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CHAPTER 4

RESULTS AND DISCUSSIONS

This chapter presents the results of the physical and mechanical property tests such as water

absorption, thickness swelling, modulus of rupture and nail pull resistance of the resulting

composite after three and seven days of curing. This chapter also presents images of the

microstructure of the gypsum board using Scanning Electron Microscope (SEM analysis). The

results were analysed and compared to the minimum requirement of the American Society for

Testing and Materials (ASTM) and existing literature studies.

4.1 Physical properties of Gypsum Board

4.1.1 Water Absorption

Water absorption tests were performed to measure the volume occupied by the

material and water that may seep into the pores of the composite material. The standard

board sizes of 100mmx100mmx12mm use for this test was recommended in a previous

study by Hashim et al., (2005) considering a series of two trials with a total of twenty-four

samples. Figure 4.1 and Figure 4.2 shows the water absorption after 3 days and 7 days of

curing of the samples respectively by each samples with fiber length of 3mm to 5mm and

fiber content of 2% to 4%.

From Figure 4.1 and Figure 4.2, for the specimens with varying amount of coconut

fiber, observed that there is a very minimal percentage of water absorption. The percentage

of water absorption decreased with the addition of volume of coconut fiber and its length.

In comparison of Figure 4.1 and Figure 4.2, a similar decreasing trend can be observed. In
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the mixes with varying length and volume of coconut fiber, water absorption ranges from

0.1% to 0.6%. It is observed that the increase in volume of coconut fiber decreases its water

absorption. It indicates that the composite can resist penetration of water and higher fiber

contents are better in terms of permeability.

2% 3% 4%
12.20
12.11
12.10
12.02
Water Absorption (%)

12.00 11.93 11.93


11.90 11.84 11.84 11.84 11.84 11.84 11.84 11.84
11.80

11.70 11.66
11.60

11.50

11.40
3 4 5 345
Fiber Length
Figure 4.1 Water Absorption after 3 days of curing

2% 3% 4%
0.40 0.36 0.37
0.35 0.33 0.32 0.32 0.33
Water Absorption (%)

0.30 0.30
0.30
0.25 0.25
0.25 0.23
0.19
0.20
0.15
0.10
0.05
0.00
3 4 5 345
Fiber Length

Figure 4.2 Water Absorption after 7 days of curing


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4.1.2 Thickness Swelling

Thickness swelling was performed to the resulting composite to determine the

stability of samples in length, width, and thickness. The standard board sizes of

100mmx100mmx12mm use for this test was recommended in a previous study by Hashim

et al., (2005) considering a series of two trials with a total of twenty-four samples. Figure

4.3 and Figure 4.4 shows the percentage of thickness swelling after 3 days and 7 days of

curing of the samples respectively by each samples with fiber length of 3mm to 5mm and

fiber content of 2% to 4%.

From Figure 4.3 and Figure 4.4, for the specimens with varying amount of coconut

fiber, it can be observed that there is a very minimal percentage of thickness swelling. The

percentage of thickness swelling decreases with the addition of volume of coconut fiber

and its length. Comparing Figure 4.3 and Figure 4.4, a similar decreasing trend can be

observed. In the mixes with varying length and volume of coconut fiber, thickness swelling

ranges from 0.19% to 0.37%. It can be observed that the increase in volume of coconut

fiber resulted to a decrease in thickness swelling. It was also observed that there is a

negligible increase of thickness swelling when the specimen is cured in 3 days and 7 days.

2% 3% 4% 0.37
0.40 0.36
Thickness Swelling (%)

0.35 0.33 0.32 0.32 0.33


0.30 0.30
0.30 0.25 0.25
0.25 0.23
0.19
0.20
0.15
0.10
0.05
0.00
3 4 5 345
Fiber Length
Figure 4.3 Thickness Swelling after 7days of curing
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0.40 2% 3% 4%
0.36 0.37
0.35 0.33 0.33
0.32 0.32
0.30 0.30
Thickness Swelling (%)
0.30
0.25 0.25
0.25 0.23
0.19
0.20

0.15

0.10

0.05

0.00
3 4 5 345
Fiber Length

Figure 4.4 Thickness Swelling after 7 days of curing

4.2 Mechanical Properties of Gypsum Board

4.2.1 Nail Pull Test

Nail Pull resistance is the measurement on the ability of the boards to hold a nail

while subjected to loadings. The values specified were the measurement of the magnitude

of force which corresponds to the extent of force when the nail is pulled out from the board.

