RECYCLED PAPER

CEILINGS

Propose to - Project 1: Better house construction and

Project5: An alternative use for waste materials

Signature

Members :

Fernando B.A.V.W.
R.A.T.Dasun
Abeysinghe A.A.C.
Hirimburegama C.J.
Hettiarachchi T.L.

(EN13523756)

..

(EN13541026)
(EN13506544)
(EN13531362)
(EN13546458)

....
..
..

SRI LANKA INSTITUTE OF INFORMATION TECHNOLOGY

DESIGN AND PROCESS GROUP PROJECT. SEM1

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Executive Summary
PROBLEM DEFINITION

Due to the increase of the population day by day, the housing constructions
also will be increased. Mainly natural wood used as a material of make
ceilings in past days. Although the constructions referred to walls and other
civil basics came with different concepts but the ceiling constructions did
not. So as a result deforestation issue happens largely in present. And people
came up with different ceiling concepts but with high cost and usings of
rare and valuable resources like wood, gypsum etc.

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Team Reflection

Initially at the beginning, its very hard to work as a team with unknown different
students with different ideas and creativenesss. So it was the main obstacle that
we faced at the beginning of our project.
But after some days. working throughout on our proposal, people shifted to
work as a team and get responsibilities by their own. All the team members get
each others contacts and also used Facebook and e-mailings to communicate our
individual ideas and other implementations with each other. At the end of the
day(project), we seriously realized that everybody is fulfill of their own different
ideas, that are necessary to have with an Engineer. And also some people got
extraordinary skills in particular objectives.
At the beginning we got 3 project proposals. And we decided to work on with the
best one, after a team discussion. This was a great experience to work with four
another four different people who met for the first time.
And during our project the most enjoyable part was our site visit. We went it like a
trip and enjoyed a lot in there. We got a chance to share experiences with civil
engineers, workmen and people in that construction site. We had several new
experiences and knowledge about constructions happening there. Finally it ends
up with nice memories.

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Table of Contents
EXECUTIVE SUMMARY

TEAM REFLECTION

TABLE OF CONTENTS

LIST OF FIGURES

1. PROBLEM DEFINITION

1.1
1.2
1.3

7
7
8

2
2.1
2.2
2.3
3
3.1
4

PROBLEM SCOPE
TECHNICAL REVIEW
DESIGN REQUIREMENTS
DESIGN OPTIONS
DETAIL OF OPTION 1
DETAIL OF OPTION 2
OPTION SELECTION
DESIGN DESCRIPTION
MANUFACTURING PROCEDURE
DESIGN DESCRIPTION SUPPORTING DOCUMENTS

9
9
9
9
9
9
10

4.1 MANUFACTURING PLAN (PRODUCT)

4.1.1 MANUFACTURING OVERVIEW
4.1.2 PART DRAWINGS
4.1.3 BILL OF MATERIALS
4.3 DISCUSSION
4.3.1 STRENGTHS AND WEAKNESSES
4.3.2 NEXT STEPS

10
10
10
14
14
14
15

15

EVALUATION

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5.1
5.2

6.2
6.3

EVALUATION PLAN
EVALUATION RESULTS

15
15

EVALUATION SUPPORTING DOCUMENTS

16

COST ANALYSIS
REGULATORY AND SAFETY CONSIDERATIONS

16
16

REFERENCES

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17

List of figures
Figure 1.10
Figure 2.11
Figure 3.11
Figure 4.12
Figure 5.12
Figure 6.13
Figure 7.13
Figure 8.15

Materials and goods we need to make the object

Refuse paper (most likely newspapers)
White Portland cement
A polypropylene fiber sheet
Water
A wood or metal structure

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Introduction

1. Problem definition

1.1

Problem scope

In the middle of the twentieth century, the world showed a rising interest in
the industrialized reuse of elements based on vegetable fibers (paper and cardboard). This was a
reaction to the accelerated reduction of the worlds forest reserves.
Paper and recycled cardboard have been used in order to avoid excessive use of traditional wood
materials and to avoid deforestation.
As a solution to these problems, the idea of the RECYCLED PAPER
CEILING was chose.
An obvious use of waste material is to reuse them in some way, and in that case the best chosen
seems to be alternative choice seems to be alternative construction materials for building houses.
The idea of the RECYCLED PAPERCEILING was to build an environmentally friendly and low
cost ceiling.

