SREE NARAYANA POLYTECHNIC COLLEGE

KOTTIYAM, KOLLAM.

A
Seminar Report On

PAPERCRETE

Submitted by
JITHIN PRAKASH . J
Reg . No . 20010226

Under the guidance of

BINI . I . G , Lecturer

DEPARTMENT OF CIVIL ENGINEERING 2020-23

 SREE NARAYANA POLYTECHNIC COLLEGE
KOTTIYAM, KOLLAM.

GOVERNMENT OF KERALA
DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE

This is to certify that the seminar entitled "PAPERCRETE” is submitted by

JITHIN PRAKASH . J bearing Register No. 20010226, final year Civil Engineering 2022-
2023, in partial fulfillment of the requirement for the award of Diploma in Civil Engineering
of the State Board of Technical Education, Government of Kerala.

Guided by

SHAINI N M TECH BINI . I . G

Head of department Lecturer
Department of Civil Engg: Department of Civil Engg:

External Examiner
 ACKNOWLEDGEMENT

First of all, I am indebted to the GOD ALMIGHTY for giving me an opportunity to excel in
my efforts to complete this seminar on time. I am extremely grateful to Sri. SANDEEP V,
Principal SREE NARAYANA POLYTECHNIC COLLEGE , KOTTIYAM, KOLLAM
and Smt. SHAINI N, Head of Department, Department of civil engineering, for providing all
the required resources for the successful completion of my seminar. My heartfelt gratitude to
my seminar guide Smt. BINI . I . G Lecturer, Department of civil engineering, for her valuable
suggestions and guidance in the preparation of seminar reports .I express my thanks to all staff
members and friends for all the help and coordination extended in bringing out this seminar
successfully in time . I will be failing in duty if I don’t acknowledge with grateful thanks to the
authors of the references and other literature referred to in this seminar. Last but not the least;
I am very much thankful to my parents who guided me in every step which I took.

Kottiyam Thanking you

November 2022 JITHIN PRAKASH . J

i
 PREFACE

I have made this report file on the topic “ PAPERCRETE “. I have tried my best to
elucidate all the relevant details to the topic to be included in the report . while in the
beginning I have tried to give a general view about this topic .

My effort and whole heated co-operation of each and everyone has ended on a successful
not I express my sincere gratitude to Smt. BINI . I . G , Lecturer , Department of Civil
Engineering who assisting me throughout the preparation of this topic . I thank her for
providing me the confidence and most importantly the track for the topic whenever I
needed it .

ii
 CONTENTS

Topic Page No.

ACKNOWLEDGEMENT I

PREFACE II

CONTENTS III

LIST OF FIGURES V

LIST OF TABLES VI

ABSTRACT VII

Chapter 1. INTRODUCTION 1

Chapter 2. MATERIALS AND PROPERTIES 2

2.1 Cement 2

2.2 Fine Aggregate 2

2.3 Coarse Aggregate 3

2.4 Papers 3

2.5 Water 4

CHAPTER 3. EXPERIMENTAL METHODOLOGY 5

3.1 Research Status in Field of Papercrete 5

3.2 Papercrete and Papercrete Blocks 6

3.3 Selection of the Proportion 7

3.4 Making of Paper Pulp 7

3.5 Making of Papercrete 7

3.6 Selection of Composition for Papercrete 8

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CHAPTER 4. PREPARATION OF SAMPLE AND TESTING 9
4.1 Sample Preperation 9
4.2 Preparation of Papercrete Cube and Cylinder 9
4.2.1 Testing of Prepared Samples 10

CHAPTER 5. RESULT AND DISCUSSION 11

5.1 Compressive Test Results 11
5.2 Split Tensile Strength of the Cylinder 12
5.3 Thermal Conductivity Test of Hollow Circular Cylinder 12
5.4 Flammability Test in a Cube 14

CHAPTER 6. CASE STUDY 15

6.1 Investigation of using Papercrete Material 15
6.2 History of Bricks 15
6.3 Innovation of Papercrete 16
6.4 Materials and Properties 16
6.5 Papercrete Bricks 18
6.6 Experimental Procedure 18
6.6.1 Specific Gravity Test for Fine Aggregate and Paper Pulp 18
6.6.2 Sieve Analysis 19
6.6.3 Determination of Bulk Density 19
6.6.4 Specific Gravity of Fly-Ash and Cement 19
6.6.5 Quality Standard Tests on Papercrete Bricks 20
6.7 Results and Discussions 20
6.8 Quality Standard Tests 21

CHAPTER 7. ADVANTAGES AND DISADVANTAGES 22

7.1 Advantages of Papercrete 22
7.2 Disadvantages of Papercrete 22

CONCLUSION 23

REFERENCES 24

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 LIST OF FIGURES

No. Title Page No.

