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BY

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--/H2013/01430
DEPARTMENT OF ----
SCHOOL OF ---
INSTITUTE OF ---

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APPROVAL PAGE

This is to certify that the research work ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' by ---, Reg. No. --/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on --- has been approved.

By
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Supervisor                                                  Head of Department.
Signature……………….                           Signature……………….        

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External Invigilator

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DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.

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ACKNOWLEDGEMENT

The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.

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TABLE OF CONTENT

COVER PAGE
APPROVAL PAGE
DEDICATION
ACKNOWLEDGEMENT
TABLE OF CONTENT

1.1 INTRODUCTION

1.2 LITERATURE REVIEW

CHAPTER TWO
2.0       RESEARCH AIM AND OBJECTIVES
CHAPTER THREE
METHODOLOGY
3.0       SCOPE OF THE STUDY
CHAPTER FOUR
4.0       JUSTIFICATION OF THE STUDY
CHAPTER FIVE
5.0       METHODOLOGY
5.1       OBTAINMENT OF THE MATERIAL
5.2       TOOLS USED FOR THE PROJECT ARE ENUMERATED
5.3       MOULD’S PREPARATION
5.4       PREPARATION OF SEPARATOR
5.5       MIXING OF THE AGGREGATE
5.6       CASTING
5.7       DETACHING OF THE MOULD
5.8       ABSORPTION OF WATER TEST
5.9       FLEXURAL STRENGTH TEST

CHAPTER SIX
6.0       RESULT AND DISCUSSION
CHAPTER SEVEN
7.0       CONCLUSION AND RECOMMENDATION
7.1       CONCLUSION
7.2       RECOMMENDATION   

1.0     INTRODUCTION
          This project deals with the design and production of ceiling board using Plaster of Paris [POP] gypsum materials. Plaster of Paris [POP] is a white powdery mixture of gypsum. It has been named such because the first deposit of gypsum was found in Paris. This powder when mixed with water solidifies, but without losing its volume. During manufacturing process, the gypsum is heated and as such, it does not necessarily require any high heat treatment like ceramics and clays [Worrall 1999]. Because of its property to harden with just water, it is used in a number of areas, but most notably for molding decorative objects.
          According to Cornelis and Hurlbut (1985), plaster results from the calcinations of gypsum (CaS04.2H20), which partially dehydrates to produce a hemi-hydrate (CaS04.1/2H2O). Although plaster of Paris a widely used today: its origin dated 9,000 years old and were found in Amotolia and Syria. It is also know fact those 5000 years ago, the Egyptians burnt gypsum in open-air fire, then crushed it into powder and finally mixed with water to make jointing material for the blocks of monuments, used model of plaster taken directly from the human body.

1.1     LITERATURE REVIEW
Plaster is one of the oldest known synthetic building materials: it was used by the Egyptians at least 4000 years ago in the construction of the pyramids, and the Greeks were producing decorative plaster work by 500 BC. The chemistry of the conversion of gypsum to plaster was also investigated early on by chemists such as Le Chatelier (1850 - 1936) and van’t Hoff (1852 - 1911).
Plaster is made by heating gypsum (CaSO4.2H2O) powder, thus converting it to calcium sulphate hemihydrate (CaSO4.½H2O). The hemihydrate is also known as stucco or Plaster of Paris. Probably so named because of the very large deposit of pure gypsum found beneath Paris. When water is added to the stucco, the material rehydrates to give a solid mass of gypsum. This rehydration is accompanied by an increase in temperature and a slight expansion of the plaster, causing the gypsum to perfectly fill a mould.

2.0     RESEARCH AIM AND OBJECTIVES
          The aim of this project is to design and produce ceiling board using Plaster of Paris (POP) gypsum materials.
          The objectives of the study are highlighted below:

• To produce durable light weight building material for ceiling
• To determine the strength of the ceiling board
• To determine its durability.
• To determine the volume and density of the ceiling board.
  

3.0     SCOPE OF THE STUDY
The scope and limitation of this project is basically the design and production of ceiling board using plaster of Paris [POP] gypsum material. In the project , the density of the sample will be determined and the flexural test will be carried out to determine the strength of the sample made up of composite quantity of POP plaster, water and Fibre [know as villas] when subjected to loading.

4.0     JUSTIFICATION OF THE STUDY
The use of plaster of Paris [POP] gypsum ceiling board for ceiling finishing should be adopted and improved because the problems associated with asbestos, which have been used as ceiling finishes for years but with the use of plaster of paris [POP] gypsum material as ceiling finishes which offers sufficient sound insulation and considerable absorption of heart from the roof and hence provide employment opportunity to the producer.

5.0   METHODOLOGY
5.1     OBTAINMENT OF THE MATERIALS
The materials obtained for the project design are plaster of Paris, fiber (villas), water and mould.
The used materials were obtained from the following:-

• A local commercial POP material dealer Mevlon located at Ibrahim Taiwo Road Ilorin, Kwara State 
• The mould used was obtained from Muhummed store at Olomoyoyo Emir’s Road, Ilorin.
• Water supply was obtained from Civil Engineering Department Laboratory.

