i

EVALUTION OF BAMBOO-EPOXY COMPOSITE AS A POTENTIONAL MATERIAL

FOR SOUND-PROOF ROOFING SHEET

A PROJECT SUBMITTED IN PARTIAL FULFILLMENT OF

THE REQUIREMENTS FOR THE DEGREE OF

Bachelor of Engineering (B.Eng.)

In Materials Science and Engineering

Of the

Kwara State University (KWASU), Malete, Kwara State, Nigeria

By

ZAKARIYYAH KEHINDE MARIAM

Matric No.: 11/67MS/001

May, 2016

Supervisors: Dr. Emmanuel Kwesi Arthur

Engr. Sefiu Adekunle Bello

ii

DECLARATION

I ……………………………………………………………………… hereby declare that the

research work titled ―Evaluation of Bamboo Epoxy Composite as a Potential Material for Sound-

Proof Roofing Sheet‖ is carried out by me and it is genuine to the best of my knowledge. All

cited works have been referenced appropriately.

Signature: ………………………………. Date: …………………………..

iii

CERTIFICATION

EVALUTION OF BAMBOO-EPOXY COMPOSITE AS A POTENTIONAL MATERIAL

FOR SOUND-PROOF ROOFING SHEET presented by ZAKARIYYAH KEHINDE

MARIAM (11/67MS/001) has been approved and found that it meets the College of

Engineering requirement for the award of Bachelor of Engineering (B.Eng) in Materials Science

and Engineering.

............................................ …………………………….

Dr. E. K. Arthur Date

(Supervisor)

…………………………….. ……………………………..

Engr. Sefiu Adekunle Bello Date

(Co-Supervisor)

………………………………… ……………………………….

Prof. A.G.F. Alabi Date

(Head of Department)

iv

DEDICATION

This project is dedicated to Almighty ALLAH, to my beloved mother ALHAJA K.

S. SAKA and my siblings for their love and support.

v

ACKNOWLEDGEMENTS

Firstly, I will like to give thanks to Almighty Allah for making this research to be a successful

one. I would like to express my sincere gratitude to my supervisor, Dr. Emmanuel Kwesi

Arthur for his supervision, guidance, support, encouragement and endless optimism during my

researches, his wide knowledge and logical way of thinking have been great value for me and his

support and providing me some facilities I cannot avoided.

I wish to give my warm and sincere thanks to my co-advisor Engr. Sefiu for his support,

suggestions and advices during my studies; I would like to acknowledge Dr. Mustapha Kabiru

and College of Engineering Laboratory Technologists for their immense support and guidance.

I am extremely thankful to Prof. A. G. F. Alabi, Head of the Department, Materials Science and

Engineering, for providing all kinds of possible help and advice during the course of this work. I

would also like to thank the all Materials Science and Engineering Department and all the staff

members.

Furthermore, I would also like to thank the department of Mechanical Engineering laboratory for

providing all kinds of help and during the period of this project.

Finally, I would like to thank my siblings, colleagues, friend such as Taiwo, Tolu, Khenny,

Rofiat, Latifat, Umar, Tobi, Victor, Adeola, Wumi, Medinat, Bimbola, for their support and

motivation to complete this project.

vi

ABSRACT

The desire for sustainable materials increased investigations into bamboo fiber/particulate epoxy

composite use as a potential material for sound-proof roofing sheet and improving their

capabilities with natural fibers/filler for reinforcement for a corrugated roofing sheet. This work

focuses on reinforced epoxy matrix composites as a potential roofing sheet to reinforce epoxy

resin matrix with bamboo fiber/particulate. Both physical and mechanical properties of bamboo

fiber/particulate-epoxy composite relevant to roofing materials were studied. Also, the chemical

degradation of the bamboo epoxy formulated composite in the presence of some selected media

was investigated. The sonorous behavior of bamboo-epoxy composite roof material was also

investigated. The bamboo-epoxy composites were found to exhibit good mechanical and

physical properties. The bamboo-epoxy composites with alkali treated bamboo fibers were found

to possess higher flexural properties

vii

TABLE OF CONTENTS

Contents CERTIFICATION ....................................................................................................................................... iii

DEDICATION................................................................................................................................................. iv

ACKNOWLEDGEMENTS ................................................................................................................................ v

ABSRACT ................................................................................................................................................... vi

1.0 INTRODUTION ........................................................................................................................... 3

1.1 Objective ......................................................................................................................................... 5

1.2 Scope of Study ................................................................................................................................ 6

1.3 Problem Statement .......................................................................................................................... 6

2.0 LITERATURE REVIEW ................................................................................................................... 7

2.1 Epoxy Resin .................................................................................................................................... 9

2.3 Polymer Matrix Composite ........................................................................................................... 10

2.3.1 Matrix ......................................................................................................................................... 11

2.3.2 Polymer Matrix .......................................................................................................................... 12

2.3.3 Properties of the Matrix ............................................................................................................. 13

2.4 Bamboo as a Reinforcement Material ........................................................................................... 13

2.5 Bamboo Fiber ................................................................................................................................ 14

2.5.1 Chemical Extraction ................................................................................................................... 15

2.5.2 Mechanical Extraction ............................................................................................................... 15

2.6 Application of Bamboo Fiber Epoxy Composite .......................................................................... 16

CHAPTER THREE .................................................................................................................................... 18

3.0 METHODOLOGY ........................................................................................................................... 18

3.1 Composite Design ......................................................................................................................... 19

3.1.1 Preparation of Composite ........................................................................................................... 19

3.2 Extraction of Bamboo Fibers ......................................................................................................... 20

3.2.1 Chemical Method ....................................................................................................................... 20

3.2.2 Fiber Treatment .......................................................................................................................... 20

3.2.3Epoxy Composites Preparation ................................................................................................... 21

viii

3.3 Tensile Test ................................................................................................................................... 22

3.4 Water Absorption Test .................................................................................................................. 23