Fig 2.1 Cement 2

Fig 2.2 Fine Aggregate 3
Fig 2.3 Coarse Aggregate 3
Fig 2.4 Paper 4
Fig 2.5 Water 4
Fig 4.1 Prepare mix of Paper Pulp, Cement, Sand and Water 9
Fig 5.1 Graph of combine results of Compressive Strength 11
Fig 5.2 Graph of Combine results of Split Tensile Strength 12
Fig 5.3 Thermal Conductivity test Specimen 13
Fig 5.4 Light Bulb inside Cylinder 13
Fig 6.1 Specific Gravity test of Fine Aggregate 18
Fig 6.2 Graph of Sieve analysis for Fine Aggregates 19
Fig 6.3 Papercrete Bricks during and after fire test 21

v
 LIST OF TABLES

No. Title Page No.

Table 5.1 Combine results of Compressive Strength 11

Table 5.2 Combine results of Split Tensile Strength 12
Table 5.3 Thermal Conductivity Testing 13
Table 5.4 Thermal Conductivity of selected material 14
Table 6.1 Papercrete properties 17

vi
 ABSTRACT

This experimental study presents an approach for the utilization of Papercrete in the
construction industry. Eco-friendly and green building materials are now the favorite material for
the construction activity since they are proficient of lighter weight, insect opposing and highly
insulative. Based on the recent studies in this field, unconventional building constructional
materials are the cost effective, light weight when dry and efficient to use. These environmental
solutions involve the use of mainly waste papers and other fibrous materials to provide additional
strength to the structural elements selected. The structural elements can be the interior wall of the
structure, some of the exterior wall, floor bricks and other division that can contribute to a cost-
effective and eco-friendly building. This thesis started from conceptualization and design of the
proportion of the various materials to be used in the laboratory testing. Laboratory testing and
analysis of the test result provided the sufficient data to prove whether it is more efficient to use
alternative eco-friendly and green materials instead of pure commercialized building materials.
Evaluation between the samples formulated was used to investigate if it may be used in the future
as a construction element or not. The objective of this experimental study is to utilize papercrete
prepared by waste paper, cement, sand and water toward attaining a sustainable development.

Key words: Papercrete, Sustainable Building Material

vii
 CHAPTER Ⅰ
INTRODUCTION

The world has been faced, with environmental problems such as global warming, forest
destruction and lack of resources. Recycling of resources help solve, these environmental
problems. Principally, paper; is one of the most effective recycling, resources to prevent global
warming. According to Resource; Information System Incorporated (RISI), paper recycling is
being done to the extent of about 60% ~ 80% in many countries. Waste management refers to
awareness regarding the collection, transport, treatment, recycling and storage, of waste. The
term usually refers to materials resulting from human activities and to the reduction; of their
effect on the people’s health, the environment, or the aspect of a habitat. Waste management
may also contribute to saving natural; resources through the reuse of recoverable parts. Waste
paper has been used as building materials for decades, especially in cementitious; matrices,
and since then a lot of research has been conducted to develop; the mechanical properties of
the composite like; compressive, tensile, flexural strength, and etc. Use of wastepaper in
structural’ concrete could; become economical and environment friendly, which helps to
minimize harmful effects of construction process. Paper is the most frequent; type of waste
found in all activity areas and exemplifies an important source of cellulous fibers. In different
forms (quality paper, mixed paper, newspapers and journals) paper exemplifies about 41% of
all household waste produced today. Paper is a recyclable material; that after reaching the
garbage dumps; has a biodegradation period of 3-12 months. That is why the benefits for nature
through paper waste recycling are very important. Paper can be recycled in the technological
flow; that has produced it for the manufacture of paper or the produce of cardboard and
pasteboard. Paper can only be recycled 6-10 times, because with each recycling, the length of
cellulose fiber is minimized, resulting in a decrease of the mechanical strength and quality
(appearance, color) of the manufactured paper and an increase of technological losses

1
 CHAPTER 2
MATERIALS AND PROPERTIES

2.1 CEMENT
 The invention of Portland cement was done by John Aspidin as fine grey powder.
 Cement is just a mixture of chalk or limestone powder and clay.
 Cement can be seldom used solely, but is majorly used to bind sand and gravel (aggregates)
together.
 Fine aggregate used with cement makes mortar and the same mortar used with coarse
aggregate forms concrete.
 In India, there are three grades of OPC, namely 33grade, 43 grade and 53 grade manufactured.
As per the standard testing procedure, the compressive strength of cement will be obtained
after 28days.

Fig 2.1 Cement

2.2 FINE AGGREGATE

 Concrete made by mixing water, cement and fine aggregate that is sand and coarse
aggregate, and mortar is also made by mixing water, cement, and fine aggregate.
Hence, sand is an essential part of any construction.
 The sand particle generally contains small grains of silica (SiO2). These are formed
during the decomposition of sandstone due to various forms of weathering.
 A disadvantage of fine aggregate is the great consumption of binder leading to
shrinkage and creep.
 The quantity of binder in the concrete can be reduced by adding plasticizers or by
pulverising the sand or by autoclaving.

2
  The locally available sand is passed through a sieve of 4.75mm and the passed sand is
used for construction as per IS.
 According to the source the sand is obtained, it is termed as Pit sand, River sand.

