mr. c.n. pandey
DESCRIPTION
Bamboo based compositesTRANSCRIPT
INDIAN PLYWOOD INDUSTRIES RESEARCH & TRAINING INSTITUTE
BANGALORE
Dr. C. N. PANDEY
DIRECTOR
CONSERVATION OF NATURAL FORESTS
THROUGH RESEARCH & DEVELOPMENT AND
ADOPTION OF EFFICIENT TECHNOLOGIES
IN THE FIELD OF WOOD AND PANEL PRODUCTS
FROM RENEWABLE FIBERS INCLUDING
PLANTATION TIMBERS AND BAMBOO
WHILE MEETING THE VITAL NEEDS OF THE
DEVELOPING SOCIETY.
VISION
INFORMATION & EXTENSION
TESTING & STANDARDIZATION
TRAINING & EDUCATION
RESEARCH & DEVELOPMENT
MANDATE
RELATING TO PANEL PRODUCTS FROM WOOD, BAMBOO AND OTHER RENEWABLE FIBRES INCLUDING AGRO AND FOREST RESIDUES
INTRODUCTION TO BAMBOO & BAMBOO BASED COMPOSITES IN INDIA
• BAMBOO IS ENDURING , VERSATILE & RENEWABLE
• THERE ARE 125 SPECIES OF BAMBOO IN INDIA SPREAD ACROSS 18 GENERA
• BAMBOO AVAILABLE IN 9.6 MILLION HECTARES IN INDIA
• 66 % GROWS IN NORTH - EASTERN STATES
• ANNUAL HARVEST IS 13.5 MILLION METRIC TONNES
• SYMPODIAL BAMBOO CONSISTS OF 67% OF GROWING STOCK
• MONOPODIAL BAMBOO COMPRISES OF 20% OF GROWING STOCK
• DECLINE IN TIMBER AVAILABILITY SPURRED INTEREST IN BAMBOO BASED COMPOSITES
• BAMBOO BASED COMPOSITES PROVIDE PROMISING LINKAGES BETWEEN ORGANISED SECTOR(RESIN BONDED BOARDS) AND UNORGANISED SECTOR(HAND WOVEN MATS)
• PROVIDES POTENTIAL FOR EMPLOYMENT OPPORTUNITIES IN RURAL AND TRIBAL AREAS ( COTTAGE SECTOR)
BAMBOO RESOURCES
1250 known Species
WORLD DISTRIBUTION
DISTRIBUTION OF BAMBOO IN INDIA
MAJOR BAMBOO GROWING REGIONS / STATES
MAIN SPECIES
D. strictus 45%
M.bamboosoides 20%
B.arundenacia 13%
D.hamiltonii 7%
B.tulda 5%
B.pallida 4%
AREA GS (percent)
North East 28 66
Madhya pradesh 20 12
Maharashtra 10 5
Orissa 9 7
Andhra Pradesh 7 2
Karnataka 5.5 3
GROWS 3 TIMES AS FAST & CAN BE HARVESTED 4 TIMES AS
OFTEN AS EUCALYPTUS
YIELDS 6 TIMES MORE CELLULOSE THAN FAST GROWING TREES
FOUND EXTENSIVELY IN NATURAL FORESTS AND
Can be grown on degraded and deforested land
Suitable for plantation or home garden cultivation
Grows in different rain fed climatic conditions
MAXIMUM BIOMASS PER UNIT AREA
SUITABLE FOR ENGINEERING AND STRUCTURAL APPLICATIONS
BAMBOO IN PANEL FORM IS WELL SUITED TO SUBSTITUTE PLYWOOD
WIDELY DISTRIBUTED, NATURALLY OCCURING & EASILY
AVAILABLE
BAMBOO – A WONDER GRASS
BAMBOO - PHYSICAL PROPERTIES
PROPERTIES OF BAMBOO VARY GREATLY FROM SPECIES TO SPECIES, AND TO SOME EXTENT WITH IN A SPECIES
CULMS ARE GENERALLY LONG & STRAIGHT AND THE HOLLOW INTERNODES MAKE IT COMPARATIVELY LIGHT
STRENGTH VARIES WITH THE SPECIES, AGE OF CULM, MOISTURE CONTENT AND PORTION OF CULM AND GENERALLY INCREASES UNTIL IT REACHES MATURITY.
