Calcium Silicate Board Research Articles

Recycling of paper sludge powder for achieving sustainable and energy-saving building materials

Calcium silicate board materials (CSBM), as a new environmental friendly and energy-saving building material, have been widely used in the construction of ceiling and insulation panel. This study aims to investigate the feasible utilization of two kinds of paper sludge powder, paper sludge ash (PSA) and alkali recovery paper sludge (ARPS), as the supplementary materials to develop a sustainable CSBM with low water-cement ratio. The experimental results indicate that single addition of 30% PSA or 20% ARPS can improve the flexural strength of CSBM effectively because a moderate addition of paper sludge can decrease the porosity. Meanwhile, the addition of PSA or ARPS notably reduces the thermal conductivity of the CSBM and DSC-TG analysis present a better thermal stability before 650 °C. Furthermore, the reinforcing capability of the hybrid PSA/ARPS to CSBM is investigated using response surface methodology (RSM). In conclusion, the utilization of paper sludge powder presents a great potential to develop sustainable and energy-saving CSBM with enhanced flexural strength and reduced water absorption.

Development of sustainable calcium silicate board: Utilization of different solid wastes

The present investigation aims to estimate the feasibility of using eggshell and rice husk ash (RHA) as ingredients to produce calcium silicate board (CSB). The solid-state route was used to prepare the calcium silicate (CS) powder through the mixing of heat treated RHA (∼93% SiO2) and calcined eggshells (∼99% CaO) at 1050°C. CSB specimens were prepared at room temperature by simple curing process followed by mixing of different proportions of CS powder, ordinary portland cement (OPC) and unground rice husk ash (URHA). Several physicals, mechanical and thermal characterizations of the cured specimens were performed. The addition of OPC and URHA with CS were significantly influenced all the properties of CSB. The wastes derived CSB was exhibited low density (<1000kg/m3), comparable bending strength (∼6MPa) and low thermal conductivity (<0.153W/mK). These properties suggest that the waste derived board may be used in the internal lining of building for insulation.

Fabrication of sustainable ceramic board using solid-wastes for construction purpose

This work aims to evaluate the feasibility of using seashell and fly ash as ingredients for fabrication of the sustainable ceramic board. The multi-phase ceramic powder (MCP) formulation was done through the mixing of 1:1 weight ratio of fly ash and heat-treated seashell as ingredients and calcined at 1100 °C. Larnite (Ca2SiO4) was a major phase, and minor phases obtained in MCP were mullite (Al4.56Si1.44O9.72), calcium aluminate (Ca3Al2O6), and anorthite (CaAl2Si2O8). Ceramic board (CB) samples were prepared by simple room temperature curing (without autoclave) process with the mixing of a different portion of unground rice husk ash (URHA), rice husk (RH) and a small amount (10 wt%) of Ordinary Portland Cement (OPC). Several physicals, mechanical and thermal characterizations especially X-ray diffraction (XRD), scanning electron microscope (SEM), water absorption, bulk density (BD), expansion in water, bending strength, compressive strength, thermal conductivity, and humidity effect of the cured specimen were analyzed. The obtained results show that the addition of URHA, RH, and OPC with MCP influence all the properties of CB. The wastes derived CB exhibits good properties than a standard internationally calcium silicate board’s technical data, i.e., low density (<1000 kg/m3), good bending strength (>6 MPa) and low thermal conductivity (<0.22 W/m-K). It suggests that these wastes derived sustainable CB can be used for the internal lining of the building for thermal insulation.