3.5 Thermal Conductivity Test ........................................................................................................... 23

3.6 Chemical Resistance ..................................................................................................................... 24

3.7 Flexural Test ................................................................................................................................. 25

3.7 Optical Microscopy ....................................................................................................................... 25

3.8 Sound Proof Test ........................................................................................................................... 26

CHAPTER FOUR ................................................................................................................................... 28

4.0 RESULTS AND DISCUSSION ................................................................................................... 28

4.1 Mechanical Properties ................................................................................................................... 29

4.1.1 TENSILE STRENGTH RESULT ....................................................................................................... 29

4.1.2Flexural result ............................................................................................................................. 31

4.2 Physical Properties Result ............................................................................................................. 32

4.2.1 Thermal Conductivity Result ..................................................................................................... 32

4.2.2 SOUND PROOF RESULT ........................................................................................................ 33

4.3Transmittance ................................................................................................................................. 34

4.10 Optical Micrographs ................................................................................................................... 37

CHAPTER FIVE .................................................................................................................................... 38

5.0 Conclusion and Recommendation .................................................................................................... 38

5.2 Recommendation .......................................................................................................................... 39

1

LIST OF FIGURES

Figure 1: Application of Bamboo Fiber Epoxy Composite ........................................................................ 17

Figure 2: organogram for experimental work ............................................................................................. 18

Figure 3: (a) sample for tensile testing of fiber (b) tensile tests were conducted using a testing machine. 22

Figure 4:immersion of composite (a) particulate, (b) fiber. ........................................................................ 23

Figure 5:Chemical degradation test for composite sample immersed in (a) NaOH (b)NaCL (c) HCL (d)

acetic acid.................................................................................................................................................... 24

Figure 6: The flexural strength and flexural modulus (a) before bending (b) after bending. ..................... 25

Figure 7: (a) the composite sample (b) optical microscopy equipment. ..................................................... 26

Figure 8: (a) prototype house for sound proof test (b) sound meter software ............................................. 27

Figure 9:(a) engineering drawing of the prototype mould (b) top halve of the prototype mould (c)bottom

halve of the prototype mould ...................................................................................................................... 28

Figure 10: (a) tensile strength bar chart (b) elastic modulus bar chart ........................................................ 30

Figure 11: (a) flexural strength bar chart (b) flexural modulus................................................................... 32

Figure 12: sound intensity result for (a) galvanized (b) bamboo epoxy composite (c) aluminum ............. 34

Figure 13: (a) transmittance for fiber 10(b) particulate .............................................................................. 35

Figure 14 : the histograms plot against the weight again and the composite formulation .......................... 36

Figure 15: chemical degradation of different chemical for (a) 24 hours (b) 48 hours .............................. 37

Figure 16: optical images of different weight percent of composite (a)1 wt.% F (b) 3 wt. %F (c)5 wt.% F

(d) 5 wt. % P (e) 10 wt.% P (f) 15 wt.% P (g) 20 wt.% P. .......................................................................... 38

2

LIST OF TABLES

Table 1: Composite design …………………………………………………………………..19

Table 2: Thermal conductivity result ………………………………………………………..31

3

CHAPTER ONE

1.0 INTRODUTION

The increase in environmental consciousness and community interest, the new environmental

regulations and unsustainable consumption of petroleum, led to thinking of the use of environmentally

friendly materials. Natural fiber/filler is considered one of the environmentally friendly materials

which have good properties compared to synthetic fiber [1], i.e., fiber/fillers coming from recyclable

sources. The natural fiber composites, also known as green composites, have shown a growth of

interest because of their recyclability, biodegradability and abundant availability.

Nowadays, due to technology development and environmental situation, noise and

vibration have become a serious environmental problem. Demand on the sound absorptive

materials increased consistently to the industrial development. There are varieties of materials

that used for sound absorption materials, affordability, low rate of CO2 emissions to the

atmosphere, and small energy and water consumptions are some of the parameters that have to

be taken into consideration when a product is designed [2]. Using green building materials which

are renewable, local and abundant is a solution that contributes to achieve these important goals.

Virtually all building constructions require roofing materials and this has led to high

demand of roofing materials. The extensive use of roofing materials in many diverse fields has

made investigators/researchers to study different materials [3]. The most widely used roofing

materials are metals such as aluminum and galvanize steels. However, the energy for extraction

of the primary raw material used in aluminum roofing sheet is high and there are strong social

and economic pressures to conserve energy due to many demands. The conventional metal roof

does not have any insulation properties layer to provide good noise and vibration insulation from the

impact of rain. Most of the houses used asbestos board for ceiling and there is no solid medium

4

between the ceiling and the roof to provide the noise and vibration insulation. New idea was

proposed to design a new solution for this matter especially low cost housing areas that used metal

roof because it is cheap compared to brick roof. Metal type roof has very high percentage to rain

noise and vibration exposure. Noise and vibration exposure make the residents feel uncomfortable.

Educational institutions, commercial buildings, theatres and stadium which utilizes metal roofing

faced the same problem of rain impact noise and vibration especially during heavy downfall. When it

rains, the raindrops excite the metal roof panels through random impact force and as a result, the

metal panels resonate and generate high level of noise and vibration, especially during heavy

downpour.