Figure 4.5 and Figure 4.6 shows the results of the nail pull resistance test using a board

(50x150x12 mm) consisting of two trials indicated by with 2%, 3%, 4% amount of fiber

and ASTM C 1395. This test was done after curing of 3 days. This results were taken and

were computed using the formula shown in the methodology and also compared to the

minimum standard as per ASTM 1395 which is 376N.

Figures 4.5 shows that specimen C3 has the highest value of 776.104N having

a 5cm fiber length and 4% fiber content while specimen A1 and A2 have the lowest
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value of 393.226N, 403.574N and 444.967N, 434.168N respectively. It shows that A1

and A2 did not pass the ASTM minimum standard. It also shows that the amount and

length of fiber affects the ability of the board to hold a nail while subjected to loadings.

The longer the length and the amount of fiber used, the higher the results.

2% 3% 4%
900.00
776.10
800.00 745.06
682.97
700.00
Nail Pull Strength

600.19 600.19
600.00 538.10 527.75
507.05
476.01 476.01
500.00 444.97
393.23
400.00
300.00
200.00
100.00
0.00
3 4 5 345
Fiber Length
Figure 4.5 Nail Pull Resstance after 3 days of Curing

Figure 4.6 shows that specimen C3 has the highest value of 776.104N having

a 5cm fiber length and 4% fiber content while specimen A1 has the lowest value of

393.226N.

It also shows that the amount and length of fiber affects the ability of the board

to hold a nail while subjected to loadings. The longer the length and the amount of the

fiber used, the higher the results.


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2% 3% 4%
1000.00 910.63
900.00 848.54
817.50
776.10
800.00 745.06
693.32 703.67
672.62
Nail Pull Strength

700.00 641.58
579.49
600.00 538.10
476.01
500.00
400.00
300.00
200.00
100.00
0.00
3 4 5 345
Fiber Length
Figure 4.6 Nail Pull Resistance after 7 days of Curing

4.2.2 Modulus of Rupture

Specimen sizes 330 x 50 x 12 mm were used for modulus of rupture determination.

The modulus of rupture was performed in accordance to ASTM C-36. Before testing, the

compression machine was calibrated for modulus of rupture test and the specimen were

marked on the center as well as on each side with an offset of 120 mm from the center after

it is cured for 3 and 7 days.

Figure 4.9 shows the maximum load in the gypsum board before failure,

consisting of two trials indicated by length of fiber (3cm, 4cm, 5cm and combination

of 3,4,5cm) with 2%, 3%, 4% amount of fiber and ASTM standard respectively. Trial

A shows that samples with fiber length of 3cm and 2% fiber content has the highest

values which is 126.98N. While Trial C, with 5cm fiber length and 4% fiber content

have the lowest value of 82.883N.


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It was observed that the increase in amount and length of coconut fiber

decreases the load it can carry. It was also observed in Figure 4.8 that the coconut fiber

have the ability to carry some load while the specimen is subjected to loading.

2% 3% 4%
140.00 126.98
114.46 118.40
120.00 110.51
98.67 98.67
100.00 90.77 90.78 86.83 90.77 90.78
82.88
Load (N)

80.00

60.00

40.00

20.00

0.00
3 4 5 3, 4, 5
Fiber Length (cm)
Figure 4.7 Bending Strength after 3 days of curing

Figure 4.8 Cross-Section of the Cracked Specimen


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Figure 4.9 shows the values of the modulus of rupture of gypsum board

(50x150x12 mm) corresponding to ASTM standards. It consists of three trials

indicated by length of fiber (3cm, 4cm, 5cm and combination of 3, 4,5cm) with 2%,

3%, 4% amount of fiber and ASTM standard respectively. This test was done after

curing of 3 days. Trials A with 2% fiber content and 3 cm fiber length had the highest

value of 211.079N while Trial C with 4% fiber content and 5cm fiber length had the

lowest value of 136.655N. It also shows that the samples from the 3 days curing failed

based on the minimum standards of the ASTM C1395-1935M.

250.00
2% 3% 4%
211.11
200.80
193.21
200.00
175.49
164.64 163.32
153.00 147.35
153.45 140.81 142.71
136.66
Load (N)

150.00

100.00

50.00

0.00
3 4 5 3, 4, 5
Length (cm)

Figure 4.9 Modulus of Rupture after 3 days of curing

Figure 4.10 shows the maximum load in the gypsum board

(50mmx330mmx12mm) before failure, consisting of four trials indicated by length of

fiber (3cm, 4cm, 5cm and combination of 3,4,5cm) with 2%, 3%, 4% amount of fiber

and ASTM standard respectively. This test was done after curing of 3 days. Trial A
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shows that samples with fiber length of 3cm and 2% fiber content has the highest

values which is 378.94N. While Trial C, with 5cm fiber length and 4% fiber content

has the lowest value of 296.011N. It was observed that the increase in amount and

length of coconut fiber decreases the load it can carry. It was also observed that the

coconut fiber have the ability to carry some load while the specimen is subjected to

loading.

