PREFABRICATED CONSTRUCTION

USING FIBER CEMENT BOARDS

Seminar Report 2020

Submitted by

RESHMA RAJEEV (VAS17CE097)

Department of Civil Engineering

VIDYA ACADEMY OF SCIENCE AND
TECHNOLOGY
THALAKKOTTUKARA, THRISSUR -680501
PREFABRICATED CONSTRUCTION
USING FIBER CEMENT BOARDS

Seminar Report 2020

Submitted by

RESHMA RAJEEV (VAS17CE097)

Department of Civil Engineering

VIDYA ACADEMY OF SCIENCE AND
TECHNOLOGY
THALAKKOTTUKARA, THRISSUR -680501
 Department of Civil Engineering
VIDYA ACADEMY OF SCIENCE AND TECHNOLOGY

Thalakkotukara, Thrissur, Kerala

CERTIFICATE

Certified that the paper titled PREFABRICATED CONSTRUCTION USING

FIBER CEMENT BOARDS was presented by Ms. RESHMA RAJEEV
(VAS17CE097) of seventh semester civil engineering Branch of this institution, as a
partial requirement for the award of B.Tech Degree in civil engineering by APJ Abdul
Kalam Technological University.

Seminar Guide: Dr. Justine Jose

Ms. Ardra P Nair Head of Department
Assistant Professor Department of Civil Engineering
Department of Civil Engineering
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ACKNOWLEDGEMENT

The success and final outcome of the seminar was due to the guiding light and helping of
many people. I sincerely thank them for their kind-hearted support.

I am deeply indebted to my beloved principal Dr SAJI C B Vidya Academy of Science

Technology. I would like to convey my immense gratitude to the HOD Dr. Justin Jose for
his timely suggestions, kind guidance and valuable support.

I am so grateful to my Seminar Guide Ms. Ardra for providing her enlightening guidance
throughout the seminar preparation. It was her encouragement and kind co-operation that
helped me to complete this report successfully.

I would like to express my deep sense of gratitude to all the FACULTIES OF CIVIL
ENGINEERING DEPARTMENT of Vidya Academy of Science Technology for their
timely suggestions kind guidance and valuable support.

I would like to express my sincere thanks to our parents for the love, support and
encouragement provided us throughout for the preparation of the seminar. I also extend
my heartfelt thanks to all my friends who helped directly and indirectly through their
valuable support.

Above all I would like to acknowledge the lord almighty, the foundation of all wisdom
who has been wonderfully guiding us step by step.

RESHMA RAJEEV
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ABSTRACT
Now a days, the Rapid Growth in Developing Countries leads to Extensive Construction
practices and the use of Prefabrication has been considered as one of the most effective
waste Minimization methods in the construction context. So the method of adapting
Prefabrication and off-site Manufacturing have been a part of Building construction for a
long time in many Countries. Later on the prefabricated constructions using fiber cement
Board has been increasingly used in the building construction in order to reduce the
construction time and to control the building quality according to required standard.
However, due to many advantage such as construction speed, minimum work on site and
high quality assurance and issues such as scarcity of both human and material resource that
are threatening Traditional Construction Practice. They are also user-friendly product for
Installation and proves a better substitute for conventional walls and any other dry wall
solutions. Also here we look at the factors considered for material selection of fiber cement
board, the test methods conducted for fiber cement board and the production process of
fiber cement will be discussed in detail. Fiber cement board aims at sustainable
development, user satisfaction and predictability of project on time. Basically, this types
of constructions can be implemented to help the Environment from the use of toxic
materials.
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CONTENTS

