The Measurement and Significance of Green Sheet Properties for the Properties of Hardened Fibre Cement By A M Cooke, M.App.
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1 The Measurement and Signiicance o Green Sheet Properties or the Properties o Hardened Fibre Cement By A M Cooke, M.App.Sc, MRACI, MAIChE Principal, Building Materials and Technology Pty Ltd, Canberra, A.C.T., Australia Summary It is common practice or manuacturers o cellulose ibre cement to measure thickness, density and water content o reshly made ibre cement as manuacturing control measures. The thickness o the green ibre cement accurately relects the thickness in the hardened state and is thereore an instantaneous direct control. However, world standards or ibre cement typically call or ibre cement to be made to a particular strength and although density and water content may be predictive o strength in general, they do not relect the orientation o the ibres and their contribution to the directional strength o inished product. The purpose o this paper is to introduce two tests o the properties o green ibre cement (green sheet tensile test and green sheet modulus o elasticity) and to show how the properties o the green sheets relate to those o the hardened product. It will be seen that both o these green sheet properties relate directly to the strength o the hardened sheet. Introduction The ormation o ibre cement by the Hatschek process is quite complex and the appearance o the reshly ormed green sheets does not by itsel predict the properties o the hardened sheet. Thus it has been common practice to measure the thickness, the density and the moisture content o the green sheet as basic quality measures to control the operation o the Hatschek machine. Control o the thickness is clearly important to ensure that the sheet meets minimal dimensional standards. Since the thickness o the green sheet is not dierent rom the thickness o the hardened sheet, green sheet thickness is directly predictive o the inal hardened sheet thickness. It would be useul to be able to predict the other properties o the hardened sheet and although density and moisture content are partially useul in this regard, they do not predict strength or other mechanical properties except in a very general sense. The purpose o this paper is to introduce two test methods applicable to green sheets and to examine how they may be applied to predict the properties o the hardened sheet. Theory o Cellulose Reinorced Cement Composites (CFRC s) Standards world-wide universally call or ibre cement to be made to speciic lexural strengths [1] despite the act that there are other important mechanical properties that determine the ield perormance o these products. Nevertheless the strength o ibre cement is an important control parameter and we will concentrate here on its prediction. Both lexural and tensile mechanical properties o ibre cement depend on its composition and the orientation o the ibres in the sheet. Fibre orientation depends on the operating conditions within the machine during sheet ormation. Thus, the relative strengths in the machine and cross machine directions are determined by multiple actors. During a lexural or tensile test, the stress carried by the sheet is carried by both the matrix and the ibres until the matrix cracks. The relative amount o stress that is carried by each depends on the relative elastic moduli o the matrix and the ibres, the orientation o the ibres and the proportion o each [2]. 1
2 Because practical CFRC s contain more than the critical volume [3] raction o ibre, we may assume that ater cracking the matrix does not carry any load and that the entire tensile or lexural load is carried by the ibre. We can also assume that ibres in alternate ilms are parallel to each other and lying at the same but numerically opposite angles to the machine direction. Under these assumptions, the ultimate directional lexural or tensile strengths may be predicted by expressions o the ollowing type. CUMD CUXD where v d v v v v CU FU c critical ibrelength MD machine direction XD u (1 ) cos c c 2 c ( ) cos d u (1 ) sin c c 2 c ( ) sin d strengtho thecomposite strengtho the ibre volume ractiono bondstrengtho ibers to matrix ibrelength ibrediameter cross direction ibre (1a ) (1b ) averageangle between ibre and machine direction We can use these expressions to estimate the average angle between the ibres and the machine direction rom the ratio o the measured strengths in the orthogonal directions. I we deine the cross-ratio (XR) as the ratio o the strength in the cross direction to the strength in the machine direction, then the average angle o the ibres ( ) is given by tan 1 (1 ) XR The orientation o the ibres does not change once the sheet has been ormed on the Hatschek Machine and it is reasonable to assume that the length and other properties o the ibres do not change with curing. Thereore, any changes in the measured strengths rom sheet to sheet, relect changes in the bond between the ibres and the matrix, changes in the strength o the matrix or changes in the ibre orientation. The strain at various parts o the stress/strain curve is also observed to change with time and degree o curing. Strain at ailure will be determined by the proportion o ibres that pull out rom the matrix during the test and this is determined by the bond o the ibres to the matrix and the length o a speciic ibre to the nearest matrix crack. I the load transerred rom the matrix to the ibre is insuicient to break it, then the ibre will pull out during racture o the specimen. (2) 2
