proportion
basis.

Mixture Set Mixture Set Binder Binder Fiber Fiber W/C Fiber Length
(Portland (BA) (BF) (EGF) Ratio (EGF/ BF)
Cement) (Water
)
A CONTROL1/ MD1 90% 0 4% 6% 0.5 5 mm
A MD2 75% 15% 4% 6% 0.5 5 mm
A MD3 70% 20% 4% 6% 0.5 5 mm
A MD4 65% 25% 4% 6% 0.5 5 mm
B CONTRO 2/ MD5 90% 0 6% 4% 0.5 5 mm
B MD6 75% 15% 6% 4% 0.5 5 mm
B MD7 70% 20% 6% 4% 0.5 5 mm
B MD8 65% 25% 6% 4% 0.5 5 mm
C CONTROL3/MD9 90% 0 5% 5% 0.5 5 mm
C MD10 75% 15% 5% 5% 0.5 5 mm
C MD11 70% 20% 5% 5% 0.5 5 mm
C MD12 65% 25% 5% 5% 0.5 5 mm

Table 3.1

Specimen Fabrication

Assembling of moulds, batching and mixing, pouring and compressing, curing and conditioning,
and trimming are the processes used for the fabrication of specimen

a. Assembly of Molds
The mould will be constructed and assembled using one fourth inch (1/4”) thick plywood.
Plywood panel for the base and mold cover for the pressing of the specimens will be prepared.
The panels will be attached by nails to form the mould. The finished mould was covered with
cut garbage bag for waterproofing and non-stick purposes.
b. Batching and Mixing
The batching of the materials is by weighing Bagasse Ash (EGA), Elephant Grass Fiber (EGF),
Bagasse Fiber (BF), Portland cement, and water following the design mix proportion given in
Table 3.1. Dry mixing of the specimen, adding of fiber to specimen, and manual mixing of
specimen was performed accordingly.
The procedure for manual mixing of materials based on the study conducted by Singh et al.
(2018) is as follows:

1) Cement and Bagasse Ash are mixed together at dry conditions for two minutes,
2) Bagasse and Elephant Grass Fiber is then added into the mixture of cement and Bagasse Ash
accompanied by constant mixing,
3) Finally, water is added into the mixture and the constituents are mixed until homogeneous
slurry is obtained,
4) The moulds prepared are then filled with the homogeneous mix and then scraped the surface
for a smooth finish,
Pouring and Compressing
Each mixture will be poured in moulds and vibrated manually to refrain from unnecessary air
voids. The samples will be covered and subjected to cold compress for 24 hours to secure the bond
between particles and attain the desired thickness of the sample.

Curing and Conditioning

 The pressed samples will be taken out of the mold, placed in an open area, and piled in a
constant humidity at room temperature for 28 days

Trimming of Specimens

Figure shows the fabricated board dimension subject for property tests. After curing, the boards
will be trimmed to required test specimen. The Elephant Grass and Bagasse Fiber Cement Boards will
be trimmed to a final dimension of 300mm x 300mm x 12mm and 100mm x 100mm x 12mm. The test
sample sizes conformed to ASTM D 1037 and C 1185 wherein each Elephant Grass and Bagasse
Fiber Cement Board in this study consists of three samples of, 50mm x 50mm x 12mm for Density,
Thickness Swelling and Water Absorption Test, 50mm x 200mm x 12mm for Flexural Strength Test
(Modulus of Rupture), 85mm x 60mm x 12mm for Thermal Conductivity test, and 50mm x 100mm x
12mm for Nail Head Pull-Through Test. Masonry grinder will be used for cutting the specimen.

Determination of Physical & Mechanical Properties of Elephant Grass Fiber Cement Board - ASTM D
1037-99
The test methods used will be based from ASTM Standards D 1037-99 (Test Method for
Evaluating Properties of Wood-Base Fiber and Particle Panel Materials) to characterize physical and
mechanical properties of each specimen of each mix design proportion.
a. Physical Tests
The physical tests for this study comprise of Density Test, Water Absorption Test, and
Thickness Swelling Test.
b. Density Test
The specimens to be used have a dimension of 50mm x 50mm x 12mm for Density Test. The
width, length and thickness of the samples will be obtained using a caliper. Density will be
calculated using equation 3.8 and 3.9, respectively.