TITLE PAGE NO

ACKNOWLEDGMENT i

ABSTRACT ii

CONTENTS iii

LIST OF FIGURES iv

LIST OF TABLES iv

1. INTRODUCTION 1
2. FIBER CEMENT BOARD 1
2.1. Advantage of Fiber Cement Board 3
2.2. Disadvantage of Fiber Cement Board 3
2.3. Uses Areas of Fiber Cement Board 3
3. SPECIFICATIONS OF FIBER CEMENT BOARD 5
4. TEST METHODS OF FIBER CEMENT BOARD 5
4.1. Density and porosity Test 5
4.2. Flexural testing to assess Ductility 6
4.3. Electron microscopy 6
5. PRODUCTION PROCESS OF FIBER CEMENT BOARD 7
5.1. Hatschek Method 10
6. INSTALLATION METHOD OF FIBER CEMENT BOARD 11
7. FACRORS CONSIDERED FPR SESLECTION OF MATERIALS 12
8. CASE STUDY 14
8.1. Introduction 14
8.2. Industrialized Building Materials (IBS) 14
8.3. Fiber cement wall by Aurum synergy 14
8.4. FCW’s Benefits and Barriers of Implementation 16
9. CONCLUSION 17
10. REFERENCE 18
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LIST OF FIGURES

1. Resident using Fiber cement Board 2

2. Fiber cement Board 2
3. Exterior Panel 4
4. Tiles wall Substitute 4
5. Cement Board Underlayment for tile flooring 5
6. Inverted 4-point Bending Test 6
7. Extraction and Imaging of a pulled-out fiber from a fractured surface 7
8. Flowchart of a sample Fiber Cement Board Production Process 8
9. Sample Flowchart of Technological process of production of cellulose
Fiber cement Board 9
10. Hatschek process 10
11. Hatschek (Industrial Process) 11

LIST OF TABLES

1. Cost of Materials 13
2. FCW’s Benefits 16
Prefabricated Construction using Fiber Cement Boards 1

1. INTRODUCTION

Prefabrication is one of the key means of increasing building ability, as we all know that
there is drastic growth of modern trends, materials and technologies in the global
Construction Industries. Modern Techniques for building construction are around for
greater output and operation. The main aim of prefabricated construction technique is to
boost construction productivity, efficiency, user satisfaction, environmental performance,
better quality, sustainable development and the predictability of delivery time of project.
Prefabrication construction using Fiber cement board has become a viable alternative to
the traditional way of construction. That is setting up a Fiber cement construction is way
simpler and quicker than the brick and mortar process. Over the last few years, some
industries have effectively adopted prefabricated techniques by combining it with cast in-
situ concrete elements. By using precast concrete components predominantly, on-site
operations are considerably reduced, providing a safer working environment. However, it
is important to have a good appreciation of its difference in management from the
conventional construction.
Foreign countries like Australia, Europe etc. are commonly following the Prefabrication
construction using Fiber cement Board. And this type of construction was rarely done in
Kerala due to its varying climatic conditions. But as Flooding and flood risk have been
important considerations for a long time in Kerala, the idea of opting Fiber cement board
become relevant due to its fast construction method.

2. FIBER CEMENT BOARD

Fiber cement board or V Board is a versatile, Green, and widely applied Building material
used for commercial, industrial and residential construction to cover the exterior of
Building. FCB Comprises of plant extract cellulose Fiber, sand, water, and cement where
cement fits as an extremely hard material for load-bearing purposes while cellulose is used
for aesthetic applications such as sidings, soffit, and trims, or as a tile backing board. It
acts as a substitute for natural wood and wood-based products, such as plywood or oriented
strand boards (OSB). The properties of FCB, as a construction material, make it preferable
for use as a ventilated, façade cladding for newly-built and renovated buildings, interior
wall coverings, balcony balustrade panels, base course and chimney cladding, and
enclosure soft-fit lining.

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The most important property of fiber cement products is its strength, which is measured
in terms of modulus of rupture (MOR). Moreover, the synthetic fiber such as
polypropylene, polyvinyl alcohol, alkali-resistance glass fibers were added in the fiber
cement product to improve the strength. When we Replace Brickwork or mortar using
FCB, the amount of waste produced during construction of a house can be drastically
reduced, thus we are helping our environment, and also lesser in cost compared to
Conventional construction. Fiber cement board is water resistant, they are also more
resistant to mold and mildew and do not disintegrate or break down due to continuous
exposure to moisture. It is made up of more than 90 % of non-flammable material hence
it is not flammable which makes it safe for use in various applications. They are also cost
affective and time saving solution for construction of dry walls.