In past few decades, natural fiber composite has got immense exposure. Natural fibers are hair-

like materials primarily composed of cellulose, hemicelluloses and lignin [4]. These natural fibers

provide a substitute for glass fibers and other constituent synthetic fibers (e.g., nylon, polyester, acrylic

and polyolefin). Natural fibers are superior to glass fibers as they are less polluting, light in weight

resulting improved fuel efficiency than that of glass fibers [5]. The most important advantage of

natural fiber is that they are renewable and bio degradable. Not only from nature‘s point of view but

also they are profitable for providing high strength, low weight, corrosion resistance and low

processing cost. The major disadvantages of natural fibers are including moisture absorption, thermal

degradation, fire and UV (ultraviolet). But this can be dealt by maintaining proper blend ratio of

chemical additives, using UV stabilizer and fire retardants [6]. Various properties and application of

many natural fibers including bamboo, sugarcane, curaua, date palm, jute, sisal, hemp and wood are

studied by different researchers. Bamboo fiber-reinforced composites have shown better mechanical

properties (flexural strength and tensile) than the glass fiber-based composites [5, 6]. Curaua fibers

have also shows higher mechanical property [7]. The study of Arundo Donax fiber/fillers-epoxy

composites shows that the size and content of Arundo Donax fillers yields higher tensile modulus,

5

flexural modulus and lower strength properties of the matrix [8]. The date palm wood flour/glass fiber-

reinforced hybrid composites of recycled polypropylene show improved mechanical properties as well

as thermal properties [9, 10]. The flexural modulus of coconut fiber polypropylene matrix composite

can be improved by using adequate fiber granulometry and extruder screw speed and that of agave

fiber-reinforced epoxy composite were significantly high due to alkali treatment of the fiber [11, 12].

The flexural strength and tensile strength of date wood palm flour-based polyethylene

composite were decreased by increasing the filler content, while the flexural modulus was increased

[13]. The tensile behavior of jute epoxy laminated composite shows that the tensile strength of jute

fiber influences the property of composite [14]. Almost all of the commonly available natural plant

fibers that are cheap and abundant in nature are being used for reinforcement in combination with non-

biodegradable matrix materials such as unsaturated polyester, epoxy resin polyethylene and

polypropylene [15]. Among these, epoxy resins are very versatile in nature. They are one of the most

important classes of thermosetting are widely used as matrices for fiber rein forced composite

materials and as structural adhesives. They are amorphous, highly cross-linked polymers and this

structure results in these materials possessing various desirable properties such as greater tensile

strength and modulus, flexural testing, fire flammability, and water absorption [17]. In order to

improve on the corrugated roofing sheet, an epoxy was reinforced with bamboo particulates and fibers

and its physical, chemical and mechanical properties were investigated.

1.1 Objective

The specific aim of this project is to investigate the suitability of bamboo fiber/particulate reinforced

epoxy matrix composites as a potential roofing sheet.

1. To reinforce epoxy resin matrix with bamboo fiber/particulate

6

2 To study both physical and mechanical properties of bamboo fiber/particulate-epoxy

composite relevant to roofing materials

3 To investigate chemical degradation of the bamboo epoxy formulated composite in the

presence of some selected media

4 To design and develop bamboo fiber/particulate-epoxy composite corrugated sheet

5 To investigate the sonorous behavior of bamboo-epoxy composite roof material

1.2 Scope of Study

This project is limited to the effect of bamboo fibers/particulate on physical (water absorption, sound

proof, chemical degradation, thermal degradation) and mechanical properties (tensile strength, flexural

strength, UV-vis spectrometer test etc).

1.3 Problem Statement

Metallic roofing sheet easily corrode due to the harsh environmental conditions. They are a good

conductor of heat because the high rate of heat transfer associated with the conventional roofing sheets

makes rooms to be hot during sunny period which makes life unbearable. Ceramic roofing sheet are

brittle, heavy and the energy for extraction of the primary raw material used in aluminum roofing sheet

is high.

7

CHAPTER TWO

2.0 LITERATURE REVIEW

For the natural fiber composite, most of the researches were focusing on experimental

test of mechanical properties of natural composites. The correlation between the mechanical

properties and the characteristic parameters, e.g., the composition of the composite and the

operating conditions, is of prime importance for designing proper composites in order to satisfy

various functional requirements. Optimization of various influencing parameter is very much

important. In this study, an attempt is made to analyze the effect of characteristic parameters on

mechanical properties of Bamboo fibers/particulate reinforced epoxy composites and to find out

the optimal combination of parameters. [17, 18].

Due to increase in population, natural resources are being exploited substantially as an

alternative to synthetic materials. Due to this, the utilization of natural fibers for the

reinforcement of the composites has received increasing attention. Natural fibers have many

Remarkable advantages over synthetic fibers. Nowadays, the application of biodegradable

plastics has been restricted due to their relatively lower strength compared to conventional

plastics such as polyacetal and nylon. Over the past few years a considerable number of studies

[18-29] have been performed on biodegradable composites containing biodegradable plastics

with reinforcements of biodegradable natural fibers. The natural fibers such as flax [18-20],

ramie [20,21], jute [20,22], bamboo [23-24], pineapple [25], kenaf [26,27], henequen [28] and

hemp [29] were used for reinforcements in these studies.

Ismail et al. [30] studied the effect of size and filler content on fiber characteristics that

cures a wound or any part of the body. Along with this, mechanical properties of Oil Palm Wood

Flour (OPWF) was also examined which is reinforced with (ENR) epoxidase natural rubber

8

composites to develop composites with good mechanical properties, chemical modification of

fiber carried out to reduce the hydrophilic behavior of fibers and the absorption of moisture [31].

Various researchers have worked on the natural fibers containing polyolefin‘s, polystyrene,

polyester and epoxy resins [17], [18]. Properties like low cost, light-weight, high specific

strength, free from health hazard are the unique selling points of these composites. Though the

presence of hydroxyl and other polar groups in the natural fibers leads to the weak interfacial

bonding between the fibers and the hydrophobic polymers, these properties can be significantly

improved by interfacial treatment [19]. Among the various natural fibers, bamboo fiber is a good

candidate for use as natural fibers in composite materials. Jindal [16] has observed that tensile

strength of bamboo fiber reinforced plastic (BFRP) composite is comparatively equivalent to that

of the mild steel, whereas their density is only 12% of that of the mild steel. Hence, the BFRP

composites can be extremely useful in structural applications. Jain and Kumar [32] have

investigated that a uniform strength can be achieved in all directions of the composites by using

multidirectional orientation of fibers. Considerable interest has been generated in the

manufacturing of thermoplastic composites due to their good fracture toughness and thermal

stability [26]-[7], and [23]. With more stringent demands for recycling standards, thermoplastic

polymers are substituting thermosetting polymers as matrix materials for high volume consumer-

driven composites [31]. Thermoplastic matrix composites materials offer an extended solution in

different applications in automotive industry, construction, electrical appliances and home/urban

furniture. Mi et al. [9] have promoted the interaction between Polypropylene (PP) and bamboo

fiber, by using a reactive agent maleic anhydride (MAH). Bio-degradable resins have received a

considerable attention as earth conscious materials in the present day engineering society. They

offer very little environmental load because they can be resolved in both water and carbon