2% 3% 4%
378.89
400.00 363.11 351.27 347.32
347.32 339.43 315.75 335.48
350.00 331.53 327.59
307.85
300.00 296.01

250.00
Load (N)

200.00
150.00
100.00
50.00
0.00
3 4 5 3, 4, 5
Length (cm)

Figure 4.10 Bending Strenght after 7 days of curing

Figure 4.11 shows the modulus of rupture on the gypsum board (50x150x12 mm)

consisting of three trials indicated by length of fiber (3cm, 4cm, 5cm and combination of

3, 4,5cm) with 2%, 3%, 4% amount of fiber and ASTM standard respectively. This test

was done after curing of 7 days. Trials A with 2% fiber content and 3 cm fiber length had

the highest value of 630.713N while Trial C with 4% fiber content and 5cm fiber length

had the lowest value of 262.488N. It also shows that the samples from the 3 days curing
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failed the minimum standards of the ASTM C1395-1935M. It was observed that at 7 days

of curing of the specimen helps to increase the strength of the gypsum board. The curing

helps to maintain moisture level on the gypsum board so that hydration can continue.

2% 3% 4%
700.00 630.71
617.08 579.16 569.39 585.92
600.00 560.44 565.94 568.53
550.06 512.71 501.63
500.00 502.49
Load (N)

400.00

300.00

200.00

100.00

0.00
3 4 5 3, 4, 5
Fiber Length (cm)
Figure 4.11 Modulus of Rupture after 7 days of curing

4.3 Property Comparison of Fiber Reinforced Gypsum Board

20 18.18
17.13

15
Flexural Strength (MPa)

10 8.90
5.85
5

0
FRGB (3 days) FRGB (7 days) Commercial ASTM
Samples Product
Figure 4.12 Flexural Strength
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Figure 4.12 shows the comparison between the strength of the Coconut Coir Fiber-

Reinforced Gypsum (3 & 7 Days) with that of the Gold Bond Interior Extreme Gypsum

Panel and ASTM Standard, respectively. The figure shows that the flexural strength of the

mix failed in the 3 days curing but passed the 7 days curing.

25 22.18
Nail Pull Strength (MPa)

20 18.01 17.85 17.80

15

10

0
FRGB (3 days) FRGB (7 days) Commercial ASTM
Product
Sample

Figure 4.13 Nail Pull Strength

Figure 4.13 shows the result of the Nail pull strength of the Coconut Coir Fiber-

Reinforced Gypsum (3 & 7 Days) in comparison with the Gold Bond Interior Extreme

Gypsum Panel and ASTM, respectively. The figure shows that the specimen tested for 3

days curing already passed the nail pull resistance of Gold Bond Interior Extreme Gypsum

Panel and ASTM Standard.


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6
5 5
5

Water Absorption (%)


4

3
1.8 1.9
2

0
1 2 3 4
Samples

Figure 4.14 Water Absorption

Figure 4.14 shows the results for water absorption. The set standard by ASTM is

that water absorption should not be greater than 5% of weight. Based on the result

gathered, the product passed the water absorption test. It indicates that the coconut fiber

can resist the penetration of water.

4.4 Scanning Electron Microscope (SEM Analysis)

4.4.1 Scanning Electron Microscope (SEM Analysis) Specimen A and B

SEM of Fiber Reinforced Gypsum Board: Specimen A with a mix design of 5cm

fiber length, 4% fiber content by weight of cement and was cured for 3 days. The size

distribution of pores in the gypsum ceiling board by SEM image analysis are

discussed. Results of the measurements done on the specimens with a water cement ratio

of 0.55 and 0.35 and were cured for 3 to 7 days are reported. The specimens were cut into
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one cm by one cm with a thickness of one centimeters. The images are two-dimensional

gray scaled images showing some parts of the samples.

In Figures 4.17, 4.18, 4.19, 4.20, the particle size is indicated by the scale bar in

the lower right corner and also shows the magnification as follows specimen a (1)

magnification × 40; (2) magnification × 300; (3) magnification × 400. The contrast of

these images shows the morphology of the samples.

