DESIGN AND FABRICATION OF KRAFT PAPER CEMENT

BOARDS FORTIFIED WITH COCONUT FIBER AS SUBSTITUTE

FOR CEILING BOARD MATERIALS

An Undergraduate Capstone Project Presented to

the Faculty of the College of Engineering
St. Michael’s College
Iligan City

In Partial Fulfillment
Of the Requirements for the Degree of
Bachelor of Science in Civil Engineering

By :
Judel F. Dagunlay
JohnLloyd D. Pendang

July 2024

Chapter 1
 THE PROBLEM AND ITS SETTING

Introduction

Having ceiling coverings available is an essential component in

the construction process. Solid wood for this purpose is becoming

increasingly difficult to obtain since mature wood is becoming

progressively scarce. Additionally, the wood that is available often

contains a significant amount of sapwood, which is easily attacked by

termites and insects. Furthermore, the use of asbestos minerals was

forbidden worldwide. The scarcity of traditional materials, together

with the related health dangers, shows the importance for developing

alternative ceiling board materials.

The escalating activities in the building industries have led to a

rise in demand for panel products, including ceiling boards. This

demand has spurred innovation in the development of alternative

materials, such as particle boards made from agricultural residues,

recycled materials, and other sustainable sources. These alternatives

not only meet the structural and aesthetic requirements of ceiling

coverings but will also contribute to environmental conservation efforts

by reducing reliance on traditional wood and hazardous materials.

Kraft paper is extensively used in packaging and various

industrial applications due to its strength and durability. In the business

industry, it is a preferred material for packaging. Kraft paper is not only

ideal for its intended uses but also an eco-friendly option, being

biodegradable and recyclable. However, waste kraft paper can

contribute to landfill overload and methane emissions during

decomposition. Recycling is crucial to minimize environmental impact

by reducing waste and conserving resources. To address these

challenges, repurposing kraft paper into innovative products provides a

sustainable solution. The versatility of kraft paper continues to drive

innovation, making it valuable for numerous applications.

There has been a recent focus on finding a way to produce

ceiling boards using the trash that comes from paper products.

Reusing Kraft paper would not only solve the disposal issue, but it will

also lower production costs because raw materials can be sourced at a

lower cost. One potential substitute for sawn timber or other wood

waste, such as sawdust, wood chips, etc., is the fabrication of ceiling

boards using waste materials like kraft papers and cement as a binder.

Since recycled kraft papers are readily available in large quantities,

using them to produce panel products will also lessen the demand for

wood and wood products for other board production, which will relieve

strain on forests and ensure sustainable preservation of forests.

Coconut fiber is a natural fiber made from the husks of mature

coconut fruits, and can be used to create durable, high-strength

products. In many applications, natural fiber-based bio-composites

have essentially replaced synthetic plastics because of the many

benefits of natural fibers, such as their abundant availability,

biodegradability, light weight, low cost, and ease of manufacturing.

The widespread availability of coconut fibers presents numerous

opportunities for sustainable development and innovation.The

utilization of coconut fibers supports the local economy and also aligns

with global trends towards sustainability. A wide range of natural fiber

composites have been proposed by numerous researchers for use in

various technical applications(Sathiparan,Rupasinghe, Pavithr,2020.)

Kraft paper and coconut fiber provide a special chance to be

combined in composite products by utilizing the advantages of both

materials together. This production can result in the creation of

modern and innovative environmentally responsible products that

satisfy the needs of numerous industries. These composites offer an

efficient yet environmentally responsible substitute for conventional

materials. We can greatly reduce the environmental impact of the

products while improving their performance through the use of these

natural materials. Coconut fiber contributes flexibility, tensile strength,

and thermal insulating qualities, while Kraft paper supplies the

required strength and durability.

 The construction industry always seek new and creative

materials that are economical, ecologically friendly, and are

sustainable.Traditional ceiling board materials, like plywood and

gypsum boards, are still in use today but come with limitations such as

moisture sensitivity, limited durability, and environmental problems.