3 Where a ibre does pull out, the stress at pullout is given by the ollowing general expression and it will be seen that this stress depends on the bond strength. where. l. d l d length o (3) stress in the eiciency actor related to orientation o bondstrengtho the iber iber to iberand diameter o the iber. matrix the iber Bond strength increases with increase in the degree o curing o product. Thereore i the properties o the product are ollowed during the curing period, it will be expected that early strengths will be low, ibres will tend to pull out during the test and strains to ailure will be high and cured strengths will be higher, ewer ibres will tend to pull out during the test and strains to ailure will be low. The act that newly ormed sheets do not disintegrate when handled indicates some bond strength o the ibres to the matrix has already developed. The matrix itsel also has some strength due to compaction. Both o these eects are due mainly to surace related orces and only slightly to the permanent bonds and strengths that develop during curing. Thereore given that the ibres do not change their orientation during curing and that curing is a progressive process, the relative directional strengths o the green sheet will predict the relative strengths in the same direction when the sheet is ully cured. It should be noted that the test does not predict the inal strength because we also have to ensure that the curing o the hardened product is not aected adversely by our choice o materials and that the other processes such as curing are properly carried out. It ollows that we have to separately ensure the quality o cement, silica and pulp is adequate. Thus irrespective o the inal strength, a test o green sheet properties is indicative o the operating conditions in the Hatschek machine and we can use the green sheet test to control these conditions. We also have to be aware o the amount o water absorbed within the composite at the time o test on the mechanical properties, as this speciically aects both the bond between the ibres and the matrix and the properties o the matrix such as its strength and MoE. However, we can control or the eects o water content by standardising the conditions under which the tests on hardened sheets are carried out. Test Methods Green Sheet Tensile Strengths The Hatschek machine o conveyor was stopped and a ull width piece o resh ibre cement sheet approximately 450mm long was taken rom a sheet that had just been removed rom the orming roller. The sheet was urther sampled by cutting out two pieces approximately 450mm wide and transported back to the laboratory supported on a lat board. Care was taken to not unduly disrupt the sheet during handling. Coupons o resh ibre cement 75mm by 150mm were cut parallel and perpendicular to the machine direction using a rectangular wad punch. The specimens were kept rom drying out prior to testing by covering with plastic sheet but no other treatment was 3
4 given. Immediately prior to testing the coupons were uncovered and their width and thickness measured and recorded to the nearest 0.1mm. The specimens were loaded into a cam actuated test grip mounted in a plastics tensile testing machine. The specimen was loaded into the grip by moving the ends o the grip apart in the test machine and inserting it into the grip so as not to disrupt its surace or bend it. The bottom eccentric was closed and the two grips were move together by activating the test machine. Once the ree end o the specimen was inside the ree grip the machine was stopped and the second eccentric was closed. The test machine was activated and the specimen placed in tension and broken. The load at break was recorded and the tensile strength was calculated in the conventional manner and recorded. Figure 1 shows the sampling positions and Figure 2 shows the tensile test arrangement. Green Sheet Flexural Modulus o Elasticity The Hatschek machine o conveyor was stopped and samples taken as described above. Strips o green sheet were cut approximately 50mm wide and 300mm long using a hammer knie. Samples were treated as above prior to testing. The density o the samples was determined and their width and thickness measured and recorded to the nearest 0.1mm. Each strip was placed on a horizontal elevated platorm so that approximately 150mm o the specimen could overhang its edge and that the trailing edge was completely unsupported. The specimen was also placed to be almost touching a sheet o graph paper mounted vertical to the plane o the specimen. The end overhanging the edge o the platorm was allowed to droop under its own weight while keeping the other end securely clamped horizontally. The specimen was allowed to come to an equilibrium position and the arc that it made to the horizontal plane was traced careully onto the graph paper without disturbing its position. Specimens were tested in the machine direction and the cross-machine direction. Figure 3 shows the arrangement o the test specimens during the test. The apparent Modulus o Elasticity o the specimen was calculated as ollows. Assuming that the specimen deormed elastically and delection at any point was due to the sum o the cantilever sel-weight o the specimen, the theoretical delection can be shown to be given by w 1 2 y ( x 2IE 2 where w I E mass/ m x 3 o thesheet 1 12 Momento sectiono thesheetand 3 the ApparentModuluso Elasticityo thesheet The delection o the specimen (y) was determined at 10 mm intervals rom the point o cantilevering (x) o the specimen rom the trace rom the test above assuming that the delection o the specimen had minimal eect on the measured overall length o the cantilever (l). The actor in brackets in the equation above was calculated or each x and a linear regression orced through zero, was used to it the measured delections y x 4 ) (4) 4
