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"Is that a firefly: Making fire resistant and environmental friendly concrete that can be used as main material for Infrastructures projects and residential houses to avoid fire Accidents" CAPSTONE PROJECT

In Partial Fulfilment Of the Requirements for the Subject Work immersion/ Research/ Culminating Activity

Submitted by:

BACOLOD, KRISTLE R. BONIFACIO, KATE ANN ROSE B. SAN JOSE, MARK ANTHONY BERBER, IVAN JULIUS

STEM – C March 2018

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Chapter 1 INTRODUCTION This chapter includes the Rationale of the project, Project context, Purpose and description of the project, Objectives of the project, Scope and limitation of the project and Definition of terms.

Rationale of the project This proposal project is all about fire resistant and environmental friendly concrete. A concrete that can be green alternative for Portland cement because of its low carbon footprints. The main materials includes to make this product are materials that contains Alumino-silicates which are industry by products such as Fly ash that is by-product from burning pulverized coal in electric generation power plants, Ground Granulated blast furnace slag that is by-product from the blast-furnaces used to make iron and Rice Husk Ash that is from burning Rice Husk. Other cementious materials includes Coarse Aggregates (Gravel, Limestone, Lime rock, Dolomite, Recycled concrete) and Fine Aggregates (Sand, Fine crushed stone), and Alkaline Activator (Sodium hydroxide and Sodium Silicate) that will serve as activators to source materials containing Aluminum-Silicate such as Fly ash, Rice Husk Ash and GGBS. We will also include some additives which is Polypropylene fibers.

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Our product becomes fire resistant because of the constituents materials (Cement and aggregates) that is included in the production which, when chemically combined within concrete, it enables concrete to act as an effective fire shield.

Project Context Fire is the one of the most generous disaster that can occur, whether it is residential or commercial in nature. Fire is adverse events with physical costs to property and human life. Fire is our greatest fear. When an item was stolen from you, it can be recovered but when it burns up, it is gone forever. In addition, fires also inflict adverse consequences on the natural environment. These include contamination of that air via the fire plume and its subsequent diffusion, with deposition of particulate and other materials likely to contaminate soil and water. The government has been consistent in taking initiatives to raise awareness through its fire prevention campaign. March is considered as Fire Prevention Month, but ironically, it is also the month when the worst fire incidents that went down in Philippine history took place. A factory in Cavite was razed by fire causing billions of pesos worth damages. Of the 30 workers inside the factory compound, one died while others sustained critical injuries. Fire insatiably consumes almost anything it touches, even lives.

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According to Bureau of Fire Protection, there's total of 615 fire events in Metro Manila in the first 2 months of 2015. In this case, the researchers are totally determined to give solution to the problem of the people. Due to the increasing cases of fire disaster not only in the Philippines but also in other country, some engineers on the past years developed fire-resistant materials that will decrease the level of spreading of fire during disaster. As researcher dream to be civil engineers, this is a very helpful for the future purposes. It will be good to minimize the fire happenings in the Philippines. The researchers chose this project because of the strong needs of the Philippines due to being prone to fire incidents. This project is all about fire resistant concrete, the researchers chose to propose concrete rather than other construction materials because Concrete does not burn, it cannot be set on fire and it does not emit any toxic fumes when affected by fire. Concrete is proven to have a high degree of fire resistance and, in the majority of applications, can be described as virtually fireproof. This excellent performance is due, in the main, to concrete’s constituent materials (cement and aggregates) which, when chemically combined within concrete, form a material that is essentially inert and, importantly for fire safety design, has relatively poor thermal conductivity. It is this slow rate of conductivity (heat transfer) that enables concrete to act as an effective fire shield not only between adjacent spaces, but also to protect itself from fire damage.

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PURPOSE AND DESCRIPTION OF THE PROJECT This project will create new highly heat resistant concrete that will be suitable to the present problem of this country. This will prevent the massive damage and destruction of buildings, residential houses and other properties. As research make it alright, it will also make the building strong, not about fire but also in any disaster. Also, in making this new concrete, there will be no use of harmful chemicals unlike the process of other concrete that the main process is relies on a high-energy manufacturing process that imparts high potential energy to the material via calcination. This means the activated material will react readily with a low energy material such as water. On the other hand, our propose concrete product uses very low energy materials, like fly ashes, slags and other industrial wastes and a small amount of high chemical energy materials (alkali hydroxides) to bring about reaction only at the surfaces of particles to act as a glue. By means of this, we can lessen the harmful effects of chemicals to our environment due to modern innovation.

