CHAPTER 3

RESEARCH METHODOLOGY

This chapter explains the procedures that the proponents used to

conduct this study including research design, data collection and analysis,

supplies and materials, tools and equipment, construction procedure,

construction time frame and cost of material per sample.

RESEARCH DESIGN

This research Fiber Cement Board made of Kraft Paper and Metal

Swarf used an experimental research method because the proponents

introduced an intervention and studied the binding effects of kraft paper and

metal swarf to cement and were grouped by chance. All the fiber cement

board were cured for 7 days. The well cured fiber cement board were

subjected to bending strength, nail-pull through, and brittleness test. The best

sample that passed the standard test were assessed using evaluation theory.

DATA GATHERING

The proponents gathered the data though journals, books, unpublished

thesis, published thesis, magazines, articles and internet inquiries and other

related materials that state significant information relative to this experimental

study.

SUPPLIES AND MATERIALS

Table 1 shows the supplies and materials needed for the fabrication of

the fiber cement board. This includes kraft paper as the fiber reinforcement,

metal swarf as metal reinforcement, cement as the binder, water as the

solvent that mixed all the materials together, and sand as the fine aggregates

of the mixture.

SUPPLIES AND MATERIALS USES

It serves as the fiber reinforcement for
Kraft Paper the experimental study of the fiber
cement board.
It serves as the metal reinforcement and
Metal Swarf responsible for the tensile strength of
the fiber cement board.
It acts as the binder that holds the
Cement materials together for the fiber cement
board.
It is used as solvent in mixing all the
Water
materials together.
It is the material that used as fine
Sand aggregates for the mixture of fiber
cement board.
Table 1. Supplies and Materials

TOOLS AND EQUIPMENT

Table 2 shows all the tools and equipment used in the construction

procedure of kraft paper and metal swarf fiber cement board that includes:

blender as the cutter of kraft paper, cutting tools for cutting the molder, mixing

tools in mixing all the supplies and materials, measuring tools for volume

measurements, and pulverizer that pulverizes the metal swarf.

TOOLS AND EQUIPMENT FUNCTIONS

It is used breaking down the kraft paper
Blender
into smaller pieces.
It is used for cutting the materials in
Cutting Tools
making the molder.
It is used for mixing all the supplies and
Mixing Tools
materials.
It is used for measuring the supplies
Measuring Tools
and materials.
It is used to pulverized the metal swarf
Pulverizer
into smaller pieces.
It is used for separating solid matters.
Strainer
Table 2. Tools and Equipment
CONSTRUCTION PROCEDURE

The process of using kraft paper and metal swarf as raw materials in

fiber cement production are as follows:

Step 1. Collection of Kraft Paper and Metal Swarf

Kraft papers are collected from junk shops, local stores and

partnerships to elementary schools. The metal swarf was collected from

machine shops specifically Poying Machine Shop located at Los Baños,

Laguna.

Step 2. Construction of Formworks

The forms or molders are made up of aluminum plain sheets and it is

cut based on the given dimensions of fiber cement board.

Step 3. Extraction of Kraft Paper Fiber

The kraft paper are ripped into small pieces then it is placed in blender

with water until it became pulp.

Step 4. Pulverizing of Metal Swarf

The metal swarf are pulverized using pulverizing machine.

Step 5. Preparation of the Fiber Cement Board mixture

The grinded kraft paper and the pulverized metal swarf are mixed with

other raw materials such as cement, sand, and water.

Step 6. Pouring of Mixture in Formworks

The mixture is then poured to the molder to form the fiber cement

board. Compaction by slightly shaking in a downward and sideways motion

the molder served to distribute particles uniformly within the molder giving a

fairly uniform density distribution.

Step 7. Drying period

The fiber cement board are allowed to dry. The drying time will depend

on the humidity and temperature of the environment.

Step 8. Removing of the Formworks

The formworks are removed and the fiber cement board is allowed to

rest and get ready for curing process.

Step 9. Curing

This state is essential for the binder to harden and provide structural

integrity to the fiber cement board.

Step 10. Testing

The finished fiber cement board are then tested in terms of bending

strength, nail-pull through, and brittleness test.

CONSTRUCTION TIME FRAME

NUMBER OF DAYS
ACTIVITIES
1 2 3 4 5 6 7 8 9 10 11 12 13
1. Collection of
Kraft Paper and
Metal Swarf
2. Construction of
Formworks
3. Extraction of
Kraft Paper Fibers

4. Pulverizing of
Metal Swarf
5. Preparation of
the Mixture
6. Pouring of the
Mixture
7. Drying period
8. Removing of
Formworks
9. Curing
10. Testing
Figure 2. Gantt Chart

This figure shows the construction time frame of the production which

includes the procedures for making fiber cement board made up of kraft paper

and metal swarf. From collection to testing, the figure shows the sequential

order of the procedures that is daily done by the researchers. The

construction time frame has a total duration of thirteen (13) days. One (1) day

for collection of raw materials, one (1) day for construction of formworks, one

(1) day for extraction of kraft paper fibers and pulverizing of metal swarf, one

(1) day for preparation of mixture, pouring of the mixture, and drying period,

one (1) day for removing of formworks, seven (7) days for curing, one (1) day

for testing.