9

dioxide after perfect biodegradation by micro-organisms. However, most of the biodegradable

resins have relatively low strength, making them a poor choice for the high strength structural

applications. Thus, a lot of research is focused to strengthen the biodegradable resins by

combining with string natural fibers like hemp, bamboo, and pineapple etc. Kori et al. have

fabricated bamboo fiber reinforced Polybutylenes Succinate (PBS) biodegradable polymer

composites [32]. Homogeneous nucleation of PBS spherulites was obtained at temperature above

150°C.Authors have shown that the size of spherules‘ increases with addition of bamboo;

however the spherules‘ are not generated from the surface of bamboo fibers with or without

treatment at any kneading temperature. The kneading temperature influences the melt visco-

elasticity above the melting point of PBS, In this project, the tensile and flexural properties at

different filler contents (wt. %) are considered as process parameter in order to determine how it

behaves for load.

2.1 Epoxy Resin

Epoxy resins were first commercialized in 1946 and are widely used in industry as protective

coatings and for structural applications, such as laminates and composites, tooling, molding,

casting, bonding and adhesives, and others.[34] The ability of the epoxy ring to react with a

variety of substrates gives the epoxy resins versatility. Treatment with curing agents gives

insoluble and intractable thermoset polymers. Some of the characteristics of epoxy resins are

high chemical and corrosion resistance, good mechanical and thermal properties, outstanding

adhesion to various substrates, low shrinkage upon cure, good electrical insulating properties,

and the ability to be processed under a variety of conditions. Depending on the specific needs for

certain physical and mechanical properties, combinations of choices of epoxy resin and curing

agents can usually be formulated to meet the market demands. However, in terms of structural

10

applications, epoxy resins are usually brittle and notch sensitive. As a result, tremendous effort

has been focused on toughness improvement during past three decades. Reviews in this area are

available. [35].

2.3 Polymer Matrix Composite

Polymer matrix composites (PMCs) are comprised of a variety of short or continuous fibers

bound together by an organic polymer matrix. Unlike a ceramic matrix composite (CMC), in

which the reinforcement is used primarily to improve the fracture toughness, the reinforcement

in a PMC provides high strength and stiffness. The PMC is designed so that the mechanical loads

to which the structure is subjected in service are supported by the reinforcement. The function of

the matrix is to bond the fibers together and to transfer loads between them. PMCs are often

divided into two categories: reinforced plastics, and ―advanced composites. The distinction is

based on the level of mechanical properties (usually strength and stiffness); however, there is no

unambiguous line separating the two. [36]Reinforced plastics, which are relatively inexpensive,

typically consist of polyester resins reinforced with low-stiffness glass fibers. Advanced

composites, which have been in use for only about 15 years, primarily in the aerospace industry,

have superior strength and stiffness, and are relatively expensive. Chief among the advantages of

PMCs is their light weight coupled with high stiffness and strength along the direction of the

reinforcement. This combination is the basis of their usefulness in aircraft, automobiles, and

other moving structures. Other desirable properties include superior corrosion and fatigue

resistance compared to metals. Because the matrix decomposes at high temperatures, however,

current PMCs are limited to service temperatures below about 316°C. Experience over the past

15 years with advanced composite structures in military aircraft indicates that reliable PMC

structures can be fabricated [37].

11

However, their high cost remains a major barrier to more widespread use in commercial

applications. Most advanced PMCs today are fabricated by a laborious process called lay-up.

This typically involves placement of sequential layers of polymer-impregnated fiber tapes on a

mold surface, followed by heating under pressure to cure the lay-up into an integrated structure.

Although automation is beginning to speed up this process, production rates are still too slow to

be suitable for high-volume, low-cost industrial applications such as automotive production

lines. New fabrication methods that are much faster and cheaper will be required before PMCs

can successfully compete with metals in these applications [38].

2.3.1 Matrix

The matrix properties determine the resistance of the PMC to most of the derivative processes

that eventually cause failure of the structure. These processes include impact damage,

delimitation, water absorption, chemical attack, and high-temperature creep. Thus, the matrix is

typically the weak link in the PMC structure. On the basis of matrix phase, composites can be

classified into metal matrix composites (MMCs), ceramic matrix composites (CMCs), and

polymer matrix composites (PMCs) [39]. The classifications according to types of reinforcement

are particulate composites (composed of particles), fibrous composites (composed of fibers), and

laminate composites (composed of laminates). Fibrous composites can be further subdivided on

the basis of natural/bio fiber or synthetic fiber. Bio fiber encompassing composites are referred

to as bio fiber composites. They can be again divided on the basis of matrix, that is, non-

biodegradable matrix and biodegradable matrix [40]. Bio-based composites made from

natural/bio fiber and biodegradable polymers are referred to as green composites. These can be

12

further subdivided as hybrid composites and textile composites. Hybrid composites comprise of

a combination of two or more types of fibers.

2.3.2 Polymer Matrix

Most commercially produced composites use a polymer matrix material often called a resin

solution. There are many different polymers available depending upon the starting raw

ingredients. There are several broad categories, each with numerous variations. The most

common are known as polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide,

polypropylene, polyether ether ketone (PEEK), and others. The reinforcement materials are often

fibers but can also be common ground minerals [41]. The various methods described below have

been developed to reduce the resin content of the final product. As a rule of thumb, hand layup

results in a product containing 60% resin and 40% fiber, whereas vacuum infusion gives a final

product with 40% resin and 60% fiber content. The strength of the product is greatly dependent

on this ratio.

