MATERIAL STUDY :

WOOD SUBSTITUTES
AND
APPLIED WALL FINISHES
(STAGE 1)
GROUP 3

ABIRAMI K A
ADWAITH SAGAR V
ADARSH S
DEVIKA P RANJITH
GANGA K
HENNA FATHIMA V
Manufacturing

When a bamboo colm, or stalk, reaches the

height of 35 to 40 feet, it is harvested and
inspected for imperfections and presence of
pests. It is then cut into slats. The slats are treated
with a borate solution to kill any pests and kiln-
dried to a moisture content of between 6 and 9
percent.After drying, the slats are planed,
inspected and graded for use as surface or
substrate material. The dried slats are then glued
edge to edge to form a single-ply panel. Two or
more sheets of laminate are then joined with glue
in a hydraulic press.
Bamboo
plywood is available in amber and natural color.
The natural color, as its name implies, is the color
of the bamboo at harvest. A heating process after
drying that caramelizes the sugars in the bamboo
produces an amber color. These darkened sugars
pigment the material evenly throughout the
entire strip, not just the surface
BAMBOO PLY
Bamboo plywood is made of fine layers
of bamboo strips laid in parallel order and kiln dried,
sanded smooth and then laminated edge to edge to
create a single-ply panel. These panels are then
laminated again to each other to create multi-ply bamboo
plywood free of formaldehyde emissions.

MANUFACTURING
When a bamboo colm, or stalk, reaches
the height of 35 to 40 feet, it is harvested
and inspected for imperfections and
presence of pests. It is then cut into
slats. The slats are treated with a borate
solution to kill any pests and kiln-dried to
a moisture content of between 6 and 9
percent.
The Plant Advantages of plywood from
bamboo:
There are more than 11,000 varieties of bamboo. These vary
widely in size and utility and are native to many parts of the • High moisture resistance.
world. While most commonly found in Asia and South America, • Natural resistance.
there is even one species native to the United States. • Natural protection against insects.
• Low price.
Structural characteristics
•Thicker panels can cover greater distances
under the same load. Disadvantages
•Shear stress is higher on the center of the panel
and 0 on outer fibers. •Bamboo is hollow,as well the plywood made out
of it,hence it can't be used to make beams or
*Energy efficient(An acre of bamboo produces 35% more columns.
oxygen than an acre of hardwood trees. An acre
of bamboo filters out of the atmosphere 4 times more carbon
dioxide than an acre of hardwood trees)
Used for
Used for

*Flooring,Kitchen cabinets,furniture and interior

walls

*plywood made of bamboo is an excellent

material for the arrangement of water supply
networks and the erection of small buildings.

*Bamboo plywood can be laminated, due to

which its appearance improves We have
*more resistant to the action of moisture and new sizes of bamboo
harmful substances. plywood now.
3000 x 1220 x 30 mm, 3100 x
*Laminated bamboo plywood does not wear out 1220 x 30 mm, 4050 x 1220 x
for a long time - it allows to use it for the lining 30 mm.
of vans and train cars, river ships and ships. 4100 x 600x 40mm, 4100 x
*When constructing large objects, such plywood 700 x 40 mm.
is very convenient 4100 x 600 x 45mm, 4100 x
*it is also lightweight, which makes it possible to 700 x 45 mm.
conduct assembly works effortlessly.
Uses

• Its high-tensile strength and light weight have proven useful in building everything from eating
utensils to temples.
• Bamboo in plywood form has become popular in the United States. Most consumers have
seen it in their local home-improvement centers.Has high potential for use in building
furniture and cabinets.
• Because of limited production facilities in China, the price of standard 4-by-8-foot ¾-inch
sheets is in excess of $150 per sheet.
• Because of its hardness, bamboo tends to be brittle. Sharp, thin-bladed saws should be used
for cuts. Pre-scoring the cuts will help as well.
• Using screws or nails within an inch of the edge can cause splitting. Pilot holes are advisable
for this type of attachment.
• When using glue or a dowel-and-glue combination, the adhesive should be first tested on a
piece of scrap. Bamboo is not very porous, so glue will tend to bond only to a thin surface layer
on each piece.
 Cement Bonded P
article Board is
made from a
mixture of wood
particles and cem
ent. Cement
board adds impact
resistance and
strength to the wall
surface. ... One
major
disadvantage