DIRECT MATERIAL COST PER SAMPLE

 This shows the cost of materials used in utilizing Kraft paper and Metal

swarf as Fiber Cement Board.

Sample A Kraft paper and Metals swarf in Fiber Cement Board (1’x2’) with a

volume of 1651.8161 cc, the proponent ratio of 50% cement, 25% Kraft Paper and

25% Metal swarf. The price indicated for cement and sand were retailed price. The

sand was set to 20% of the cement, and the water was set at 3.5 x 10 ⁻⁵ cu.m. The

total direct material cost for Sample A amounted to ________.

Materials Volume Quantity Unit Unit price Amount

4” x 2”
(%) (Php) (Php)

Cement 50 kg

Kraft Paper 25 kg

Metal 25 kg
Swarf

Sand 20 (cement) kg

Water cu.m

Sub Total

Table 3. Direct Cost Material Cost for Sample A

Sample B Kraft paper and Metals swarf in Fiber Cement Board (1’x2’) with a

volume of 1651.8161 cc, the proponent ratio of 60% cement, 20% Kraft Paper and

20% Metal swarf. The price indicated for cement and sand were retailed price. The

sand was set to 20% of the cement, and the water was set at 3.5 x 10 ⁻⁵ cu.m. The

total direct material cost for Sample B amounted to _______.

 Materials Volume Quantity Unit Unit price Amount
4” x 4”
(%) (Php) (Php)

Cement 60 kg

Kraft Paper 20 kg

Metal Swarf 20 kg

Sand 20 (cement) kg

Water cu.m

Sub Total

Table 3.1 Direct Cost Material Cost for Sample B

Sample C Kraft paper and Metals swarf in Fiber Cement Board (1’x2’)

with a volume of 1651.8161 cc, the proponent ratio of 70% cement, 15% Kraft

Paper and 15% Metal swarf. The price indicated for cement and sand were

retailed price. The sand was set to 20% of the cement, and the water was set

at 3.5 x 10 ⁻⁵ cu.m. The total direct material cost for Sample C amounted to

__________.

Materials Volume Quantity Unit Unit price Amount

4” x 2”
(%) (Php) (Php)

Cement 70 kg

Kraft Paper 15 kg

Metal Swarf 15 kg

Sand 20 (cement) kg

Water cu.m

Sub Total
 Table 3.2 Direct Cost Material Cost for Sample C

Sample D Kraft paper and Metals swarf in Fiber Cement Board (1’x2’)

with a volume of 1651.8161 cc, the proponent ratio of 40% cement, 30% Kraft

Paper and 30% Metal swarf. The price indicated for cement and sand were

retailed price. The sand was set to 20% of the cement, and the water was set

at 3.5 x 10 ⁻⁵ cu.m. The total direct material cost for Sample D amounted to

__________.

Materials Volume Quantity Unit Unit price Amount

4” x 4”
(%) (Php) (Php)

Cement 40 kg

Kraft Paper 30 kg

Metal Swarf 30 kg

Sand 20 (cement) kg

Water cu.m

Sub Total

Table 3.3 Direct Cost Material Cost for Sample D

Sample E Kraft paper and Metals swarf in Fiber Cement Board (1’x2’)

with a volume of 1651.8161 cc, the proponent ratio of 30% cement, 35% Kraft

Paper and 35% Metal swarf. The price indicated for cement and sand were

retailed price. The sand was set to 20% of the cement, and the water was set

at 3.5 x 10 ⁻⁵ cu.m. The total direct material cost for Sample E amounted to

Materials Volume Quantity Unit Unit price Amount

4” x 4”
 (%) (Php) (Php)

Cement 30 kg

Kraft Paper 35 kg

Metal Swarf 35 kg

Sand 20 (cement) kg

Water cu.m

Sub Total

Table 3.4 Direct Cost Material Cost for Sample E

SUMMARY OF COST PER SAMPLES

Tables _ shows the difference of the price of the materials used in

difference samples. Sample A with ₱___, Sample B with ₱___, Sample C with

₱___, Sample D with ₱___ and Sample E with ₱___. Sample E with the ratio

35:35:30 of Kraft paper, Metal Swarf and concrete mixture is cheaper and has

the lowest material cost, respectively.

Sample Result
(Kraft Paper - Metal Swarf - Cement)
(Php) Remarks

A (25:25:50)
Sample with lesser concrete
mixture is cheaper. Sample E
B (20:20:60)
with the ratio 35:35:30 of
Kraft paper, Metal swarf and
C (15:15:70) concrete mixture has the
lowest price
D (30:30:40)

E (35:35:30)

Table 4. Summary of Direct Material Cost per Sample