𝑉=𝑙 𝑥 w x t (Equation 3.8)

m
ρ= (Equation 3.9)
v

where:
𝑉 = volume of specimen, m3
ρ = density of specimen, kg/m3
m = mass of specimen, kg
𝑤 = width of specimen, m
t = thickness of specimen, m
𝑙 = length of specimen, m

Water Absorption and Thickness Swelling Test

Diverse blends of cement-bonded board have several effects on the dimensional stability of the
fabricated material. Water absorption and thickness swelling tests therefore is allowed in accordance to
the American Society for Testing Materials D 1037 (ASTM 1995) with some modifications.

Samples of 50mm x 50mm x 12mm were cut from the fabricated board as based from ASTM D
1037. Water absorption and thickness swelling tests will be determined by submerging the specimens
horizontally in water at room temperature for 24 hours. After each submersion period, samples will be
drained of excess water and measured for change in thickness and amount of water absorbed.
Thickness swelling will be measured from two marked points along the length of each sample with a
caliper. Water absorption and thickness swelling will be expressed as a percentage of the original
weight and thickness, respectively.

WA as −WA bs
WA% = x 100% (Equation 3.10)
WA bs

T f −T i
TS% = x 100% (Equation 3.11)
Ti

where:
WA = water absorption percent after 24 hours
WA as= weight of sample after soaking for 24 hours, g
WA bs= weight of sample before soaking for 24 hours, g
T f = final thickness
T i= initial thickness

Mechanical Tests
The mechanical tests for this study include Flexural Strength Test, Thermal Conductivity, and
Nail Pull-Through Test.

Flexural Strength Test (Modulus of Rupture)

ASTM C 1185-91 (Sec. 5) Modulus of Rupture (MOR) determined the resistance of the board
against bending using the Universal Testing Machine (UTM). Test specimen dimension is 50mm x
200mmx 12mm. Force with of 6mm/min was applied uniformly and perpendicularly to the sample, as
shown in Figure 3.17. Load capacity of the specimen will be determined based on the reading in the
compression machine. It will be computed using the formula:

MOR
( )
k gf
cm
2
=
(3 x L x P)
2
(2 x P x t )
(Equation 3.12)
where:
L = length of the sample (cm)
P = load based on the UTM (kgf)
W = width of the sample (cm)
t = average thickness (cm)

Thermal Conductivity Test

The test specimens will be trimmed by 60mm x 100mm x 12mm and will be tested according to
ASTM C 518-15. The testing will be held at Cavite Testing Center (CTC), Imus, Cavite. Materials
needed were guarded box, electric stove, and infrared thermometer. Procedure of testing was
performed respectively. Thermal conductivity will be calculated using the formula:

qd
λ¿ (Equation 3.13)
T 1−T 2❑

Where:
λ = Thermal Conductivity
q = quantity of heat passing through a unit area of sample in unit time (W/m2)
d = mean thickness of the samples/specimen (m)
T1 = Temperature of hot plate
T2 = Temperature of cold plate
The quantity of transferred heat q is given by:

Q W
q= ( ) (Equation 3.14)
A m2

Where:
Q = quantity of heat passing through a base area of the sample (W)

W= J/s ; J = (kg * m2) / s2

A = base area of the sample (m2)
m = mass of the specimen (kg)

Nail Pull Through Test

Nail Pull Through Test (NPT) will be used to determine the resistance of the cement-bonded to
having the head of a nail or other fastener pulled through the board. Test specimen dimension is 50mm
x 100mm x 12mm. Lead holes will be predrilled using a drill 0.125 in. Common wire nails (2 inches) will
be driven through the board at right angles to the face with the nail head flushed with the surface of the
board. The samples attached in a center specimen – holding fixture in which the edge of the opening
provides the support to the specimen during testing with the point of the nail up. The pointed end of the
nail will be gripped with a tension grip and loads will be applied by separation of the platens using a
Universal Testing Machine. The average nail-pulls out is then computed by using equation

L1 + L2
NPT = (kgs .) (Equation 3.15)
2
where:
L1 = maximum load 1
L2 = maximum load 2