The combination of Kraft paper and coconut fibers offers an increased

moisture resistance and a strong foundation and also helps to lessen

the environmental impact of building materials. These boards can be

easily recycled and encourage biodegradability, it also enable to lessen

the environmental impact of typical ceiling materials. This study

explores the potential of producing Kraft paper cement boards fortified

with coconut fibers as an alternative ceiling board material.

1.1 Background of the Study

In recent years, the construction industry has increasingly sought

sustainable and innovative materials to meet the demands of modern

building practices.Cement -bonded boards provide a lot of potential as a

building material for commercial and industrial structure. The

concentration of additives in the board determines its strength and

dimensional stability, signifies that they rise as the concentration of

chemical additives does.

 This result to examine the suitability of Kraft papers bounded with

cement reinforced with coconut fiber as materials for ceiling board

production. By exploring this composite approach, which combines the

strength and reuse of Kraft paper with the reinforcing properties of

coconut fiber, the study seeks to improve the mechanical strength,

durability, and environmental sustainability of ceiling boards. These

boards are also anticipated to exhibit improved resistance to moisture

and mechanical stress, making them ideal for applications where

traditional materials like plywood and gypsum boards fall short.

1.2 Statement of the Problem

The proponents have identified the following problems:

 Traditional materials become increasingly limited or difficult to

procure, particularly due to environmental concerns or

depletion of natural resources.

 The absence of established methodologies for integrating

components into cement board poses challenges in ensuring

structural stability and consistent performance.

 Determining the optimal ratios and methods of integrating kraft

paper, cement, and coconut fiber to achieve ceiling boards that

meet industry standards for strength, durability, and cost-

effectiveness.
1.3 Objectives of the Study

This study aims to:

 To develop sustainable alternative materials using kraft paper,

cement, and coconut fiber for ceiling board production.

 To establish standardized methodologies for combining kraft paper,

cement, and coconut fiber into cement board production.

 To obtain mechanical properties of the fabricated boards, including

compressive strength, tensile strength and flexural strength.

 To produce an economical cement board that also meet or exceed

industry standards for ceiling board materials.

1.4 Significance of the Study

The study will focus to establish a standardized fabrication

procedures and determine the right ratios of Kraft paper, cement, and

coconut fiber in producing an alternative ceiling board material to

meet industry standards. This study will enhanced a sustainable and

durable ceiling boards through producing kraft paper cement board

fortified with coconut fiber as a substitute for standard ceiling board.

This innovative product utilize recycled Kraft papers and locally

sourced coconut fiber to produce a standardized fabricated particle

board for ceiling cover. The aim is to ensure that the final product

meets or exceeds current industry norms for ceiling applications, also

to assess the practical applications of these ceiling boards in real-world

conditions, promoting an alternative in the construction industry.

This study is beneficial to the construction industry by providing

a sustainable and durable alternative for ceiling materials.

Environmental advocates will appreciate the use of renewable

resources like coconut fiber and recycled Kraft paper, reducing waste

and promoting eco-friendly practices. It supports the local economy by

sourcing materials locally, benefiting farmers and markets.

Researchers gain valuable insights for further innovation in sustainable

building materials, while policy makers can use the findings to update

building codes. Consumers and homeowners benefit from safer, more

sustainable building materials for healthier and cost-effective living

environments.

1.5 Scope and Limitation of the Study

This study focuses on developing Kraft paper cement boards

fortified with coconut fiber as sustainable alternatives for ceiling board

materials. It encompasses designing standardized fabrication

procedures, optimizing material ratios, and conducting comprehensive

testing to evaluate properties like tensile strength and durability. The

specimen data testing will be conducted at the Civil Engineering

Laboratory of St. Michael’s College BED Campus, Iligan City, utilizing

their advanced laboratories and testing facilities. The Kraft paper and

coconut fiber, essential materials for this study, will be gathered and

available from Tambo Wet market in Iligan City. This setup ensures

access to adequate resources and facilities necessary to carry out

comprehensive testing and analysis for the development of Kraft paper

cement boards fortified with coconut fiber as ceiling board materials.