Fig 2.2 Fine Aggregate

2.3 COARSE AGGREGATE

 The locally available crushed blue granite stones confining of 12.5 mm size are used for
construction as per IS 383-1970.
 Stones having specific gravity of 2.77 and which passes through 4.75 mm sieve are mostly
used for casting specimens.
 Several experimental investigation reveal that the size of aggregate must be limited to the
strength on composite.
 The cement to aggregate ratio influence the strength of concrete.

Fig 2.3 Coarse Aggregate

2.4 PAPERS
 Paper is the natural fibrous polymer which is made of wood cellulose, which is the
most abundant organic compound on the planet.

3
  Cellulose is a polymer made up of units of monomer glucose (polysaccharide). The
linking is done by a type of sugar called ß-D-glucose. Regardless of containing
several hydroxyl groups, cellulose is a water insoluble compound. The reason to
this stiffness of the chains is the hydrogen bonding between two -OH groups on the
adjacent chains.
 When the networks or matrices of fibres and fibrils dry, they interweave and
adhere together with the power of the hydrogen bond.

Fig 2.4 Paper

2.5 WATER
 Water is an important ingredient in any kind of concrete, papercrete also requires
water as it vigorously participates in the chemical reaction with the cement.
 The water used must be free from organic matter and the pH value of the water must
be between 6 and 7.

Fig 2.5 Water

4
 CHAPTER 3
EXPERIMENTAL METHODOLOGY

This research study conducted an experimental procedure on testing of the green

building materials. The group targeted to determine a new construction material which can
maximize the use of sand, cement, gravel and other commercialized products. There are several
considerations, specifications and constraints that need to be considered in order to provide
another type of material which can be used for the construction activity. Specifications to be
considered include the rigidity, in which the material should be stiff and provides little loosen
for inner walls for better insulation. Another consideration is the durability. The material
should be durable in such a way that the structure can survive up-to certain living conditions
as well as long lasting, in which the material to be localized should expect logical life
expectancy. Lastly, having a light weight construction material having the same amount of
strength should also be considered. Taking into consideration that the innovative construction
materials are localized, there are certain factors that may influence the stability of the material.
Consecutively to use it in, parameters should be investigated first before implementation takes
place in any area. Variation in climate should also be considered; comparing our climate to
those areas that has a much lower temperature possibly will cause changes and different
variations which can’t be approximated due to its compositions and reactions as a result of
weather changes. Constituent resistance may also be included because this construction
material is not included in our National Building Codes (NBC) and other references so further
studies should also be made in order to achieve a certain objective.

3.1 RESEARCH STATUS IN THE FIELD OF PAPERCRETE

Papercrete has not been researched for the profitable applications until now. Simply
residences have been made from papercrete; consequently, increasing the size of the buildings
to cover the piles is a challenge. The weather conditions will play an important role in this
process. Papercrete loses its strength when it absorbs water; therefore, it must be sealed to
prevent the moisture from reaching the papercrete. On the other hand, the papercrete can’t be
coated with water-proof material while the papercrete is curing. To make best use of its
strength, papercrete needs to dry, as well as cure.
Cement concrete sets during the first 24 hours after pouring into the desired location;
the hydration process occurs over many years. Concrete achieves approximately 70% - 80% of

5
its strength in the first 7 days of curing (Fintel 1985). If the concrete were wet for those 7 days
period, it would still gain the same strength. However, if the papercrete were kept wet for 7
days period, the strength of the material would not increase until the moisture was removed
and the papercrete was allowed to dry. This means that the sealant for the papercrete cannot be
applied until after the papercrete is fully dried. For small structures, this is not much of a
concern because the small wall thickness takes less time to dry. On the other hand, when the
walls on the structures increase in thickness, the drying time for the papercrete also increases.
This will increase the construction time; therefore, weather plays a very important role in
industrial structures.
The papercrete can be constructed to bear up wind loads; though, the walls must be
thick enough. This produces two problems. First one, the amount of the material needed
increases, which increases the overall cost of the construction. But more important, the drying
time of the papercrete increases to the point where drying is becoming very difficult. Fluid
transport through the wall delays as the wall becomes thicker; therefore, the walls will not be
strong enough to support themselves for many months. This situation provides two options:
1) Find a method to dry the walls quicker, which can be costly, and does not eliminate the
trouble with the amount of material used.
2) It reduces the amount of papercrete needed by adding a stronger material to the building.

3.2 PAPERCRETE AND PAPERCRETE BLOCKS

Papercrete or Papercrete Blocks are newly developed building construction materials
with limited information and structural properties. This building construction material is
chiefly composed of re-pulped Paper fibers and Portland pozzolana cement or Clay. Portland
pozzolana cement is a common construction material which would benefit to harden the paper
pulp up to its maximum capacity depending on its mixing ratio. The papers to be used can be
found in a diversity of sources; dumping sites, junk yards and other establishment bins are
useful in collecting and gathering the sufficient volume of paper required in certain
construction uses. Categorization from different sources is a useful way of collecting paper that
can be used as a construction material. Fibers from those collected papers are then processed
and turned into a useful material which can provide light weight at a very low cost. The mixture
outcome for this re-pulps paper fibers is like the texture of oatmeal and is normally mixed with
ratio to attain a certain desirable strength, after which it will be poured into forms to achieve
the desired shape and size depending on where it will be used. The methodology is much

6
similar to the process in making adobe to attain papercrete blocks for different purposes.