These boards can later be painted with contact primer or water-based acrylic. For a more
natural texture, Eco Pro Fiber cement boards come pre-painted with a unique technology
called “stains” wherein there is no need to paint the walls except with a protective coating
material if required. The walls with ‘stains’ retain the beautiful grainy texture of a Fiber
cement composite, compared to the components of concrete, shows improved toughness,
ductility, flexural capacity, and crack resistance. A major advantage of the fiber
reinforcement is the behavior of the composite after cracking has started, as the fibers
bridge the matrix crack (matrix-bulk material, in which the fibers are dispersed). Then, the
stress is transferred to the high-resistance system of fibers, capable of withstanding the
load. Post-cracking toughness allows the use of FCBs in construction.

Fig.1 Resident using Fiber cement Board Fig 2 Fiber cement Board

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2.1. Advantage of Fiber Cement Board

➢ It withstands Numerous Environment conditions including salty air

➢ It is Not Inflammable
➢ It Offers an Appearance which is Remarkably Realistic
➢ It Provides complete protection against Rot, Insects and Vermin
➢ It is Environmentally Neutral
➢ Relatively easy to handle due to its less weight

2.2. Disadvantage of Fiber Cement Board

➢ Not Available for Direct Order from Manufacturer

➢ Higher labor cost than other materials
➢ It is not a recyclable material.
➢ It is a heavy product that some home structures might not accept
➢ It does not offer independent testing or quality controls as a product
➢ It may have limited Availability in your area

2.3. Uses Areas of Fiber Cement Board

2.3.1 Exterior Siding

Fiber cement boards have gained considerable popularity as a siding materials. This is
because they are far more durable than alternatives such as vinyl siding and wood
siding and more economical than stucco, stone, and brick (considering the cost of
installation as well). Apart from the fact that fiber cement boards are extremely
resistant to external influences such as ultraviolet rays, salt spray, rain, and heat. They
are also impenetrable by birds or insects. Further, they are immune to temperature
changes and impact, and they require minimal maintenance. In addition, fiber cement
boards are available in many different styles with varying textures and colors. This
allows homeowners to choose the design that best suits their needs. Moreover, fiber
cement boards are available in different shapes and can thus be used for soffits and
trim applications. That said, fiber cement boards have and more durable.

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Fig.3 Exterior Panel

2.3.2 Tiled Wall Substitute

.FCB are ideal as tile backing boards, particularly in bathrooms and kitchens. Since fiber
cement boards are usually either water resistant or waterproof, they make for ideal tile
backing material in wet areas of the house. They are more resistant to mold and mildew
and do not break down as a result of the constant moisture. Moreover, they help the tiles
adhere to the walls better, making your tiled walls more durable. They also offer a smooth
finish, which is extremely important for tile installation. Owing to their water
resistant/waterproof and durable nature, fiber cement boards are also used for kitchen
counters and bathroom slabs/shelves.

Fig.4. Tiles wall substitute

2.3.3 Underlayment of Flooring

Fiber cement boards are the perfect substrate for tile flooring. These can be used anywhere
in the house, but are most commonly used as an underlayment for bathroom and kitchen
floors. Since these boards adhere well to both wood and tiles and provide a smooth and
strong surface, they make an excellent choice for an underlayment. When using fiber
cement boards as an underlayment, it is important to use the ½-inch boards. These prevent
tile and grout cracking and breaking, and also provide you with a rigid surface to work
on. The ¼-inch boards are more commonly used as tile backing boards on walls..

