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Engineering properties of insulation material made with cotton waste and fly


ash

Article  in  Journal of Material Cycles and Waste Management · January 2014


DOI: 10.1007/s10163-013-0218-6

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Hanifi Binici Orhan Aksogan


XX University Cukurova University
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Engineering properties of insulation
material made with cotton waste and fly
ash

Hanifi Binici & Orhan Aksogan

Journal of Material Cycles and Waste


Management
Official Journal of the Japan Society of
Material Cycles and Waste Management
(JSMCWM) and the Korea Society of
Waste Management (KSWM)

ISSN 1438-4957
Volume 17
Number 1

J Mater Cycles Waste Manag (2015)


17:157-162
DOI 10.1007/s10163-013-0218-6

1 23
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1 23
Author's personal copy
J Mater Cycles Waste Manag (2015) 17:157–162
DOI 10.1007/s10163-013-0218-6

ORIGINAL ARTICLE

Engineering properties of insulation material made with cotton


waste and fly ash
Hanifi Binici • Orhan Aksogan

Received: 1 August 2013 / Accepted: 25 November 2013 / Published online: 19 February 2014
Ó Springer Japan 2014

Abstract Huge amounts of cotton and fly ash wastes are Introduction
disposed in countries all over the world. The majority of
cotton wastes and fly ash are abandoned. It is a big problem In a thermal power plant, superfine particles are collected
to propose utilization of these by-products from the aspects in electro-filters as they are carried by chimney draught.
of disposal, environmental pollution, and health hazards. They drift with chimney gases and gain pozzolanic prop-
This paper presents a parametric experimental study which erties by immediate cooling upon contact with air. The
investigates the potential use of cotton waste and fly ash in diameters of these spherical-shaped ashes are generally
combination for producing a new low-cost and lightweight between 1 and 100 microns. This pozzolanic material is
composite as a building material. The physical and called ‘‘fly ash,’’ and it is a well known industrial waste.
mechanical properties of concrete mixes containing cotton Millions of tons of fly ash are disposed from thermal power
waste and fly ash are investigated. The compressive plants as waste products. Unfortunately, small amounts of
strength, flexural strength, unit weight, and water absorp- these waste products are used in cement production, dam
tion properties of this proposed material conform to rele- injections, and brick manufacturing. The amount of dis-
vant standards. The thermal insulation test of the proposed posed fly ash is increasing due to indispensable energy
material was also carried out. The cotton waste and fly ash requirements; there are various potential common usage
block house has been found to be superior to the concrete areas of fly ash for many countries such as agriculture,
block house for sustained comfortable indoor temperatures. chemical industries, ground improvement, and various
The process undertaken can be easily applied in classic construction material productions [1, 2].
brick plants. It yields a lighter weight composite having More cohesive concretes can be produced by adding fly
potential to be used for walls as an economical alternative ash as an aggregate, but a viscous material should be used
to concrete blocks, ceiling panels, sound barrier panels, etc. because fly ash decreases the viscosity value of mortar [3].
The aim of using such a pozzolan is to save energy and to
Keywords Cotton wastes  Fly ash  Thermal insulation  provide functional properties to fresh or hardened concrete.
Block The improvement of concrete due to a pozzolan additive
varies according to the mineralogical and chemical struc-
tures, the activity and the amount of the additive, and the
properties of the other components of the concrete. Fly ash
containing large amounts of CaO increases the strength of
H. Binici (&)
concrete at early ages and provides concrete an extremely
Department of Civil Engineering, Kahramanmaras Sutcu Imam
University, Kahramanmaras 46100, Turkey high ultimate tensile strength. A new era has begun in high
e-mail: hbinici@ksu.edu.tr strength concretes by using fly ash with superviscous
materials [4]. Currently, they are generally used in mass
O. Aksogan
concrete production to block thermal shrinkage. They can
Department of Civil Engineering, Toros University,
Mersin 33140, Turkey also be used in dense concrete production due to their
e-mail: aksogan@cu.edu.tr superfine particles [5].

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158 J Mater Cycles Waste Manag (2015) 17:157–162