3.3 SELECTION OF THE PROPORTION

In order to investigate the behavior and strength capabilities of the Papercrete, normal
concrete testing was done to determine the material and structural properties. We decided to
have different specimen ratio to have the comparative data and evaluate to conclude how they
vary from each ratio. Based on those data, we can now conclude and simply say what ratio best
fits the Papercrete thought and its properties as the concrete established.

3.4 MAKING OF PAPER PULP

Initially, we collected the recycled papers like newspapers, waste official papers old
test papers and anything with fibrous materials most specially papers may do. Paper samples
were weighed since it’s hard to weigh them when it is wet after getting soaked for 24 hrs. The
next step done was soaking the paper samples for next 24 hrs to soften the fibrous composites
and for the easier mixing.

3.5 MAKING OF PAPERCRETE

The composition or proportion of the various materials for making of the papercrete
used for the structure is one of the most significant parts of the research work. To determine if
huge structures can be constructed from papercrete, the material properties must be determined.
Consequently, five different compositions of papercrete were tested to determine the
compressive and split tensile strengths of each. This process reduced the number of
compositions from five to one. The mixtures of papercrete tested used different compositions
of paper, sand and cement. The amount of water used for the mixture varied to maintain the
mixture at a consistent viscosity to ensure proper mixing.

3.6 SELECTION OF THE COMPOSITION FOR PAPERCRETE

A number of different compositions of papercrete were tested to determine their
physical properties. The paper, cement and sand percentages were varied in the different
mixture. Five different compositions were tested to determine the compressive strength. The
accurate compositions were selected to create a variety of strengths, which would allow us to
determine the most economical and practical mixture to be used for the building construction.
The concrete mixture provided bonding between the paper fibers therefore, more concrete

7
added increases the strength more than the other two components. However, concrete was more
expensive than paper and sand; therefore, cost was directly related to strength. The paper was
used as a light weight “filler material” that increased the volume, thus making the building
material less costly. The more paper used, the weaker the papercrete. Sand increased the
compressive strength of the mixed material during the setting period.
Papercrete with a higher percentage of sand was more stable after the setting period.
This made handling the “wet” papercrete less complicated, because the papercrete with the
higher percentage of sand had more strength upon setting. The sand is also believed to decrease
the amount of shrinkage that occurred in the samples. The reduction of shrinkage would reduce
the tendency to crack upon drying. The amount of the water in the compositions played a very
important role in the physical strength. More water was needed to pulp the paper than was
needed in the process of heat of hydration however, surplus water weakened the papercrete.
This meant that any supplementary water reduced the strength of the papercrete; though, the
volume increased, which reduced the overall cost of the mix. Excess water in the mix also
meant that the papercrete required more time to dry after the setting period. The papercrete
became stronger as it dried. The papercrete required to be completely dry to increase the
strength to a maximum level.
Primarily, water was added and mixed to maintain a similar flowability and viscosity
throughout the various compositions. The amount of water was then increased to make mixing
the papercrete less complicated. After testing the samples, it was determined that the water
content of the papercrete was very important. It might be beneficial to mix the papercrete with
higher water content and then drain the water out of the mix to increase the physical strength
of the papercrete, while still making it less viscous during the mixing. The results from the
different compositions are shown in the next several sections.

8
 CHAPTER 4
PREPARATION OF SAMPLE AND TESTING

4.1 SAMPLE PREPARATION

The sample Mix-I was set to have a 1 kg of paper pulp, 8 kg of cement and 1 kg of
sand. Water added varied depending upon the required workability of the mixture. Because of
the limited information and properties of Papercrete, it was not safe to set the amount of water
because the paper pulp already contains water which may vary through the mixture. The
amount of water depended on the workability of the mixture. The cube molds and cylinder
mold used in the experiment have the measure of 150 mm X 150 mm X 150 mm and the
cylindrical molds have the diameter 150 mm with height 300 mm. Paper pulp, cement and sand
were mixed depending on their desired proportions. Water was added to the mix until it reached
the better workability. Adding too much water resulted to a failure and the procedure was
repeated from the starting and measures to accurately determine the amount of water added to
each and every sample specimen was done.

4.2 PREPARATION OF PAPERCRETE CUBE AND CYLINDER

The prepared mix was poured into molds to form cubical blocks and the cylindrical
molds for testing later for compressive strength and split tensile strength. Papercrete mixture
was placed into the metal cylinders and cubical mold to form into its desired shape and size.
After 24 hours of concrete poured in to the molds, the specimens were removed from their
mold and allowed to be cured by soaking them again to a bath of water in preparation for testing
for physical strength.