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Fig.5 Installing cement Board Underlayment for tile flooring

3. SPECIFICATIONS OF FIBER CEMENT BOARD

➢ Sheet sizes vary slightly from manufacturer to manufacturer but generally they range
between 2400 – 3000 mm in length and 900 –1200mm in width (600 & 450 mm
increments).
➢ This manufactured size minimizes on-site wastage as residential floor, wall and roof
structures lay structural members at 450 or 600mm centers.
➢ When used as siding boards, widths between 130mm and 300mm (5.25 inch to 12 inch)
are available.
➢ Fiber cement thicknesses vary between 4.5-18mm and also vary in density – the lower
density resulting in a fibrous rough edge when cut and the higher density having a
cleaner smoother edge when cut.
➢ Thermal resistance and sound transmission can vary greatly between fiber cement
products. Fiber cement sheet products rate poorly in thermal resistance and sound
transmission and separate wall insulation is highly recommended.
➢ Generally, the thicker and denser the product the better resistance it will have to
temperature and sound transmission.

4. TEST METHODS OF FIBER CEMENT BOARD

4.1. Density and porosity Test

ASTM C642 [37] is used to measure the bulk density and porosity of a laboratory-made
mixture. Bulk density is determined in an oven dry condition and represent the weight of
the composite per unit bulk volume including the internal porosity and air voids.

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4.2. Flexural testing to assess Ductility

Ductility of laboratory-made samples was measured using inverted 4-point bending test.
The distance between the centers of the two load heads was 220 mm and the bottom
supports were 101.6 mm apart. The load was applied in the form of displacement at a rate
of 1 lm/s. Two linear variable differential transformers (LVDT) were used to measure the
deflection of the boards at their mid span. A digital camera was used to image the tensile
face of the boards and set to take pictures every 10 s during the test. The images were
synchronized with the load-deflection data and used to monitor crack propagation. The
boards were polished and painted in white to increase the contrast and crack visibility.
Flexural load-deflection data was used to calculate the maximum stress-strain at the mid-
span for each sample. In addition, commercial FC board samples were tested to investigate
the relationship between their ductility and matrix strength.

Fig.6.Inverted 4-point bending test setup

4.3. Electron microscopy

Microstructural imaging and elemental X-ray micro-analysis the commercial FC board

samples was performed using scanning electron microscopy with energy dispersion
spectroscopy (SEMEDS). Three specimens (7 _ 10 _ 40 mm) cut from the commercial
boards were impregnated with low viscosity epoxy resin, polished to <1 lm roughness,
and imaged. Cross section of the fibers and fiber-matrix interface was studied, at 10 or
more locations in each specimen, to look for any sign of fiber mineralization and damage.
To further investigate the mineralization and surface damage of the fibers, a pulled-out
fiber was extracted from the fractured surface of a C1 board sample using a focused ion

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beam (FIB) technique. A SEM with FIB capability was used for real time imaging of the
process. The fractured surface was first coated with iridium to prevent electrical charging.
Next, a stainless-steel needle was brought into contact with the surface of a pulled-out
fiber and the fiber was soldered to the needle by localized deposition of platinum via a
gas injection system (GIS). Then, the cross section of the fiber was cut using a finely
focused (10 nm) beam of high energy gallium ions (3.00 kV and 0.39 nA). Figure shows
the procedure as well as the fiber cross section and lumen. The cross section of the
extracted fiber was further studied under SEM.

Fig.7 Extraction and imaging of a pulled-out fiber from a fractured surface: (a) the
manipulator needle is brought into contact with the surface of a pulled-out fiber, (b) the
fiber is soldered to the needle by deposition of platinum and then the fiber is cut using a
focused gallium ion beam, (c) the soldered fiber is extracted, (d) the cut cross section of
the fiber imaged using field emission SEM. 0.0

5. PRODUCTION PROCESS OF FIBER CEMENT BOARD

A modern process of FCB Production consists in laying thin paper-like films on top of
each other until a desired sheet thickness is obtained (13,14). The process distributes the
reinforcing fibers in planar uniformity, taking the best advantage of the reinforcing fibers
to increase the in-plane strength of the sheet. Thus, the strength of sheets made using this
process is approximately 50% greater than the sheets formed to full thickness in a single
action using a filter press or the extruding processes. In a process detailed below, a thin