TENSILE STRENGTH IS HIGH PARALLEL TO THE GRAIN
BAMBOO FAILS IN SHEAR BEFORE IT FAILS IN TENSION & THEREFORE MODULUS OF RUPTURE IS USED TO CALCULATE STRENGTH
DUE TO WEAK TRANSVERSE BONDS BETWEEN FIBRES, IT CAN BE SPLIT EASILY ALONG THE LENGTH(RADIAL OR TANGENTIAL)
Specific gravity 0.575 to 0.655
Average weight 0.625 kg/m
Fibre stress at elastic limit 390 to 1000 kg/cm2
Modulus of rigidity 610 to 1600 kg/cm2
Modulus of elasticity 1.5 to 2.0 x 105 kg/cm2
Ultimate crushing stress 320 to 720 kg/cm2
Average tensile stress @ yield point 1400 to 2800 kg/cm2
Ultimate compressive stress 794 to 864 kg/cm2
Safe working stress in compression 105 kg/cm2
Safe working stress in tension 160 to 350 kg/cm2
Safe working stress in shear 115 to 180 kg/cm2
Bond stress 5.6 kg/cm2 (which can be increased up to 10 kg/cm2 i.e. equal to that of steel with concrete after suitable treatment)
BAMBOO - MECHANICAL PROPERTIES
SEASONING OF BAMBOO
ESSENTIAL PRE-REQUISITE FOR MAINTAINING SHAPE AND STRENGTH OF BAMBOO
METHODS
AIR SEASONING
MODIFIED AIR SEASONING
CHEMICAL SEASONING
BAKING OVER OPEN FIRE
KILN SEASONING
BAMBOO - PRESERVATIVE TREATMENT
Boucherie Process
Dip Diffusion
Inter nodal Injection Method
Hot & Cold
BAMBOO PROCESSING INVOLVES TWO STEPS
(a) PRIMARY PROCESSING
(b) INDUSTRIAL PROCESSING
BAMBOO PROCESSING
PRIMARY PROCESSING MACHINES
Cross- Cutting m/c Splitting m/c
Knot Removing, Width sizing & Planing m/c
Slab Making m/c
MAT WEAVING
BAMBOO PRIMARY PROCESSING UNIT IN THE INSTITUTE
Growing stock in natural forest 3-4 tonnes/ha/yr
Growing stock in Plantation 5-12 tonnes/ha/yr
No. of bamboo required for CFC per year of 20 ft length
3,00,000 Nos.
Quantity of Bamboo 1000 tonnes
Land requirement of bamboo (5 tonnes per ha)
200 ha.
No. of mats of size 2.5m x 1.3m 1,50,000 mats/yr
Capital investment $120 thousand
Bamboo required per day 3.33 tonnes
Cost of Bamboo $40/- per tonne
cost of raw material per day $130/-
COMMON FACILITY CENTRE FOR PRIMARY BAMBOO PROCESSING
A Bird’s Eye View
(a) Operation of machinery and quality control – 40 persons
(b) Mat weaving – 500 mats per day – 200 persons
Labour
Mechanic cum Quality control operator $1.6 / per day $64
Mat weaver $1 per day $200$264
Electricity, water, maintenance, advertisement, depreciation and other contingencies 40% of raw material cost
$53
TOTAL $450
Cost of production per mat $0.9
Selling price $1.2
Net Profit per day $151
Net profit per year $45360B/C ratio 1:1.34
EMPLOYMENT GENERATION AT CFC
INDUSTRIAL PRODUCTS DEVELOPED AT IPIRTI
1. BAMBOO MAT BASED PRODUCTS1. BAMBOO MAT BASED PRODUCTS• BAMBOO MAT BOARD• BAMBOO MAT VENEER COMPOISTE• BAMBOO MAT CORRUGATED SHEETS• BAMBOO MAT TRAY• BAMBOO MAT MOULDED SKIN DOOR• BAMBOO MAT RIDGE CAP
2. BAMBOO STRIP BASED PRODUCTS2. BAMBOO STRIP BASED PRODUCTS BAMBOO-WOOD (LAMINATES) FROM INDIAN BAMBOOS DEVELOPMENT OF TRANSPORT VEHICLE FLOORING
3. BAMBOO IN ROUND / SPLIT / COMPOSITE FROM 3. BAMBOO IN ROUND / SPLIT / COMPOSITE FROM BAMBOO BASED HOUSING SYSTEM Bamboo Match Sticks
Bamboo Mat Board
HIGH MODULUS OF RIGIDITY COMPARED TO PLYWOOD
HIGH IN–PLANE RIGIDITY
HIGH RACKING STRENGTH
MORE FLEXIBLE THAN EQUILAVENT PLYWOOD
ECONOMICAL COMPARED TO PLYWOOD