PMCs are very popular due to their low cost and simple fabrication methods. Use of non-

reinforced polymers as structure materials is limited by low level of their mechanical properties,

namely strength, modulus, and impact resistance. Reinforcement of polymers by strong fibrous

network permits fabrication of PMCs, which is characterized by the following:

i. High specific strength

ii. High specific stiffness

iii. High fracture resistance

iv. Low cost

v. Good impact resistance

vi. Good corrosion resistance

13

vii. Good abrasion resistance

viii. Good fatigue resistance

Disadvantages of polymer matrix composite are as follows:

i) High coefficients to thermal expansion

ii) Low thermal resistance

2.3.3 Properties of the Matrix

Properties of different polymers will determine the application to which it is appropriate. The

chief advantages of polymers as matrix are low cost, easy process ability, good chemical

resistance, and low specific gravity. On the other hand, low strength, low modulus, and low

operating temperatures limit their use [42]. Varieties of polymers for composites are

thermoplastic polymers, thermosetting polymers, elastomer, and their blends.

Thermoplastic polymers: Thermoplastics consists of linear

or branched chain molecules having strong intermolecular bonds but weak intermolecular bonds.

They can be reshaped by application of heat and pressure and are either semi crystalline or

amorphous in structure. Examples include polyethylene, polypropylene, polystyrene, nylons,

polycarbonate, polyacetals, polyamide-imides, polyether ether ketone, polysulfone,

polyphenylene sulfide, polyether imides, and so on.

2.4 Bamboo as a Reinforcement Material

Usually, in the process of embedding bamboo fibers in resin, the bamboo strips are molded and

pressed under the certain pressure. Kushwaha and Kumar [43] used bamboo strips mat to

reinforced epoxy and unsaturated polyester materials. The prepared composites were cured in

oven at 80ºC for 4 and a half hour. As compared the treated to untreated bamboo fiber

composite, the elastic modulus of treated bamboo fiber composite increased. To improve the

14

mechanical properties of fiber reinforced thermosetting resin, cyanoethylation technique was

used. In this method cellulosic fibers can be chemically modified. Phenolic resin has been used

widely in wood industry to make composite. Yang et al. [44] adjusted phenolic resin to bamboo

fiber bundles at room temperature. The glued specimen were pressed with a cold press machine

in a mold under 82 MPa pressure and then cured in an oven. In contrast with raw bamboo fiber

and other bamboo based composites, both tensile and compression strength of bamboo fiber

composite were increased. The specific properties of long bamboo fibers such as low density and

specific strength and stiffness can be compared with glass fiber [12], [26], [44]. The created

products based on bamboo have been used in many applications such as transport, furniture,

packing and other fields [45]. Recently, the utilization of bamboo fibers as reinforced polymer

composite material has been increased by advanced processing technology. Table I displays the

advantages of bamboo fibers over glass fiber which is one of the most common polymer

materials.

2.5 Bamboo Fiber

Extraction of Bamboo Fiber There is a limited knowledge regarding bamboo fiber extraction;

only a few investigations have been done with different processes to define the mechanical

properties and the usage of bamboo fiber as reinforced polymer composite. In more scientific

studies in order to extract fibers from bamboo culm firstly, the diaphragm and node has been

removed, and then the hollow portions have been used for processing. Subsequently, various

methods have been used to extract bamboo fibers based on their application in the industries.

These processes are classified as chemical, mechanical and combination of mechanical and

chemical [46], [47]. The usual methods to extract fiber are follows:

15

2.5.1 Chemical Extraction

In chemical procedure alkali or acid retting and Chemical Assisted Natural (CAN) are used to

remove the amorphous regions and reduce the lignin content of the elementary fibers [48]. In

addition this treatment has effects on other components of bamboo microstructure such as pectin,

and hemicellulose. In chemical procedure after removing the bamboo nodes the internodes are

sliced into the defined dimensions. Bamboo strips with the size of chips was soaked in 4% mass

over volume of NaOH for 2 hours to influence on cellulosic and non-cellulosic parts. This

method was repeated several time under a certain pressure for extracting fiber in the form of pulp

[49]. The problem of this technique was that some macro meter size of fiber bundles were

formed during extraction. On the other hand Abhijit et al. [50] soaked bamboo strips with the

small size in 1N sodium hydroxide for 72 hours to facilitate fiber extraction. Jianxinet et al. [51]

extracted fiber by using different percentage of sodium sulphite, sodium silicate and sodium

polyphosphate solution. Bamboo chips were dried for 30min at 150ºC and dipped in water at

60ºC for 24 hours and then dried in air. Later, the fibers were washed with hot water and then

treated with xylanase. After, cooking and bleaching bamboo fibers, they were treated in

sulphuric acid solution. The size of obtained fiber was 2.5mm. In order to produce a long fiber

some cell parts of the plant such as pectin and lignin were needed to be connected.

2.5.2 Mechanical Extraction

This method involves different mechanical procedures such as steam explosion or heat steaming,

high pressure refinery, crushing and super grinding [52], [53]. All these mechanical methods

have some advantages and disadvantages. For instant: in heat steaming method the natural

strength of the bamboo fibers reduce. The steam explosion procedure can remove lignin from the

woody materials of a plant. Shunliu et al. used steam explosion to extract fiber from bamboo this

16

method the bamboo chips were exploded under 2 MPa pressure and 210ºC temperatures for 5

minutes. The lignin is discharged from the cell wall and covered the surface of the fiber. Kazuya

et al. [54] used the same method but they were not able to remove lignin completely from the

fibers [23]. The method that was used in chemical procedure was degumming and in mechanical

the fibers were extracted with retting process. They found that chemical procedure to extract

fiber in spite of being expensive, reducing the tensile strength and modulus; it could increase the

strain in comparison with mechanical methods. Moreover mechanical process is more eco-

friendly [34]. In this process they could extract long and fine fiber and the mechanical properties

of treated fibers with various concentration of alkali and untreated fibers were compared. In

untreated fiber the longitudinal flexural strength was the highest.