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film formed from a diluted fiber slurry is usually 0.25-0.4 mm thick and each FCB
comprises a stack of these films. Thus, the final sheet consists of approx. 20-30 or more
thin films. A large number of layers partially suppresses the imperfection of the considered
method: the films formed on a sieve are not uniform in composition but due to
sedimentation they have a fiber-rich side and a fiber-poor side. Additionally, 2.5-3 mm long
fibers bridge the sieve holes, slightly blocking the feed of other particles and forming a
fiber-rich layer. The portions formed last can be relatively fiber-poor. On this account, an
advanced fiber orientation and distribution devices have been developed and introduced
into the actual chain of FCB fabrication.

Fig.8 shows a flowchart of a sample fiber cement board production process. The
particular sub-processes named in the flowchart are detailed below.

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Zone1
Zone 5 Zone2

Zone 7

Fig.9 shows a sample flowchart of the technological process of production of cellulose

fiber cement boards, including seven zones corresponding to the specific production
stages

➢ The Production of cellulose FCB starts in the preparation zone(zone1), where

cellulose fibers are mixed with water in a mixer (pulper) until a uniform dispersion is
produced. Bulk components (cement with additives) in specific proportions are added
to the batched water and mixed until a homogeneous plastic compound is obtained .
➢ There are two main catagories of cellulose fiber cement: Low temperature curved and
high temperature curved or autoclaved curve . Low (air) curved formulations usually
contain larger amounts of portland cement combined with fine-ground filers such as
clay, silica fume, Ground limestone ,or flyash. Autoclaved formulations contain less
portland cement and more pozzalanic components and fillers.
➢ The mixture explained above is transferred to a board forming machine. The Hatschek
or flow-on machine is used (zone2) to form boards with fixed thickness of 4-14mm.
➢ The next (optional) production stage involves a pressing of stacked board (zone3).
➢ A presssing force suitable for the type of board fabricated exterior or interior cladding
board is applied. Due to cement Hydration heat Warm cellulose fiber cement boards
directly after pressing or forming are transferred to a pre-curing Tunnel (zone4) where
they remain for about 14hours.
➢ Next , the board be taken off the stack and placed on a pallet. This must be done as
quickly as possible since the boards are still quite warm and damp, and so they should
not be allowed to cool and dry too much or too quickly.

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➢ The boards placed on the pallets are left to mature and are cured in steady thermal-
moisture conditions, e.g., in special airtight tarpaulin tents (zone 5) for about 14 days.
➢ After that time, the boards obtain the proper bending strength, and some moisture is
removed naturally. After the maturation period, the boards are transferred to a final
drying oven (zone 6 ) where they are subjected to Three-stage druing at 180°C, 160
and 120°C, respectively at stage 1, 2, and 3. Then, the boards are cooled naturally for
about 20-30 minutes depending on their thickness. This is a critical stage of the
fabrication process

5.1. Hatschek Method

Fig.10 Hatschek process

The Hatschek process was initially developed for the production of asbestos composites ,
but it is now used for the manufacture of non-asbestos, cellulose fiber reinforced cement
composites.
Hatschek machine consist of one or more vats with a cylindrical sieve rotating in contact
with diluted water based fiber slurry capable of forming a filtering film and minerals,
including Portland cement. The sieve is driven by a continuous felt wrapped around the
top of rotating cylinder by a couch roller, The filtering film moves on the felt to a forming
roller. The felt continuously travels between a driven roller and a tail roller.
.The sheets are formed in the Hatschek machine in Accordance with the following
procedure. When the clean slurry is pulled under the slurry in the vat , water from the slurry
runs through the sieve to deposit a soft porous film of fibers and cement on the surface of
the sieve. The sieve moves the film onto the felts. The excess water is removed when the
sieve is pressed to the felt. The felt transfer the film onto the forming roller. When the
required number of films is wrapped around the forming roller to form a sheet of required
thickness, the stack of films is removed from the roller and laid out flat to form a board.
The draining of successive films in contact with each other under pressure is sufficient to

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bind the films together and form a continuous solid material.

