FABRICATION OF ROOFING SHEETS
USING AGRICULTURAL WASTE
MATERIALS
Research Proposal
By: CHRISHVIN MADUSHANKA FERNANDO
CL- HDCVL-PR-01-22
TABLE OF CONTENTS
TABLE OF CONTENTS ...................................................................................................... 1
LIST OF FIGURES ............................................................................................................... 2
LIST OF TABLES ................................................................................................................ 3
ACKNOWLEDGMENT ....................................................................................................... 4
ABSTRACT .......................................................................................................................... 5
INTRODUCTION ................................................................................................................. 6
RESEARCH AIM AND OBJECTIVES ............................................................................... 8
2.1 Research Aim .................................................................................................... 8
2.2 Research Objectives .......................................................................................... 8
LITERATURE REVIEW ...................................................................................................... 9
3.1 Introduction to Sustainable Building Materials ................................................. 9
3.2. Use of Agricultural Waste for Construction .................................................... 10
3.3. Advantages of Straw Reinforced Mud Composites ........................................ 10
3.4. Roofing Materials with Agricultural Waste .................................................... 11
3.5. Straw-Reinforced Composites ......................................................................... 12
3.6. Research Gap & Justification .......................................................................... 13
RESEARCH METHODOLOGY AND DATA COLLECTION STRATEGY .................. 14
4.1 Research Framework ....................................................................................... 14
4.2 Materials and Mix Ratio Justification ............................................................. 15
4.3 Fabrication Process .......................................................................................... 15
4.4 Testing Procedures .......................................................................................... 16
4.5 Summary and Strategic Suggestions ............................................................... 18
PROPOSED PLAN AND TIMELINE ................................................................................ 19
REFERENCES .................................................................................................................... 20
1
LIST OF FIGURES
Figure 1: Agricultural byproducts (a) rice husk, (b) bagasse and (c) straw .......................... 6
Figure 2: Several natural fibers which are currently utilized in the construction industry ... 9
Figure 3: Microscopic images of the inner and outer surfaces of the rice straw
(Montesinos-Martínez et al., 2024) ............................................................................. 11
Figure 4: Schematic of enhanced thermal insulation using areca nut husk and bagasse
fiber-reinforced epoxy composite (Mahmud et al., 2025)........................................... 12
Figure 5: Process of methodology ....................................................................................... 14
Figure 6: (a) Raw straw drying under cover, (b) Raw straw, (c) Manual forage cutter and
(d) Fiber cut with the manual cutter (Montesinos-Martínez et al., 2024). .................. 15
Figure 7: Experimental set up various mix panel and strain curve (Jayaraman et al., 2023)
..................................................................................................................................... 17
Figure 8: DRPL-I Thermal Conductivity Tester (Zhang et al., 2023) ................................ 17
2
LIST OF TABLES
Table 1: Common Agricultural Waste Materials Used in Construction (Rabi et al., 2009) 10
Table 2: Agricultural Wastes Utilized in Roofing Material Production (Saravanan et al.,
2017) ............................................................................................................................ 12
Table 3: Mechanical Properties of Straw-Reinforced Composites ..................................... 13
3
ACKNOWLEDGMENT
I'd like to take this opportunity to thank everyone who contributed to the research's
successful completion. Foremost in my appreciation is my supervisor for their everlasting
support, their invaluable guidance, and constructive observations during the course of the
study. Whatever little wisdom and encouragement I received from them were most helpful
in maturing this study. I truly appreciate my institution for providing the enabling
environment for conducting this research. Special mention goes to laboratory personnel and
technical assistants for their help and support during material preparation and testing. I
acknowledge the colleagues and associates whose contributions have been stimulating to
discussion and supportive in all aspects, thereby benefiting this research. I also appreciate
the local communities and practitioners who provided relevant information and insights
beneficial for the study. Finally, I sincerely acknowledge my family and friends for their
unyielding support, patience, and encouragement throughout this journey. I would never
have reached this milestone without their faith in me.
