A Quality Analysis of the Thickness of Part and Corrugated Asbestos Roofing Sheets of Emenite Limited
Chapter One
Purpose of the study
Consumers of goods and services rely on quality standard products displayed for consumers. What is responsible for this trend? Is statistical quality control standard still made use of in industries? This are what this research project intend to solve and make appropriate recommendation.
The project research will
- Determine the process standards and establish the process capability
- Check if the process average and variability are under control in respect of the measurement of flat sheet.
- Check if the process average and variability are under control in respect of the measurement of corrugated sheets
- Set up appropriate control charts for monitoring the future output of the process.
CHAPTER TWO
LITERATURE REVIEW
Overview of Asbestos
Asbestos is the name given to various forms of naturally occurring fibrous silicate materials. These materials all have in common their eponymous asbestiform habit: long (1:20 aspect ratio), thin fibrous crystals, with each visible fiber composed of millions of microscopic ‘fibrils’ that can be released by abrasion and other processes. Asbestos is a chemically inert material that is fire-resistant and does not conduct heat or electricity, thus making it a commonly used insulator.
Asbestos is a term used to refer to six naturally occurring silicate minerals. All are composed of long and thin fibrous crystals, each fiber being composed of many microscopic ‘fibrils’ that can be released into the atmosphere by abrasion and other processes. Asbestos is an excellent electrical insulator and is highly heat-resistant, so for many years it was used as a building material. However, it is a well-known health and safety hazard, and today, the use of asbestos as a building material is now illegal in many countries. Inhalation of asbestos fibres can lead to various serious lung conditions, including asbestosis and cancer.
Archaeological studies have found evidence of asbestos being used as far back as the Stone Age to strengthen ceramic pots, but large-scale mining began at the end of the 19th century when manufacturers and builders began using asbestos for its desirable physical properties. Asbestos was widely used during the 20th century until the 1970s, when public recognition of the health hazards of asbestos dust led to its prohibition in mainstream construction and fireproofing in most countries. Despite this, and in part because the consequences of exposure can take decades to arise, at least 100,000 people per year are thought to die from diseases related to asbestos exposure.
Despite the severity of asbestos-related diseases, the material has been widely used all around the world, and most pre-1980s buildings are thought to contain asbestos. Many developing countries still support the use of asbestos as a building material, and mining of asbestos is ongoing, with top producer Russia having produced about one million tonnes in 2015.
It has high tensile strength, insoluble and odorless. Due to these properties, asbestos has been used in a wide range of manufactured goods including roofing materials, ceiling and floor tiles, paper and cement products, textiles and coatings as well as friction products such as automobile clutch, brake, transmission parts and sewer pipes. When used due to its resistance to fire or heat, it is woven into fabrics or mats, while when used for building material, such as roofing sheets it is often mixed with cement.
The major producers of asbestos include Canada, Kazakhstan, Ukraine, Russia, India, South Africa and Zimbabwe. Asbestos is a hazardous material with extremely fine fibers and can remain suspended in air for hours. If handled without caution, it may cause serious health problems such as asbestosis, lung cancer and mesothelioma.
Types of Asbestos
- Chrysolite Asbestos: This is the most commonly used form of asbestos and can be found today in roofs, ceilings, walls and floors of homes and businesses. Although it is more prevalent, some studies show it takes more exposure for chrysolite than other types of asbestos to develop related diseases.
- Chrysotile Asbestos: The fibers are generally finer with high flexibility and good heat resistance. It accounts for about 90-95% of asbestos used in commercial products like cement, gaskets, brake pads, brake linings and roofing materials.
- Amphibole Asbestos: These types have fibers that are straight and longer than chrysolite fibers. Studies suggest that it may take less exposure to amphibole asbestos to cause mesothelioma than chrysolite asbestos.
- Amosite Asbestos: According to the American Cancer Society, exposure to amosite asbestos creates a higher risk of cancer in comparison with other types of asbestos. In its natural state, amosite is known as the mineral grunerite. Amosite asbestos offers good tensile strength and heat resistance.
- Actinolite Asbestos: This is an amphibole that is generally dark in colour. It can appear in multiple forms such as dense and compact or brittle and fibrous, along with different colours including grey, brown or green.
- Crocidolite Asbestos: Multiple asbestos studies suggest crocidolite asbestos may be responsible for more deaths than any other type of asbestos because its fibers are so thin, about the diameter of a strand of hair. Crocidolite is also known as ‘Blue Asbestos.’ This form can be translucent or nearly opaque. Crocidolite containing materials are also more brittle than other amphibole asbestos products, meaning they break down sooner and can more readily lead to asbestos exposure.
CHAPTER THREE
MATERIALS AND METHODOLOGY
General
The purpose of this work is to carryout an analysis of the thickness of part and corrugated asbestos roofing sheets of Emenite limited. The materials used for casting samples are described below.
Materials used
Cement
The cement used was Portland pozzolana cement fly ash based (43 grade) conforming to IS 1489-1991.Portland pozzolana cement (PPC) is manufacture by intergrinding of OPC clinker with 10 to 25% of pozzolanic material. A pozzolanic material is essentially a siliceous or aluminous material which while in itself possessing no cementitious properties, which will, in finely divided form and in the presence of water, react with calcium hydroxide, liberated in the hydration process, at ordinary temperature to form compounds possessing cementitious properties. The pozzolanic materials generally used for manufacture of PPC are calcined clay or fly ash.
CHAPTER FOUR
RESULTS AND DISCUSSIONS
From various mix proportions and tests the following results are obtained. The compressive strength and average compressive strength of cement mortar cubes with 1:2,1:3 and 1:4 cement mortar ratio are shown in Table 3 and 4 respectively. The compressive strength of 1:2 cement mortar cube with various percentage of polyester fibre , Polypropylene fibre and glass fibre are shown in Table 5,6 and 7 respectively. The flexural load, impact strength and water absorption of corrugation of roofing sheets are shown in the Table 8, 9 and 10 respectively. Table 3 Compressive strength of cement mortar cubes with 1:2, 1:3 and 1:4 cement mortar ratio
CHAPTER FIVE
CONCLUSIONS
This study examined the quality analysis of the thickness of part and corrugated asbestos roofing of Emenite Ltd.
Based on the experimental results of this project, the following conclusions are drawn. Polyester, Polypropylene and glass fibres of 0.2%, 0.4%, 0.6%, 0.8% and 1% from total volume of cement are added to 1:2 cement mortar and compressive strength of the mortar is found out experimentally. Polyester fibre shows higher compressive strength at 0.4%, polypropylene fibre shows higher compressive strength at 0.8%, Glass fibre shows higher compressive strength at 0.2% addition of fibres.
Bending Strength
The bending strength of the specimen is increased by using a polyester fibre. Glass fibre shows 38% less bending strength compared to that of polyester fibre. Polypropylene fibre shows 83% lower strength than the polyester fibre.
Impact Strength of Corrugations
The results of the impact strength of fibre reinforced corrugated sheets are given in Table-9. It shows glass fibre has absorbed 47 % higher energy than polyester and polypropylene fibres.
Water Absorption
The water absorption of tiles is within the standard value of 6%. For a given mix the water requirement decreases due to the addition of fibres.
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