CEMENT PARTICLE of cement board is

the weight per
square foot which
is quite high and

BOARD makes its handling

by one person
difficult.
 Characteristics

Cement Bonded particle board(CBPB) is smooth

and high durable particle board. Cement
Bonded Particle Board is a unique combination
of strength of cement and workability of wood.
Understanding material This unique technology make these boards
totally fire resistant and moisture resistant.
Cement bonded particle board made CBPBs are ideal for Industrial, Commercial and
out of 62% cement 28% Residential usage
wood. The wood used is of
fast growing species like
Eucalyptus and Casurina.
Due to adoption of special
manufacturing process, the
panel acquires the strength
the durability of cement and
easy workability of wood - a
combination of qualities
absent in other boards
Physical properties-Fire Resistance
It is highly fire resistant and has been classified as
incombustile material in many countries around the
globe.
Sound Insulation
Air borne sound reduction varies between 30 and 37
Db for the frequency range 100-3150 HZ according to
thickness of cement Panel.
Weather Resistant
With cement constituting 62% of its composition
the Cement Particle Board
Panel offers excellent resistance to weather. The
board has been subjected to many cycles of
soaking, freezing and heating without any sign of
disintegration.
The board should generally be painted for external
application to provide a weather seal.
Biological
Due to mineralisation of wood
particles by cement,
Panel is resistant to termite
and vermin attack. It does not
support fungus growth. Even
untreated samples exposed to
contact with the ground
surface for several years have
shown no sign of rot or decay.
Manufacturing Process

Cement Bonded Particle Boards are manufactured from cement,

wood and some additive.
1. A mixture of Portland cement, wood and water is made in the
ratio 3:1:1 of the respective components. Water evaporation is
monitored constantly and more water added if necessary.
2. Calcium chloride is also added to the mixture to assist the cement
setting more quickly.
3. The mixture is fed at a uniform rate onto a conveyor driven series
of caul plates moving at uniform speed. The constant pouring and
conveyor speeds guarantee a mat of uniform thickness.
4. The mat is subsequently cut into lengths of the same size as the
caul plates.
5. These mats are stacked and compressed together to one third of
its original height over a 2-3 minute period.
6. The mats are clamped and heated in a chamber at 70-80 degrees
Celsius for 6-8 hours.
7. The cauls are removed and the boards dried, trimmed and stored
for 12-18 days until the cement cures.
 Applications Of Cement Bonded Particle Board

(1)False Ceiling (2)Prefabricated Shelter

(3)Wall cladding
(4) Cabins
(5) Partitions
(6) Cabinets

Formwork

• Usually, in monolithic construction, formwork is a temporary

structure that is removed once the initial hardening of concrete is
complete. RATE
• The use of CPB allows you to combine the preparation of formwork
with finishing work. Permanent formwork is made from these Cement Particle Board have a market
plates, which remain as part of the wall, immediately forming a value of Rs.27 per square feet
smooth surface that does not need plastering.
 Roofing systems
• CPB is applied in flat, including exploited, roofs
installation. Sheets are laid on top of insulation and
then covered with a waterproof membrane.
• Due to rigidity of the sheets, the insulation is not
exposed to concentrated load
• Depending on the load, roofing systems use plates of
up to 20 mm thick, and in special circumstances
thicker than 20 mm.

Floor

• This material is extremely suitable for the subfloor- the so-called

dry screed. Instead of spreading a layer of cement-sand mixture,
smoothing and waiting for it to harden, the CP boards are laid on
the prepared “beacons” and it allows to have and immediately
smooth and ready base for further work, as well as heat insulator.
• The thickness is determined by the density of the insulation and
calculated loads. For subfloor, boards that are at least 16 mm thick
are used.
Sheathing of walls and partitions
• CPB is well-suited for wall cladding, both massive as well as
frame ones.
• Environmental safety makes it a good material for interior
decoration, whereas moisture resistance allows it to be used
for premises with high moisture as well as for exterior
building decoration.
• One of the types of frame structures is internal partitions.
CPB serves as sound insulating material that reduces
acoustic communication between rooms separated by a
partition. Boards (up to 20 mm thick) are used for frame
sheathing
Hinged facade systems
• Hinged ventilated facade is one of the natural applications
of CPB.
• CPB is able to withstand high mechanical loads, does not
deteriorate from moisture or spread flame, even in
conditions of strong traction in the ventilation gap.
Lightweight boards of up to 12 mm thick are used in this
area.
 RUBWOOD
Rubber plantations have existed for hundreds of years in Tropical
countries. These Plantations have been used mainly for the
production of latex. After the economic life of the rubber tree,
which is generally 30 years, the latex yields become extremely low
and the planters then fell the rubber trees and plant new ones.

