POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

Chapter 3

METHODOLOGY

The study falls under the category of Experimental Method since it functions

as a systematic and scientific approach wherein the researchers manipulate one or

more variables, at the same time control and measure any changes in other

variables.

Herein, the independent variables were the main raw materials used in the

manufacturing process of the GFRG blocks namely the glass fibers and calcinated

gypsum. The standard tests used to assess the effectiveness of the conventional

CHBs (ASTM C140/C140M, ASTM C1006-07, and ASTM E119-00a) were also

retained and remained unchanged, making it classified under the same manner. On

the other hand, the variables controlled and measured by the researchers, therefore

termed as those under the dependent variables, are the Raw Material Resources,

Mechanical Properties, and Mix Proportions.

Through experimental method, the researchers were able to provide a

logical, scientific, and systematic way of manufacturing GFRG blocks which serves

as effective block replacement.

This chapter presents the discussion on the research design of the study, the

flowchart of research design/process, description of research instruments used,

material requirements, mix design, specimen details, and laboratory experiment/field

experiment.
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Research Design

This section describes how the researchers approached the investigation for

their scope of the study. As an overview of the means that the researchers have

undertaken, the researchers highlighted the following details:

a. Sample

The specimens of focus were the 15 GFRG blocks composed of glass

fibers and gypsum.

b. Setting

Bestowed with ISO Certification for Standard Testing of Specimens, the

laboratory experiments were conducted at E.B Testing Center during the

summer term of the academic year to provide the needed time and in-

depth analyzation of data.

c. Method/Approach

Testing Standards namely ASTM C140/C140M – 15, ASTM C1006 – 07,

and ASTM E119 – 00a served as the primary source of data to

demonstrate the mechanical properties of the GFRG blocks.

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Flowchart of Research Design/Process Flowchart

Gathering of Calcinated Gypsum,

Glass Fiber and Portland Cement

Manufacturing of Glass Fiber Reinforced Gypsum

Applying Standard Test Methods to block samples

Comparison of the Results after Conducting

Standard Test to the conventional block samples

Is there any
significant difference between
the mechanical properties of
GFRG and CHB?

YES

NO Based from
The comparison, is using NO
GFRG better than
YES
using CHB?

Recommend Using GFRG Blocks

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Description of Research Instruments Used

In this study, the researchers divided the instruments into two categories:

1. for sample manufacturing operations; and

2. for sample testing methodologies

Under the sample manufacturing category, the instruments used during

operations were a block molder machine, shovel, mixing tub, tamping rod, and curing

kiln. For the sample testing methodologies, the researchers generated further

classifications for the types of materials used.

To identify the Density and Water Absorption of the specimens, Weighing

Scale/Balance, Water Tank, Measurement Devices such as Calipers, Micrometers,

Steel Scales, Dividers, and an Oven were used, as per ASTM C140. Moreover, a

Universal Testing Machine (UTM) was also used to measure the Compressive

Strength of the specimen.

In compliance with ASTM C1006-07 for Tensile Strength Testing, Bearing

Rods, Supplemental Bearing Bar or Plate, and Universal Testing Machine were

used.

Fire Resistance testing under ASTM E119 occupied a whole facility for its

instrumentation. This facility is equipped to perform standardized tests for flame

retardancy and fire resistance.

All apparatus stated should be in best condition, well-calibrated, and

standardized by organizations that issue the regulations of methodologies such as

the ASTM.
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Material Requirements

Based on the required specifications and qualities to achieve effective block

serviceability, the materials needed in the manufacturing of GFRG blocks should

conform to specific qualifications. This category illustrates the requirements of all the

raw components in the creation of the blocks:

a. Gypsum

Gypsum is an industrial waste product which is the main raw material of

GFRG. Through heating process, it becomes calcined gypsum that

serves as a good base for gypsum plaster. The calcined gypsum shall

conform to ASTM C471M – 01 which is the Standard Test Method for

Chemical Analysis of Gypsum and Gypsum Products.

b. Glass Fiber

Glass Fiber acts as the main reinforcing material for the GFRG blocks

which is known for its distinct advantage of combining a very high

strength with low density and, most of all, a very reasonable cost. The

glass fibers shall conform to ASTM C1666/C1666M – 08 or the Standard

Specification for Alkali Resistant (AR) Glass Fiber for GFRC and Fiber

Reinforced Concrete and Cement.

c. Water

Mixing water shall be free from deleterious matter that may interfere with

the color, setting, or strength of the facing and backing and shall conform

to ASTM C1602 which stands for the Standard Specification for Mixing

Water Used in the Production of Hydraulic Cement Concrete.

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d. Waterproofing Chemicals

The focus of these waterproofing standards on admixtures concentrates

on the penetration of moisture or water through a treated surface or

membrane. Waterproofing Chemicals shall conform to ASTM C494,

Type S – Specific performance admixtures.

e. Retarder

Retarding admixtures cause a decrease in the rate of hydration of

hydraulic cement and lengthen the setting time of concrete. Such

admixtures shall conform to ASTM C494, Type B – Retarding

Admixtures.

f. Setting Consistency Acid

Accelerators are used to shorten setting time and to increase early

strength development. This admixture shall conform to ASTM C494,

Type C – Accelerating Admixtures.

Mix Design

This section provides specific mix proportions and designs applied in the

manufacturing of the GFRG blocks. The proportions were based on the application

of the standard mix designs from the traditional CHB incorporated with the works of

previous researches in their design proportions of GFRG panels.

