Manufacturing of Roofing Sheets Reinforced with
Pretreated Cornhusk Residues as an Alternative for
Asbestos Sheets
T.N. Fernando
Agricultural Engineering and Machine Devlopment
2021 From Innovation To Impact (FITI) | 978-1-6654-8325-4/21/$31.00 ©2021 IEEE | DOI: 10.1109/FITI54902.2021.9833063
National Engineering Research and Development Centre
Industrial Estate, Ekala, Sri Lanka
nilanthifernando45@yahoo.com
Abstract—The aim of the present study is the manufacturing
of an alternative roofing sheet to replace the asbestos sheet. Pre-
treated cornhusk fibers from alkaline hydrogen peroxide (AHP)
pre-treatment was used as a reinforcing material of the
composite mixture with ordinary portland cement. The existing
AHP pre-treatment was modified in the present study for the
application of the pre-treatment at industrial level, to prepare
pre-treated fibers in a short time and cost effectively.
Additionally, poly vinyl alcohol (PVA) and poly propylene are
also used as reinforcement materials to improve the properties of
the sheets. The developed roofing sheet had average water
absorption of 17.09%, and the average flexural load of 0.6kN,
which are within Sri Lankan standards of concrete roofing semi
sheet.
Keywords—Alkaline hydrogen peroxide pre-treatment,
Cellulose, Cornhusks, Roofing sheet
I. INTRODUCTION
Roofing materials are one of the most important
construction materials, which are used for the safety and
beauty of the building. Over centuries, sustainable roofing
materials such as weaved coconut leaf, palmyra leaf, paddy
straw etc. have been in use, but they have low life spans. These
materials have been changed into roofing materials with longer
life such as clay tiles, cement fibre sheets (Asbestos) and zinc
or galvanized metal sheets [1]. In present era, asbestos roofing
sheets and clay roofing tiles are the most popular common
roofing methods in Sri Lanka. Clay tiled roofs require more
wooden strips to support roof tiles; hence, they are relatively
costly and not lightweight. Therefore, asbestos sheets are
mostly used in modern constructions. It has been revealed that
some common type of roofing materials of cement asbestos
fibre reinforced and coated metal sheets etc. have significant
environmental impacts, not only during manufacturing but also
during usage and disposal phases.
Sri Lankan researchers have carried out studies to prepare
environmentally friendly alternative fibre materials to replace
asbestos for roofing sheets [2]. However, outcome of some
research have been limited due to low strength of the final
product. Further, some companies in Sri Lanka have
manufactured eco sheets (roofing and ceiling) using cellulose
978-1-6654-8325-4/21/$31.00 ©2021 IEEE
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I.P. Batuwita
Civil Engineering Department
National Engineering Research and Development Centre
Industrial Estate, Ekala, Sri Lanka
ibatuwita@gmail.com
fibre, polyester resin and various type of plastics [3] as raw
materials but some of these are expensive.
Natural polymers have various advantages over synthetic
polymers due to their low-cost, availability, and
biodegradability. As a result, lignocellulose biomass from
plants has become the main focus in developing eco sheets in
the bio-refining industry. Cellulose fibres are used as the
substitute for asbestos in roofing sheets to avoid the hazards of
asbestos [4]. Recently, biodegradable polymer (cellulose fibre)
materials are becoming more important, as environmental
contamination and waste disposal problems associated with
plastics and related products from synthetic polymers became
more severe. Hence, cellulose fibre roofing sheets are
considered a greener product in building construction. Further,
cellulose fibres are unique reinforcing materials that offer
numerous advantages [4] as follows:
• Non-hazardous
• Renewable, and readily available at relatively low cost
• Good alternative for hazardous asbestos fibres
• Application to the reinforcing mixture increases the
strength of the developed fibre-reinforced composites
Cotton is the naturally available cellulose and is not
abundantly available in Sri Lanka. However, some agro plant
residues of cornhusks, corn leaves, bagasse, and guinea grass
are rich in cellulose and widely available in Sri Lanka. Pre-
treatment methods are necessary to extract cellulose from agro
plant residues. Researchers have shown that application of
alkaline hydrogen peroxide (AHP) pre-treatment is an effective
pre-treatment in comparison to alkaline and biological pre-
treatment and can be conducted at atmospheric pressure and
room temperature [5]. Out of all available agro plant residues
in Sri Lanka, the present study is focused on using corn plant
residues to extract cellulose due to its bulk availability.
Wayside kiosks selling boiled cobs of corn along roads in
pilgrimage and tourist areas are common in Sri Lanka.
Additionally, in some areas corn plants are grown in large
fields to obtain flour for different food industries. Although
there are no reports on quantities of cornhusks and cob residues
that are wasted in Sri Lanka, the bulk of cornhusks and cobs
are burnt after obtaining seeds and kernels.
 The present study focused on manufacturing an alternative
roofing sheet for the asbestos sheet, by reinforcing pre-treated
cornhusk residues using a modified alkaline hydrogen peroxide
pre-treatment at industrial level.
II. MATERIALS AND METHODOLOGY
A. Materials
Ordinary Portland cement (OPC) - 8 kg of cement was used
for preparation of the roofing sheet within the size of length-
0.914 m × width- 0.609 m × thickness- 0.008 m; the required
cement weight was determined from the preliminary studies.
Polyvinyl alcohol (PVA) - 1% PVA by weight was added
to cement as mentioned in literature [6]. Polypropylene (PP) -
0.14% PP was added considering the findings of previous work Fig. 1. NaOH, H2O2 and Cornhusks mixture during the AHP pre-
[7]. Commercial grade sodium hydroxide (NaOH), hydrogen treatment
peroxide (H2O2), and hydrochloric acid were used.
Fibres from 400 g of raw cornhusks, pre-treated using
AHP, were used. The pretreated fibers required for the
reinforcement of 8 kg of cement was determined from the
preliminary studies. The computerized universal texting
machine (model: UTM-10W) at the National Engineering
Research and Development Centers was used.
B. Methodology
The study comprised of a procedure developed for the
manufacturing of roofing sheets in small-scale industries.
1) Pre-treating of cornhusk sample
A cornhusk sample was pre-treated using AHP (by
preparing the pre-treatment solution using 1.0 mol/L NaOH Fig. 2. Testing of tensile load using a universal testing machine (a)
and 99.9% H2O2), as described in the previous article [5]. sample holder of the machine (b) screen of the computer, which is used
to record readings
According to the AHP pre-treatment procedure in the article
[5], an electric shaker has been used for the pre-treatment,
which is not cost effective at an industrial level. Therefore, pre- 3) Preparation of corrugated sheet
treated materials were added to fill 1/3 of a plastic container First, a rexine sheet was spread on the sheet making bed
leaving 2/3 volume for the reaction of the pre-treated materials and a molding iron frame (length - 0.914 m × width - 0.609 m
in the container (Figure1). Further, in every 10 minutes the pre- × thickness - 0.008 m) was fixed on the bed as shown in Figure
treatment solution was mixed manually for 30 minutes until the 3. The prepared homogenous mixture was spread in a uniform
mixture settled (low bubbling of the solution). The above step thickness onto the iron frame and properly leveled. The bed
represents the novelty of the present study. Then, the cellulose was then allowed to vibrate for 3–4 minutes to make a uniform
percentage was determined using a chlorination method as flat sheet as shown in Figure 3. Then, the molding frame was
mentioned in literature [8]. The tensile load of the raw and pre- removed carefully and the flat molded mortar specimen was
treated fibres were measured using a computerized universal moved on to a corrugated asbestos sheet, which was used as a
testing machine and the graph of flexural load could be mold to make a corrugated roofing sheet. Finally, the prepared
obtained from the computerized machine as shown in Figure 2. wet roofing sheets were kept at 60–70 oC for 1 hour. The
The Fourier transform infrared (FTIR) spectroscopic analysis biopolymer processing temperature was chosen for heating of
of raw cornhusks and pre-treated fibres were performed to the wet roofing sheets to avoid any degradation of the raw
confirm that the extracted fibres were cellulose [5]. materials used prior to reinforcement. Also, it is required for
converting of insoluble PVA crystals to liquid form and for
2) Preparation of composite mixture removal of air bubbles from the casted sheet to reduce porosity.
Pre-treated fibres and PP fibres were mixed with three liters Then, the molded sample was allowed to dry in the shade
of water. Then, 8 kg of OPC cement and PVA were added and outdoors over 3 days. After 3 days, the prepared sheets were
continuously mixed until the mixture became homogenous. removed from the mold and kept for 28 to 30 days for curing.
4) Testing of the prepared sheets
a) Morphological characteristics of prepared roofing
sheet
The internal structural arrangement of ingredients used in
the prepared roofing sheet was identified using a scanning
electron microscope (SEM).