5.2     TOOLS USED FOR THE PROJECT ARE ENUMERATED THUS:-

• Scrapper
• Measuring tape
• Mixing bowl
• Bucket
• Ranges
• Saw 

5.3     MOULD’S PREPARATION
Already made mould (frame work) is used with dimension 710mm x 710mm x 14mm.

5.4     PREPARATION OF SEPARATOR
The separator is a mixture of premier soap and groundnut oil. It is applied to the mould for easy removal of the sample from the mould.

5.5     MIXING OF THE AGGREGATE
Mixing is the process of thoroughly combining different materials to produce a homogeneous product. In this case water and P.O.P plaster are mixed to form a mortar with mix proportion 3 liter of water to 2kg of P.O.P plaster mixed vigorously to form a homogeneous mixture.

5.6     CASTING
The underlisted steps explain the casting of POP ceiling board:-

• Firstly, the mortal was mixed in a clean container (mixing bowl). 
• Water was poured into the container (mixing bowl) and plaster of Paris was sprinkled over it.
• It took two minutes approximately before absorption.
• Then hand was used to mixed the mortal and shake vigorously to obtain a fully homogeneous mixture.
• The mortar was poured on the mould and sprayed to ensure it cover all the surface of the mould as first layer
• Fibre/villas was added which serves as reinforcement on the poured mortar.
• Similar mortar was prepared and poured on it and it was ensured that it covered the entire surface as well which serves as the second layer.
• Finally, the sample was left for 13 - 15 minutes to set.

5.7     DETACHING OF THE MOULD
The detaching of the ceiling board from the mould was done with the adoption of a special technique after the final setting. The setting period is very important and must be adversely followed to avoid breakages.
5.8     ABSORPTION OF WATER TEST
Water absorption test was carried out on the sample to determine the water absorption capabilities. This test becomes pertinent to measure its response to water leakages from the roof after or during a down – pour. Seven samples was weighted and then immersed in water from one to seven days (1-7) of speculated in sample test, thereafter they were removed from the water and re-weighed as per the speculated days of immersion. The obtained data were recorded against each mass fraction and the mean obtained.

Ms = mass of immersed sample
Md = mass of dry sample
5.9     FLEXURAL STRENGTH TEST
The flexural strength of the sample was determined by carrying out flexural test on the sample produced by supporting the sample at both edge and thereafter placing a wooden rod of known weight at mid-span of the sample (this serves as the medium through which load is applied on the sample). The sheets were loaded until there is a longitudinal crack along the sample to determine the flexural load.
Dimension of sheets = 710mm x 710mm x 14mm
Flexural strength,

 = Modulus of Rupture
F = ultimate load applied to failure (N)
L = length of specimen (mm)
B = breadth of sample (mm)
D = depth of sample (mm2)
The unit of flexural test is N/mm2

6.0     RESULT AND DISCUSSION
The plates below shows how the project was carried out 

 

Plate 6.1: shows the mould used for the project           Plate 6.2: Application of separator to the mould

 

Plate 6.3: Application of villas                                    Plate 6.4: Mixing of aggregate

 

 

Plate 6.5: Casting process one, first layer             Plate 6.6: Casting process two, introduction           
                                                                                                            of villas

 

Plate 6.7: Casting process three, second layer                   Plate 6.8: Demoulding

 Plate 6.9: Waiting for the sample to set        Plate 6.10: Showing of the sample
 
          TABLE 6.1          WATER ABSORPTION TEST

SAMPLE NO	Dry weight (kg)	Wet Weight (kg)	Percentage of water absorption %
SAMPLE1	5.440	7.27	33.64
SAMPLE2	5.129	6.36	24.00
SAMPLE3	4.181	6.49	55.23
SAMPLE4	5.938	8.31	39.95
SAMPLE5	5.030	7.28	44.73
SAMPLE6	4.815	6.55	36.06
SAMPLE7	5.141	7.30	42.00

Ms = mass of immersed sample
Md = mass of dry sample
Sample 1 =            7.27-5.440 x100
5.440
=33.64%

Sample2  = 6.360-5.129X100
5.129
=24.00%
Sample3 =  6.49-4.181x100
4.181
= 55.23%
Sample4   =          8.310-5.938 x100
5.938
= 39.95%
Sample5 =  7.28-5.030 x100
5.030
= 44.73%

Sample6 =  6.55-4.814 x100
4.814
=   36.06%
Sample 7 = 7.30-5.141 x100
5.141
=  42.00%

Average water absorption%= 33.64+24.00+55.23+39.95+44.73+36.06+42.00
7
= 275.61
7
= 39.37%
The average percentage for the water absorption test of the Plaster of Paris POP boards is 39.37% which is a relatively good value. Asbestos board which area inorganic materials has an average water absorption result of 0.5%. This indicates that POP ceiling boards which are organic materials absorb more water readily in case there is any drip or leakage of water from the roof.

