Utilization of Corn Skin Fiber (Zea mays) as a Gypsum Mixture for Making Ceiling with Epoxy Resin Binder

Abstract

Gypsum materials have been prepared for ceiling applications from a mixture of raw materials: gypsum powders, corn husk fibers and epoxy resins by heat compression method with variations of gypsum powder composition: corn fiber: epoxy resin 25%: 0%: 40%, 23%: 2 %: 40%, 21%: 4%: 40%, 19%: 6%: 40%, 17%: 8%: 40%, and 15%: 10%: 40% wt. Sampling is done in three stages. The first stage of gypsum flour is sifted 100 mesh while the corn husk fiber is treated by immersing 2% NaOH then blended and sieved with a particle size of 100 mesh. The second stage of the filler (gypsum powder and corn husk fiber) is mixed with dry mixing and then mixed with epoxy resin as a matrix and thinner as a catalyst. The third stage of the homogeneous mixture is then inserted into the mold and compacted by heat to be more dense with 1 atm pressure held for 20 minutes at 70 °C. Each ready-mixed gypsum ceiling sample includes: physical properties (density, water absorption, and functional groups), mechanical properties (fracture strength, tensile strength, modulus of elasticity, and impact strength) and thermal properties (melting point) . The results of characterization showed that optimum composition in the composition of gypsum powder: corn husk fiber: epoxy resin 15%: 10%: 40%wt have density value 1,589 x 103 kg/m3, water absorption 2,84%, composed of OH and CH from cellulose and C = C groups of lignin. Mechanical properties with fracture strength 335,47 MPa, tensile strength 1845,43 MPa, modulus of elasticity 238,53 MPa and impact strength 278,9719 kJ/m2. Thermal properties with a melting point of 452.07 oC whose characterization results have met the conventional ceiling board standards. The results of gypsum-based composite gypsum powder material and reinforced epoxy resin fiber skin fiber can be applied as a ceiling roof.