KUAT TEKAN PANEL DINDING BETON RINGAN EXPANDED POLYSTYRENE DENGAN LAPIS LUAR PAPAN KALSIUM SILIKAT

The need for housing in Indonesia reaches around 1 million houses per year is the reason behind an increasing demand for building materials. Prefabricated wall panels can be used as alternative building materials that have easy and fast advantages in installation. In addition, the use of precast wall panels will also save labor costs. In this study, expanded polystyrene (EPS) lightweight concrete wall panels were a composite with calcium silicate boards. Furthermore, the unity of these materials are called a sandwich panel. The purpose of this study was to determine the potential use of sandwich panels as structural wall panels in terms of compressive strength. Test specimens were 9 EPS panels measuring 1800x610x75mm; 3 of them were a composite with GRC board, 3 other with GRC board outer layer and bolt connector, and 3 panels without reinforcement. The used calcium silicate board is a trade name of GRC board with a thickness of 4mm. Compressive strength testing is carried out referring to SNI 03-3122-1992 (Fibrous Lightweight Concrete Panel).The test results obtained the compressive strength of PP-T, PGP-T, PGB-T panels in a row of 0.72 MPa, 0.84 MPa, and 1.43 MPa. The pattern of damage to the test object was marked by the release of the outer layer of the GRC board and the wall panel was fractured. It can be concluded that the addition of the GRC board outer layer and bolt connector can increase the compressive strength of the wall panel up to 200%. In contrast, the PP-T, PGP-T, and PGB-T panels do not meet the requirements of SNI 03-3122-1992. The resulted compressive strengths are so low that make the expanded polystyrene concrete panel is not avaiable for bearing wall purpose.

Flexural Strength and Thermal Conductivity of Fiber-Reinforced Calcium Silicate Boards Prepared from Fly Ash

AbstractA novel fiber-reinforced calcium silicate board was prepared from fly ash. The effects of compression pressure, pulp fiber content, and cement content on the flexural strength and thermal c...

Fire performance of steel and plasterboard sheathed non-load bearing LSF walls

Light gauge steel-framed (LSF) walls are used as load bearing and non-load bearing building components in traditional concrete framed buildings and emerging all-steel structures. Recent building fire disasters around the world have highlighted the necessity for improved fire performance in such building components. While the fire performance of gypsum plasterboard, magnesium oxide board, calcium silicate board and oriented strand board (OSB) sheathed LSF walls has been assessed using fire tests and numerical analyses in the past, fire performance of steel sheathed walls remains unknown. Steel sheathing can improve the in-plane shear capacity of steel framed walls and is an accepted lateral load carrying system with widespread applications in the cold-formed steel construction industry. This paper presents the results of a series of small-scale fire tests conducted on steel and gypsum plasterboard sheathed composite panels and framed walls, and also an enthalpy based analytical study using the experimental results. Provision of steel sheathing either only internally, only externally or both internally and externally in combination was found to enhance the fire performance of plasterboard panels and plasterboard framed walls. The confinement of water within plasterboards for a prolonged duration with the provision of steel sheathing was found to be the prime cause of this improvement. Furthermore, the formation of thermal bridges across the stud in cavity insulated walls was found to reduce the fire performance significantly.

Testing and modeling the behavior of sandwich lightweight panels against wind and seismic loads

The behavior of non-structural sandwich lightweight panels against wind and seismic loadings is not well understood. Such panels are typically composed of two calcium-silicate board (CSB) wythes separated by a core infill made of expanded polystyrene lightweight concrete (LWC). This paper provides understanding regarding the mechanisms of panel connectivity by tongue-and-groove, including transfer of forces through steel dowels to the existing structure. Series of LWC mixtures having 470 to 975 kg/m3 density were tested using suitably established testing procedures to determine the flexural strength, core shear strength, interfacial bond between LWC and CSB, and pullout forces transmitted through the steel dowels. Special emphasis is placed on modeling the effect of wind and seismic loads on a 3.6 × 3 m2 partition wall constructed using LWC sandwich panels. The highest stresses and deformations generated from the model are compared to those determined experimentally, which allowed establishing different charts that can predict the safety factors as a function of LWC density and type/magnitude of the lateral loading applied.

Certain Building Materials with Respect to Their Thermal Properties as Well as to Their Impact to Environment

Thermal properties of certain building materials were studied with respect to environmental aspects. The building materials with significant insulation properties were laboratory tested using the special equipment based on Peltier module. During the experimental work, the samples of the following materials were tested: Expanded polystyrene (EPS), Autoclaved aerated concrete (AAC): Ytong, Calcium Silicate Board: Super-Isol and Foam glass (Cellular Glass Insulation): PERINSUL. The temperature was measured directly in connection of material with the Peltier module as well as in the distances of 5mm, 27.5mm, 50mm and 95mm from the Peltier module. The temperature taken at the surface of Peltier module reached -22°C, a typical temperature in the cold winter season. The results of the laboratory experimental work were modelled using the graphic representation. Modelling the thermal distribution will help to determine the ideal material thickness in the design of the building insulation.