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 b) Water Absorption Test
Thirty days after curing, a water absorption test was
conducted. The three set pieces prepared were dried out at
60oC for 4 hours in an electric oven until the weight became
constant and then immersed in water for 24 hours. The
difference in weight was obtained and water absorbed by
sheets were found and calculated to be given as a percentage
using the eq 1.
Water absorption = [(A – B)/B] x 100% (1)
Where, A = weight of specimen after 24 hours of immersion,
B = weight of the dry specimen
c) Testing of Flexural lord Fig. 4. Setup used to measure flexural load of prepared roofing sheet
The method designed by Eswaramoorthi et al. [9] was used
for the testing of the flexural load using a universal testing
machine and the setup is shown in Figure 4. Then, the prepared
sheets were subjected to a central line load over a simply
supported span of 400 mm. Then, the load was gradually
applied until failure of the specimen occurred.
d) Test of water tightness
The Sri Lankan Standard described for the specification for
concrete roofing semi sheets [10] was referred for the design of
the test specimen. Sheets to be tested was stored at least 5 days
at ambient temperature. The test sample was prepared as
shown in Figure 5. Two small weirs were prepared using
cement mortar to allow water to stand in a pool with a
maximum depth of 10 to 15 mm. Also, air was allowed to Fig. 5. Method of Specimen prepared for the testing of water tightness
circulate freely over all sides of each sheet. Then, the test was
carried out at temperatures 25 °C to 30 °C and at a minimum of III. RESULTS AND DISCUSSION
40% relative humidity for 24 h and it was recorded if drops of Figure 6 shows the shredded cornhusk and pre-treated
water had fallen from the underside of the sheet during the cornhusk samples that were used in the preparation of roofing
period of 20 h. sheet. The neutralized cornhusk sample appeared light yellow
to white color. The comparison of wavenumbers of FTIR
results of raw cornhusk fibres and pre-treated fibres from AHP
pre-treatment, confirmed that the extracted fibres were
cellulose as described in the previous study [5] and the result of
the chlorination method indicates the presence of 79.2%
cellulose in the pre-treated fibres. The tensile loads were 0.076
kN (Fig.7) and 0.049 kN (Fig.8), respectively in pre-treated
fibre bundle with fifty fibres and raw cornhusk bundle with
fifty fibres. Further, the result of the tensile load indicates that
the tensile load was higher in pre-treated fibres compared to
raw fibres. Furthermore, the study of Ashori et al. [11]
indicates that a pre-treated surface is essential in forming
chemical bonds between the fiber and matrix. This mechanism
is clearly shown on the SEM diagram of the prepared roofing
sheet as shown in Figure 9. Further, in SEM diagram a porous
structure can be observed and the diameter of some pores are
Fig. 3. Composite mixture spread on iron mold in a bed of a vibration more than 20 µm. Figure 10 shows the visual observations of
machine wet and dried roofing sheets, which were prepared in the
present study. All sheets had good handling strength and
surface cracks were not observed on both surfaces.
Accordingly, adding 400 g of pre-treated fibres from raw
cornhusk, PVA and PP are sufficient for the reinforcement of
composite mixture with 8 kg of cement to prepare roofing
sheets of length - 0.914 m × width - 0.609 m × thickness -
0.008 m. The average flexural load was 0.6 kN (60 kg) and the
average percentage of water absorption was 17.16% (Fig.11).