4
ABSTRACT
The construction industry’s dependence on traditional building materials such as cement and
steel are highly carbon-emissive, resource-exhaustive, and an increasing expense, resulting
in low costs of housing for society's marginalized groups. In Sri Lanka, agricultural waste
such as paddy straw is often discarded or burned, thereby adding to environmental troubles.
Using this waste in construction would provide a sustainable and cost-effective alternative
and solve durability and insulation problems. The aim of this study is to assess the feasibility
of paddy straw-reinforced roofing sheets made of mud as an eco-friendly alternative to
conventional roofing. The study aimed at enhancing mechanical strength, thermal insulation,
and water resistance by reinforcing mud with paddy straw. Experimental methods involve
the preparation and testing of roofing sheets for tensile and compressive strengths, thermal
insulation properties, and water absorption behavior. The tests on durability and performance
were carried out according to ASTMs. The findings of the study could pave the way to
constructing an affordable and sustainable roofing material for rural and low-income housing
in Sri Lanka, thereby linking to the broader search for eco-friendly construction material.
5
INTRODUCTION
Carbon emissions, energy-heavy consumption, and resource depletion have made a
significant mark on the environment by the construction industry. Traditional materials such
as cement, steel, and bricks are produced through processes consuming a lot of energy that
contribute to global warming (Tay et al., 2018). As a result, sustainable alternatives are
drawing attention, especially in developing nations wherein the material cost is high.
Agriculture waste reinforcement of construction materials presents a feasible solution; this
includes rice husk, bagasse, and straw as indicated in Figure 1.1. These byproducts lend
several advantages: biodegradability, thermal insulation, and lower environmental impact
(Lawanwadeekul et al., 2024). Studies have shown their suitability for walling, insulation,
and roofing (Murali et al., 2020).
(a) (b) (c)
Figure 1: Agricultural byproducts (a) rice husk, (b) bagasse and (c) straw
Paddy straw is readily available in Sri Lanka and is often burned or left to rot and decay,
causing air pollution, while not making for the efficient use of the resource (Madu &
Sundararajan, 2018). It is, however, a potential reinforcement in sustainable construction,
being beneficial both environmentally and economically. Although studies have shown the
benefit of straw fibers to improve the mechanical performance of earthen construction,
scarce studies have looked into roofing sheet applications (Murali et al., 2020). The fibrous
nature of paddy straw may enhance the mechanical strength and water and thermal insulation
properties of mud-based composites.
They are trained on data until October 2023. Construction materials cost so very much in Sri
Lanka; reliance on imported cement and steel makes housing within the reach of low-income
groups impossible. Affordable and sustainable alternative sources are paddy straw-
reinforced muds. Traditional mud-based materials are not durable and do not resist water.
6
However, the property improvement through due reinforcement of paddy straw makes them
flexible for roofing (Tay et al., 2018). The country is hot, humid, hence demanding thermal
efficient materials. Studies state that insulation from fiber-reinforced mud composites is
better than metal or asbestos, thus reduces indoor temperatures and energy use (Ahmed et
al., 2016).
However, despite the associated advantages, there are still gaps in experimental data
regarding mechanical strength, water resistance, and insulation properties of paddy straw-
reinforced mud roofing sheets for Sri Lankan climatic conditions (Murali et al., 2020; Madu
& Sundararajan, 2018). There is also a lack of comparative study against conventional roof
materials and optimization of mixture ratios for durability (Tay et al. 2018). Thus, this study
intends to fill these gaps through experimental evaluation of mechanical, thermal, and water-
resistant properties, providing an affordable, sustainable solution for rural and low-income
communities. The construction industry should further pursue environmentally friendly
solutions to enhance affordability and sustainability.
7
RESEARCH AIM AND OBJECTIVES
Research is undertaken on paddy straw-reinforced mud roofing in view of the need for
sustainable materials exercising strength, insulation, and water resistance as alternatives to
traditional roofing.