Objectives of the Project General Objectives: To propose new fire resistant and environmental friendly concrete that can

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be used as main material for Infrastructures projects. Specific Objectives: 

To prevent fire damage



To used fly ashes, slags and other industrial wastes to become useful and not just treated as wastes.  



To create a highly cost effective fire resistant concrete.



To make a product that is beneficial to the people.



To make a product that is environmental friendly.



To enhance the quality of concrete used in buildings



To become fully equipped and prepared for fire disaster



To ensure the safeties of properties such as houses, buildings and other infrastructures.

Scope and Limitation of the Project The project was done to make fire resistant and environmental friendly concrete that can be used as main material for Infrastructures projects and residential houses to avoid fire accidents not just in the Philippines but also to the other country. The project will only focus on creating a new highly fire resistant

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concrete with the use of industrial waste as main materials in creating the product. This project will took place in Teresa Rizal which will be the location in creating this product before it release and sell. The estimated time to make and produce the materials is 2 to 3 months due to the things that are needed to produce them.

Definition of Terms. The following are define in terms of Conceptual and Operational used. Additives.

Are the

ingredients in concrete other than

cement, water,

and aggregate that are added to the mix immediately before or during mixing. Alkaline Activation. Is a chemical process in which a powdery aluminosilicate is mixed with an alkaline activator to produce a paste capable of setting and hardening within a reasonably short period of time. Coarse Aggregates. Generally range between 9.5mm to 37.5mm in diameter. Concrete. is a major building material which is formed by homogeneous mixing of aggregate (fine and course), cement, and water and with or without chemicalmineral additives in the conformity with the production technology, initially it is in plastic form and later it hardens and gain strength.

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Curing. Is the maintaining of an adequate moisture content and temperature in concrete at early ages so that it can develop properties the mixture was designed to achieve. Fly Ash. Is a by-product from coal-fired power plants that is frequently used as an admixture in concrete to replace a portion of the Portland cement. Fine Aggregates. Generally consist of natural sand or crushed stone with most particles passing through a 9.5mm sieve. Fire Resistant. Is one that is designed to resist burning and withstand heat. GGBS. Is a by-product of iron manufacturing which when added to concrete improves its properties such as workability, strength and durability. Portland cement. Is the most common type of cement in general use around the world as a basic ingredient of concrete, mortar, stucco, and non-specialty grout. Rice Husk Ash.

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Chapter 2 REVIEW OF RELATED LITERATURES AND PROJECTS This chapter represents the various literature and projects of foreign and local settings which are pertinent of the studies.

Foreign Literature and project Hao-wen Ye et. al. (2013) Ultra-high-performance concrete is an artificially synthesized material low in water-cement ratio and high in strength, density, impermeability, and brittleness. These traits make it easy to crack in case of fire, which results in reduction in strength. Adding polypropylene fibers not only helps enhance concrete’s strength and elasticity, but also provides ventilating vessels when the surrounding temperature rises. With these merits, ultra-highperformance concrete with fibers is able to tolerate heat and pressure for a relatively long time without getting seriously damaged, thus making time for fire fighters to save people’s lives and their properties. In relation to the project, polypropylene fibers will add to the concrete to resist to shrink & crack, Increase seepage resistance, Increase friction resistance, Increase freezing and thawing resistance that will give fully enhance to our proposed product which is the fire resistant concrete.

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Local Literature and project Aquino J.F. et. al. (2014) States on their research entitled “Concrete Strength Analysis: Replacement of Parts of Sand with Sawdust and Parts of Cement with Fly Ash for Slab on Grade “ that Fly ash particles provide greater workability of the powder portion of the concrete mixture also lowering of water requirement for the concrete of same consistency. Pump ability is greatly enhanced. Also, fly ash generally exhibits less bleeding and segregation than plain concretes. This makes the use of fly ash particularly valuable in concrete mixtures made with aggregates deficient in fines; it has lower heat of hydration. This is related to the present project since fly ash is one of the main material in producing our product which is fire resistant concrete because Fly ash is a solid material that serves as a waste by product produced by thermal power plants which is composed of free lime that give a self-hardening characteristic that is made to have a good compressive strength. This is also the reason why our product becomes environmental friendly.