Fig 4.1 Prepare mix of Paper pulp, cement, sand and water

9
4.2.1 TESTING OF PREPARED SAMPLES:

a) Compressive Strength Test

This research paper was focused on different phases of Papercrete: compressive

strength. For this, the Papercrete specimen was tested for its capacity at compression point.
Sample Specimens are tested after 7, 14 and 28 days to have comparative data on how the
behaviour of Papercrete develops as it matured with time. The prepared specimens were tested
for compressive strength in the laboratory. The test was performed on compression testing
machine (CTM) and the results of various specimens were noted for further analysis.

b) Split Tensile Strength Test

Split tensile strength test was also performed on compression testing machine (CTM)
in the laboratory on cylindrical samples of diameter 150 mm and height 300 mm. These sample
specimens are also tested after 7, 14 and 28 days to have comparative data on how the
behaviour of Papercrete develops as it matured with time (Mindess, 2004).

A cylinder splitting test was used to determine the split tensile strength of the
papercrete. The same data and equipment were used to determine the tensile strength that was
used for the compressive strength test. To determine the split tensile strength of the papercrete,
a cylinder was placed in the actuator horizontally. The actuator was set to load the sample at a
constant load per second. To perform the test, a force was applied to the cylindrical specimen.
When papercrete was compressed, the material had vertical displacement and fractures. The
force and displacement were automatically recorded every 2 seconds. The test was stopped
when the sample fractured.

When the concrete is compressed, the vertical displacement is smallest, and when it
fails, it has an abrupt fracture (Hassoun 2002). In comparison, when papercrete is compressed,
the material has extra displacement and then slowly fractures.

c) Thermal Conductivity Test

The Thermal conductivity of the papercrete was tested to determine its insulation value.
To measure the thermal conductivity a cylinder approximately 2 feet long, with an 8- inch
outside diameter and a 4-inch inside diameter, was made from the papercrete. Light bulbs were
evenly spaced inside the cylinder that provided heat from the inside.Thermometers were placed
on the inside and outside of the cylinder to determine the temperatures.

10
 CHAPTER 5
RESULT AND DISCUSSION

5.1 COMPRESSIVE STRENGTH TEST RESULTS

Prepared samples are tested according to its specific time of settlement containing
different ratio of mixtures from paper pulp, cement, sand and water. Each sample are tested up
to its failure point to determine its capacity whether it can survive large amount of stress
otherwise it would not be part of the recommended ratio to be used for structural construction
purposes

Table 5.1 : Combine results of compressive strength after 7, 14 and 28 days for all Mixes.

No. Mix Compressive Compressive Compressive

strength at 7 strength at 14 strength at 28
days (Kg/cm2) days (Kg/cm2) days (Kg/cm2)

1 Mix - I 44.81 91.31 157.19

2 Mix - II 41.48 77.56 152.96

3 Mix - III 38.81 73.04 139.85

4 Mix - IV 37.04 69.26 125.04

5 Mix - V 36.81 67.56 108.59

Fig 5.1 : Graph of combine results of compressive strength after 7, 14 and 28 days for all Mixes

11
5.2 SPLIT TENSILE STRENGTH OF THE CYLINDER
The split tensile strength test was performed in the laboratory as per the specification
by Indian Standard. The following steps were followed to complete this test.

Table 5.2 : Combine results of split tensile strength after 7, 14 and 28 days for all Mixes

No. Mix Split tensile Split tensile Split tensile

strength at 7 strength at 14 strength at 28
days days days
(kg/cm2) (kg/cm2) (kg/cm2)

1 Mix - I 7.24 15.44 23.48

2 Mix - II 6.84 11.86 18.56

3 Mix - III 6.18 10.07 13.86

4 Mix - IV 5.50 7.52 11.30

5 Mix - V 4.83 6.51 9.95

Fig 5.2 : Graph of combine results of split tensile strength after 7, 14 and 28 days for all Mixes

5.3 THERMAL CONDUCTIVITY TEST OF HOLLOW CIRCULAR

CYLINDER
To measure the thermal conductivity a cylinder approximately 2 feet long, with an 8-
inch outside diameter and a 4-inch inside diameter, was made from the papercrete.

12
 Fig. 5.3 Thermal conductivity test specimen

Light bulbs were evenly spaced inside the cylinder that provided heat from the inside.
Thermometers were placed on the inside and outside of the cylinder to determine the
temperatures. The ends of the cylinder were then sealed with fiberglass insulation. The light
bulbs were turned on, and the temperatures inside and outside were allowed to reach steady
state, which took approximately 5 hours. The steady state temperatures were then recorded.

Fig. 5.4 Light bulb inside cylinder

After the lights were turned on inside of the cylinder, it took approximately 5 hours for
the temperatures to reach equilibrium. The lights were left on for several more hours to ensure
the temperatures stayed constant. A temperature distribution (Table 5.3) across the cylinder
was caused by Papercrete porosity.

Table 5.3 : Thermal Conductivity Testing

Port 1 Poet 2 Port 3 Port 4

Outside Temperature 280C 270C 270C 270C

Inside Temperature 990C 1020C 1020C 1030C

13
 The cylinder was made 2 feet long so that end effects would have minimal effects on
the temperatures. The temperature in the middle section was constant showing that the
temperature loss from the ends did not affect the calculations. The testing shows that the density
of the papercrete affects the thermal conductivity. The temperature increased the most near the
thermometer ports where the density of the cylinder was the lowest. The density effect was
observed from the porosity of the material. A comparison for effect of density on the thermal
conductivity was not thoroughly analyzed; these were merely observations to explain the
testing results.