2.1 Research Aim
To investigate the viability of producing roofing sheets with paddy straw as reinforcement
in a mud matrix to increase their mechanical strength, thermal insulation, and water
resistance for use in environmentally friendly building construction.
2.2 Research Objectives
1. To fabricate straw-reinforced mud roofing sheets by using locally obtained mud and
paddy straw in a 70:30 weight ratio.
2. To evaluate the manufactured roofing sheets' mechanical qualities, such as their
durability under stress, tensile strength, and compressive strength.
3. To measure the temperature differential between the roofing sheets' surface and the
underlying surface in a simulated environment in order to assess the thermal insulation
qualities of the sheets.
4. To measure water absorption and retention following water application in order to assess
the roofing sheets' water resistance.
8
LITERATURE REVIEW
3.1 Introduction to Sustainable Building Materials
Adoption of sustainable materials is the way forward in the construction industry to
minimize environmental degradation and consumption of resources. The energies consumed
and carbon emissions released by conventional materials like concrete and steel are
substantial (Tay et al., 2018). Agricultural waste like paddy straw, rice husk, and wheat straw
have been investigated as materials because of their biodegradability, availability, and
thermal insulation properties (Murali et al., 2020). They provide low-cost and
environmentally friendly alternatives, especially in rural and developing areas, where
conventional materials may either be very expensive or unavailable. Figure 3.1 shows most
of the bio-based materials such as sugar palm, pineapple, hemp, jute, kenaf, areca, banana,
bamboo, and sisal.
Figure 2: Several natural fibers which are currently utilized in the construction
industry
9
3.2. Use of Agricultural Waste for Construction
Agricultural waste has emerged as a material for better performance in construction with
mechanical and thermal properties as shown in Table 3.1. Fibers of wheat straw, rice husk,
and coir were added to these mud composites to improve tensile and compressive strength
while reducing thermal conductivity (Tay et al. 2018). Hassan and Ali (2019) have shown
how natural fibers enhance tensile strength while improving insulation properties. In
addition, Madu and Sundararajan (2018) found that mud composites reinforced with
agricultural wastes showed greater compressive and flexural strength than the conventional
mud structures. These observations highlight that paddy straw is a feasible strengthening
material for a wide range of mud-based construction applications.
Table 1: Common Agricultural Waste Materials Used in Construction (Rabi et al.,
2009)
Agricultural Waste Applications in Construction
Rice Husk Concrete additives, insulation, pozzolanic material
Wheat Straw Straw bale construction, insulation panels
Corn Husk Bio-composites, reinforcement in concrete
Coconut Coir Insulation, roofing sheets, fiber-reinforced composites
Paddy Straw Roofing sheets, insulation material
Bagasse Particleboard, insulation, cement additive
3.3. Advantages of Straw Reinforced Mud Composites
Microscopic images of the inner and outer surfaces of the rice straw is indicated in Figure
3.2 (Montesinos-Martínez et al., 2024). Mud composites reinforced by straw create
possibilities such as improved mechanical strength, thermal insulation, and water resistance.
It has been found by Murali et al. (2020) that compressive strength improved and water
absorption reduced while durability was retained by adding 30% straw to mud-based
materials. Mahmud et al. (2025) developed agro-waste-based hybrid composites revitalized
for enhanced thermal insulation and moisture resistance, making them amenable to use in
diverse climates. In the roofing applications of innovative bio-based binders, Álvarez-
Barajas et al. (2023) highlighted the importance of alternative, eco-friendly building
materials. These all studies show that straw-reinforced composites lessen dependency on
10
synthetic, high-carbon-emission materials in performance improvement and sustainability
thereby increasing welfare in structures.