5 to determine the slope w 2IE. The density and the dimensions o the specimen and the slope o the regression were used to calculate the apparent Modulus o Elasticity. Comparison with Hardened (Autoclave Cured) Fibre Cement Samples were taken o the same batch o hardened ibre cement in an adjoining sheet to that sampled or green sheet properties. Hardened sheets were sampled and cut to size, saturated or 24 hours in water at 25 C and tested or lexural properties in 3 point bending. A comparison was made o the properties o the hardened ibre cement and the green sheet to see i the hardened sheet properties could be predicted rom those o the green sheets. Test Results and Analysis 2. Green Sheet Tensile vs Hardened Modulus o Rupture (MoR) Table 1 below shows a comparison o the green sheet properties with the MoR o the same sheet that has been cured and hardened. Mechanical strengths are shown in the green and hardened states in both the cross and machine directions. Analysis o the results i. Correlations between the variables. Table 2 shows the partial correlation coeicients between the variables. For the purposes o this analysis, the tensile and lexural strengths were aggregated into one table o values. It will be seen rom the table that the only variables that are signiicantly correlated are Moisture content and the Density o the sheet and MoR (hardened lexural strength) and the Green Sheet Tensile Strength. It would be expected that the moisture content would tend to decrease as the density increases given that the nominal ormula o the mix was the same in all cases even though the cellulose content varied. This is expected because the sheet is compressed during ormation and the removal o more moisture will compact the sheet and increase its density. The relationship is shown in Figure 4 below where it will be seen that there is considerable scatter. (Note that only 8 points are shown despite there being 18 points in the tensile data. This has occurred because the 18 points o tensile data represent 9 samples o data in each o the machine directions and one outlier has been eliminated.) It is signiicant that the second most important determinant o density is cellulose content and that the correlation coeicient also shows that decreasing cellulose content increases the density. It may be expected that there will be a better correlation between the density and a combination o cellulose and moisture content but this is not explored here. ii. Signiicant Relationships The relationship between the Green sheet tensile strength and the MoR is most signiicant and it clearly shows that there is a direct relationship between these measures. Cellulose content has a small eect on the MoR but the density is not particularly signiicant. To some extent this is due to the aggregation o the numbers in the analysis as this splits the results into two groups associated respectively with the cross and the machine direction strengths. (Figure 5). However, the results clearly show that there is a strong correlation between the measured green sheet tensile directional strengths and the corresponding directional strengths o the hardened sheet. 5
6 The results can be explained in the act that the cellulose ibres are the principal contributors to the strength o the inal composite and that the development o strength is due to the progressive development o bond between the matrix and the ibres during curing. The dierence between the machine and the cross directions is most apparent and this is due entirely to the orientation o the ibres relative to the machine or the cross directions. The green sheet tensile strength can thereore be used to determine the proper operation o the ibre directional devices within the operating machines. It can also be used to give an indication o the inal strengths o the hardened products. Figure 5 shows the relationship between green sheet tensile strength (kpa) and the inal hardened lexural strength. The regression equation relating these parameters explains a little less than 80% o the total variation o MoR. There is however a considerable scatter o results about the trend line and clearly there are other actors that are aecting our prediction. It has been inerred above that it is necessary to control other parameters in the preparation o the raw materials and the ormation on the machine, so this is not particularly surprising since the results presented here were gathered over an operating period o approximately one week. It is also important to note that we are comparing the lexural strength o the hardened product with tensile strength in the green product and that a better correlation could be expected between a hardened tensile strength. Unortunately tensile data rom hardened sheets was not available and this comparison could not be made. 2. Green Sheet Modulus o Elasticity Table 3 presents the results o the measured delections o one set o specimens o 8mm thick green sheet together with the calculated values o the bracketed actor in equation 4 above. A set o data is given or the cross and the machine directions. The graphs in Figures 6 & 7 show the delection. Table 4 shows the results o the calculation o MoE and comparison o the green sheet MoE with typical hardened sheet properties. It is clear that the regression calculation to determine the slope o the delection/actor curve is very signiicant and the actual and expected delections are close to identical. We can thereore conclude that the delection o the specimen can be represented as though it is elastic. It may be noted that the author ound that it is necessary to limit the amount o overhang to avoid breaking o the specimens and that the allowable overhang seems to be related to thickness o the specimens It is probable that the overhang o specimens may have to be adjusted in accordance with thickness to maintain specimens in the elastic range. The comparison o the green and hardened specimens is quite interesting. The MoE o the hardened and the resh specimens are not closely correlated, however the apparent green sheet MoE is correlated with the inal hardened strength. Since hardened MoE is a truer measure o MoE in this case, this implies that the mechanism o delection o the green sheet depends more on the ibres than the matrix. Hardened MoE is determined rom the slope o the irst approximately elastic portion o the Stress/strain curve and is dependent on the matrix as well as the ibres. Thus there is little dierence between the machine and cross direction MoE s. In the green state however, the tensile strength o the matrix can be considered to be almost zero and the entire stress in the specimen is taken by the ibres. The compressive strength o the reinorced matrix can however be considered high due to point to point contact o the non-ibrous material held in place by the ibres. Thus the green specimens 6
