Title of Technology: Coconut Fiber (Coir)-Cement Board Production and Application

Years Developed: 1992-2005 Target Clients: Small-scale entrepreneurs = P3M - P15M

DEFINITION
Coconut fiber-cement board (CFB) is a product manufactured from fibrous materials like coconut coir, fronds, spathes or shredded wood Fiber is mixed with Portland cement at a predetermined ratio of 70% cement and 30 fiber by weight. The cement-fiber mixture is formed into mats and pressed to the desired thickness

Two types of coir - cement boards

1. Three-layered wood-coirwood board with density ranging from 650-800 kg/m3. Coir fiber is at the core.

Two types of coir - cement boards

2. Single homogenous layer coir fiber-cement board with density ranging from 800 kg/m31200 kg/m3.

COCONUT FIBER-CEMENT BOARD

PRODUCT SPECIFICATION Thickness = 8 mm, 12.5 mm, 25 mm Width = 0.6 m Length = 1.22m and 2.3 m Density = 650 to 1200 kg/cu.m.

Basic Properties of CFB as a Construction Material

Water Absorption = 32% Thickness Swelling= 4.2% Heat Conductivity = 0.090W/m.K (DIN 52612, Part 1) Bending Strength (Modulus of Rupture) = 2 8.30 kg/cm2

CFB STANDARD MANUFACTURING PROCEDURE

1. Equipment The basic machines needed in the production of fiber-cement boards are as follows: Decorticating machine Wood shredding machine (optional) Cement-fiber blender Hydraulic cold press Trimmer

CFB STANDARD MANUFACTURING PROCEDURE

2. Accessory equipment and tools Dipping vat Weighing scale Form boxes Wood fillets Plastic sheets Steel bolts

PRODUCTION PROCESS

Extract fiber from husks

Soak the fiber in tap water for at least 18 hrs

Weigh the fiber and cement separately

Mix/Blend the pre-weighed cement & coir

Form the mixture into mat using the wooden moulder

Press the matted fiber-cement blend. Maintain pressure for 24 hrs

Trim the boards to the final dimension

Dry and condition boards for about 28 days

Paint-coated boards ready for use

CONSTRUCTION APPLICATIONS
Board Dimension 1 x 2 x 4 Density 800-1200 kg/cu.m. 650 kg/cu.m. Application Flooring/ External Walls Partitions/ Ceiling Roofing Furniture component

1 x 2 x 4

3/8 x 2 x 3 3/8 x 2 x 4

650-800 kg/cu.m. 800 kg/cu.m.

2. Specific Applications
a. Wall Panel System

Installation of wall panels

b. Roofing System

c. Flooring System

Formwork and flooring for upper-level

Rivet

d. Ceiling/Partitions

COIR HOLLOW BOARDS

CORRUGATED COIR ROOF BOARDS

EXPOSURE TEST OF ROOF BOARDS

e. Furniture/boxes components

COIR CEMENT BOARDS CHAIRS WITH COCOWOOD FRAME

CFB TABLE WITH COCOWOOD FRAME

COCONUT FIBER-CEMENT BOARDS AS CONSTRUCTION MATERIAL COCONUT FIBER-CEMENT BOARDS AS CONSTRUCTION MATERIAL

Roof Sheathing

Component of furniture (tables, chairs, etc.), cabinets, boxes and vases

Base Support for upper-level flooring

Basic Properties of CFB Board Density = 550 -650 kg/cu.m. Water Absorption = 32% Thickness Swelling = 4.2% Bending Strength (MOR)= 8.30kg/cm2 Thermal Conductivity = 0.090W/m-k

Internal & exterior walls, partitions and ceilings

FINANCIAL ASPECTS

I. INVESTMENT REQUIREMENTS
ITEM NUMBE R& UNIT 500m
3

TYPE

YEAR ACQUIR ED/

VALUE/AC QUISITION COST (PhP) 400,000

ESTIMATE D LIFE (YEARS) 20

I. Land

Plant/ storage house storage

Building 2. Deco. machine Blending machine Hydraulic press Trimming machine Lifter Dipping tank Hauler truck TOTAL