Fly ash obtained from a thermal power plant should textile factories, but their facilities are faced with the dif-
certainly be considered in material demands for foundation ficulty of removing huge amounts of textile wastes. Dif-
stabilization, concrete production for some infrastructures, ferent textile wastes evolve at the end of different
and cover concrete production [6, 7]. However, it is not manufacturing processes. Cotton waste is the output of the
suitable for cement production due to its inadequate total ginning process in which harvested cotton bundles are
amounts of SiO2, Al2O3, and Fe2O3 (\70 % in weight) and opened up and cleaned to remove the cotton seed before
its high CaO content. Consequently, it causes both storage spinning or any other processing. It is also obtained at the
and environmental problems. It is a versatile and functional end of various processes in spinning mills, especially in the
material to be used in alternative construction materials [8]. harvesting line.
Since the energy consumption and global warming This paper presents a study on a lightweight construc-
problems are becoming more and more of an issue, tion material containing fly ash and heterogenic cotton
researchers have presented many processes to save energy wastes. The engineering-oriented properties of the samples
in residential and commercial buildings. For this reason, were determined experimentally by considering corre-
the use of thermal insulation in buildings is the key tool to sponding Turkish Standards.
control heat transfer in and out of buildings, keep the
interior temperatures at comfortable levels, and maintain
building temperatures appropriately without having to run Material and method
air conditioning or heating systems for long periods of time
[9, 10]. Increased energy consumption and environmental Material
pollution is a big challenge we are facing in the 21st cen-
tury. The fossil fuel supplies are depleting daily due to a In this study, cotton waste and classless fly ash were used
drastic increase in demands from which major environ- as aggregates in building material production. Cotton
mental pollution results [11]. Particularly, this has become wastes were supplied from textile factories (Fig. 1).
a pressing issue in developing countries such as China, Fineness of fly ash was determined as 3600 cm2/g after
which has become the second largest global energy con- passing it through a 200 micron sieve. The foregoing
sumer and carbon dioxide emitter [12]. As the largest materials were blended with cement known as CEM I. The
building component, the thermal insulation materials play chemical contents and physical properties of fly ash and
an important role in achieving energy efficiency in build- cement are given in Tables 1 and 2, respectively.
ings [13].
Textile wastes are end products that cannot be repro- Method
cessed to manufacture any textile surface. There are many
Fly ash has a bright appearance due to its glassy structure.
It is very fine and passes through the chimney filters of a
thermal power plant. In this study, different amounts of fly
ash and cotton waste were mixed with cement and water.
Standard properties and compressive strengths of samples
were tested after they had been cured for 28 days. Cotton,
being an organic material, is susceptible to corruptive
bacteria that could generate in the resulting mixture.
Hence, an anti-bacterial agent was used in order to over-
come this problem. Mixing ratios of different compositions
are shown in Table 3.
With these different compositions, blocks were pro-
duced with 5 9 9 9 19 and 10 9 20 9 40 cm molds. The
appearances of these blocks are seen in Fig. 2. In the
Fig. 1 Cotton waste used in this study mixing process of the samples, fly ash, cement, and cotton

Table 1 Chemical contents of fly ash and cement (% by weight)


Material SiO2 Al2O3 Fe2O3 CaO MgO K2O Na2O SO3 Loss on ignition

Fly ash 18.30 9.20 3.22 53.46 1.76 0.37 0.20 11.42 2.20
Cement 19.40 5.36 3.79 64.30 2.25 0.90 0.09 2.47 1.22

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J Mater Cycles Waste Manag (2015) 17:157–162 159

waste mixes were placed in a concrete mixer and mixed for Physical properties and water absorption capacities of
5 min. To obtain more homogeneous mixes, the correct the blocks were tested by considering TS 2823 [14] and
amount of water was then sprayed by an air pump on the ASTM 67-03 [15] standards, respectively. Thermal con-
mixes while the mixer was turning. Then, fresh mortar was ductivity properties of the samples were determined
poured into steel molds, and 40 tons compressive force was according to TS 415 [16]. Furthermore, 105 9 90 9 75
applied for 2 min to compact the mortar in the mold. After and 105 9 225 9 75 mm samples were prepared in order
2 days the block samples were removed. Then, following a
10-day curing process, the samples were dried in the oven
at 110 °C. Two different model houses were constructed
with dimensions 1 9 1 9 1 m to compare their perfor-
mances. One of them was built with cotton waste and fly
ash blocks and the other was constructed with standard
concrete blocks (Figs. 3, 4).
During this experiment, the houses’ outdoor temperature
inside the laboratory was kept constant at 15 °C by
checking it frequently to avoid temperature changes. Both
houses were heated from inside with a temperature regu-
lator for 150 min. The internal temperatures of the model
houses were recorded at the center of the floor.

Table 2 Physical properties of fly ash and cement


Fig. 3 Model house constructed with cotton waste and fly ash blocks
Material Specific Specific Fineness
weight surface
(g/cm3) (cm2/g) Residue on Residue on
200 lm (%) 90 lm (%)

Fly ash 2.32 3600 0.31 1.69


Cement 3.10 3250 0.23 1.53

Table 3 Designation of mixtures


Series Components (g)
Fly ash Cement (CEM I) Cotton waste Water

A 400 300 200 490


B 500 400 200 520
C 400 500 100 520
D 500 400 100 450
Fig. 4 Model house constructed with concrete blocks