1.6 Conceptual Framework and Design

Collection of Resources/
Materials

Extracting of Coconut Fibers Milling of Kraft Paper

Mixing of
Components

Molding

Testing

Product

Figure 1.1 Conceptual Diagram of the Design and Fabrication

of Kraft Paper Cement Boards Reinforced with Coconut Fiber

 This framework outlines the production process of Kraft paper

cement boards reinforced with coconut fibers. It begins with the

collection of materials, including coconut husks, Kraft paper, cement,

and water. The husks are processed to extract fibers, and the Kraft

paper is milled to a fine texture. These components are then mixed

with water, molded into the desired shape, and tested for quality

before being finalized as the end product.

1.7 Operational Definition of Terms and Variables

American Society for Testing Materials (ASTM). An international

organization that develops and publishes voluntary consensus

technical standards for a wide range of materials, products, systems,

and services.

ASTM C109. ASTM C-109. A compression test determine the

compressive strength of hydraulic cement and other mortars. The

results of the ASTM C109 compression test may be used to determine

compliance with specifications.

ASTM D570-98. A water absorption test, specifies the method for

determining the water absorption of plastics, also involves measuring

the thickness of a specimen before and after immersion in water to

determine the swelling.

ASTM D790-02. The flexural test, determines the mechanical

properties, such as modulus of elasticity (MOE) and modulus of rupture

(MOR), of the particle board.

Ceiling Covering. Materials used to cover and finish the ceiling

surface in a building, providing aesthetic appeal and functional

protection.

Coconut Fiber. Natural fibers extracted from the husks of mature

coconut fruits, used to reinforce the Kraft paper cement boards to

enhance their mechanical properties and sustainability.

Composite. A material made from two or more different substances

that, when combined, produce a material with characteristics different

from the individual components, such as Kraft paper and coconut fiber

cement boards.

Conventional. Existing, widely accepted methods or materials

currently used in construction, like traditional plywood and gypsum

ceiling boards.

Curing. The process of maintaining adequate moisture, temperature,

and time to allow the cement in the Kraft paper cement boards to

achieve its desired properties and strength.

Defibering. The process of separating coconut fibers from the husks,

making them suitable for reinforcement in the cement boards.

Fabrication. The process of manufacturing Kraft paper cement

boards, including the mixing, molding, curing, and finishing stages.

Fortified. Strengthened by adding coconut fiber to the Kraft paper

cement boards, enhancing their mechanical properties and durability.

Industry. The construction sector where the proposed ceiling

materials can be applied, emphasizing the study's relevance to

industry standards and practices.

Integration. The process of combining Kraft paper and coconut fibers

into cement boards, ensuring the materials work together effectively

to provide enhanced properties.

Kraft Paper. A strong, durable paper used in the proposed composite

material, valued for its environmental sustainability and mechanical

properties.

Mechanical Properties. Characteristics of the Kraft paper cement

boards that define their behavior under various loads, such as tensile

strength, flexural strength, and compressive strength.

Ratios. The proportions of Kraft paper, coconut fiber, and cement

used in the composite material.

Standard. Established benchmarks and criteria that the proposed

ceiling materials must meet or exceed to be considered viable for

commercial and industrial use.

Traditional Materials. Common materials currently used in ceiling

applications, such as plywood and gypsum boards.

Typical Ceiling Materials. Common materials used for ceilings in

buildings, which include plywood and gypsum boards, known for their

widespread use but also for their limitations.

 CHAPTER 3

METHODOLOGY

The methodology for this study focuses on creating Kraft paper

cement boards fortified with coconut fiber as an alternative to ceiling

board materials. It describes the systematic procedure of collecting

materials, setting up experiments, and analyzing data to determine the

mechanical qualities and practicality of composite boards. This

organized strategy ensures compliance to industry standards and

sustainability objectives, with the goal of optimizing material ratios and

manufacturing techniques effectively.

