Recycled Paper Ceilings

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Propose to - Project 1: Better house construction andProject5: An alternative use for waste materials

Signature

Members : Fernando B.A.V.W. (EN13523756) ………………………..

R.A.T.Dasun (EN13541026) …………………………

Abeysinghe A.A.C. (EN13506544) ……………………....

Hirimburegama C.J. (EN13531362) ………………………..

Hettiarachchi T.L. (EN13546458) ………………………..

SRI LANKA INSTITUTE OF INFORMATION TECHNOLOGY

DESIGN AND PROCESS – GROUP PROJECT. SEM1

RECYCLED PAPER

CEILINGS


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Executive Summary

PROBLEM DEFINITION

Due to the increase of the population day by day, the housing constructions

also will be increased. Mainly natural wood used as a material of make

ceilings in past days. Although the constructions referred to walls and other

civil basics came with different concepts but the ceiling constructions did

not. So as a result deforestation issue happens largely in present. And people

came up with different ceiling concepts but with high cost and using’s of

rare and valuable resources like wood, gypsum etc.


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Team Reflection

Initially at the beginning, it’s very hard to work as a team with unknown different

students with different ideas and creativeness’s. So it was the main obstacle that

we faced at the beginning of our project.

But after some days…. working throughout on our proposal, people shifted to

work as a team and get responsibilities by their own. All the team members get

each other’s contacts and also used Facebook and e-mailings to communicate our

individual ideas and other implementations with each other. At the end of theday(project), we seriously realized that everybody is fulfill of their own different

ideas, that are necessary to have with an Engineer. And also some people got

extraordinary skills in particular objectives.

At the beginning we got 3 project proposals. And we decided to work on with the

best one, after a team discussion. This was a great experience to work with four

another four different people who met for the first time.

And during our project the most enjoyable part was our site visit. We went it like a

trip and enjoyed a lot in there. We got a chance to share experiences with civil

engineers, workmen and people in that construction site. We had several new

experiences and knowledge about constructions happening there. Finally it ends

up with nice memories.


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Table of Contents

EXECUTIVE SUMMARY 2

TEAM REFLECTION 3

TABLE OF CONTENTS 4

LI ST OF FI GURES 6

1. PROBLEM DEFINITION 7

1.1 PROBLEM SCOPE 7

1.2 TECHNICAL R EVIEW 7

1.3 DESIGN REQUIREMENTS 8

2 DESIGN OPTIONS 9

2.1 DETAIL OF OPTION 1 9 2.2 DETAIL OF OPTION 2 9

2.3 OPTION SELECTION 9

3 DESIGN DESCRIPTION 9

3.1 MANUFACTURING PROCEDURE 9

4 DESIGN DESCRIPTION SUPPORTING DOCUMENTS 10

4.1 MANUFACTURING PLAN (PRODUCT) 10

4.1.1 MANUFACTURING OVERVIEW 10 4.1.2 PART DRAWINGS 10

4.1.3 BILL OF MATERIALS 14

4.3 DISCUSSION 14

4.3.1 STRENGTHS AND WEAKNESSES 14

4.3.2 NEXT STEPS 15

5 EVALUATION 15


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5.1 EVALUATION PLAN 15

5.2 EVALUATION R ESULTS 15

6 EVALUATION SUPPORTING DOCUMENTS 16

6.2 COST ANALYSIS 16

6.3 R EGULATORY AND SAFETY CONSIDERATIONS 16

REFERENCES 17


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List of figures

Figure 1……………………………………………………………………… .10

Figure 2……………………………………………………………………… .11

Figure 3……………………………………………………………………… .11

Figure 4……………………………………………………………………… .12Figure 5……………………………………………………………………… .12

Figure 6……………………………………………………………………… .13

Figure 7……………………………………………………………………… .13Figure 8……………………………………………………………………… .15

Materials and goods we need to make the object

Refuse paper (most likely newspapers)

White Portland cementA polypropylene fiber sheet

WaterA wood or metal structure


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Introduction

1. Problem definition

1.1 Problem scope

In the middle of the twentieth century, the world showed a rising interest in

the industrialized reuse of elements based on vegetable fibers (paper and cardboard). This was areaction to the accelerated reduction of the world’s forest reserves.

Paper and recycled cardboard have been used in order to avoid excessive use of traditional wood

materials and to avoid deforestation.As a solution to these problems, the idea of the RECYCLED PAPER

CEILING was chose.

An obvious use of waste material is to reuse them in some way, and in that case the best chosenseems to be alternative choice seems to be alternative construction materials for building houses.

The idea of the RECYCLED PAPERCEILING was to build an environmentally friendly and low

cost ceiling.