2.6 Application of Bamboo Fiber Epoxy Composite

In recent years, the use of bamboo has been enhanced to exploit bamboo as a renewable wood

fiber. Evolution in theoretical and applied research on bamboo-based products has increased year

by year and expanded its use in almost all applications, especially in building, furniture, product,

transport, packaging and others. Bamboo composite was accepted in the global market in

applications replacing traditional wood interior and exterior products [26]. This proved the

strength of bamboo is found 10 times stronger than wood materials [12]. Various positive

advantages found in composite products from bamboo as dimensional stability, longevity,

weather resistant, high impact resistant, low maintenance, non-toxic, low flame spread, etc.

17

(a) (b)

(c) (d)

Figure 1: Application of Bamboo Fiber Epoxy Composite

18

CHAPTER THREE

3.0 METHODOLOGY

This chapter details the materials and methods used for making the composites as well as the

chemical treatments and the machines and methods used to characterize the composites

Figure 2: Organogram for experimental work

Acquisition of Materials

Chemical extraction of bamboo fibers

Alkali Pre-treatment

Epoxy resin formulation

Thermal Test

Water Absorption Test

Tensile Test

Bamboo fiber/particulate reinforced composite

Characterization

Mechanical extraction of bamboo powders

Prototype Design and Fabrication

Microstructure Examination

Sound Absorption Test

19

3.1 Composite Design

Modulus

(GPa)

Tensile

Strength

(MPa)

Flexural

strength

(MPa)

Thermal

conductivity

(W/Mk)

Density

(g/cm3)

Rule of

mixtures

Bamboo fiber 38 415 150 0.07 1.1

Bamboo

particulate

5.835 1.7 31.3 0.09 1.4

Epoxy 4 60 137 0.18 1.15

3.1.1 Preparation of Composite

The raw materials needed for manufacturing the composites are:

1. Epoxy resin

2. Bamboo powder

3. Short Bamboo Fiber

4. Hardener

Table 1: Composite design

20

Sets of samples are to be prepared. Set with alkali treated fibers and particulate. The procedure

for chemically treating the fibers is been described

3.2 Extraction of Bamboo Fibers

There is a limited knowledge regarding bamboo fiber extraction, only a few investigations have

been done with different processes to define the mechanical properties and the usage of bamboo

fiber as reinforced polymer composite. In more scientific studies in order to extract fibers from

bamboo Culm firstly, the diaphragm and node has been removed, and then the hollow portions

have been used for processing. Subsequently, the method has been used to extract bamboo fibers

based on their application in the industries. The process is chemical method [13, 14]. The usual

methods to extract fiber are follows:

3.2.1 Chemical Method

In chemical procedure alkali or acid retting and Chemical Assisted Natural (CAN) are used to

remove the amorphous regions and reduce the lignin content strips with the size of chips was

soaked in 5% mass over volume of NaOH for 60 hours to influence on cellulosic and non-

cellulosic parts of the elementary fibers. In addition this treatment has effects on other

components of bamboo microstructure such as pectin, and hemicelluloses. In chemical procedure

after removing the bamboo nodes the internodes are sliced into the defined dimensions. Bamboo

chips were dried for 4 hours at 105ºC and dipped in water at 25ºC for 24 hours and then dried in

air. Later, the fibers were washed with distilled water for 5 times and then dried.

3.2.2 Fiber Treatment

All selected fibers were initially washed in distilled water and soaked in 10% NaOH solution for

1 hour to remove lignin, pectin and dirt from the fiber surface. The NaOH treated fibers were

again washed in distilled water to completely remove the sticking of NaOH on the fiber surface

21

.After this, the bamboo fibers were separated (filtered) and thoroughly washed with distilled

water and subsequently neutralized with 2% HCl solution. During the entire neutralizing time

litmus paper test was carried out at proper intervals to check the neutrality. Finally the NaOH

treated fibers were dried in an oven at 80oC for 24 hours to completely remove moisture.

3.2.3Epoxy Composites Preparation

In the fabrication process, the epoxy resin and hardener, with a ratio of 2:1, was uniformly mixed

using an electric mixer and poured into the desired mold. The mold was placed in a vacuum

chamber ( SVAC2E, SHEL LAB, SHELDON MANUFACTURING INC,USA,CORNELLIUS)

with a 0.5 bar pressure to get rid of any air bubbles which may have been trapped in the mould in

between the fibers. The vacuumed block was kept for curing at room temperature for 24 hours.

The volume fraction of the fiber in the matrix was controlled to be about the mixture was poured

into various molds, keeping in view the requirements of various testing conditions and

characterization standards. The composite samples of 8 different compositions (control sample,

particulate are prepared. The composite samples are prepared having three different percentages

of Bamboo fibers (5 wt %, 10 wt %, 15 wt % and 20wt%) and bamboo particulate (1 wt%, 3

wt%, 5wt %) and control sample( 0%) respectively. This is done while keeping the epoxy

content at a varying percentage (i.e. fibers, 100%, 95%, 90%, 85%, 80%, and particulate are

(99%, 97% and 95%), while keeping the length of the bamboo constant at 10 mm and bamboo

particulate at a size of (250, 300, 600, 850 µm) by the use of sieve shaker/set for particle size

distribution ( codecoits) The detailed composition and designation of composites is done by the

use of rule of mixture. A releasing agent (ethanol) is used on the mould release sheets to

facilitate easy removal of the composite from the mould after curing. The samples have been

22

prepared by varying fiber loading for the two fibers, the alkali treated bamboo/particulate

reinforced epoxy composites.