This eco-friendly Rubber wood (Hevea Brasiliensis) when

Processed becomes an excellent substitute for hard wood. We can
make the eco-friendly rubber wood, making furniture and finger
jointed edge glued panel boards. These products are marketed
under the brand name of ‘RubWood‘.

The wood from the trees is light in colour and straight grained
making it easy to stain and match in woodworking. Part of the
industry adoption of rubwood was an international campaign to
avoid use of a previously used light straight grained wood which
was harvested from South East Asia's endangered wetland "Ramin"
 MANUFACTURING
First Step: Pressure Treatment
This is where the sawn wood is treated to ensure it has the longevity
needed. The pressure chamber is vacuum sealed and preservatives are
applied to treat the wood so that it will resist fungal and termite attack.

Second & Third Steps: Stacking & Sorting followed by Kiln Drying
After pressure treatment, the timber will be sorted, properly stacked
for drying in a kiln before the next step.

Fourth, Fifth & Sixth Steps: Cross-cutting , Moulding & Finger Joints
After the timber is dried, it will be ready for cross-cutting to get the
useful wood pieces out of the timber. The cut pieces are then moulded
and then joined into longer strips by the process of finger jointing.

Seventh, Eight & Ninth Steps: Lamination, Furniture Parts, Wood Working & Spraying
Subsequently the strips go through a lamination process to produce laminated boards. These
are then further machined to various furniture parts that are cut in accordance to the design
of a particular set of furniture. Wood working is a further process to bring the various
furniture parts to the required shapes and smoothness. Finally, the various furniture pieces
are sprayed with relevant paint and dried.
 Tenth, Eleventh and Twelfth Steps: Assembly, Packing and Storing
Assembly of the various pieces of furniture is done before these are packed in cardboard boxes. The complete packed assembly is then
stacked and stored awaiting shipment to customers.

CHARACTERISTICS
• naturally a light blonde to medium tan colour, sometimes with medium brown streaks. Colour tends to darken slightly with age. Frequently
colored or stained when used in furniture construction.

• Grain is straight, with a somewhat coarse, open texture. Low natural lustre.

• Diffuse-porous; large to very large pores in no specific arrangement, very few; solitary and radial multiples and rows of 2-4; tyloses and
heartwood mineral/gum deposits (brown) occasionally present; growth rings usually indistinct; narrow to medium rays barely visible without
lens, spacing normal to fairly close; parenchyma diffuse-in-aggregates and banded (reticulate).

• Rubberwood is perishable, and has very little natural resistance to decay. It is also susceptible to fungal staining and insect attacks.

• Easy to work with both hand and machine tools. Rubberwood tends to warp and twist in drying, though it is fairly stable in service once
seasoned. Glues, stains, and finishes well.

• Rubberwood has an unpleasant sour odor while being worked, especially when green, which subsides upon drying.

• Rubberwood is rarely exported in raw lumber form, but is instead worked into a variety of furniture, kitchen, and other household items and
then exported and sold elsewhere.
CHEMICAL TREATMENT
Rubberwood is susceptible to fungal and insect attack that
limited its use in the past. However, in the 1980s, the
development of chemical treatment processes allowed the
wood to be more widely used for furniture making and
frames. Today, rubberwood is generally treated soon after
sawing by pressurized immersion in boron preservatives,
followed by kiln-drying to diffuse the chemicals and to
control moisture content
ALLERGIES OR TOXICITY
Besides the standard health risks associated with
any type of wood dust, no further health
reactions have been associated with Rubberwood
in particular. However, individuals with natural
latex or rubber allergies may have reactions to
Rubberwood.
SUSTAINABILITY
This wood species is not listed in the
CITES Appendices or on the IUCN Red
List of Threatened Species. Rubberwood
lumber is typically taken from rubber
plantations where the trees are tapped
for latex, and harvested at the end of
their useful life cycle—typically after
about thirty years.
It is not suitable for outdoor use, as rain
can leach the protective chemicals from
the wood, exposing it to fungus and insect
attacks. Excessive moisture will also cause
the wood to warp and rot.
SMALL SIZE
Compared with other timber the
boards have approximately 1.8 m in
length and 50 mm thickness which
indicate a smaller size.
STAINS
After exposing it to chemicals from the
seasoning process the rubber wood will
get a fragile outlook.
PRONE TO DENTS
Because rubberwood is a moderate
hardness wood some impacts can
potentially create dents.
• NO STRUCTURAL
APPLICATIONS
• PERCIEVED AS A LOW COST
WASTE WOOD
• RUBBER WOOD IS SLIPPERY
DRYING
Kiln drying is the primary wood
drying process for rubber wood
because it has been widely used for
a long time.
The drying temperature is
approximately 100°C which is a
medium drying temperature and
can also be used to dry any type of
wood.
Before kiln drying it is subjected to
air drying in lower temparatures
PRICE