INSTITUTE IS INSTRUMENTAL IN THE FORMATION OF SPECIFICATION ‘IS:13598’ “BAMBOO MAT BOARD FOR GENERAL PURPOSES”
BMB CAN BE UTILIZED FOR SHEATHING MATERIAL IN STRUCTURAL AND SEMI STRUCTURAL PURPOSES SUCH AS WALL PANELING, PARTITIONS, ROOF SHEETHING, DOOR SKINS, BOX FURNITURE, BUILT UP HOLLOW BEAMS, GUSSETS, AND CONTAINERS
BAMBOO MAT BOARD
IS:13598
BMB - STRENGTH PROPERTIES
Sl.No. Property
1 Thickness of the panels 3mm 6mm 6mm 8mm 9mm
2 Density, kg/m3 766 711 935 790 892
3 I.B. Strength N/mm2
Dry
Wet
2.18
1.98
2.42
2.14
0.82
0. 61
1.97
1.73
2.2
1.8
4 Surface Strength N/mm2
Dry
Wet
11.42
11.42
11.23
10.47
4.9
3.47
9.47
9.10
13.10
10.5
5 Tensile strength N/mm2 22.69 26.59 89.19 29.54 31.4
6 Compressive strength N/mm2 16.77 30.35 50.60 35.30 57.5
7 Mod. of Rupture N/mm2 50.74 56.31 102.57 59.35 68.8
8 Mod. of Elasticity, N/mm2 3678 3220 12033 3114 3930
9 Mod. of Rigidity, N/mm2 5881 6050 3527 6066 5750
Physical & Mechanical Properties of BMB of different thickness
USE OF VENEERS FROM PLANTATION TIMBER ALONG WITH BAMBOO MATS FOR MANUFACTURE OF HIGHER GRADES OF PLYWOOD.
AN ALTERNATIVE TO STRUCTURAL AND SHUTTERING GRADE PLYWOOD WITHOUT WARPAGE
MOE AND MOR OF BMVC ARE HIGHER THAN EQUIVALENT PLYWOOD
BMVC WILL BE ECONOMICAL IN HIGHER THICKNESS AS COMPARED TO BMB
FOR ALL PRACTICAL PURPOSES BMVC CAN BE USED IN A SIMILAR WAY TO PLYWOOD.
INSTITUTE IS INSTRUMENTAL IN THE FORMATION OF SPECIFICATION ‘IS:14588’ “BAMBOO MAT VENEER COMPOSITE FOR GENERAL PURPOSES”
BAMBOO MAT VENEER COMPOSITE(BMVC)
Bamboo Mat Veneer Composite
IS:14588
REPLACEMENT OF HIGH PRICED IMPORTED VENEERS WITH BAMBOO MAT
RESIN FORMULATIONS OPTIMIZED FOR THE MANUFACTURE OF HIGH DENSITY SHUTTERING GRADE PANELS.
DENSITY OF THE PANELS ACHIEVED IS 1.1gm/cc TO 1.2gm/cc
PANELS WITH BAMBOO MATS ALONE AND IN COMBINATION OF BAMBOO MATS & VENEERS WERE MADE
THE STRENGTH PROPERTIES MEETS THE REQUIREMENT OF IS: 4990 – 1993, “SPECIFICATION FOR SHUTTERING GRADE PLYWOOD” IN ALL CONSTRUCTIONS.
EASE THE PRESSURE ON IMPORT OF TIMBER
BAMBOO MAT COMPREGHIGH DENSITY SHUTTERING GRADE PANEL
Bamboo Mat Compreg
BMC overlaid with Phenolic Film
BMCS IS A GREEN ROOFING MATERIAL COMPARED TO OTHER
ROOFING MATERIALS IN THE MARKET SUCH AS ACCS,CFRP,CAS,CGIS
THE MANUFACTURE OF BMCS DOES NOT AFFECT THE HEALTH OF
WORKERS AND ENVIRONMENT.
ENERGY REQUIREMENT IS LOW
HAS IMMENSE POTENTIAL AS AN ECOFRIENDLY ROOFING MATERIAL
IS HIGHLY RESILIENT,LOW WEIGHT,LOW THERMAL CONDUCTIVITY,
GOOD AESTHETIC APPEARANCE
INSTITUTE IS INSTRUMENTAL IN THE FORMATION OF INDIAN STANDARD
SPECIFICATION ‘IS:15476’ “BAMBOO MAT CORRUGATED SHEETS”
BAMBOO MAT CORRUGATED SHEET(BMCS)
Bamboo Mat Corrugated Sheet IS:15476’
Particulars
Thicknessmm
Width in mm
Max Load
N
Load bearing capacity in
N/mm
Weight of sheet (2.44m x1.05m)
in kgsBMCS[4 layers]
3.7 400 1907 4.77 9.78
GI Sheet 0.6 400 1937 4.84 10.43Aluminium sheet
0.6 405 669 1.67 3.92
ACCS 6 330 1800 5.45 21.5
STRENGTH PROPERTIES OF BMCS IN COMPARISON WITH OTHER EXISTING ROOFING SHEETS
BMRC IS COMPATIBLE FOR ROOFING
WITH BAMBOO MAT CORRUGATED
SHEETS
SUITABLE FOR WIDE RANGE OF ROOF
ANGLES
REPLACEMENT FOR THE PRESENT
PRACTICE OF USING THIN FLAT BOARDS
WHICH CAUSES PERFORATIONS DUE TO
WEATHERING.