3.3 Tensile Test

Tensile tests and flexural tests were conducted using a Universal testing machine Instron,

respectively. Tensile tests were performed at a strain rate of1mm/min and a gauge length of 50

mm. Flexural tests were performed at a crosshead speed of 1 mm/min and aspen length of 48

mm. Five specimens were prepared and analyzed. A 95% confidence interval was calculated by

statistical analysis.

Figure 3: (a) sample for tensile testing of fiber (b) tensile tests were conducted using a

testing machine.

23

3.4 Water Absorption Test

Water absorption test used 8 specimens for each case and it followed the standard of room

temperature. Before the test, specimens were dried in the oven at 70˚C for 24 hours. After dry,

specimens were sodden in to the water. Total 5 times (1, 3, 24, 48, 72, hours after), sodden

specimens take out from water and measure weight of specimens. When before using scale,

specimens were cleaned by paper towels.

Figure 4: immersion of composite (a) particulate, (b) fiber.

3.5 Thermal Conductivity Test

Thermal conductivity of the composites as a function of weight fraction, temperature and fiber

orientation was measured by putting a water inside a constructed plain wood house inside sun

and measuring the temperature of the water before and after one hour.

24

Where q is the heat flux (Wm-2), k is the thermal conductivity (Wm-1 K-1), T1-T2 is the

difference in temperature (K), L is the thickness of the sample (m), and R is the thermal

resistance of sample (m2KW)

3.6 Chemical Resistance

Chemical degradation experiment was done by immersing the composite inside different

chemical (NaOH, Acetic acid, HCL, and NaCl) for 24 hours and 48 hours.

(a) (b)

Figure 5: Chemical degradation test for composite sample immersed in (a) NaOH (b)NaCl

(c) HCl (d) acetic acid.

25

3.7 Flexural Test

The flexural strength and flexural modulus was determined using universal testing machine. The

cross head speed for flexural test was maintained at 10 mm/min respectively. In each case 2

samples were tested and the average values were reported.

(a) (b)

Figure 6: The flexural strength and flexural modulus (a) before bending (b) after bending.

3.7 Optical Microscopy

Optical microscopy provides an excellent technique for examine the surface morphology of the

fracture surface of the composite.

(a) (b)

26

Figure 7: (a) the composite sample (b) optical microscopy equipment.

3.8 Sound Proof Test

Android sound meter software was used to determine the intensity of sound in Decibel

(dB).Thermal conductivity of the bamboo-epoxy was done by placing a water in the prototype

house and the initial and final temperature was recorded after 1 hour.Thermal conductivity

values were then compared with conventional roofing materials such as (galvanize and

aluminum roofing sheet).

(a) (b)

27

Figure 8: (a) prototype house for sound proof test (b) sound meter software

3.9 Prototype Design and Fabrication of Mould

(a)

28

(b) (c)

Figure 9:(a) engineering drawing of the prototype mould (b) top halve of the prototype

mould (c)bottom halve of the prototype mould

CHAPTER FOUR

4.0 RESULTS AND DISCUSSION

This chapter discusses the results of experimental values and analysis of thefiber/particulate

reinforced epoxy composite

29

4.1 Mechanical Properties

4.1.1 TENSILE STRENGTH RESULT

Stress-strain curves of epoxy and composites are shown in Figure 7. Tensile strength increases

from 2.70 MPa of epoxy to 3.53, 3.91 , 3.01 and 2.80, 4.66, 4.83, 4,42 MPa in case of 0 wt. %, 1

wt F. %, 3 wt. % F, 5 wt. % F and 5 wt.% P,10wt. % P, 15wt.% P, 20 wt.% P composites

respectively (Fig 7). Young‘s modulus was calculated from the slope of the linear region of plots

for composites. For Epoxy, 1 wt F. %, 3 wt. % F, 5 wt. % F and 5 wt.% P,10wt. % P, 15wt.% P,

20 wt.% P respectively. Considerable increase in tensile strength and decrease in modulus in

composites can be explained on the basis of better interaction and homogeneous distribution of

bamboo fiber/particulate powder in the epoxy matrix. It seems that at higher content

agglomeration and inhomogeneous distribution of filler is taking place which results in the

decreases in tensile strength and modulus. Elongation at break increase from 0 wt. % in case of

epoxy bamboo fiber/particulate composites respectively. This decrease in the elongation at break

in the composites may be attributed to the brittle nature of the coconut shell powder particles

which acts as defects from macroscopic point of view. With the increase in the filler content in

the polymer matrix mechanical properties improve up to a certain limit, beyond that they start

deteriorating. Poor adhesion between matrix and filler is also a one of the factor responsible for

this decrease.

(a)

30

untre

ated

fibe

r

treated

fibe

r --

0 wt.

%

1 wt.

% F

3 wt.

% F

5 wt.

% F --

5 wt.

% P

10 w

t % P

15 w

t % P

20 w

t % P --

0

1

2

3

4

5

6

Ten

sile

Str

en

gth

(M

Pa)

(b)

untreate

d fiber

treate

d fiber --

0 wt. %

1 wt. %

F

3 wt. %

F

5 wt. %

F --

5 wt. %

P

10 wt %

P

15 wt %

P

0

1

2

3

4

5

6

7

Elas

tic M

odul

us (G

Pa)

Sample

Figure 10: (a) tensile strength bar chart (b) elastic modulus bar chart

31

4.1.2Flexural result

The variation of Flexural strength with the ratio of percentage bamboo fiber in these composites is

presented below. In this case also the Bamboo composites are found to have good Flexural properties.

The Flexural strength of these composites are found to be enhanced when alkali treated bamboo fibers

were used in the hybrid composites. Similarities observation was made in the case of some bamboo

composites and polymer coated bamboo fibers.

(a)

0

wt.

%

1 w

t. %

F

3 w

t. %

F

5 w

t. %

F --

5 w

t. %

P

10 w

t % P

15 w

t % P

20 w

t % P

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

Fle

xura

l S

tren

gth

(M

Pa)

Sample

(b)

32

0 wt.

