ABSTRACT
This
project, Design and production of ceiling board using Plaster of Paris (POP)
Gypsum materials. Gypsum is basically the raw material required in the manufacturing
Plaster of Paris (POP) which posses an outstanding property and a good material for producing ceiling
board.
The
materials procured for the project are plaster of Paris, fiber, water and
mould. The equipment used for the project are scrapper, measuring tape, mixing
bowl, bucket. Firstly, water was poured into the container (mixing bowl) and
plaster of Paris sprinkled, two minutes was waited for absorption and then the
mortar was mixed with hand and shaked vigorously to obtain a fully homogeneous
mixture and thereafter the mortar was sprayed on the mould and fiber was added
which serves as reinforcement.
Water
absorption test was carried out on the sample and the result indicated that
plaster of Paris (POP) ceiling board has an average 8.4 percent water absorptivity
compare to Asbestos with 0.5 percent. Therefore plaster of paris (POP) ceiling
board absorb water readily in case there is water leakage of the roof. Flexural
strength test was carried out and the result obtained showed that plaster of
paris (POP) ceiling board has a mean flexural strength of 11.4 N/mm2
and Asbestos has an average flexural strength of about 1.00 N /mm2.
To this end, it is proved that plaster of
paris (POP) ceiling board posses sufficient strength and it is durable for Civil
Engineering works.
TABLE OF CONTENTS
Title
page i
Certification ii
Dedication iii
Acknowledgement iv
Abstract
v
Table
of contents vi
List
of plates ix
List
of tables x
CHAPTER ONE
1.0 Introduction 1
1.1 Statement of problem 3
1.2 Aim and Objectives 3
1.3 Justification of study 3
1.4 Scope of the study 4
CHAPTER
TWO
2.0 Literature Review 5
2.1 History of Gypsum 6
2.2 Old use of Gypsum 7
2.3 Modern use of Gypsum 8
2.4 Gypsum Credential 9
2.5 Gypsum product and its unique properties 10
2.5.1 Fire Resistance 10
2.5.2 Acoustic Properties 11
2.5.3 Thermal Properties 11
2.5.4 Aesthetics and Design 12
2.5.5 Sound Isolation Properties 12
2.6 Manufacture of plaster from Gypsum 12
2.7 Physical Properties of Gypsum 13
2.8 Chemical Properties of Gypsum 14
2.9 Survey on Hemp core fiber 14
CHAPTER
THREE
3.0 Methodology 17
3.1 Procurement of Materials 17
3.2 Equipment used for the project 17
3.3 Preparation of Mould 17
3.4 Preparation of separator 18
3.5 Mixing of Aggregate 18
3.6 Casting 18
3.7 Demoulding 19
3.8 Water Absorption Test 19
3.9 Flexural Strength Test 20
CHAPTER
FOUR
4.0 Result and Discussion 21
4.1 Plates 21
4.2 Tables and Calculation 32
CHAPTER
FIVE
5.0 Conclusion and Recommendation 34
5.1 Conclusion 34
5.2 Recommendation 35
REFERENCES 36
LIST
OF PLATES
Plate 4.1 Mould
used for the project 21
Plate 4.2 Application
of separator 21
Plate 4.3 Mixing
of Aggregate 22
Plate 4.4 Casting
process 1 23
Plate 4.5 Casting
process 2 24
Plate 4.6 Casting
process 3 25
Plate 4.7 waiting
for the sample to set 26
Plate 4.8 Demoulding 28
Plate 4.9 The
Sample 30
Plate 4.10 Weighing
of the sample 31
LIST
OF TABLES
Table 4.1 Water Absorption test Result 32
Table
4.2 Flexural Strength test Result 33
CHAPTER ONE
1.0 INTRODUCTION
This
project deals with the design and production of ceiling board using POP gypsum
materials. Plaster of Paris (POP) which is calcium sulphate with half molecule
of water of crystallization (CaSO4.1/2H20) and
hygroscopic characteristic obtained by duly calcined the material that is Gypsum (CaSO4.2H20).
It possess an outstanding property of setting and subsequent hardening when
mixed with water (Smith, 1896).
Gypsum
is basically the raw material require to manufacture Plaster of Paris. This is cleaned
and washed for removal of impurities, dried in sunlight and then pulverized.
Gypsum powder are calcined in a rotary drum calcinatory using light diesel
oil/firewood/coal as fuel. The low pressure burner is sufficient to reach the
calcinations temperature range from 160oc to 180oc.The
process of calcinations is done over a period of about 2 hours so that one –
halves molecule of water is removed to obtain the required properties after
cooling, the calcined powder is passed through 150 mesh and packed in airtight
polythene lined bags.
Modern
Gypsum board has it predecessor a product called “sackett board”. A composite
material that was made of layer of thin plaster placed between four piles of
wool felt paper. Sackett board was
patented in 1894, By Augustine Sackett, The man generally
considered to be the grandfather of gypsum board manufacturing industry.
Prior
to 1894, Gypsum had been used for thousand of years as building material and as
an architectural detailing element. The first use of gypsum in building
construction appears to occurred in 3700BC, when an Egyptian used gypsum blocks
and plaster applied over woven straw lath in the building of the pyramid of
cheops.
A
French chemist (Lavoiser, 1710), Analysed the chemical make up of gypsum, his work and subsequent research
by a group of his contemporary chemists coupled with the discovery and mining
of huge reserve of gypsum near Paris leads to the wholesale use of plaster of Paris
as a building material.
Plaster
of Paris is extensively used in ceramics industry for preparation of models and
moulds. It is also used as main raw material in the manufacture of toy and
statues, chalk, crayon, gypsum plaster board and decorative picture frame
besides wide range of application in interior decoration of building and other
establishment (Alfred, 1896).
As
there is growing building construction activities and advancement in
technology, POP gypsum board are used in home and offices
and indeed all
type of building where
people congregate such as schools, halls, churches, mosques, airports
e.t.c.
POP
gypsum ceiling board provides more aesthetic outlook, offer adequate resistance
to heat and sufficient resistance to fire.
1.1
STATEMENT
OF PROBLEM
Recent studies indicate that asbestos ceiling
contains hazardous material from the health point of view. Prolonged inhalation
of asbestos fiber can cause lung cancer, mesothelioma, asbestosis. Therefore it
has been banned from use in many developed country due to the chrysotile
content.
To this end, there is
need for alternative ceiling material which is durable, reliable and
affordable.
1.2
AIM
AND OBJECTIVES OF THE STUDY
The
aim of this project is to design and produce
ceiling board using POP gypsum materials
The objectives of the
study is highlighted below :-
·
To produce durable lightweight building
material for ceiling
·
To determine the strength of the ceiling
board.
·
To determine it durability.
·
To determine the water absorption capacity.
1.3
JUSTIFICATION
OF THE STUDY
The use of gypsum
ceiling board for ceiling finishing should be adopted and improved because the
problems associated with asbestos, which have been used as ceiling finishes for
years but with the use of POP gypsum material as ceiling finishes which offers
sufficient sound insulation and considerable absorption of heat from the roof
and hence provide employment opportunity to the producer.
1.4
SCOPE
OF THE STUDY
The scope and
limitation of this project is basically the design and production of ceiling
board using POP gypsum material. In this project, water
absorption test and flexural strength test was carried out to determine the
water capacity, strength and durability of the sample made up of composite
quantity of POP plaster, water and fibre (villas) when subjected to loading.
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