3.1 Research Design

The study aims to produce Kraft paper cement boards fortified

with coconut fibers, offering enhanced mechanical strength, durability,

and environmental sustainability. The study's flowchart is portrayed in

the figure below, detailing each stage step by step. This flowchart

illustrates the production process of Kraft paper cement boards

fortified with coconut fibers, commencing with the collection of raw

materials: coconut husks, Kraft paper, and cement. The husks and

Kraft paper are initially soaked in fresh water to soften, then milled to

extract coconut fibers and achieve the finest Kraft paper texture.

These fibers undergo washing and drying to eliminate impurities.

Afterwards, Kraft paper is combined with cement, coconut fiber, and

water to create a composite mixture. This mixture is then pressed into

molds to form board shapes, which are subsequently removed and

cured under controlled conditions to attain the desired strength.

Following curing, the boards are edged and trimmed to achieve the

desired dimensions. Finally, the finished boards undergo

comprehensive testing for tensile strength, compressive strength, and

flexural strength to ensure compliance with industry standards.

Collection of Resources/
Materials

Soaking of Husk Soaking of Kraft

Paper

Defibering Milling

Washing and Drying Drying

Mixing of
Components
 Pressing
Removal

Curing

Edging and Trimming

Testing

Product

Figure 3.1 Flowchart of Design and Fabrication of Kraft Paper

3.2 ResearchCement
Locale Board Fortified with Kraft Paper
This study aims to enhance sustainable and durable ceiling

boards by producing Kraft paper cement boards fortified with coconut

fiber as a substitute for standard ceiling boards. The materials used for

this study include Kraft paper, cement, coconut husk, and water. The

Kraft paper and coconut fiber, necessary for this research, will be

gathered at Tambo Wet Market, Iligan City, where the local resources

are abundant. The materials will be transported to Bagong Silang,

Iligan City, for the production of the Kraft paper cement boards fortified

with coconut fiber. The specimen sample will then be transported at

the Civil Engineering Laboratory of St. Michael’s College BED Campus,

Iligan City, utilizing their advanced laboratories and testing facilities.

Additionally, this study will assess the practical applications of these

ceiling boards in real-world conditions, promoting an alternative in the

construction industry.

3.3 Research Participants and Key Informants

For this study, the researchers will be working with a diverse

group of participants to get a well-rounded view of the new Kraft paper

cement boards fortified with coconut fiber. The researchers will involve

construction workers and builders who have hands-on experience with

traditional ceiling materials to share their practical insights. Material

scientists and engineers will help with the technical evaluations, while

environmental scientists will look into the sustainability aspects of the

boards. Architects and interior designers will provide feedback on how

the boards look and function in various settings, and end-users or

homeowners will give us their perspectives on performance and

satisfaction.

The researchers will also consult key informants such as local

vendors at Tambo Wet Market, who will supply the raw materials, and

researchers and faculty at St. Michael’s College, who will be involved in

testing the boards. Local government officials from Iligan City will offer

guidance on regulations and support, and industry experts will share

their knowledge on market trends and commercialization strategies.

Lastly, representatives from environmental advocacy groups will weigh

in on the boards' environmental benefits and community impact.

Engaging this wide range of voices will help ensure we get a thorough

and accurate evaluation of these new ceiling boards.

3.4 Data Gathering Methods and Procedure

To gather data for this study, the researchers start with a

thorough literature review to understand the current research and

pinpoint any gaps. Next, the researchers will collect and prepare the

materials needed for making the boards, which includes soaking,

milling, washing, and drying the Kraft paper and coconut husks. Once

the materials are ready, it will be mixed with cement and water, then

press this mixture into molds to form the boards. These boards will be

cured under controlled conditions to achieve the right strength. Then

the boards will be tested for their tensile, compressive, and flexural

strength, as well as their resistance to moisture and general durability.

 In addition to these technical tests, the researchers will gather

feedback from various stakeholders through interviews, surveys, and

focus groups. This includes talking to construction workers, architects,

material scientists, and end-users to get their opinions on how the new

boards perform and how they might be used in real-world settings.

After collecting all this data, it will be analyzed to assess the

performance and sustainability of the boards. Finally, we’ll compile our

findings into a detailed report and review them with key informants to

ensure everything
Figure 3.4isGantt
accurate andFor
Chart relevant.
Thesis Project Timeline

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