200 m 1 1 1

100,000 150,000 200,000 550,000 60,000

20 10 10 10 10 10 10 10

1 2 1

430,000 40,000 450,000 2,280,000

II. OPERATING EXPENSES

Item A. Supplies/Raw Materials (please itemize) Coconut fiber Portland Cement Flat steel Lumber fillet Plastic sheets Wooden moulds Bolts and nuts Wooden cauls B. Miscellaneous Expenses Electricity Water TOTAL 1,500 kwh 80 m3 3 2 4,500 160 200,103 22425 kg 1308 bags 25 pc 83 pc 167 pc 01 pc 4 pairs 17 bd ft 1.5 180 450 25 25 450 75 25 33,638 235,440 11,250 2,075 4,175 450 300 425 Unit & Number Per Month Cost/Unit (PhP) Total Value (PhP)

III. LABOR REQUIREMENTS

Type Of Labor A. Direct Labor Machine Operators Truck Driver/Lifter Operator B. Indirect Labor Manager Bookkeeper/Encoder
TOTAL

Number

ManDays/Month

Wage Rate/Month

Total Value

12 1

6,000/mo 6,000/mo

72,000 6,000

1 1

20,000 6,000

20,000 6,000
104,000

IV. PRODUCTION
Unit Quantity Price/Unit Total Value

Item Production Fiber-cement boards 8 mm 12 mm 25 mm By-Products Coir dust

TOTAL

pieces pieces pieces kilogra ms

1667 pcs 833 pcs 625 pcs 16,667 kgs

180 210 285 2.5

300,060 174,930 178,125

41,668
694,792

COST AND RETURN

ITEM Gross Income Cash Income - Sales from cementbonded boards - Sales from coir dust Total Cash Income Total Gross Income

VALUE (PHP)* PER MONTH PER YEAR

653,125 41,667 694,792 694,792

7,837,500 500,000 8,337,500 8,337,500

*Currency Exchange Rate : 1 US$ = 46.5 Philippine Pesos

Expenses Variable Cost Hired labor Supplies and materials Coconut fiber residues Cement Flat steel Lumber fillet Plastic sheets Wooden moulds Bolts and nuts Wooden cauls Water Electricity Marketing and Selling Cost Interest on Operating Capital (12% p.a.) Total Variable Cost 104,000 33,638 235,440 11,250 2,075 4,175 450 300 425 1,600 4,500 6,948 35.090 438,450 1,248,000 403,650 2,825,280 135,000 24,900 50,100 5,400 3,600 5,100 1,920 54,000 83,347 421.075 5,260,555

Fixed Cost Fixed Cash Costs Interest on fixed Capital Investment Total Fixed Cash Costs Fixed-Non Cash Costs Depreciation Total Fixed-Non Cash Costs Total Fixed Costs Total Costs Net Cash Income Gross Margin Net Income 13,090 13,090 14,100 14,100 27,190 465,640 681,693 256,332 229,142 157,080 157,080 169,200 169,200 326,280 5,586,835 8,081,396 3,076,841 2,750561

Market:
Commercial production of CFB is expected to contribute to the government's national shelter program, specifically on socialized and low-cost housing. CFB can replace construction materials such as tiles, bricks, plywood, asbestos and cement hollow blocks. It is used for internal and exterior walls, partitions and ceiling. It can also be used as a component in the fabrication of furniture, cabinets, boxes and vases, among others. Potential market outlets are construction material suppliers, building contractors and government/private agencies involved in low-cost housing projects. Other target markets are the low and middle-income households who would like to own houses at affordable prices.

Regulatory Requirements: PHILSA STANDARD 105-1975 provides minimum product specification for particle boards. Risks: Decorticating of coconut husks and the disposal of waste water being used for soaking the fibers can cause environmental problem. Proper attention should be taken to minimize if the totally eliminate this perceived problem Source of Technology: Researchers:, Luisito J. Peamora, Neil J. Melencion and Rolendio N. Palomar Agency Affiliation: PCA-Zamboanga Research Center,San Ramon, Zamboanga City Telephone Nos.: (062) 982-0302 Fax Nos.: (062)9820302 Email Address: pca_zrc@pldtdsl.net