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Chapter 3 TECHNICAL BACKGROUND Things that needs to consider in producing fire resistant and environmental friendly concrete

Description of the Project This project is all about fire resistant concrete, the researchers chose to propose concrete rather than other construction materials because Concrete does not burn, it cannot be set on fire and it does not emit any toxic fumes when affected by fire. This project will create new highly heat resistant and eco-friendly concrete and will use the following materials such as Fly ash, Granulated Glass Blast Slag (GGBS), Rice Husk Ash, Fine aggregates and coarse aggregates, polypropylene fibers and Catalytic liquid system (CLS) to activate the source materials (containing Si and Al) such as fly ash and GGBS.

Production Process Ultimately, the objective of the production process is to create goods or product that will be beneficial to the people.

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The production process of creating a fire resistant concrete involves Raw materials and Preparation, Mixing Process, Molding and compressing, Curing and handling.

The following steps is how to create Fire resistant concrete using small equipment. 1) Preparation of the materials Prepare the raw materials including: Fly ash, GGBS, Fine and Coarse aggregates, admixtures and Alkali Activators. 2) Combine the solid materials Combine the materials with appropriate amount of ratio 3) Mix using mechanical Mixer Mix the raw materials using mechanical mixer 4) Add the Catalyst liquid (activator) Add the Sodium hydroxide and sodium silicate in the raw materials 5) Mix using mechanical mixer Mix the raw materials and catalyst liquid using mechanical mixer 6) Put in a square container (molding)

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After the mixing process, put the cement in a square container and flat 7) Place on top of vibrating table for 2 minutes The square container will place in a vibrating table and wait until 2 minutes 8) Remove the concrete on the container after 8 hours After two minutes, remove the container in a table and live it for 8 hours 9) Place it on the large oven for 3 days After 8 hours, remove the concrete in the container and place it in curing conveyor oven for 3 days 10) Handling After 3 days the concrete is ready to sell.

START

HANDLING MIXING PROCESS

RAW MATERIALS AND PREPARATION

CURING

MOULDING AND COMPRESSING

FIGURE 1 Production Flowchart

END

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1) Raw Materials and Preparation The researchers will prepare the safe working place and at the same time the materials needed to create a fire resistant materials. The raw materials includes are fly ash which is by-product from burning pulverized coal in electric power generating plants, Granulated Blast furnace slag which is by-product of steel manufacturing process, Rice Husk ash which are made from burning Rice Husk, Fine aggregates which are crushed stones and sand etc., coarse aggregates which are gravel, limestone, dolomite, limerock and recycled concrete etc., Alkaline Activator such as, Sodium Hydroxide (NaOH) and Sodium silicate (Na2SiO3), and polypropylene fibers.

2) The Mixing Process The materials that had been prepared before should be weighed accordingly based on the design ratio. Then the materials need to be put into the mixer by following the sequence which is waste material before sand and lastly alkaline activator accordance to the standard. The sequence is important due to different properties in each material that affect the mixing process. Before mixing it, the sand should be prepared in a right condition that is surface saturated dry. This condition is important to make sure that the sand does not add or absorb any solution in the mix. The source of material need to mix first before the alkaline activator was

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added to the mix. After all the material already being put into the mixer then press mixer button on. The duration of mixing process is depending on the design ratio and material used. Usually the mixing process does not take more than 20 minutes for each batch

3) Moulding and compressing After the mixing already is mixed, on mixer moving switch then open the nozzle by switching on the nozzle switch. Then switch on upper cylinder button. After an accordance suitable time, switch off upper cylinder and switch on lower cylinder. To move the brick, switch on the mixer moving switch again. Then the brick will be move into the curing oven thru the extension conveyor.

4) Curing For curing operation, the brick will be automatically moved in and out of the oven by the stainless still belt at the curing conveyor oven. The temperature need to be set to required temperature before the brick being pulled into the oven by using oven temperature control at the control board. After the brick finish going thru the curing conveyor oven, the brick end product will go to end gravity conveyor and ready to be use.

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5) Handling After the product is test, it is now ready to distribute and sold. Production Capability and Schedule The table below is the schedule for the production of the fire resistant and environmental friendly concrete. Raw material and Preparation Mixing process Moulding and Compressing Curing

1 month 15 minutes – 20 minutes 3 minutes – 5 minutes 24 hours Table 1

Production Schedule

Physical Facilities This are large piece of equipment that is built specific for purpose. 1. Main Facility In the production of Fire resistant concrete, there must be an appropriate work place, a safe and neat place that is relevant to avoid some hazardous even that might happen during construction. 2. Finished product Storage After the production process, the finished product should store in one room 3. Raw material Storage

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The raw materials that is needed for the production will place separately based on their categories. 4. Recycle Storage The dumping storage are the storage of waste materials from concrete that can be use latter on as Coarse aggregates in the production of new fire resistant concrete.