7 delect as though they were elastic aggregates o the ibres. Thus the MoE relects the ibre content and orientation and ultimately is better correlated with hardened strength. Conclusions and Final Remarks Conclusions It can be seen rom the above that the mechanical properties o the green sheets relect the same properties in the hardened sheets. Thus the measured properties o the green sheet can be used to ensure that sheets are being properly ormed on the production machinery beore they are put to the expense o curing. That the properties o the green sheet relect those o the hardened sheet should not be surprising, since the properties o the hardened sheet are determined in the main by the development o bond strength between the ibres and the matrix. Providing nothing happens to alter the course o normal development o bond and matrix strength, it should be possible to observe a progressive change in the properties o the sheet with curing up to a limit determined by the ability o a maximally bound ibre to carry load. The two test methods proposed give predictive results o the strength o the hardened properties. Direct tensile strength is easier to calculate but requires additional equipment or its perormance. The measurement o apparent MoE is extremely simple but requires more sophistication in the calculation although it should be easy to automate this with modern computers. Final Remarks Only limited data is presented here and there is a need to extend the scope o the investigation. It would be useul to extend the investigation to include the comparison o direct tensile strengths and strains o green sheet and hardened sheets as this may prove more ruitul than the present techniques to the understanding o the mechanisms at work during ailure o specimens. It would also be useul to carry out more extensive work on the relationship between the cross and machine direction measurements to assess the accuracy o the predictions. Extension o the present work is recommended. Having said that however, it would appear that the MoE test is predictive, is easily within the scope o most laboratories and requires little equipment or its implementation. A word o warning may be added in conclusion because it is common in the industry to ind that sheets may ail by delamination. This may occur even with otherwise perectly ormed sheets and is oten due to the use o stale mix ater a shutdown. It is not known whether the results presented here would relect poor interlaminar bond ormation although since they were carried on good sheet, but it is expected that the MoE test would give some early indication. It would be useul or the manuacturer to have a predictive green sheet ILB test that could point to problems in the hardened sheet. A peel test similar to that used to test adhesives could be useul, however some work would need to be done to develop and standardise it. Reerences: 1. Standards such as, ASTM C1186 Standard Speciication or Flat Non-Asbestos Fibre-Cement Sheets, 7
8 ASTM C1225 Standard Speciication or Non-Asbestos Fibre-Cement Rooing Shingles, Shakes and Slates ASTM C1288 Standard Speciication or Discrete Non-Asbestos Fibre-Cement Sheets Interior substrate Sheets AS/NZS Cellulose-cement products - Corrugated Sheets AS/NZS Cellulose-cement products - Flat Sheets 2. Hannant D J, Fibre Cements and Fibre Concretes Chapters 3 and 4, John Wiley and Sons, Ibid. Section 3.3 8
9 Samples and Test Coupons 3.66 m Green Sheet 1.50 m Sampling position Figure 1 Application o Force Section through Grip showing Eccentric Cam Fibre Cement Specimen Section through Grip showing Eccentric Cam Application o Force Green Sheet Tensile Test Figure 2 9
10 Green Sheet Density kg/m3 perpendicular to sheet Graph paper mounted Pencil used to trace surace o drooping sheet on graph paper Sheet droops under its own weight Strip o Green Sheet supported on block and clamped to it Dotted line shows original position o sheet Solid line inal position y Trace o cantilevered Specimen l x Delection o MoE Specimen Figure 3 Determination o Green Sheet MoE Figure 4: Greensheet Density vs Water Content Moisture Content % 10
11 Delection y (mm) Delection y (mm) Hardened Sheet MoR MPa Figure 5: Hardened Sheet MoR (Mpa) vs Green Sheet Tensile (Kpa) MoR = 1.108GrShT R 2 = Green Sheet Tensile Strength KPa Figure 6: Machine Direction Delection vs Cantilever Cantilever Distance x (mm) Figure 7: Cross Direction Delection vs Cantilever Cantilever Distance x (mm) 11
12 Specimen Moisture Density Cellulose Number % Kg/m3 % XD MD XD MD Statistics Table 1: Green Sheet and Hardened Sheet compared Green sheet properties Tensile Strength (KPa) Hardened Properties MoR (MPa) Maximum Minimum Average Std Dev'n MoR 1 MoR GS Tensile Moisture Density % Cellulose GS Tensile Table 2: Correlation Matrix Moisture Density % Cellulose Table 3: Results o Green sheet MoE Measurements Delection mm Cantilever Bracketed Cross Direction Machine Direction mm Factor #1 #2 #3 Average #1 #2 Average
13 Table 4: Calculation o MoE and Comparison MD XD Slope o Delection/Factor Curve Apparent MoE N/mm2 (MPa) Regression Statistics Multiple R R Square Typical Hardened sheet Properties MoR (MPa) MoE (GPa)
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