Behaviour of tunnel lining material in road tunnel fire

The worldwide road tunnel linings are protected against possible fire scenarios to safeguard the structure and assist in occupant evacuation. There are various choices of active and passive protection available, passive protections includes calcium silicate boards, polypropylene fibers, vermiculite cement based sprays, and other intumescent materials. Tunnel fire is a complex phenomenon and researchers in the past has highlighted that there are various factors which affect the tunnel fires. The effect of passive protection techniques on tunnel fire is not well understood, especially for the insulation boards. It’s been understood from past research that for a heavy good vehicular (HGV) fire in the tunnel, the heat feedback effect is significant. Insulation boards may also affect the tunnel fires by altering the heat feedback effect in vehicular tunnels and hence this can affect the overall heat release rates and temperature profile inside a tunnel. This study focuses on studying the role of insulation boards in tunnel fires and evaluating its effect on overall heat release rate and tunnel temperatures.

Experimental Study on the Fire Performance of Tubular Steel Columns with Membrane Protections for Prefabricated and Modular Steel Construction.

Experimental research was conducted to study the fire resistance of steel tubular columns used in prefabricated and modular construction. In order to achieve high-efficient prefabrication and fast on-site installation, membrane protections using board products and thermal insulation blankets are adopted as the favorable protection method. Three protected tubular columns were tested in a full-scale column furnace with axial load applied. The study variables were different membranes, including fiber reinforced calcium silicate (FRCS) boards, rock wool and aluminum silica (Fiberfrax) insulations. The results suggest that one layer of 12 mm FRCS board with rock wool insulation has insufficient fire protection. However, steel columns protected with two layers of 12 mm FRCS boards with insulation appeared to have good fire resistances and could achieve a fire resistance rating as high as 2.5~3.0 h.

Post-fire mechanical performance of modular GFRP multicellular slabs with prefabricated fire resistant panels

Abstract Investigation of the post-fire mechanical performance of large-scale glass fibre reinforced polymer (GFRP) structures assembled with prefabricated fire resistant panels is reported in this paper. The GFRP structures were four modular web-flange multicellular sandwich slabs fabricated of face panels and web box sections using adhesive bonding. Three sandwich slabs had fire resistant panels installed, either glass magnesium (GM) board, gypsum plaster (GP) board or calcium silicate (CS) board, at the outer face of the lower face panel using screws. These three specimens were exposed from the underside to an ISO 834 fire curve for up to 70–90 min and then cooled to room temperature. Subsequently they were tested in four-point bending and compared to the fourth specimen without fire exposure. The composite action between face panels and web box sections is discussed and the failure modes of specimens are identified. Importantly, the effects of fire resistant panels on the post-fire mechanical performance of the GFRP multicellular assemblies are highlighted and quantified. Analytical modelling is further developed to estimate post-fire bending stiffness and load-carrying capacity considering the recovery of resin after glass transition but before decomposition and the contribution from the remaining continuous rovings for the decomposed GFRP materials, with satisfactory agreement with the experimental results. It was demonstrated that the specimen with the glass magnesium board showed superior post-fire mechanical performance, with more than half of the post-fire stiffness and capacity remaining after 90 min fire exposure.

The Standard Fire Testing and Numerical Modelling of the Behavior of Calcium Silicate Board Metallic‐Framework Drywall Assembly with Junction Box

The metallic‐framework drywall is used as the specimens in this research. The standard fire test and finite element simulation were performed once on 300 cm × 300 cm area specimen and twice on 100 cm × 100 cm area specimens, to quantify and evaluate the effect of the junction boxes on the fireproof property after being embedded into the metallic‐framework drywall. The results of the experiment show that the temperature of unexposed surface rises faster due to the higher thermal conductivity of the internal metal junction box. The general junction box whose material is PVC can be softened off when heated, affecting the integrity of the firewall and also leading to rapid transfer to the unexposed surface. The prediction of finite element simulation temperature is highly correlated with the results of the real experiment. It is effective to strengthen the original weaknesses by adding a calcium silicate board behind the junction box and using metal panels instead of PVC. The temperature of the temperature junction box surface which is the highest temperature point of unexposed surface decreased most significantly at 72.9°C after the reinforcement. In addition, after reinforcement, the fire resistance time can reach to 1 hour by inserting the junction box into the metallic‐framework drywall.