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Table 1

The Mix Design Proportions

Raw Materials Units

Plaster (Gypsum) 61 kilograms
300-350 mm in length,
Glass Fiber 1280 grams
Water 40 liters
Waterproofing 1650 grams
Retarder 27 grams
Setting Consistency Acid 7 grams

Note: The Mix Design Proportions stated in the table above is for the

manufacturing of the 15 samples that undergone the Testing Methodologies.

Specimen Details

Exhibiting the study’s end product, this section provides the actual specimen

appearance with its corresponding dimensions.

Figure 1. Specimen Dimensions

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Laboratory Experiment/Field Experiment

A. ASTM C140 / C140M – 15: Standard Test Methods for Sampling and Testing

Concrete Masonry Units and Related Units

These test methods provide general testing requirements for application to a

broad range of concrete products. Those general testing requirements are included

in the body of this standard.

In this Sample Testing methodology, three (3) mechanical properties of

concern were calculated namely the Density, Water Absorption, and Compressive

Strength of the masonry unit specimen.

For the computation of the Density and Water Absorption, the immersed,

saturated and oven-dried weight (kg) of the specimen was first measured.

The immersed weight of the specimen was drawn from soaking the samples

underwater at a temperature of 60 to 80°F [15 to 27°C] for 24 to 28 h such that the

top surfaces of the specimens were at least 6 in [150 mm] below the surface of the

water, afterward weighing the specimens while suspended by a metal wire and

completely submerged in water.

After removing the specimens from water and allowing it to drain by placing

them on a 0.375-in [10-mm] or coarser wire mesh, the visible surface water was

removed with a damp cloth. Then, by weighing the sample 60 ± 5 s following removal

from water, the saturated weights of the specimens were identified.

Subsequently, all specimens were dried in a ventilated oven at 230 6 9°F

[110 6 5°C] for not less than 24 h and until two successive weighings at intervals of
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2 h show an increment of loss no more than 0.2 % of the last previously determined

weight of the specimen. This weight is then assigned as the dried weight of the

sample.

The Density of the specimen (kg/m3) was calculated by dividing the oven-

dried weight by the difference between saturated weight and immersed weight (all in

kilograms) and subsequently multiplied the result by 1000.

For the calculation of Water Absorption of the specimen (%), the oven-dried

weight was subtracted from the saturated weight then divided by the value of the

oven-dried weight and finally multiplied by 100.

By applying a compressive axial load to masonry units, compressive strength

results were also recorded. The Net Area Compressive Strength of the specimen

(MPa or psi) was determined by dividing the maximum compressive load (N or lb)

by the average net area of the specimen (mm2 or in2). For the determination of the

Gross Area Compressive Strength of the specimen (MPa or psi), the maximum

compressive load (N or lb) was divided by the gross area of the specimen (mm2 or

in2). The value of the maximum compressive load was determined through the use

of the Universal Testing Machine (UTM). This procedure was conducted to get the

compressive strength needed in this study.

B. ASTM C1006 – 07: Standard Test Method for Splitting Tensile Strength of

Masonry Units

Masonry units alone and within assemblages commonly fail in a tensile mode

when loaded in compression to failure. These tensile stresses result from differences

in modulus of elasticity and Poisson’s ration between the masonry unit and mortar.
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Additionally, the dissimilarity in behavior of the grout within cores of masonry units

under load leads to tensile stresses in the units and results in a splitting failure.

The test value provides an indicator of masonry-unit splitting tensile strength.

Additionally, the presence of defects such as visible voids or impurities in masonry

units may be revealed.

This method covers the procedure to measure the tensile strength of the

specimen to be used in this study. Initially, the bearing rods were aligned parallel to

each other and placed with the centerline of the plates then eventually the load was

applied. To identify the tensile strength (kPa or psi), the quotient of twice the

maximum applied load indicated by the testing machine (kPa or psi) over pi(π)

multiplied to the product of split length (mm or in) and the distance between rods

(mm or in) were calculated

C. ASTM E119 – 00a: Standard Test Methods for Fire Tests of Building

Construction and Materials

The performance of walls, columns, floors, and other building members

under fire exposure conditions is an item of major importance in securing

constructions that are safe, and that are not a menace to neighboring structures nor

to the public. Recognition of this is registered in the codes of many authorities,

municipal and other. It is important to secure balance of the many units in a single

building, and of buildings of like character and use in a community; and also to

promote uniformity in requirements of various authorities throughout the country. To

do this it is necessary that the fire-resistive properties of materials and assemblies

be measured and specified according to a common standard expressed in terms that

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are applicable alike to a wide variety of materials, situations, and conditions of

exposure.

Such a standard is found in the methods that follow. They prescribe a

standard exposing fire of controlled extent and severity. Performance is defined as

the period of resistance to standard exposure elapsing before the first critical point

in behavior is observed. Results are reported in units in which field exposures can

be judged and expressed.

The methods may be cited as the "Standard Fire Tests," and the performance

or exposure shall be expressed as "2-h," "6-h," "~-h," etc.

When a factor of safety exceeding that inherent in the test conditions is

desired, a proportional increase should be made in the specified time-classification

period.

The ASTM Manual did not provide a direct set of procedures under this

Standard Test Method. The researchers consulted a certified facility with

standardized instruments for the gathering of data needed for Fire Test Standards.