1.2 Technical Review

The main purpose of this design is to reduce deforestation and to obtain themaximum usage from the waste materials like newspaper we use daily. In case of another

product available in the market called Malaysian ceiling need gypsum and cement in a larger

amount. So gypsum is an expensive thing and can’t found simply as refuse papers. Gypsum is are-product of cement. And doctors investigated that there is a possibility to causing lung cancers

when people breathe the dust of Malaysian ceilings.


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1.3 Design requirements

REQUIREMENT WHY IT’S IMPORTANT? SOURCE

Cost of materialsOur target is to build a

economical and a high strength

ceiling. Cost of materials

directly impact our overall costtherefore it’s a important

requirement

Internet. Local hardware stores

Material availability Whatever our plans may be thy

becomes useless unless thereare enough materials in the

local market to match our product .therefore this is aimportant issue.

Internet

Local retail & wholesaledealers.

Governmentregulations

To carry out any development project a proper authorization is

required. That’s why it’s a

important aspect.

Regulatory frameworks

The design had to meet the following requirement.

Should have no contact with waterThe ceilings need to have no contact with water. Because it can cause damages.

Environmental friendly design.

Must be cost effective.


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1.4 Detail of Option 1

RECYCLED PAPER CEILING are panels made of recycled paper, polypropylene fibers, and

white Portland cement. The panels are used to make interior walls and ceilings.

Recycled paper and water are subjected to a process of mixing and blender for 8minites. Then

remove excess water and mix white Portland cement in a ratio of 1:4 by weight. Under the pressure 5mm thick layers are made.

Then, a reusable reinforcement of polypropylene fibers is extended over the initial layer made of

mixture. After that, a second 5mm thick compacted mixture is added on top. Finally thethickness of the sheet is 15mm.

1.5 Detail of Option 2

Recycled paper and water are subjected to a process of mixing and blender for 8minites. Thenremove excess water and mix white Portland cement in a ratio of 1:4 by weight. Under the

pressure 15mm thick layer are made.

1.6 Option Selection

In option 1 with the combination of materials used it gives more mechanical strength and

cohesion.

2 Design Description

2.1.1 Manufacturing Procedure

First a layer of recycle papers is designed.

Secondly lay a fiber layer over the recycle paper layer.Then over that lay another layer of recycle papers.


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3 Design Description Supporting Documents

3.1 Manufactur ing Plan (Product)

In the manufacturing of Recycled paper ceiling, recycled paper and water are subjected to a process of mixing and homogenization in an industrial blender for 8 min. This produces paper

pulp.

Subsequently, the wet paper pulp is compacted under a hand press to remove excess water untilit reaches about 60% water content. Then, the Portland cement is mixed with the recycled paper

pulp in a ratio of 1:4 parts by weight.Recycled paper ceiling is fabricated in two stages. Each stage consists of a discharge of the

mixture (paper pulp, cement, and water) under pressure to form a compact layer.

Originally, a layer of uniform compacted mixture of 5 mm in height is poured on a flat andsmooth surface. Then, a reusable reinforcement of polypropylene fibers is extended over the

initial mixture layer from sacks to generate greater stability in the material. Finally, a second

5mm thick compacted mixture is added on top. Recycled paper ceiling obtains a final thicknessof approximately 15 mm.

3.1.1 Manufacturing Overview

First the recycle papers are put in to water and keep it there for about two days. Then it is blended about 8 min and get that mixture out without water by hand pressing. Then cement is put

to the mixture in 1:3 ratio and mix it up. Next that layer is put into the frame under the pressure

1.2kpa and then over that lay another layer of fiber. Over that lay another layer of recycle papers.

3.1.2 Part Drawings

Figure 1: top view


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Figure 2: Right view

Figure 3: Section View


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Figure 4: Section View

Figure 5: Isometric view


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Figure 6: Front view

Figure 7: Front view


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3.1.3 Bill of Materials

Papers

Portland cementPolypropylene fiber sacks

3.2 Discussion

3.2.1 Strengths and Weaknesses

Our objective was to design an ecofriendly economical ceiling design using waste

materials (recycled paper). Our design is a success because we were able meet our objectives.

But there are strengths and weaknesses in our design. When looking at the strengths our design is

Economical

Our materials used are low cost and even the construction procedure is simple there for even thelabor cost is low. Therefore its range of price comes within an affordable range for low income

holding families.

Materials used

All of the materials we used are either ecofriendly or a waste material especially the paper and polypropylene fiber .so in this aspect we have achieved our objective.

Unique design

Because of using a polypropylene fiber layer between the paper pulp-cement mixes gives some

extra stability in the material.

So looking at the weaknesses of the design:

Storage

The thickness of the sheet is too large when comparing the normal grey ceiling sheet. This is a

limitation when it comes to mass storage.