DIMENSIONALLY STABLE, NON
PERMEABLE , ANTI-TERMITE AND
WEATHER RESISTANT
READY & EASY TO FIX FOR ROOFING
PURPOSE.
BAMBOO MAT RIDGE CAP(BMRC)
Bamboo Mat Ridge Cap
FLEXI- PLY WITH BAMBOO MAT AS CORE
FLEXI–PLY BASED ON BAMBOO
MAT & WOOD VENEER IS A NEW
ENGINEERED PRODUCT
HAS A GREAT POTENTIAL FOR
APPLICATIONS IN MAKING CABINS
OF HEMISPHERICAL SHAPES AND
ARCHES WITH SHARP CURVATURES
Flexi-Ply
Flexi-Ply Centre Table
REDUCTION IN THE CONSUMPTION
OF TIMBER FOR MAKING DOORS AS
THEY ARE HOLLOW DOORS
WITHOUT WOOD BATTENS
SAVES ABOUT 1/3 QUANTITY OF
TIMBER
THEY ARE MORE STRONGER THAN
IMPORTED SKIN BOARDS MADE
FROM HIGH DENSITY FIBRE BOARD
BECAUSE OF ITS HIGH IMPACT
RESISTANCE
LEADS TO IMPORT SUBSTITUTIONBamboo Mat Moulded
Skin Board
Door with Bamboo Mat Moulded Skin Board
BAMBOO MAT MOULDED SKIN BOARD(BMMSB)
Bamboo mat chair
BAMBOO MAT TRAY & CHAIR SEATS
WATER RESISTANT
HEAT RESISTANT
SCRATCH RESISTANT
UNBREAKABLE
ECOFRIENDLY Bamboo Mat Tray
BAMBOO LAMINATES
Horizontal Laminate
Vertical Laminate
SPECIES TESTED : Bambosa bamboose, B. nutan, Dendrocalamus hamiltoniiYIELD : ABOUT 15%Mfg.COST : Rs 650/ m2 (approx.)/13 USDB/C ratio : 1.5STATUS : READY FOR COMMERCIALIZATION
Laminated product
SUBSTITUTE FOR WOOD
Magazine holder
Laminated Bamboo Centre Table
Table Calendar
& Pen Stand
BAMBOO LAMINATES contd..
STRENGTH PROPERTIES OF LAMINATES
Sl.no Property Vertical Laminates Horizontal Laminates (MUF)
UF MUF PF
1 Density, Kg/m3 728 745 796
782
2 MOR, N/mm2 122.5 149.1 145.2
164.4
3 MOE, N/mm2 12028 16570 16800
17300
4 Compressive strength N/mm2
61.7 84.7 96.0
87.9
5 Block shear strength, N/mm2
11.89 12.81 2.7
9.65
6 Screw withdrawal strength, N
Face Edge
4999 4006 4683
2333 3659 3216
3235
5375
BAMBOO – OLDEST & MOST VERSATILE BUILDING MATERIAL
EASY AVAILABILITY
LOW COST
HIGH STRENGTH WEIGHT RATIO
CAPACITY TO ABSORB MORE ENERGY
RENEWABLE RESOURCE
INSPITE OF THIS THE USE OF BAMBOO HAS BEEN LARGELY RESTRICTED TO
TEMPORARY STRUCTURES AND LOWER GRADE BUILDINGS DUE TO
LIMITED NATURAL DURABILITY
DIFFICULT IN JOINTING
LACK OF STRUCTURAL DESIGN DATA
EXCLUSION FROM BUILDING CODE
BAMBOO JOINTS
TRADITIONAL PRACTICES
END JOINTING LAP JOINT BUTT JOINT SLEEVES & INSERTS SCARF JOINT REBATED JOINTS
BEARING JOINTS BUTT JOINT TENON JOINT CROSS OVER JOINT OBLIQUE JOINTS
ANGLE JOINTS
TRADITIONAL JOINTING PRACTICES
MODERN JOINTING PRACTICES
MILD STEEL BOLTS AND DOWELS
M. S. WIRE AND PINS
PLYWOOD AND BMB GUSSETS
GLUED PLYWOOD/WOOD INSERTS
Wall in fill: non-load-bearing, comprising a grid of split
bamboo covered in wire mesh and cement mortar
Roof structure: bamboo rafters or trusses
supporting bamboo purlins
BAMBOO BUILDING SYSTEM
To date, a prototype building system has been
developed comprising
Foundations: individual column footings
Columns: bamboo culms set in (or on) concrete
footings
Floor: raised by two or three brick courses, filled
with rubble and secreeded
BAMBOO BUILDING SYSTEM
1.Rafters & purlins Dip diffusion
22
3.Columns
Internodal injection or Boucherie
33
11
2.Grid Dip diffusion
Treatment
BAMBOO BUILDING SYSTEM
Roof covering: corrugated bamboo mat board
Doors and windows: frames of sawn plantation timber with bamboo mat
board infill panels.