Figure 3: Microscopic images of the inner and outer surfaces of the rice straw
(Montesinos-Martínez et al., 2024)
3.4. Roofing Materials with Agricultural Waste
The use of bio-based materials for roofing applications as indicated in Table 3.2 has gained
significant interest in sustainable construction research. Investigations into the feasibility
and performance of agricultural-waste-based roofing materials primarily focus on their
potential to replace conventional roofing solutions. Methyl ester residue was examined as a
binding alternative in eco-friendly roofing tile applications by Teoh et al. (2024), providing
evidence for its sustainable construction applications. The comparison of the thermal and
acoustic properties of agricultural waste-based panels by Lawanwadeekul et al. (2024) and
Mahmud et al. (2025) recognized their potential for energy-efficient buildings and improved
insulation properties as shown in Figure 3.3. Nevertheless, research dedicated to mud-based
roofing sheets reinforced with paddy straw has still not yet gained much relevance. This
research intends to fill up the gap by focusing on investigating the feasibility, performance,
and long-term durability of mud-based roofing sheets reinforced with paddy straw.
11
Table 2: Agricultural Wastes Utilized in Roofing Material Production (Saravanan et
al., 2017)
Agricultural Waste Source Application in Roofing
Partial replacement of river sand in
Rice Husk Rice milling by-product
roofing tiles
Combined with rice husk for low-cost
Corn Cob Maize processing waste
roofing tiles
Production of roof board insulation
Sugarcane Bagasse Sugar industry residue
material
Combined with other fibers for roof
Coconut processing
Coconut Husk
waste insulation boards
Mixed with mesocarp fiber for roof
Empty Fruit Bunch Palm oil industry waste
insulation boards
Figure 4: Schematic of enhanced thermal insulation using areca nut husk and bagasse
fiber-reinforced epoxy composite (Mahmud et al., 2025)
3.5. Straw-Reinforced Composites
Several studies have investigated the mechanical, thermal, and durability properties of straw-
reinforced composites as shown in Table 3.3. Murali et al. (2020) established that at 30%
straw content, strength and insulation of the resulting composite can be optimally balanced.
Madu and Sundararajan (2018) further strengthened their argument by claiming that
agricultural fibers improve tensile and flexural strength of mud so that structural integrity
can be enhanced. Singh and Patel (2017) worked on fiber-reinforced and concluded that it
plays a significant role in imparting ductility and resistance to cracking. Hassan and Ali
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(2019) elaborated on water resistance for straw-reinforced composites and found that the
application of nontoxic waterproofing agents helped promote longevity. The study
conducted by Teoh et al. (2024) indicated the improvement in durability and weather
resistance of bio-based binders used for roofing tiles. Therefore, the above studies do affirm
the promise of the straw-reinforced mud composite, needing to be further treated to improve
its compositional optimization and suitability for roofing usages.
Table 3: Mechanical Properties of Straw-Reinforced Composites
Tensile Strength Flexural
Composite Material Reference
(MPa) Strength (MPa)
Rice Straw/LLDPE
Xu et al., 2022
12.5 25.3
Composite
Cotton Straw/TPU Kumar & Pabla,
32.5 45.8 2022
Composite (40% fiber)
Wheat Straw/Polyester
Sreekala et al., 2015
18.7 30.2
Composite
3.6. Research Gap & Justification
Nevertheless, there are still many gaps identified in the literature. One of such gaps is that
the straw-mud ratios were not standardized, which has led to inconsistencies in the strength
and durability of the composites. Research findings are also disparate and thus it is vital to
derive optimized composition ratios to produce improved performance. Also, water-proof
treatment studies are very few concerning straw reinforced mud sheets, as moisture has
highly serious effects on these materials in terms of durability or life span. It is also very
much true that though straw composites are said to be affordable, the life cycle cost
differences in comparison in the literature do not have much in terms of comparative
assessment for most economic evaluations. Finally, even though there were some
preliminary investigations on the performance of paddy straw-based roofing sheets in
tropical climates, they need to be further tested in terms of the suitability of environmental
adaptability for additional research. Our study aims therefore to bridge the gaps by
determining optimized straw-mud composite ratios, assessing long-term durability through
accelerated aging tests, and studying the climatic adaptability of paddy straw-reinforced mud
roofing sheets to address these gaps. Thus, making strides towards more sustainable and
cost-effective building materials for diverse environments.