The reported thermal conductivity for the papercrete was based on the middle section
of the cylinder. The thermal conductivity was 0.17 W. Concrete has a thermal conductivity
between 1.25 and 1.75 W. Papercrete has a much lower thermal conductivity than concrete;
therefore, its insulation value is much higher. The papercrete thermal conductivity is similar to
several other materials (Table 5.4).

Table 5.4 : Thermal Conductivity of Selected Material.

Material kW/(m·K) Concrete

Concrete 0.80

Mortar 0.17

Papercrete 0.0044

Fiber glass Insulation 0.14

Plywood 0.16

Table 5.4 shows that papercrete has great insulating value. Although papercrete must be
approximately 4 times thicker than fiberglass insulation to provide the same thermal resistance,
concrete must be 8 times thicker than papercrete to provide the same thermal resistance.
Papercrete is a very good insulating material.

5.4 FLAMMABILITY TEST IN A CUBE

A flame was applied to a papercrete sample. The flame was applied and the papercrete
did not ignite. The papercrete started to smolder; however, it never ignited. When the flame
was removed from the papercrete there were visible marks where the flame was applied, but
itself extinguished; therefore, papercrete is not a flammable material.

14
 CHAPTER 6
CASE STUDY

6.1 INVESTIGATION OF USING PAPERCRETE MATERIAL

As there is a great demand in the industry for the building materials especially due to
this largely increasing population which has created a paucity of these materials, the civil
engineers all around the world are being challenged to find new alternatives or convert the
industrial waste as an alternative to this paucity age. This study involves experimental
investigation of potential uses of waste paper for producing very low coast and light weight
concrete as a building material. The concrete in this study is prepared using waste paper as one
of the ingredient. In any construction there are several materials required like steel, brick, stone,
glass, clay, mud, wood etc., but utilizing paper in concrete opens many gates for innovation.
Today, cement remains the main ingredient to be used for binding the materials, although
aggregate and other materials remain to act just a filler material where paper can also be
utilized. For the suitability and adaptability, the paper is the best material to be used in
construction industries as it is eco-friendly, conserve resources, economic, protect the
environment and proper utilization of energy [1]. The paper has a very sluggish life as from
the day it is manufactured; it is stored and utilized either for academic or educational purpose
or for packaging purpose. After the usage it is recycled or filled in landfills or burnt as a fuel,
but only 60% of the papers are recycled, mostly are burnt. Using the other 40% as coarse
aggregate is the best possible option for paper industry as its demand will increase, for
construction industry as a cheap alternative is available and for environment.

6.2 HISTORY OF BRICKS

 Bricks are the most commonly used construction materials for the construction of any
structure mostly buildings.
 The bricks are made using the moulds and the clay is used as the main constituent as only
one shape and mould of is used all bricks are of uniform shape and size, after the moulding the
bricks are dried and burned.
 The bricks are uniform in size and shape, they can be properly placed and arranged.
 The brick is one of the oldest building materials and it is exhaustively a leading material in
construction.

15
 The process making the bricks has not changed from many centuries except some minor
changes.
 There is effort being put by the people of industry to enhance the quality of bricks.
 Bricks have two drawbacks one is its self-weight and the other being its brittleness.

6.3 INNOVATION OF PAPER CRETE

Papercrete was discovered 80 years ago as a construction material and is currently being
emphasized. Papercrete consists of waste paper which are fibrous in nature and Portland
cement. Both the constituents are mixed thoroughly and well blended to create a paper cement
pulp, which can shaped using a mould and dried to get a proper papercrete brick which can be
used as a durable building material. Papercrete being rediscovered is relatively as new concept
and has limited scope in construction. Papercrete can be further divided categorising according
to the uses, like Fibrous Cement, Padobe and Fidobe. The fibrous concrete is prepared by
mixing fibrous paper, portland cement and water. There are non-harmful by-products or
excessive energy use in the production of Papercrete- Fibrous Cement.Padobehas no Portland
cement and is a mix of waste paper, water and earth clay, clay is the binding material. Rather
than using thecement, earth is used in this type of bricks.This earth mus thave clay more than
30%.As in regular brick, if the clay content is too high the brick may crack while drying, but
adding fibrous paper to the earth mix strengthens thedryingblock.It gives flexibility which
helps to prevent cracking.Fidobe is similar to padobe, but it may contain other fibrous material
rather than paper.