1.2

Technical Review

The main purpose of this design is to reduce deforestation and to obtain the
maximum usage from the waste materials like newspaper we use daily. In case of another
product available in the market called Malaysian ceiling need gypsum and cement in a larger
amount. So gypsum is an expensive thing and cant found simply as refuse papers. Gypsum is a
re-product of cement. And doctors investigated that there is a possibility to causing lung cancers
when people breathe the dust of Malaysian ceilings.

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1.3

Design requirements
REQUIREMENT

WHY ITS IMPORTANT?

Cost of materials
Our target is to build a
economical and a high strength
ceiling. Cost of materials
directly impact our overall cost
therefore its a important
requirement

SOURCE

Internet.
Local hardware stores

Material availability

Whatever our plans may be thy

becomes useless unless there
are enough materials in the
local market to match our
product .therefore this is a
important issue.

Internet
Local retail & wholesale
dealers.

Government
regulations

To carry out any development

project a proper authorization is
required. Thats why its a
important aspect.

Regulatory frameworks

The design had to meet the following requirement.

Should have no contact with water
The ceilings need to have no contact with water. Because it can cause damages.

Environmental friendly design.

Must be cost effective.

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1.4

Detail of Option 1

RECYCLED PAPER CEILING are panels made of recycled paper, polypropylene fibers, and
white Portland cement. The panels are used to make interior walls and ceilings.
Recycled paper and water are subjected to a process of mixing and blender for 8minites. Then
remove excess water and mix white Portland cement in a ratio of 1:4 by weight. Under the
pressure 5mm thick layers are made.
Then, a reusable reinforcement of polypropylene fibers is extended over the initial layer made of
mixture. After that, a second 5mm thick compacted mixture is added on top. Finally the
thickness of the sheet is 15mm.

1.5

Detail of Option 2

Recycled paper and water are subjected to a process of mixing and blender for 8minites. Then
remove excess water and mix white Portland cement in a ratio of 1:4 by weight. Under the
pressure 15mm thick layer are made.

1.6

Option Selection

In option 1 with the combination of materials used it gives more mechanical strength and
cohesion.

Design Description

2.1.1

Manufacturing Procedure

First a layer of recycle papers is designed.

Secondly lay a fiber layer over the recycle paper layer.
Then over that lay another layer of recycle papers.

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Design Description Supporting Documents

3.1

Manufacturing Plan (Product)

In the manufacturing of Recycled paper ceiling, recycled paper and water are subjected to a
process of mixing and homogenization in an industrial blender for 8 min. This produces paper
pulp.
Subsequently, the wet paper pulp is compacted under a hand press to remove excess water until
it reaches about 60% water content. Then, the Portland cement is mixed with the recycled paper
pulp in a ratio of 1:4 parts by weight.
Recycled paper ceiling is fabricated in two stages. Each stage consists of a discharge of the
mixture (paper pulp, cement, and water) under pressure to form a compact layer.
Originally, a layer of uniform compacted mixture of 5 mm in height is poured on a flat and
smooth surface. Then, a reusable reinforcement of polypropylene fibers is extended over the
initial mixture layer from sacks to generate greater stability in the material. Finally, a second
5mm thick compacted mixture is added on top. Recycled paper ceiling obtains a final thickness
of approximately 15 mm.

3.1.1

Manufacturing Overview

First the recycle papers are put in to water and keep it there for about two days. Then it is
blended about 8 min and get that mixture out without water by hand pressing. Then cement is put
to the mixture in 1:3 ratio and mix it up. Next that layer is put into the frame under the pressure
1.2kpa and then over that lay another layer of fiber. Over that lay another layer of recycle papers.

3.1.2

Part Drawings

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Figure 1: top view

Figure 2: Right view

Figure 3: Section View

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Figure 4: Section View

Figure 5: Isometric view

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Figure 6: Front view

Figure 7: Front view

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3.1.3

Bill of Materials

Papers
Portland cement
Polypropylene fiber sacks

3.2 Discussion
3.2.1

Strengths and Weaknesses

Our objective was to design an ecofriendly economical ceiling design using waste
materials (recycled paper). Our design is a success because we were able meet our objectives.
But there are strengths and weaknesses in our design. When looking at the strengths our design is
Economical
Our materials used are low cost and even the construction procedure is simple there for even the
labor cost is low. Therefore its range of price comes within an affordable range for low income
holding families.
Materials used
All of the materials we used are either ecofriendly or a waste material especially the paper and
polypropylene fiber .so in this aspect we have achieved our objective.
Unique design
Because of using a polypropylene fiber layer between the paper pulp-cement mixes gives some
extra stability in the material.