13
RESEARCH METHODOLOGY AND DATA
COLLECTION STRATEGY
4.1 Research Framework
This research follows an experimental research design incorporating material selection-
preparation-fabrication-testing and comparative analysis for testing. It probably involves
evaluating the material in terms of mechanical strength, thermal insulation, and water
resistance property as applied on paddy straw reinforced mud roofing sheets. It aims to
validate this material as a sustainable substitute for conventional roofing by standardized
methods (Murali et al., 2020; Madu & Sundararajan, 2018).
Conducting a detailed literature review
Study and identify the production of roofing sheets with paddy straw as
reinforcement in a mud matrix to enhance their multi-functional performance as
eco-friendly construction
Fabrication Process
Material Preparation
Molding and Shaping
Drying and Curing
Testing Procedures
• Mechanical Properties and Durability Testing
• Thermal Insulation Testing
• Water Absorption and Resistance Testing
Summary and Strategic Suggestions
Figure 5: Process of methodology
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4.2 Materials and Mix Ratio Justification
The materials that were used for this research are purely indigenous mud and paddy straw,
mixed in a ratio of 70:30 by weight. The principal matrix is mud because of its availability,
economically analysed value, and its known ability in binding fiber reinforcements (Singh
& Patel, 2017). Paddy straw was used as a reinforcement to develop tensile strength,
ductility, and thermal insulation (Tay et al., 2018; Hassan & Ali, 2019). Other alternative
mixing ratios like 80:20 and 60:40 were also put into consideration, but previous studies
have met the conclusive benchmark that at 30% straw content, maximum balance between
strength and insulation is achieved (Murali et al., 2020). Going beyond 35% fiber content
weakens the structure, as matrix binding would not be sufficient, while a fiber content below
20% causes most advantages of reinforcement to be lost (Madu & Sundararajan, 2018).
4.3 Fabrication Process
OBJECTIVE 1: To fabricate straw-reinforced mud roofing sheets by using locally
obtained mud and paddy straw in a 70:30 weight ratio.
4.3.1 Material Preparation
The rice straw is chopped into lengths between 5 and 10 cm as indicated in Figure 4.2 to
allow easy distribution within the mud matrix while avoiding the possibility of clustering
together, which could provide localized weak points (Murali et al. 2020). Sieving the mud
through a mesh of size 2 mm withdraws large particles and impurities from the mix for
uniformity. Water is added slowly during kneading to achieve a paste state to facilitate fiber
dispersion and prevent voids (Singh and Patel 2017).
Figure 6: (a) Raw straw drying under cover, (b) Raw straw, (c) Manual forage cutter
and (d) Fiber cut with the manual cutter (Montesinos-Martínez et al., 2024).
15
4.3.2 Molding and Shaping
The prepared mud-straw mixture is then molded and pressed at a pressure of 1.5 MPa, using
a standardized metal mold (Formula-100 cm × 50 cm × 2 cm), to obtain rid of air pockets.
Proper compaction could be acknowledged for enhancing the potential load the fibers could
carry and the serviceability of fiber-reinforced earthen material (Tay et al., 2018; Hassan &
Ali, 2019). After molding, the sheet would be subjected to a 24-hour drying phase under
ambient temperature conditions so that the bond formation could become more effective and
the internal stress cracks could be reduced (Teoh et al., 2024).
4.3.3 Drying and Curing
To allow the gradual evaporation of moisture from the roofing sheets, they are sun-bathed
for a period of seven to ten days. This very low-energy and eco-friendly method avoids the
formation of surface cracks due to rapid dehydration (Singh & Patel, 2017). Selected samples
are then treated with lime to make them water resistant, a method found to be effective in
traditional earth construction (Murali et al., 2020), thereby improving their durability.