%

1 wt.

% F

3 wt.

% F

5 wt.

% F --

5 wt.

% P

10 w

t % P

15 w

t % P

20 w

t % P

0

5

10

15

20

25

30

Fle

xura

l M

odulu

s (M

Pa)

Sample

Figure 11: (a) flexural strength bar chart (b) flexural modulus

4.2 Physical Properties Result

4.2.1 Thermal Conductivity Result

The conventional roofing sheet such as aluminum and galvanized roofing sheet have high

temperature compare to bamboo epoxy because metal conduct heat easily so it is easy for heat to

transfer.

Table 2: Thermal conductivity result

The variation of Flexural strength with the ratio of percentage bamboo fiber in these composites is

presented below

33

ROOFING SHEET INITIAL TEMPERATURE FINAL TEMPERATURE

ALUMINIUM 24 36

GAVANIZED 30 38

BAMBOO/EPOXY 30 34

4.2.2 SOUND PROOF RESULT

The aluminum roofing sheet has the high sound follow by galvanized, and bamboo –reinforced

epoxy composite is the lowest .because bamboo have a low sonorous properties. Epoxy is a

thermoset polymer in which it is elastic in nature. Aluminum and galvanized roofing sheet are

metal in which they have high sonorous properties.

(a) (b) (c)

34

Figure 12: sound intensity result for (a) galvanized (b) bamboo epoxy composite (c)

aluminum

4.3Transmittance

Figure 10(a) shows that increase in the fiber content of the composite will lead to a decrease in

transmittance. This might be due to the fact that epoxy is more transparent than fiber. So an increase in the

fiber content reduces the transparency of the composite. Fig 10(b) shows that increase of the weight percent

of the particulate, lowers the transparency of the composite. This may be due to the particulate acting as

scattering centers hence they reduce the intensity of light that passes through the composite. For 5 wt.%

35

reinforcement, the transmittance is lower for fibers than for particulates. This may be due to the fact that

the density of the fibers is lower so there is greater quantity in the 5 wt.% reinforcement.

(a) (b)

300 450 600 750 900

-2

0

2

4

6

8

10

Tra

nsm

itta

nce (

%)

Wavelength (nm)

5 wt. % Fiber

1 wt. % Fiber

3 wt. % Fiber

300 450 600 750 900 1050

0

7

14

21

28

35

Transm

itta

nce (

%)

Wavelength (nm)

5 wt. % Particulate

10 wt. % Particulate

15 wt. % Particulate

20 wt. % Particulate

Figure 13: (a) transmittance for fiber 10(b) particulate

4.6 Water Absorption

From figure 11, the fiber consist of 0 wt%, 1 wt% , 3 wt% and 5wt% . The fiber matrix composite with

the highest weight % absorbs more water when immersed in the water since the fiber is bamboo which

is hydrophilic. From the first section of the bar chart, it was observed from the experiment that the

36

composite which took a long length of time in the water gain more weight. In conclusion, when the

volume of the fiber is reduced and the time the composite inserted in the water is also reduced, it

shows that composite has a less weight gain since the bamboo fiber which is hydrophilic has been

reduced in volume. From the experiment, it was observed that the particulate matrix composite also

absorbed water when immersed in water for highest tine duration.

0wt.%

F

1 w

t. %

F

3 w

t. %

F

5 w

t. %

F --

0wt.%

p

1 w

t. %

p

3 w

t. %

p

5 w

t. %

p

0.00

0.01

0.02

0.03

0.04

0.05

0.06

Wei

gh

Gai

n

Composite Formulation

1 h

3 h

24 h

48 h

72 h

Figure 14 : the histograms plot against the weight again and the composite formulation

4.7Chemical Degradation

Figure 12(a) show the increases in the fiber of the composite which mean weight gain occur the more

the increase of fiber for different chemicals such as NaOH react more on the 5wt.% than other the

same thing occur for the rest of the chemical. (b) there is weight gain in the particulate

37

(a) (b)

NaOH NaCl HCl Acetic Acid0.0

0.1

0.2

0.3

Weig

ht

Gain

Chemical

0 wt. % F

1 wt. % F

3 wt. % F

5 wt. % F

NaOH NaCl HCl Acetic Acid0.00

0.02

0.04

0.06

0.08

Wei

gh G

ain

Chemical

0 wt. % P

5 wt. % P

10 wt. % P

15 wt. % P

20 wt. P

Figure 15: chemical degradation of different chemical for (a) 24 hours (b) 48 hours

4.10 Optical Micrographs

The optical images provides an excellent technique for examine the surface morphology of the

fracture surface of the composite. The surface morphology of the fiber is different from the

particulate in term of the level of smoothness and roughness of the surface. They also show the

interfacial bond that exists between the fiber/particulate and the matrix which was used as the

reinforcement.

(a) (b) (c)

38

(d) (e) (f) (g)

Figure 16: optical images of different weight percent of composite (a)1 wt.% F (b) 3 wt. %F

(c)5 wt.% F (d) 5 wt. % P (e) 10 wt.% P (f) 15 wt.% P (g) 20 wt.% P.

CHAPTER FIVE

5.0 Conclusion and Recommendation

39

5.1 Conclusion

The bamboo epoxy composites of fiber/particulate reinforced epoxy were made. Their mechanical and

physical properties were studied, water absorption of bamboo is quite high. The effect of alkali treatment of

the bamboo fibers on these properties was studied. These bamboo-epoxy composites were found to exhibit

good mechanical and physical properties. The bamboo-epoxy composites with alkali treated bamboo fibers

were found to possess higher flexural properties. The elimination of amorphous weak hemi cellulose

components from the bamboo fibers on alkali treatment may be responsible for this behavior.

5.2 Recommendation

I recommend that further studies should be carried out on the bamboo-epoxy composite (hardness,

fracture toughness, fatigue strength, creep resistance, fire resistance, thermal degradation etc)and

Scalability of bamboo-epoxy composite.

40

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