Typical sieve mesh size are approx. 0.4mm, whereas the non-fibrous particles are
significantly smaller (approximately 50 μm in diameter). Therefore, these particles can
freely pass through the sieve out of the formal layer , whereas the fibers are retained on sieve,
Thus, the entrapment of non-fibrous materials within the film on surface of the sieve
depends on the structure of the fiber layers formed.

Fig.11 Hatschek (Industrial scale)

6. INSTALLATION METHOD OF FIBER CEMENT BOARD

Fiber cement cladding is a very heavy product and requires two people to carry the uncut
sheets. Thin fiber cement cladding is fragile before installation and must be handled
carefully because it is prone to chipping and breakage if improperly handled. Once the
product is cut it may again require two people to install, one to hold the sheet flush against
studwork and the other to nail the product in place. The Foundation is built after doing
piling on the land. Steel frames are then erected on the foundation.

Cutting fiber cement sheeting:

Sheeting can be cut to size in three ways:

➢ Thinner sheets can be scored with a heavy duty cutting blade and snapped
➢ Using a hand- or electric-powered "fibro cutter" (Australian term)
➢ A mechanical saw using a diamond blade (masonry blade) is needed to cut thicker
and denser sheets

When hanging fiber cement sheets, an approximately 5-millimetre (0.2 in) gap is required
between end-joints (cladding seams), later to be filled with caulking made for fiber cement
siding. Metal 150 mm × 150 mm (6 in × 6 in) step flashing is required behind overlapping

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seams to prevent sheathing damage from water. Hot-dipped galvanized roofing nails are
used to secure the sheets.

Some caution must be exercised to properly ventilate areas where fiber cement siding
(FCS) is being cut; long-term exposure to the silica dust generated during the installation
process can cause silicosis.
Fiber cement cladding can be painted or stained before or after installation. For areas of
exposure, weatherproof paint must be used. Once the product is fixed the joints are usually
covered with timber battens and the entire wall surface is painted.

7. FACRORS CONSIDERED FPR SESLECTION OF MATERIALS

➢ Economical Factor: Fiber cement board is an economically fit option since it offers
good workability, ease in finishing and minimum overall cost. Overall cost include
painting, furnishing, Plastering.
➢ Durability: Durability is same as that of conventional house construction, this product
is considered the most resistant to common enemies of residential siding. The material
doesn’t rot or wrap and is crack resistant. UV exposure does not degrade it and it
resist hail, snow, and ice. Wind is not a threat, in locals that experience a high incidence
of hurricane and tornadoes, many local building codes actually specify the use of fiber
cement siding. Pests that attack conventional wood siding, notably termites and wood,
show no interest in fiber cement.
➢ Resistance to fire: Some types of siding, like brick, are naturally resistant to fire, but
traditional varieties, including vinyl and wood, are often vulnerable to flames. Vinyl
siding can melt or warp when exposed to flame, and won’t do anything to keep your
house from setting ablaze. Fiber-cement siding, on the other hand, offers near-perfect
protection against fire. There are consistently more than one million houses fire every
year, fiber cement siding greatly reduces the possibility that your home will suffer that
level of fire damage.
➢ Aesthetic Value: Fiber cement siding can be customized to suit almost any taste, but
the baseline curb appeal of fiber cement puts it above vinyl, brick, or other materials
for most consumers. It doesn’t degrade over time the way vinyl does, and looks “new”
for decades after its initial installation. It’s also possible to re-paint fiber-cement siding,
though it’s less necessary than with traditional siding materials, so you can always
change your mind later or give your house a different look.