TABLE 6.2 FLEXURAL STRENGTH TEST

SAMPLE NO	Maximum Load (N)	Flexural Strength (N/mm)
1	70.24	7.80
2	70.24	5.73
3	70.24	0.24
4	70.24	0.27
5	70.24	1.95
6	70.24	1.43
7	70.24	2.81
	Mean	2.89

 = Modulus of Rupture
F = ultimate load applied to failure (N)
L = length of specimen (mm)
B = breadth of sample (mm)
D = depth of sample (mm2)
The unit of flexural test is N/mm2
Sample1=   f= 70.24N, L=710mm, b=710,        d=3mm
F= fl\bd2    
70.24x710  =49870.4    =7.80N/mm2
710x32                6390

Sample2=   d=3.5mm
70.24x710  =49870.4    =5.73N/mm2
710x112           8697.5

Sample3=   d=17mm
70.24x710  =49870.4    =0.24N/mm2
710x172            205190

Sample4=   d=16mm
70.24x710  =49870.4    =0.27N/mm2
710x162           181760

Sample5=   d=6mm
70.24x710  =49870.4    =1.95N/mm2
710x62               25560

Sample6=   d=7mm
70.24x710  =49870.4    =1.43N/mm2
710x72               34790

Sample7=   d=5mm
70.24x710  =49870.4    =2.81N/mm2
710x52               17750

Base on the test result shown above, the Plaster of Paris POP boards were subjected to a load of 70.24N each which yield a mean flexural strength of 28.9N/mm2. This is as a result of the increasing moisture content test days. The flexural strength 2.89 N/mm2 when compared with that of the asbestos for the same moisture content test days, asbestos has a mean flexural strength of 0.6 N/mm2. This, therefore shows that P.O.P boards are obviously stronger and more durable than Asbestos.

7.0     CONCLUSION AND RECOMMENDATION
7.1     CONCLUSION
Usually, ceiling is the top inside surface of the room. It is an overhead interior or exterior surface that covers the upper limit of the room. Ceiling is usually termed also as finishing’s in the construction of buildings and it is not a structural element. Only that its dead weight/self weight and the imposed load on it is being transferred to the structural member carrying or supporting the roof on the structure or building.
Through, Asbestos are predominantly being used as ceiling materials in buildings of which possess many health hazards. Then, different effort was made to produce ceiling boards from other eco-friendly and less hazardous materials, which prompt the use of Gypsum materials as better ceiling materials than asbestos.
From the water absorption test carried out on the samples, the result shows that plaster of paris (P.O.P) ceiling board has an average 39.49 (%) percent water absorption rate than asbestos ceiling board which has an absorption rate of 0.5 (%) percent. Therefore, it is deduced from the test that plaster of paris (P.O.P) or gypsum board ceiling readily absorb water in case there is any leakage of water from the roof.
It was also deduced from flexural strength test carried on the (P.O.P) boards and on the asbestos boards, the result from the test show the plaster of Paris ceiling boards has a mean flexural strength of 2. N/mm2 compared with that of the asbestos of 0.6 N/mm2. This, therefore conclude that plaster of Paris (P.O.P) boards posses sufficient strength and durability than asbestos.    

7.2     RECOMMENDATION
Plaster of Paris (P.O.P) boards has enough strength to withstand damages due to moisture activates and also more durable than asbestos. Except for its economics perspective as it is usually expensive than the asbestos, P.O.P boards should have gain more use than the asbestos. Therefore, the following recommendations were made base on the carried out projects

• The production of gypsum boards put little or lesser pressure on the environment, which makes the boards not hazardous to the health.
• The boards possess sufficient strength and prove more durable than asbestos, therefore it is prescribe to be use as ceiling finishing.
• The gypsum boards are sound absorbs, electrical insulator, and therefore can also be used as demarcating panels and partition walls.
• P.O.P board used in partition walls can also be used in the installation of dry wall systems for commercial and industrial buildings       

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CHAPTER TWO: The chapter one of this work has been displayed above. The complete chapter two of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' is also available. Order full work to download. Chapter two of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material''consists of the literature review. In this chapter all the related work on ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' was reviewed.

CHAPTER THREE: The complete chapter three of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' is available. Order full work to download. Chapter three of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' detector consists of the methodology. In this chapter all the method used in carrying out this work was discussed.

CHAPTER FOUR: The complete chapter four of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' is available. Order full work to download. Chapter four of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' detector consists of all the test conducted during the work and the result gotten after the whole work

CHAPTER FIVE: The complete chapter five of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material''is available. Order full work to download. Chapter five of ''design and production of ceiling board using plaster of paris (p.o.p) gypsum material'' detector consist of conclusion, recommendation and references.

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