6.4 MATERIALS & PROPERTIES

The constituents used in preparation of the Papercrete and their properties.For proper
results, ingredients were collected from various sources. Collecting Material is the basic and
important step in any project. Yet, the material that is used in any project should not cause any
harm or damage to the environment.
The various materials include:
 Ordinary Portland Cement
 Flyash
 Fine Aggregate
 Coarse Aggregate

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 Waste Paper
 Water

Table 6.1 Papercrete properties

Physical properties

Mass m 56.6
Density 382.6
Shrinkage [%] 6.00
Available and processibility Waste paper is widely available material.
Easy to process after hardening.
Cost [ \ kg] 0.02 pure mix
0.04 adding colorants and additives

Mechanical properties

Compressive strength [Mpa] 1.12

Flexural strength [Gpa] 0.318
Youngs Modulus E [Gpa] 8
Fracture toughness 0.2
Brittleness Brittle behaviour
Hardness Soft material
Creep Ooh damn, yes

Functional properties

Sound Insulation Good

Thermal conductivity 0.08
Thermal diffusivity 1000
Thermal Expansion coefficient 21000000
Specific heat capacity 1000

Environmental properties

Embodied energy per volume 4700

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6.5 PAPERCRETE BRICKS

The objective of the study is to investigate the properties of Papercrete bricks that were
prepared out of waste paper, quarry dust and Fly Ash in varying proportions of 25%, 40% and
55%. The following properties were studied and a comparative study with conventional bricks
was done:
• Mechanical properties
• Weight comparison
• Quality Standards like hardness, soundness and fire resistance
• Environmental compatibility

6.6 EXPERIMENTAL PROCEDURE

6.6.1 SPECIFIC GRAVITY TEST FOR FINE AGGREGATE AND PAPER PULP

• A clean and dry pycnometer with its cap is taken and weighed in grams (W1).About 200g of
dry sample (quarry dust or paper pulp) passing through it was put in it and gross weight of the
pycnometer and the sand was again taken (W2).
• The pycnometer was then filled with distilled water up to the hole in the conical cap and
shaken gently until all the air bubbles escaped. Then the weight of the pycnometer with the
sand and water was taken in grams (W3).
• The pycnometer was then emptied and cleaned thoroughly. The clean pycnometer was then
filled with distilled water up to the hole in the conical cap and weighed in grams (W4).

Fig 6.1 Specific Gravity test of fine aggregate

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6.6.2 SIEVE ANALYSIS

About 1 kg of dry sample of fine aggregate was taken and sieved on IS sieve number:
470, 240, 60, 30 and 15. This operation was continued until number particles passed through
the sieves finally. Then the material retained in each sieve was collected and weighted. The
results were tabulated and the percentage of fine aggregate of varying size that passes through
each sieve was calculated and recorded. The value obtained was compared with grading limit
chart for fine aggregate and the actual zone, to which particular fine aggregate comes under,
was determined.

Fig 6.2 Graph of sieve analysis for fine aggregates

6.6.3 DETERMINATION OF BULK DENSITY

To find, the bulk density of quarry dust, the following procedure was employed. The
empty weight of the container was taken as Wc. The container was filled with aggregates
sample for about one third height and was tamped evenly with 25 blows. Similarly same
quantities of aggregates were added as second layer and were tamped with 25 blows. A third
layer of aggregate was added until it overflows and was tamped with 25 blows. Using tamping
rod as a straight edge, the surplus aggregate was struck off. Measure the weight W1. The
container was emptied and it was filled again until it over flows using a shovel, aggregates
being poured from a height not exceeding 5 cm above the top of the container.

6.6.4 SPECIFIC GRAVITY OF FLY-ASH AND CEMENT

The procedure to find the Specific Gravity of Fly - Ash/Cement is as follows . Having
taken a clean and dry Le Chatlier Flask with its stopper, its weight was measured as W1. Filling
half the flask with test specimen (fly ash/cement) the weight was measured as W2. Following

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which kerosene was added until it is partially filled. The mixture was mixed using a glass rod
to remove entrapped air. Stirring was continued and more kerosene was added up to the
graduation mark. The weight W3 was measured. Emptying the flask and refilling it with clean
kerosene up to the graduation mark the weight W4 was measured.

6.6.5 QUALITY STANDARD TESTS ON PAPERCRETE BRICKS

This involves the study of various qualities of Papercrete bricks. The presence of
soluble salts was determined by efflorescence test. In which the fibrous concrete brick was
immersed in water for 24 hours. Following which they are kept in shade to dry. Having taken
all the three proportion bricks, the hardness of the brick was determined by making a scratch
on the brick surface. To study the soundness property of the brick, two bricks of same
proportion were struck with each other. By setting a few bricks to fire, it enabled the study on
the fire resistive nature of the bricks. In projects we prefer a simple and easy test that can be
conducted in a very short span of time for certain specifications and to control the quality. The
very thought is that we can make use of rapid chloride permeability test (RCPT). By observing
the quantity of flow of electrical current through a 50 mm thick by 100 mm in diameter sample
for duration of 6 hours, the rapid chloride permeability test was performed. The sample was
cut as a slice of a core or cylinder. Throughout the test a potential difference of 60V DC was
sustained across the electrodes. One lead was immersed in a 0.3 Mcaustic soda (NaOH)
solution and the other in a 3.0% salt (NaCl) solution. A conditional ranking was madefor the
concrete’s permeability based on the charge that passes through the sample. Finally, in
compression testing machine the brick was tested for cracking pattern under different loads.