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 According to the Sri Lankan standard for concrete roofing semi
sheet [10], a flexural load should not be less than 500 N and
the maximum percentage of water absorption should be less
than 28%. The results of the flexural load and the percentage of
water absorptions are within the SLS standers of the semi
corrugated sheet. The visual observations of the water
permeability test shows some water patches (not water
droplets) on the underside of test specimens due to penetration
of water through the corrugated sheet. The porous structure of
the prepared sheet may be the reason for this penetration. Some
studies [12] have mentioned that a low porosity of the matrix, a
homogeneous dispersion of the fibers in the matrix, and an
optimized percentage of fibres affect the final properties of
cellulose fibre-cement composites. In a product for which a
patent [13] was granted, bentonite clay has been used as a filler
to make a fibre-based sheet. Therefore, adding bentonite clay Fig. 8. Tensile load of pre-treated cornhusks
or other grouts as a filler in the amount of about 10 to 20% to
the composite mixture, proper preparation of homogenous
composite mixture and applying compression force onto the
molded composite mixture to spread on iron frame after
vibration to reduce voids in the prepared corrugated sheets can
improve properties (flexural load, percentage of water
absorption, and water tightness) of the corrugated sheet.
Considering the total cost for materials and energy, cost per
sheet amounted to LKR 291.00, which is less in comparison to
that of a similar sized asbestos roofing sheet.

Fig. 9. The SEM image of casted roofing sheet

Fig. 6. Visual observation of shaded cornhusk and pre-treated fibres from

AHP Fig. 10. (a) Wet and (b) dried prepared roofing sheets

Fig. 11. Variation of Perscentage of water absorbtion

IV. CONCLUSIONS
The earlier alkaline peroxide pre-treatment method was
modified in the present study, so that it could be applied at an
industrial level to pre-treat a bulk amount of cornhusk
Fig. 7. Tensile load of raw cornhusks
effectively, within a short time at low cost. The flexural load
and water absorption characteristics of the prepared corrugated
sheet in the present study are within SLSI standards. The water

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 permeability can be reduced by adding suitable filler when Development), Deputy Director General (Services) and Board
preparing the composite mixture. Proper preparation of of Director of the NERD Centre for their valuable support to
homogenous composite mixture prior to the manufacturing of initiate this research project at the NERD Centre. They also
the roofing sheet and applying compressive force on to the thank the Director, Agricultural Engineering & Machine
composite mixture can improve all properties of the developed Development Department, the Director, Civil Engineering
sheets. Department, and all at the NERD Centre, including technical
staff members, for the success of this project. Special thanks
V. RECOMMENDATIONS go to Mr. B. Gunaratne for making this manuscript a success.
The mechanism indicated in the Figure 12 can be
recommended for the manufacturing of roofing sheet with best REFERENCES
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The Authors would like to express their gratitude to
Director General, Deputy Director General (Research and

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