Fig. 2 Different sizes of cotton waste and fly ash blocks

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160 J Mater Cycles Waste Manag (2015) 17:157–162

to measure their compressive and bending strengths, absorption tests of the samples and cotton content values
respectively. are directly proportional. The results of water absorption
tests ranged from 29 to 34 %, which is acceptable for
lightweight construction materials (maximum water
Results and discussion absorption for lightweight construction materials is
required to be 35–40 % by the Turkish standard). The
Table 4 shows the average test results obtained during this coefficients of thermal conductivity of specimens tested
experiment. The compressive strength values of specimens ranged from 0.231 to 0.260 (kcal/hm2 oC), which is satis-
tested in the present study ranged from 9.35 to 14.40 MPa, factory for insulation building materials.
and these are higher than those required by the Turkish Generally, there was a direct relationship between the
standard (the minimum compressive strength value of thermal conductivity coefficient and specific weight (see
insulation materials should have 5 MPa according to the Fig. 5). Thermal insulation performance of the light test
Turkish standard). The obtained test results show that sample was poorer than those of the others (see the result
according to the minimum flexural strength requirements for sample A). On the other hand, sample C, containing
of the Turkish standard, the high compressive and flexural large amount of cement, had the highest compressive
strengths of the samples render it possible to decrease the strength but also the lowest bending strength. Internal
thickness of walls substantially. The results of water temperature values of the model houses are given in

Table 4 Results of compressive and bending strength tests


Samples Compressive Bending strength Specific weight Water absorption Coefficient of thermal
strength (MPa) (MPa) (kg/m3) (%) conductivity (kcal/hm2 oC)

A 9.35 2.93 740 29 0.230


B 13.25 2.81 757 32 0.232
C 14.40 2.39 788 32 0.260
D 13.60 2.44 799 34 0.261
Average 12.40 2.64 771 31.75 0.245

Fig. 5 Thermal conductivity 1600


Coefficient of thermal conductivity

0,4
0,325

coefficients and specific weights

1200
of samples
Specific weight (dry)(kg/m 3)
0,261
0,2392

0,26

0,3 1200
0,23
(kcal/m 2 h°C)

799
788
757
740

0,2 800

0,1
400

0
C
A

0
Concrete
Blocks

Concrete
Blocks

Table 5 Temperature variation in the model houses


Model house Heating Temperature Temperature Total temperature
time (min) after 30 min (oC) after 150 min (oC) change (oC)

Concrete blocks 30 45.3 27.4 17.9


Cotton and fly ash blocks 30 60.2 49.6 10.6

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Fig. 6 Variation of 65
temperature in model houses
60
55
50

Temperature (°C)
45
40
35
30
25
20
15
0 5 10 15 20 25 30 40 50 60 90 120 150 180
Time (min)

Concrete blocks Cotton/fly ash

Table 5, and temperature changes in them are given in well as help to keep the environment clean. The best use
Fig. 6. of it will be as an insulator in external panels and
The use of insulation materials has been a major issue in ceilings.
today’s construction industry as it aims to conserve energy. Huge amounts of cotton and fly ash wastes are disposed
The present study demonstrated potential uses of cotton in countries all over the world. The majority of cotton
and fly ash bricks in pursuit of this aim. The thermal wastes and fly ash is abandoned and can cause serious
conductivity variations of cotton bricks showed a similar environmental problems. An environmentally friendly
trend to their density variations (see Fig. 5). Hence, using thermal insulation material, cotton wastes and fly ash mix,
cotton bricks with lower densities will prevent energy loss was used without resins and other chemical additives.
from buildings. Block samples with sizes of 105 9 90 9 75 and
The variations in temperature inside the model houses 105 9 225 9 75 mm were bonded by cotton fibers and fly
after 30 min of heating and 150 min of cooling are given in ash during pressing. Based on measurements of thermal
Fig. 6. Despite the decrease in temperature for the concrete conductivity of the blocks, the material proved to be an
house, in general, the improvement is even better, because excellent insulating component for building construction,
the difference of the temperature for the cotton/fly ash especially used in walls for energy conservation. The data
house in comparison to that of the laboratory is much indicate a positive relationship between thermal conduc-
higher than that for the concrete house. tivity and density. The thermal conductivity coefficients of
the insulation blocks with density of 740–799 kg/m3 ran-
ged from 0.230 to 0.260 kcal/m2h oC. Since these blocks
Conclusion are made from natural and renewable raw materials and
without any chemical additives, it is an environmentally
In this work, insulation applications of lightweight con- friendly material and can successfully compete with other
struction materials containing different amounts of fly insulation materials.
ash, cotton waste, and cement were experimentally The advantages of composite blocks made with cotton
studied. The results show that fly ash and cotton waste wastes and fly ash can be summarized as below.
can be used together in producing a construction material
1. These blocks have a perfect insulation property.
with very good insulating properties. There was a negli-
2. Their compressive and bending strength properties are
gible heat loss inside the model house built with blocks
good enough for use as a construction material.
made using cotton waste and fly ash mixed with cement.
3. Their use helps decrease environmental pollution.
It was observed that the thermal conductivity coefficient
4. They can be used perfectly as wall material because
of the composite blocks was 29 % less than that of the
these composite blocks can be manufactured in desired
concrete ones. This comparison explains the rapid heating
dimensions.
of the model house constructed with cotton waste and fly
ash blocks. Using the proposed composite material will By decreasing building weight, damages and casualties
economically provide better insulation to buildings as can be reduced in case of an earthquake. Hence, this

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