Weight

Because the thickness is high the weight could also go higher than the regular one. This could

effect when placing the ceiling sheet to the roof

Other limitations

Contact with the water can reduce the strength of the ceiling sheet which is also a limitation for a

regular ceiling sheet.


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And that can also definitely reduce the lifetime of the sheet

3.2.2 Next Step

As the next steps we could try mixing some hay with the pulp mix, it will reduce thecost of paper somehow, but what will it effect to the existing strength should be

evaluated or tested. And also the mixing ratio also should be considered. In this project we used two layers of pulp-cement mix and a polypropylene fiber

layer in between, as a next step using three pulp-cement mix which will a small

amount than the previous one and applying two polypropylene fiber layers in between those two. In this step also have to consider the points before do it.

Placing a plastic or polythene coat over the sheet can reduce the effect when contactto the water.

This also tested before mass production.

4 Evaluation

4.1 Evaluation Plan

Cost of materials – the plan to evaluate this is to get quotations from suppliers and compare it

with the last actual price.

Material availability- checking the local markets and from available sources.

Government regulations-present the plan to local authorities.

4.2 Evaluation Resul ts

Combustion test

This test is performed on prototypes of 0.25 m x 0.25 m to determine the capacity of thermal

conductivity of the material, the point of ignition, combustion and calcination. A type Kthermocouple was used to calculate the combustion temperature of Recycled paper ceiling.

Points of ignition, combustion and calcination were identified [12 – 14], see Fig. 8 and Table 8.

Figure 8


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Figure 8. Recipanel fire test

5 Evaluation Supporting Documents

5.1

Cost Analysis

components units Price per

unit

cost

Papers 8 kg 20 160

Portland cement 2 kg 20 40

Polypropylene fiber sacks 2 25 50

Other(water,electricity,machinery,labour….) 100

Total 350

When we do this in vast production we can get all these materials at low cost. Then the cost for a

ceiling sheet gets even low.

Normal price of a ceiling

The price of our new product

Therefore the cost effectiveness--of our ceiling

5.2

Regulatory and Safety Considerations

When creating the prototype following safety precautions were taken

Full cover goggles were used to prevent the dust, cement dust… Contacting the eyes

Waterproof gloves were used to avoid the cement pulp mix to contacting the hands

Overall kits were used to prevent cement mix contacting the body and skin

Pairs of rubber boot were also used to avoid contacting cement mix with the foot

A ph. Neutral soap was also used to wash the body after the work is done.

Temperature (0C)

Ignition Calcination Combustion

150 230 300

Prototype temperature


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6 Conclusion

Our first aim is was to do a design that doesn’t affect environment. So when we

think about all the topics, low cost housing & creating a new design from waste

materials is the best topics we’ve seen according to our aim.

These days when constructing buildings & houses, ceiling is one of the main things

we have seen. This is mostly made of wood so it causes for the vast deforestation

as today constructions are high. So we made a solution making a ceiling of recycle

papers. So from this design we have found a solution to this problem and also this

a good solution for high cost ceilings made of cement.


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REFERENCES

Linbachiya, M. and Roberts J. Construction and demolition waste. Thomas Telford, London,2004.

Anink, D., Boonstra, C. and Mak, J. Handbook of Sustainable Building. and Environmental

Preference Method for Selection of Materials for Use in Construction and Refurbishment.Editorial James and James Ltda, London, 1996.

Muñoz, A., Chejne, F., Espinel, J. and Londoño, C. Evaluation of the cellulose of paper and coal

ashes, like alternative insulating materials. Dyna, Año 73, 148, pp. 1-8, 2006.

http://www.cement.org/basics/concretebasics_working.asp

http://www.housingauthority.gov.hk/en/common/pdf/business- partnerships/resources/pictorialguide/EngChapter11.pdf

http://www.cement.org/basics/concretebasics_working.asphttp://www.cement.org/basics/concretebasics_working.asphttp://www.housingauthority.gov.hk/en/common/pdf/business-partnerships/resources/pictorialguide/EngChapter11.pdfhttp://www.housingauthority.gov.hk/en/common/pdf/business-partnerships/resources/pictorialguide/EngChapter11.pdfhttp://www.housingauthority.gov.hk/en/common/pdf/business-partnerships/resources/pictorialguide/EngChapter11.pdfhttp://www.housingauthority.gov.hk/en/common/pdf/business-partnerships/resources/pictorialguide/EngChapter11.pdfhttp://www.housingauthority.gov.hk/en/common/pdf/business-partnerships/resources/pictorialguide/EngChapter11.pdfhttp://www.cement.org/basics/concretebasics_working.asp


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Recycled Paper Ceilings

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