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➢ Workability: FCB offers Good workability by easy cutting and insertion of Board and
also without using much Building Materials it also shows zero void spacing which
Indicates quality of material. Alignment and Demolishing of FCB structures can be
done easily without cause any harm to the Environment.
➢ Ease of Transportation: Transportation cost is lesser than that of conventional
construction
➢ Low Cost and Maintenance: The costs of a constructed facility to the owner include both
the initial capital cost and the subsequent operation and maintenance costs. Each of
these major cost categories consists of a number of cost components. The capital cost
for a construction project includes the expenses related to the initial establishment of the
facility: Land acquisition, including assembly, holding and improvement, Planning
and feasibility studies, 0Architectural and engineering design, Construction, including
materials, equipment and Labor, Field super vision of construction, Construction
financing, Insurance and taxes during construction, Equipment and furnishings not
included in construction, Inspection and testing.

Cost of the materials used is listed out in table.1

Table.1. Cost of Materials

Fiber Cement Board for flooring 23400.00

Partition wall(Fiber cement panel 3rd exterior 93700.00
and 2nd interior)
Joiner(UPVC and Aluminum Fabrication) 3900.00

Roofing (Tiles) 26500.00

Ceiling(Fiber Cement Board) 7500.00

➢ Water Resistive Barrier: The water-Impermeable layer beneath siding Protects walls
from rain and snow, and often functions as building’s air barrier. No matter how
carefully it is applied, siding is probably going to leak at some point in its service life.
The layer beneath the siding, the water-resistive barrier, or WRB, is what will protect
the plywood or oriented strand board (OSB) sheathing from any water that sneaks in.
➢ Termite Resistant: Fire proof board will not be eaten damaged by White Ants termite
damage Made from a completely unique and non-toxic fiber composite mix, Fiber
cement Board is impervious to termites and the like Control of these termites can be
very costly with regular use of expensive chemicals regardless of being approved in

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human safety or not, do have other undesirable effects on the environment.

➢ Light Weight and Impact Resistant: FCB is stronger and will last up to 4x longer than
standard building board being a product of superior quality and build than other
building boards, replacement and maintenance is never an issue. The weight of 10 mm
thickness panels is 10.04kg/m2 after making the wall with the light steel keel and is
about 1/10 to the ordinary solid clay brick wall, It’s intensity of impact resistance is 2-
3 times to wall of ordinary gypsum board, it’s easy to install, also could shorten time for
a project effectively.

8. CASE STUDY
8.1. Introduction

Malaysian construction industry has undergone through numerous innovative revamp

recently, as proven by contemporary or modernized construction used in certain project
implementation. The utilization of Industrialized Building System (IBS), innovative
materials, efficient construction plants and modern machineries make construction phase
excellent, subsequently help raise productivity and change the paradigm of the
conventional method. In essence, IBS is a practical approach in the industry. This study
will discuss about the issue of acceptance level from construction players towards IBS.
The study will also dissect the factors or barriers of implementing IBS in Malaysia as well
as analyzing the reason the IBS has yet to be widely used in Malaysia.

8.2. Industrialized Building Materials (IBS)

Industrialised building system (IBS) is a term used in Malaysia for a technique of

construction where by components are manufactured in a controlled environment, either
at site or off site, placed and assembled into construction works. Worldwide, IBS is also
known as Pre- fabricated/Pre-fab Construction, Modern Method of Construction (MMC)
and Off-site Construction.

8.3. Fiber cement wall by Aurum synergy

Realize the construction industry as a builders are not guaranteed the sustainability in
business, Aurum Synergy have move another phase in industry as a manufacturer and
supplier of the Industrialized Building System (IBS) component. Fiber cement wall is a
building material used to cover the exterior of a building in both commercial and domestic
applications. Fiber cement is a composite material made of sand, cement and cellulose