4.4 Testing Procedures
Testing stage encompasses the properties of mechanical, thermal, and water resistance that
affect the durability of paddy straw-reinforced mud roofing sheets with a view to assessing
their applicability in construction. Each test follows generally accepted procedures to
evaluate structural integrity and performance. It’s proposed to have three number of
specimens for each test and consider the average effect.
OBJECTIVE 2: To evaluate the manufactured roofing sheets' mechanical qualities,
such as their durability under stress, tensile strength, and compressive strength.
Mechanical testing comprises examinations of compressive strength, flexural strength, and
tensile strength. The compressive strength test (ASTM C39) measures a construction's
resistance to axial loads with a Universal Testing Machine (UTM). Adding natural fibers
such as paddy straw could improve the bonding inside the mud matrix, thus enhancing its
load-bearing capacity (Murali et al., 2020). The flexural strength test (ASTM C293)
measures how well a sample withstands bending forces, significant in roofing applications
since such reinforced composites tend to crack less under a load (Singh and Patel, 2017).
16
Similar would be the cases of tensile strength tests performed to investigate fiber
reinforcement effects to weaken the brittle failure propensity through improvement of
fracture behavior (Teoh et al., 2024). The flexural testing machine is used to evaluate the
maximum strength attained by direct incremental load application as shown in Figure 4.2
(Jayaraman et al., 2023).
Figure 7: Experimental set up various mix panel and strain curve (Jayaraman et al.,
2023)
OBJECTIVE 3: To measure the temperature differential between the roofing sheets'
surface and the underlying surface in a simulated environment in order to assess the
thermal insulation qualities of the sheets.
Thermal performance is examined through thermocouple sensor data on temperature
variances across the exterior and interior faces. As natural fibers create tiny air pockets that
inhibit heat transfer, they are, therefore, better insulators (Tay et al., 2018). The mud sheets
reinforced with paddy straw are expected to keep the indoor temperatures cooler when
compared with conventional clay tiles and metal sheets, thereby reducing reliance on
mechanical cooling (Murali et al., 2020). Test instrument used for thermal conductivity test
is indicated in Figure 4.3 (Zhang et al., 2023).
Figure 8: DRPL-I Thermal Conductivity Tester (Zhang et al., 2023)
17
OBJECTIVE 4: To measure water absorption and retention following water
application in order to assess the roofing sheets' water resistance.
Water resistance is determined by the ASTM D570 water absorption technique in which
specimens are soaked for 24, 48, and 72 hours and weight increment is noted. Natural fibers
absorb moisture that can weaken the structural integrity, unless it is treated with hydrophobic
coating (Hassan and Ali, 2019). Capillary rise test would still be used for water movement
through the mud matrix, which is important for durability in humid environments for the
long term (Madu and Sundararajan, 2018).
4.5 Summary and Strategic Suggestions
Other advantageous features of paddy straw-reinforced mud sheets are their environmental
friendliness and cost-effectiveness, with the concomitant improvement of mechanical
strength and thermal insulation (Murali et al., 2020; Madu & Sundararajan, 2018). However,
high water absorption is a drawback that must be countered using hydrophobic coatings
(Hassan & Ali, 2019; Teoh et al., 2024). The comparative analysis emphasizes their
environmental advantages in minimizing the extensive use of energy-demanding materials
(Tay et al., 2018). Future areas of research must focus on optimizing the fiber content, hybrid
types of reinforcements, and real-life testing (Singh & Patel, 2017). Collaboration between
researchers, policymakers, and industry practitioners will be greatly beneficial in promoting
large-scale utilization and thus improving the performance of this option as a feasible
solution for sustainable housing (Madu & Sundararajan, 2018).
18
PROPOSED PLAN AND TIMELINE
2024 November – Nov. Dec. Jan. Feb.
2025 February 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Topic selection
Familiarizing with
the topic, identifying
aim and objectives
Literature review
Planning
methodology per
objectives
Finding data on
sample preparation,
test roofing sheet
Proposal report
submission and
presentation
19
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