Rubber wood price

Since rubberwood is a agricultural by-product it
has a low raw material cost, good woodworking
properties and today it is one the cheapest solid
wood furniture you will find.

STRENGTH

Rubberwood is strong, it has a Janks score

of 980 lbs which makes it harder than some
coniferous species so will not scratch easily
having approximately the same hardness as
walnut and teak but a little bit softer than
oak.
APPLICATION

Construction of wooden floors

Production of furniture for houses
,offices and interior design for sales
shop,display showroom.
Construction of shelves
Production of hall chairs and cinema
chairs
Production of outdoor furniture
which has resistance to mold, water
retention and anti termite
Framing, 3D engraving or printing on
wood
Fine-art handicraft products
Another use of the wood are in the
moulding and joinery industry like
parquet and strip flooring or
staircase. Small rubberwood residues
parts are glue together which ends
up in longer pieces and better
strength of the joint.
 E- board is a cement cellulose fiber board used
for false ceiling partition mezzanine
floor. FALSE CEILING. Gypsum false ceiling. T- grit
false ceilings. A high performance cellulose fibre
cement sheet manufactured with sand, cement,
cellulose fibre and additives.

KEY BENEFITS
Excellent weathering properties, high tensile
strength, high MoE, smooth finish for paint,
excellent acoustic
performance. A very strong, versatile board.

MAIN CHARACTERISTIC
Environmental friendly materials
Excellent Strength and toughness
Waterproofing and fireproofing
Antisepsis and moth-proofing
Good acoustic insulation and weather resistance

E-BOARD Good thermal and heat insulation

Durability and long lifetime
APPLICATION
Exterior decoration panel
Intergrative facade panel for exterior wall thermal insulation
Interior wall decoration panel
Flooring for loft interlayer, container house, light steel villa
For subway, tunnel, baseboard, outdoor furniture
Coating board
Thinner liniing board for stone

PHYSICAL PROPERTIES
Incombustible.
Non-melting.
Water proof.
Resistant against water and moisture.
Resistant against different climate conditions.
Durable against strokes and beats.
Paintable.
Resistant against most chemicals.
Good heat and sound insulation.
MANUFACTURING PROCESS

The Fibre Cement Boards are manufactured using the Hatschek

process, which involves several
laminations of slurried mix of core ingredients on a large steel
cylinder known as the 'BOLE with a specific
embossed pattern for Designer Boards). When the desired
thickness is achieved, the green/wef board is
cut and put on a conveyer where it is trimmed to size and then
stacked and left for a short period of pre-
curing.

The final curing is done through autoclaving that involves High

Pressure Steam Curing (HPSC). This
hydration process changes the chemical structure of the
cement/silico & quartz and selected mineral fibre
matrix to produce a highly durable and versatile fibre cement
building board. After autoclaving, the boards

are allowed to go through o short stabilisation period to bring about

equilibrium with the ambient moisture
content a controlled environment.
TECHNIQUES OF APPLICATION

Cement board is hung with corrosion resistant screws or ring-

shank nails. Cement board has very little
movement under thermal stress, but the boards are usually
installed with a slight gap at joints in shower
pans, bathtubs, and each other. These joints are then filled
with silicone sealant or the manufacturer's
taping compounds before applying a finish. The filled joints are
taped like conventional gypsum board, but
with fiberglass tapes that provide additional water resistance.
Combined with a water impermeable finish,
cement board is a stable, durable backing board.

RATE
Rates of E Board starts from Rs.50 per square feet and the rate
extends upto several thousand rupees according to the quality
and size of the boards.
SIZE
E Boards are available at different sizes
starting from 1 square feet.Among these sizes
2ft*2ft, 4ft*4ft and 4ft*8ft are commonly
used.