So looking at the weaknesses of the design:

Storage
The thickness of the sheet is too large when comparing the normal grey ceiling sheet. This is a
limitation when it comes to mass storage.
Weight
Because the thickness is high the weight could also go higher than the regular one. This could
effect when placing the ceiling sheet to the roof
Other limitations
Contact with the water can reduce the strength of the ceiling sheet which is also a limitation for a
regular ceiling sheet.
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And that can also definitely reduce the lifetime of the sheet
3.2.2

Next Step
As the next steps we could try mixing some hay with the pulp mix, it will reduce the
cost of paper somehow, but what will it effect to the existing strength should be
evaluated or tested. And also the mixing ratio also should be considered.
In this project we used two layers of pulp-cement mix and a polypropylene fiber
layer in between, as a next step using three pulp-cement mix which will a small
amount than the previous one and applying two polypropylene fiber layers in
between those two. In this step also have to consider the points before do it.
Placing a plastic or polythene coat over the sheet can reduce the effect when contact
to the water.
This also tested before mass production.

4
4.1

Evaluation
Evaluation Plan

Cost of materials the plan to evaluate this is to get quotations from suppliers and compare it
with the last actual price.
Material availability- checking the local markets and from available sources.
Government regulations-present the plan to local authorities.
4.2

Evaluation Results

Combustion test
This test is performed on prototypes of 0.25 m x 0.25 m to determine the capacity of thermal
conductivity of the material, the point of ignition, combustion and calcination. A type K
thermocouple was used to calculate the combustion temperature of Recycled paper ceiling.
Points of ignition, combustion and calcination were identified [1214], see Fig. 8 and Table 8.

Figure 8

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Prototype temperature
Ignition
150

Temperature (0C)
Calcination
230

Combustion
300

Figure 8. Recipanel fire test

5
5.1

Evaluation Supporting Documents

Cost Analysis

components

units

Papers
Portland cement
Polypropylene fiber sacks
Other(water,electricity,machinery,labour.)

8 kg
2 kg
2

Price per
unit
20
20
25

cost

Total

350

160
40
50
100

When we do this in vast production we can get all these materials at low cost. Then the cost for a
ceiling sheet gets even low.
Normal price of a ceiling
The price of our new product
Therefore the cost effectiveness-of our ceiling

5.2 Regulatory and Safety Considerations

When creating the prototype following safety precautions were taken
Full cover goggles were used to prevent the dust, cement dust Contacting the eyes
Waterproof gloves were used to avoid the cement pulp mix to contacting the hands
Overall kits were used to prevent cement mix contacting the body and skin
Pairs of rubber boot were also used to avoid contacting cement mix with the foot
A ph. Neutral soap was also used to wash the body after the work is done.

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6 Conclusion
Our first aim is was to do a design that doesnt affect environment. So when we
think about all the topics, low cost housing & creating a new design from waste
materials is the best topics weve seen according to our aim.
These days when constructing buildings & houses, ceiling is one of the main things
we have seen. This is mostly made of wood so it causes for the vast deforestation
as today constructions are high. So we made a solution making a ceiling of recycle
papers. So from this design we have found a solution to this problem and also this
a good solution for high cost ceilings made of cement.

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REFERENCES
Linbachiya, M. and Roberts J. Construction and demolition waste. Thomas Telford, London,
2004.
Anink, D., Boonstra, C. and Mak, J. Handbook of Sustainable Building. and Environmental
Preference Method for Selection of Materials for Use in Construction and Refurbishment.
Editorial James and James Ltda, London, 1996.
Muoz, A., Chejne, F., Espinel, J. and Londoo, C. Evaluation of the cellulose of paper and coal
ashes, like alternative insulating materials. Dyna, Ao 73, 148, pp. 1-8, 2006.

http://www.cement.org/basics/concretebasics_working.asp
http://www.housingauthority.gov.hk/en/common/pdf/businesspartnerships/resources/pictorialguide/EngChapter11.pdf

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