6.7 RESULTS AND DISCUSSIONS

A number of tests were carried out to study the properties of the brick as per the given
procedure, results of which are as follows –
 Specific gravity test- on conducting this test on fine aggregates for three different samples
the specific gravity was determined as 2.52.
 Sieve analysis– performed on quarry dust, displays a fineness modulus of 2.8.
 Determination of bulk density - conducted on quarry dust, assisted in calculating the bulk
density of compacted quarry dust as 1.7 kg/l and 43% for loaded quarry dust.
 Specific gravity of fly ash and cement – by le chatelier method the specific gravity of cement

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was determined as 3.13 and that of fly ash was 2.33.

6.8 QUALITY STANDARD TESTS

 Efflorescence test – this test resulted in no white or grey surface deposits on the bricks, thus
the bricks are clear from soluble salts.
 Hardness test – the outcome of this test shows that the brick is hard enough with a less
impression due to scratch.
 Soundness test – the clear ringing sound produced shows that the bricks are good.
 Fire resistance- in an open flame the papercrete bricks did not burn. They burnt slowly similar
to charcoal. Although they would be reduced to ashes if kept flaming for several hours. With
the provision of interior plaster and exterior stucco, the papercrete bricks will not burn. Also
application of plaster without any holes or leakage in the bricks and absence of oxygen, will
prevent burning on the inside. We are aware that corrosion of the reinforced steel which is held
within the concrete as a result of chloride intrusion is a major factor that guides to the downturn
of the concrete structures. This is the followed by high cost of repairs which is why this
longevity issue has received widespread awareness recently.
 Rapid chloride permeability test (RCPT) – results noted for chloride permeability as per
ASTM C1202 is high. As compared to conventional bricks, which are highly brittle in nature
and fail as soon as load is applied breaking into multiple pieces, the papercrete bricks never
failed miserably, instead they just compress like squeezing rubber. Thus, for test conducted
under full compression, even at higher load th e structure experiences outer face cracks and
peels out without any structural fail, although papercrete brick failed. Reason being the high
elastic nature at failure which compresses like rubber. The roof collapse as a result of
compression under heavy loading, thus resulting its application for non – load bearing partition
walls alone.

Fig 6.3 Papercrete Bricks during and after fire test

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 CHAPTER 7
ADVANTAGES AND DISADVANTAGES

7.1 ADVANTAGES OF PAPERCRETE

 The equipment used is relatively low-tech and cheap.

 Papercrete has a compressive strength of 0.99–1.12 MPa.

 It has excellent heat and sound insulating properties.

 The Papercrete is lightweight and can be used to make inexpensive roofing options.

 Paper-Crete is very useful and it can be made easily in various sizes such as blocks,
panels, and sheets.

 It does not easily catch fire but catches smugglers for hours.

 They are dimensionally very stable.

 The more cement and mineral content used, the more fireproof it becomes.

 It is recycling paper waste.

 Also, reduces the amount of concrete in construction.

 The lightweight construction material is safe and easy to work with the body.

 Also, suitable for hot/dry climate.

7.2 DISADVANTAGES OF PAPERCRETE

 It cannot be used on doors and windows without some additional support, either wood
or conventional concrete.

 It absorbs water so it should be protected from water during the rainy season.

 Raw materials are very expensive and not freely available.

 It resists rodent and insect infections.

 The R-value is about 2.0 and 3.0 per inch.

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 CONCLUSION

This research work targeted to develop a new eco-friendly and green material which
possibly will be better for the construction activities. With the use of waste and recycled
materials that also came from our nature, discovering its abilities and properties can offer us
new ideas for a cleaner and greener tomorrow. Investigational procedures were executed in
order to characterize the Papercrete building blocks and panels. Significant possible thoughts
that can support the use of this green and eco-friendly material made up of paper pulp can
replace a percentage of cement and sand which are highly commercialized at the present time.
Papercrete is an experimental material which is close to standardization and definite
finalization, that could help in the developmental process of the architectural concepts.
Even though there are only limited information available about this material,
continuous research are held by different people from the different places which chose to
localize their personal concepts and arithmetical values in order for them to accept the unique
concept depending on their situation like climatic condition and other significant conditions.
We conducted several different tests and samples were made with the different proportions and
proportionality in order to attain and determine the most efficient mixture of this newly
developed construction material. Physical, economic, environmental and construction
considerations were also included to have an appropriate description of what is efficient to use
from those tested ratios
Based on the test result of our study, it was concluded the following things:
 The making of light weight Papercrete is very easy, which is significantly 50% lighter
than a conventional concrete specimen containing the same volume
 The workability of the Papercrete mix is visibly identical compared to the conventional
cement concrete mixtures.
 It has a difficult standardization because the behaviors of paper composition or paper
pulp are not that constant and is unpredictable.
 More researches are required to determine the accurate mixture for this challenging
material that could be possibly feasible for development.
 Papercrete in general is a good construction material. The material has restricted
application and properties that are not well predefined up to this instant.
 Using the Papercrete blocks will reduce the self-weight of the structure.
 Papercrete is a non-flammable material.

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