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fibers. In appearance fiber cement siding most often consists of overlapping horizontal
boards, imitating wooden siding, and clapboard and imitation shingles. Fiber cement
siding is also manufactured in a sheet form and is used not only as cladding but is also
commonly used as a soffit/ eave lining and as a tile underlay on decks and in bathrooms.
Fiber cement siding is not only used as an exterior siding, it can also be utilized as a
substitute for timber fascia and bargeboards in high fire areas. Sheet sizes vary slightly
from manufacturer to manufacturer but generally they range between 2400- 3000 mm in
length and 900 –1200mm in width (600 & 450 mm increments). The manufactured size
minimizes on-site wastage as residential floor, wall and roof structures lay structural
members at 450 or 600 centre. When used as siding boards, widths between 130mm and
300mm (5.25 inch to 12 inch) are available. Fiber cement thicknesses vary between 4.5-
18mm and also vary in density – the lower density will result in a fibrous rough edge when
cut while the higher density will have a cleaner smoother edge when cut. Thermal
resistance and sound transmission vary greatly between fiber cement products. Fiber
cement sheet products rate poorly in thermal resistance and sound transmission and
separate wall insulation is highly recommended. Generally the thicker and denser the
product the better resistance it will have to temperature and sound transmission. The
external cladding products require very little maintenance once installed and painted. The
thicker or denser fiber cement products have excellent impact resistance but the thinner
and less dense products need to be protected from impact Compared to wooden siding,
fiber cement is not susceptible to termites or rot. Fibre cement siding using base board
materials that have been classified, by accredited laboratories, as Category A according to
BS EN 12467: 2004 Fiber cement flat sheets - Product specification and test methods are
sidings which are intended for applications where they may be subject to heat, high
moisture and severe frost.

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8.4. FCW’s Benefits and Barriers of Implementation

Benefits Description

Faster construction Factory Prepared panels dramatically reduce construction times

Reduced supervision A reduction in on-site labour means a reduction in supervision time and costs

Less skilled labour Pre-manufactured componentry and simplified construction cuts on-site
labour significantly,assures quality and reduces the amount of trade skills
required on-site.

Improved Quality control The FCW’s system is manufactured using quality materials and assembly
techniques, providing high-quality consistent component panels

Better Strength and Durability Stronger and more durable than hollow cement block construction,

Reduced Warrenty cost Resists visible cracking, reducing remedial/repair work and warranty costs

Table.2. FCW’s Benefits

Department of Civil Engineering

Seminar 2020
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9. CONCLUSION

Prefabrication construction using fiber cement board has brought the designers to a brand
new stage and has given rise to new philosophy of construction. Fiber cement board is
most affordable and eco-friendly means of construction with its sustainable benefits. Fiber
cement board significantly reduces the exterior maintenance required for your home, it also
possess durability, good dimensional stability, acoustics and thermal insulation properties
and low production cost. Making use of Fiber cement board in Buildings, reduces the stress
to the foundation eventually reducing the time and cost. Hence it can replace the bricks
used as a major masonry units in buildings and considerably reduces the waste produced
during constructions and thus we are helping our environment. FC boards are relatively easy
to handle due to its light weight and it can be used in areas of varying climatic changes, as
it can withstand many properties such as fire or Heat resistant, water resistant, etc. As
flooding and flood risk is being a common consideration for a long Time in Kerala, Fiber
cement Board constructions can be implemented for fast construction for people suffering
for their shelters.

Department of Civil Engineering

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10.REFERENCE

1. Fadel Kareem,Fazil.P-”Construction of Prefabrication houses using Fiber cement

board (VBoard)”- IJERT ISSN:2278-0181Vol.8 Issue 05, May2019
2. Noura Balboul Shawia, Mohammed Ali Jabber and Abbas Fadhil Mamouri-
“Mechanical and Physical properties of Natural fiber cement board for building
partition” - Vol2(3),pp.49- 53,September 2014
3. Fadel Kareem, Fazil.P- ”Design and Construction of Prefabrication houses for flood
victims in kerala, India – IJSE Volume10,Issue5, May -2019
4. Material Science Forum-“ The Barriers and Stratergies of implementing the new
Building Materials”ISSN:16629752,Vol.857,pp 314-318
5. Zbigniew Ranachowski and KrzysztofScabowicz-“TheFabrication,Testing and
Application of Fiber cement Board.

Department of Civil Engineering

Seminar 2020