Investigation on the formation of tobermorite in calcium silicate board and its influence factors under autoclaved curing

Compared with the traditional partition board, the superior properties of calcium silicate board are attributed to the generation of tobermorite, which can be influenced by many preparation conditions. The purpose of this study is to investigate the effect of Ca/Si ratio, and some others factors on the preparation and formation of tobermorite in calcium silicate board. The results reveal that the optimal cement content is 72%, at this time, Ca/Si ratio in calcium silicate board reaches 1.22. The tobermorite will gradually fade away when Ca/Si ratio continues to increase. XRD and mercury intrusion porosimetry after compression molding demonstrate that the molding pressure has mainly no effect on the hydration production and only has improvement on the structure of specimens. Due to the transformation of hydration production, autoclaved curing time and curing temperature should be controlled in specific range of 4–8h and 190–195°C, respectively. Additionally, the strength tests in different preparation factors present that the synthesis conditions confirmed in this paper are very promising to be applied in calcium silicate board.

Thermal performance of modular GFRP multicellular structures assembled with fire resistant panels

Modular glass fibre reinforced polymer (GFRP) multicellular structures were formed using pultruded GFRP box sections incorporated between two GFRP flat panels by adhesive bonding. Three types of fire resistant panels, namely glass magnesium (GM) board, gypsum plaster (GP) board and lightweight calcium silicate (CS) board, were installed at the outer face of the lower GFRP flat panel using screws. The lower surfaces of the built-up specimens were then exposed to fire. The thermal responses of the GFRP multicellular specimens assembled with different fire resistant panels were measured and comparatively analysed, in association with the damage patterns observed. It was found that the fire resistant panels effectively mitigated the temperature progressions developed in the GFRP components, thereby improving the fire insulation performance of those structural assemblies. The GM board provided the best fire insulation performance, with the highest temperature at the outer face of the upper GFRP flat panel (the surface unexposed to fire) being less than 120°C after 90min of fire exposure. Further, the effects of cavities and end closure configurations of the multicellular assemblies on the heat transfer were evaluated and highlighted.

Fire tests of non-load bearing light gauge steel frame walls lined with calcium silicate boards and gypsum plasterboards

Light gauge Steel Frame (LSF) wall systems are made of cold-formed steel studs and tracks, and lined with wall lining materials. Conventionally, gypsum plasterboards are used as wall lining material in LSF wall systems. The fire performance of LSF walls is mainly dependent on the type and configuration of wall lining material, which delays the heat transfer through the wall and protects the steel studs from being heated rapidly. Recently, calcium silicate board lining is increasingly used in LSF wall systems because of its improved physical and thermal properties while being lightweight, cost effective, impact and moisture resistant. However, their fire performance has not been investigated in detail. Hence two full scale fire tests were conducted on non-load bearing LSF walls lined with calcium silicate boards. For comparison purposes two fire tests were also conducted on conventional gypsum plasterboard lined LSF walls. This paper presents the details of this experimental study on the fire performance of LSF walls and the results including fire resistance levels and time-temperature profiles across the wall panels. Effects of using calcium silicate board lining are discussed by comparing the fire test results of LSF wall lined with gypsum plasterboards and previously conducted studies on magnesium oxide board lined LSF walls. The results showed that the fire performance of calcium silicate board lined walls was similar to that of conventional gypsum plasterboard lined walls, but was superior to that of magnesium oxide board lined walls. The failure criterion of these calcium silicate board lined walls was found to be insulation as opposed to being the integrity failure observed in previous studies.

Effect of paint composition, nano-metal types and substrate on the improvement of biological resistance on paint finished building material

This study aims to compare the biological resistance of paint materials which contain different resin types (i.e., acrylic v.s. polyvinyl acetate) and resin percentages (i.e., 20%, 30%, and 40%) before and after nano-metal treatment, as well as to explore the fungicidal effect of nano-metals (i.e. Ag, Cu and Zn) to improve fungal resistance of paints and the effect of the applied paint substrate (i.e. stainless steel, calcium silicate board and cement board) on the fungal growth. The Aspergillus brasiliensis or Penicillium funiculosum was inoculated on each sample and their growth was visually evaluated according to ASTM G21-09. The results show that Penicillium growth was a bit stronger than Aspergillus for each test under same conditions, and fungi could grow on paints whether they contain acrylic or polyvinyl acetate resins. Specifically, paints with 40% resin level were able to prevent fungal growth without treatment of nano-metals. The effect of nano-metals varied depending on substrate materials. For stainless steel, its effect was more visible on the speed of fungal colonization. On the final level of fungal contamination, the effect was only visible for Aspergillus on some combination of materials. For calcium silicate board and cement board, its effect was obvious on both speed and final level of fungal infestation. Nano-zinc seems to be the most favorable nano-metal for most test painted substrates in terms of reducing speed of fungal growth. Fungal growth on calcium silicate board and cement board with high porosity tends to slower than on stainless steel with low porosity.