As shown are the numbers of surface cracks, pores and bonding of the fiber in the

cement-gypsum board shown. The pores occurred due to the bonding of fiber itself and

also the penetration across the specimen ranges from 10-70 μm had straight pore edge

and clear grain boundary without any dissolution. Cracks and pores varies directionally

on the percentage of fiber of the mix design.

Figure 4.17 Scanning the surface of specimen A Figure 4.18 Scanning the surface of specimen A
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Figure 4.19 Scanning the surface of specimen A Figure 4.20 Scanning the surface of specimen A

SEM of Fiber Reinforced Gypsum Board: Specimen B with a mix design of 3cm

fiber length, 2% fiber content by weight of cement and was cured for 7 days. The size

distribution of pores in the gypsum ceiling board by SEM image analysis are discussed.

Results of such measurements are reported with a water-cement ratio 0.55 and 0.35 and

of ages ranging from 3 to 7 days. The specimen were cut to one cm by one cm with a

thickness of one centimeter. The images are two-dimensional grey scaled images

showing some part of the samples.

In Figures 4.21, 4.22, 4.23, 4.24, the particle size is indicated by the scale bar in

the lower right corner and also shows the magnification as follows specimen a (1)

magnification × 40; (2) magnification × 300; (3) magnification × 400. The contrast of

these images shows the morphology of the samples. As shown are the number of surface

cracks, pores and bonding of fiber in the cement-gypsum board. These cracks can be

attributed due to of the preparation and cutting of specimen which has a required

dimension for the SEM analysis. Pores occur due to the bonding of fiber itself and also
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the penetration across the specimen. Cracks and pores varies directionally on the

percentage of fiber in the mix design.

As shown in the picture, there are lesser number of surface cracks, pores as

compared to specimen A. These cracks can be attributed due to the preparation and cutting

of specimen which has a required dimension for the SEM analysis. The micro-fractures

were also identified in some samples, the widths of the micro fractures ranged from 2 μm

to 10 μm, with the majority between 2 μm and 5 μm, while their lengths were up to 10 mm.

Pores occur due to the bonding of fiber itself and also the penetration across the specimen

this kind of pores ranged between 30 μm and 100 μm and presented various irregular

shapes, characterized by relatively large pore sizes and good connectivity shown in

Fig.4.23. Some Cracks and pores varies directionally on the percentage of fiber of the mix

design.

Figure 4.21 Scanning the surface of specimen B Figure 4.22 Scanning the surface of specimen B
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Figure 4.23 Scanning the surface of specimen B Figure 4.24 Scanning the surface of specimen B

4.5 Statistical Analysis (ANOVA)

Analysis of variance (ANOVA) was performed in order to determine whether there is any

statistically significant difference between the means of two or more variables used in the study.

With the use of ANOVA for statistical analysis of the obtained results, a hypothesis has been

proposed. The hypothesis, which is the length and amount of coconut coir fiber affects the strength

of the gypsum board, can be rejected by comparing the P-values obtained to the standard P-value

which is 0.05. The statistical significance of the results can be obtained by comparing the F-value

to the F-crit values. If the F-value is higher than F-crit, then the hypothesis is not true and the

independent variables affect the independent variables significantly.

As shown from the ANOVA of two groups in Tables 4.7 and 4.8, both F-value are higher

than F-crit value. This means that the mean of the results deviates with the increase of length and

addition of percentage of coconut coir fiber. This also means that the hypothesis can be rejected,

thus implying that the length and percentage of coconut coir fiber influences the strength of

gypsum board.
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Table 4.7 One-way Analysis of Variance (ANOVA) of Length of Fiber

SUMMARY
Groups Count Sum Average Variance
3 mm 2 757.78718 378.89359 4.45213
4 mm 2 702.53187 351.26593 26.23777
5 mm 2 631.48932 315.74466 9.03125
3, 4, 5 mm 2 694.63825 347.31913 54.39245

ANOVA
Source of Variation SS df MS F P-value F crit
Between Groups 4011.15356 3 1337.05119 56.82712 0.00098 6.59138
Within Groups 94.11360 4 23.52840

Total 4105.26715 7

Table 4.8 One-way Analysis of Variance (ANOVA) of Percentage of Coconut Fiber

SUMMARY
Groups Count Sum Average Variance
2% 2 757.78718 378.89359 9.03125
3% 2 726.21272 363.10636 8.67445
4% 2 694.63825 347.31913 6.54496

ANOVA
Source of Variation SS df MS F P-value F crit
Between Groups 996.94690 2 498.47345 61.66515 0.00366 9.55209
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Within Groups 24.25066 3 8.08355

Total 1021.19756 5

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