FIGURE 2 Physical Facilities

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Production Input INPUT

NAME

DESCRIPTION

The

structure

of

QUANTITY

the

COST

TOTAL COST

8,000

8,000

mixer

including mixing tank, spindle shaft, and body of mixer was Mixer

made with mild steel structure coated with powder coating. The motor

installed

were

spindle

motor with 2 horse power helical gear. The speed of motor for mixing process was 10 rotations per minute that can be control with

controlling

board.

The

capacity of the mixing tank was 40 kg.

1

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The main component of compactor is air cylinder pressing with force capacity of 40 tonne. Moulding and Compactor

The size of the mould is 9” x 4” x 2.5” accordance with the standard size based on British Standard BS 3921: 1985 [10]. There are three plates in the moulding and compactor. The first plate is top support plate made with 12 mm steel plate to support the air cylinder presser. Then 12 mm steel pressing plate that hold the top pressing plate and bottom base plate connected

1

10,000

10,000

20

with mould made with 15 mm steel plate. The conveyor belt was made with nylon

with

frame. Conveyor Belt

The

aluminium speed

profile of

the

conveyor can be controlled with conveyor

speed

controller

at

1

7,000

7,000

1

15,000

15,000

maximum speed of 200 mm per second. The stand levelling is adjustable and heavy duty. This can be used for a wide variety

of

heat

processes

including drying, curing, aging, Ouring Conveyor oven

annealing,

stress

relieving,

bonding, tempering, preheating and forming. In either a horizontal or

vertical

configuration,

the

Conveyor Oven offers the ability to handle high production rates.

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The purpose of this machine is to roll the end product of brick specimen to be use. The whole End Gravity Conveyor

process

of

concrete

making

1

7,000

7,000

1

7,000

7,000

machine is being control either automatically

or

manually

by

using control panel board.

The whole process of concrete making machine is being control Control Panel Board

either automatically or manually by using control panel board

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Is a fine powder which is a byproduct from burning pulverized Fly Ash

coal in electric generation power plants.

1 sack

650.50

650.50

723.40

723.40

150

150

(25kg)

is a cementitious material whose GGBS (Ground granulated blast slag)

main use is in concrete and is a by-product from

the

blast-

furnaces used to make iron

Rice

husk

ash from

1 sack (25 kg)

burning

of rice husks (RHA) has already demonstrated that it is one of the Rice Husk Ash

most promising supplementary cementing

materials

(SCM),

given its high specific surface and great amount of silica soluble in alkaline conditions.

1 sack (50 kg)

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Sand is

a

naturally

occurring

granular material composed of Sand (Fine Aggregate)

finely divided rock and mineral particles. It is defined by size, being

finer

than

gravel

2 Sack

100

200

2 sack

50

100

and

coarser than silt.

Crushed stone or angular rock is a form of construction aggregate, Crushed stone (Fine aggregate)

typically produced by mining a suitable

rock

deposit

and

breaking the removed rock down to

the

crushers.

desired

size

using

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Limestone (Coarse Aggregate)

Limestone is a sedimentary rock composed mostly of the mineral calcite and comprising about 15% of the Earth's sedimentary crust. It is a basic building block of the construction industry (dimension stone) and a chief material from which aggregate, cement, lime and building stone are made.

Dolomite,

also

known

2 sack

150

300

2 sack

200

400

as

"dolostone" and "dolomite rock," is a sedimentary rock composed Dolomite (Coarse Aggregate)

primarily of the mineral dolomite, CaMg(CO3)2. Dolomite is found in sedimentary basins worldwide. It is thought to form

by

the

alteration

of

limestone

by

groundwater.

postdepositional lime

mud

and

magnesium-rich

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Used

as

secondary

reinforcement, polypropylene polypropyle ne fibers 

fibers help reduce shrinkage and control cracking. To use these

1 kg

54.71

54.71

1 gallon

300

300

fibers, concrete mix design does not have to be altered, and no special

equipment

or

slump

modifications are required, even for pumping or shotcreting. Concentration

of

sodium

hydroxide is the most important Sodium Hydroxide

factor for geopolymer synthesis. The solubility of aluminosilicate increases

with

increase

in

hydroxide concentration. The use of higher concentration of sodium hydroxide compressive

yield strength

geopolymer concrete.

higher of

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Sodium

silicate

has

already

found multiple uses cementitious

in

materials.