The Effect of Waterproof Processing Method on Properties of Calcium Silicate Board

In this paper, the effect of waterproof processing method on properties of calcium silicate board was studied in view of the requirement of calcium silicate board for building external wall. Experiments adopted waterborne epoxy resin in the test to do waterproof processing by three ways, which means taking the measure of waterproof processing respectively on two surfaces of the sample, on two surfaces and two lateral faces of the sample, and on all the six surfaces of the sample. The results showed that the sample could easily get wet from the side to the center, and it could only get satisfactory results when taking waterproof processing on all the six surfaces of the sample. Meanwhile, the water absorption rate of the sample decreased from 18.4% to 4.4% and its bending strength significantly got improved even after that the sample was treated separately by freeze-thaw cycles, dry-wet circulation, and soaking in hot water. Moreover, the performance of moisture deformation of the sample got reduced.

Experimental Study on Vertical Wooden Façade Combustion

Abstract This work presents the summarized results based on eight large-scale tests carried out to study the fire behaviour of vertical wooden facade combustion. The main purpose of these tests is to get some information on fire spread along a combustible facade in order to assess the ability of numerical codes to simulate flame propagation. If many researches on combustible facades exist, it is difficult to find academic configurations with a large instrumentation and consequently with a large database.Generally, these studies focus on observations concerning fire behaviour of complex facades, and for most of them, instrumentation consist to measure the temperature at different levels.During the eight large-scale tests have been measured: the temperatures in the fire room, on the facade and in front of it at different levels, the mass loss of wood cribs used as fuel in the room fire as well as the components of combustion gases.The first two tests were made without any combustible cladding on the calcium silicate board in order to measure the temperature of an inert facade. The facade of the other tests were composed of a cladding of 18 mm thick plywood mounted directly onto the calcium silicate board. In these tests, two different species of wood are used, Birch Wood and Okoume (African Wood). The aim was to observe the influence of the speeches with different densities on flame propagation. In addition to the numerous temperature measurements mentioned above, measurements of residual claddings thickness were made. Thus, the present research tries to understand the influence of the thermal stress level along the facade to the wood-burning rate through the wall.

Calcium Silicate Board as Wall-facade

Wall as spatial partition and facade of a building gives impact not only for building aesthetic, but especially for the occupant's convenience. In the preference of wall material, especially for high rise apartments, hotels or offices, its mass/m2 and its noise reduction become an important criteria that must be considered by the building owner and architect in order to give a more lightweight construction and a quieter interior for occupant's convenience and privacy. In this paper, lightweight material that has been investigated is calcium silicate board, as an alternative to brick as a common wall material. The findings of this research, by flexural strength test in normal condition, are generally categorized in class 2 and 3. By soak-dry test as durability test for outside uses, there are no cracks found in all samples and the flexural strength decreases but less than 30% so that it meets the SNI 7705:2011 standard. By warm water test, this material cannot withstand against temperature at 60 degree centigrade or higher. By heat and rain test, this material can withstand the heat and rain conditions. By noise reduction as sound isolating enclosure, this material is unable to perform as a noise barrier.

Coating mechanism and near-infrared reflectance property of hollow fly ash bead/TiO2 composite pigment

Nanometer titanium dioxide was deposited on hollow fly ash beads using a chemical liquid deposition method. Surface modification of hollow fly ash beads with Ca(OH)2 saturated solution resulted in the presence of calcium silicate hydrate. The surface modification had a great influence on the growth and micro-morphology of TiO2 nanoparticles on the surfaces of hollow beads. Electrostatic repulsive forces between the modified hollow bead surfaces and hydrated TiO2 were significantly reduced after the surface modification, favoring the formation of a homogeneous and uniform TiO2 film with high TiO2 loading. A possible growth mechanism of TiO2 coatings was proposed. Moreover, the near-infrared solar reflectance of hollow bead/TiO2 composite pigment reached 0.68, which was approximately 1.8 times as high as that of hollow beads. An approximately 28.1°C decrease in temperature was obtained for the inner surface of a calcium silicate board coated with composite pigments. Therefore, hollow fly ash bead/TiO2 composite pigments are excellent candidates for near-infrared reflective pigments used in solar reflective coatings.