For

example, it is used as an alkaliSodium Silicate (water glass)

activator

in

alkali-activated

cements. In concrete, it is used as a setting accelerator and also applied in the form of silicate mineral

paint

to

enhance

waterproofing And improve durability.

TABLE 2 Production Input

1 gallon

250

250

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Waste and Waste Disposal Method In the production, there is no waste that is produce, that’s because the materials needed to make a fire resistant materials should be measure at the proper ratios, all the materials are supposed to be a concrete after the production. The container, tools and other equipment will not dispose after the usage.

Utilities The Utilities needed are electricity and water. Electricity is needed in able for the machineries to work and without electricity, it is not possible to attain the compressive strength of our product because it will only attain by placing the concrete on a high rate of temperature or in Curing Conveyor oven which needs electricity to work. On the other hand, Water supply also needed, even though it is not part of our materials, it is also needed for sanitizing and cleaning the tools, equipment, machineries and Working area.

Location Map The location Map of our Working area is located in Teresa, Rizal Philippines. Teresa is a second class municipality in the province of Rizal,

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Philippines. According to the 2015 census, it has a population of 57,755 people. The municipality is named after Reyna Teresabanta, the only female datu in precolonial Philippines.

FIGURE 3 Location

Plant size and Layout The working area contains different rooms and facilities that will be used in the production of the product which are the production room, Raw materials storage or stock room, Finished product storage, Recycle storage, Employer’s room, the workers room and the comport room.

FLOOR PLAN

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BIBLIOGRAPHY

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CURRICULUM VITAE PERSONAL DATA Name

:

Kristle R. Bacolod

Date of Birth

:

July 24, 2000

Place of Birth

:

Pangasinan

Home Address

:

061 Lumang ilog St. Brgy. Evangelista Baras, Rizal.

Sex

:

Female

Religion

:

Catholic

Name of Parents

:

Tessie A. Rico Nathaniel B. Bacolod

EDUCATIONAL BACKGROUND

Secondary

:

Tomas Claudio Colleges (Senior High School) Taghangin Morong, Rizal 2016 – 2018

Morong National High School (Junior High School) Morong, Rizal 2012-2016

Primary

:

Baras Elementary School Baras, Rizal 2006 – 2012

32

CURRICULUM VITAE PERSONAL DATA Name

:

Kate Ann Rose B. Bonifacio

Date of Birth

:

June 29, 1999

Place of Birth

:

Teresa, Rizal

Home Address

:

Teresa, Rizal

Sex

:

Female

Religion

:

Catholic

Name of Parents

:

Rose Bonifacio Andy Bonifacio

EDUCATIONAL BACKGROUND

Secondary

:

Tomas Claudio Colleges (Senior High School) Taghangin Morong, Rizal 2016 – 2018

St. Rose of Lima Montessori School (Junior High School) Teresa, Rizal 2012-2016

Primary

:

Teresa Elementary School Teresa, Rizal 2006 – 2012

33

CURRICULUM VITAE PERSONAL DATA Name

:

Mark Anthony D. San Jose

Date of Birth

:

August 10, 1999

Place of Birth

:

Teresa, Rizal

Home Address

:

Teresa, Rizal

Sex

:

Male

Religion

:

Catholic

Name of Parents

:

Medel San Jose Analyn San Jose

EDUCATIONAL BACKGROUND

Secondary

:

Tomas Claudio Colleges (Senior High School) Taghangin Morong, Rizal 2016 – 2018

St. Rose of Lima Montessori School (Junior High School) Teresa, Rizal 2012-2016

Primary

:

Bagumbayan Elementary School Teresa, Rizal 2006 – 2012

34

CURRICULUM VITAE PERSONAL DATA Name

:

Ivan Julius Berber

Date of Birth

:

October 19, 1999

Place of Birth

:

Teresa, Rizal

Home Address

:

268 F. Gonzales St.

Prinza Teresa rizal Sex

:

Male

Religion

:

Catholic

Name of Parents

:

Jovito D. Berber Bernadette I. Berber

EDUCATIONAL BACKGROUND

Secondary

:

Tomas Claudio Colleges (Senior High School) Taghangin Morong, Rizal 2016 – 2018

Tomas Claudio Colleges (Junior High School) Morong, Rizal 2012-2016

Primary

:

Prinza Elementary School Teresa, Rizal 2006 – 2012