BAMBOO BUILDING SYSTEM
BAMBOO HOUSE CONSTRUCTION TECHNIQUES
TREATED BAMBOO COLUMNS 75-100 mm DIAMETER SPACED AT 1.2 M INTERVAL AND SET IN CEMENT CONCRETE FOOTING
FOUNDATION OF STONE MASONRY AND BASEMENT OF CEMENTCONCRETE BLOCKS
GRID PREPARATION
BAMBOO HOUSE CONSTRUCTION TECHNIQUES
PLASTERING
FIXING OF TRUSSFLOORING FIXING OF PURLINS
BAMBOO HOUSE CONSTRUCTION TECHNIQUES
FIXING OF BMCS
INNER VIEW OF HOUSE FINISHED HOUSE
SHOCK RESISTANCE AND IMPACT TESTS RACKING RESISTANCE TEST
TESTING
WALL PANEL
JOINT TESTING CRUSHING FAILURE TEST
ROOF TRUSS TESTING
FLAME TEST
EXPOSURE TEST BENDING TEST
TESTING
SUCCESSFULLY TESTED ON SHAKE TABLE AT CPRI, BANGALORE. WITHSTOOD ZONE 5 (NBC 83) EARTHQUAKE INTENSITY WITHOUT ANY VISIBLE FAILURE
TESTING
BAMBOO HOUSES CONSTRUCTED AT IPIRTI CAMPUS
Two bedroom Guest HouseSecurity Cabin
Demonstration house built @ IPIRTIPrefabricated BMB Wood Shelter
BAMBOO HOUSES CONSTRUCTED AT DIFFERENT PLACES IN INDIA
Bamboo House Built at Agartala
Bamboo Housebuilt at Chennai
PRE-FABRICATED HOUSE
BAMBOO PANEL WALL & ROOF
COMPONENTS CAN BE USED
PREFABRICATED MODULE HOUSES
FOR THE EMERGENCY RELIEF AND
TEMPORARY USE
THEY ARE FEASIBLE IN TECHNICAL
/ECONOMICAL/ ENVIRON-MENTAL
ASPECTS.
FAST ERECTION, EASY FOR
ASSEMBLY/STORAGE
/TRANSPORTATION
Pre-fab House
SPECIES TRIED
BAMBUSA BAMBOSE
DENDROCALAMUS STRICTUS
STRENGTH CONFORMS TO IS 1140:1970
HEAD FIXING CONFORMS TO IS 2653:1993
NO AFTER GLOW
BURNING - CONTINUOUS TEMP ACHIEVED 300OC
PATENT
Application # 627/MAS-7-8-2000
BAMBOO MATCH STICK
CONCLUSION
THE USE OF TROPICAL HARDWOOD IS CURTAILED MANIFOLD
BECAUSE OF ENVIRONMENTAL REASONS
NON- WOOD MATERIALS SUCH AS PLASTICS , METALS,
REQUIRE HIGH ENERGY LEADING TO MORE AIR AND WATER
POLLUTION
ALMOST ALL PRODUCTS THAT CAN BE MADE FROM WOOD
CAN ALSO BE MADE FROM BAMBOO
GROWTH & USE OF BAMBOO HELP IN FIXING ATMOSPHERIC
CARBON AND NEEDS LESS ENERGY WHILE PROCESSING
BAMBOO PRODUCTS ARE BIODEGRADABLE & DO NOT
POLLUTE THE NATURE.
BAMBOO IN ALL FORMS ARE ENVIRONMENT FRIENDLY
BAMBOO IS RENEWABLE RESOURCE AT SHORT
INTERVAL
BAMBOO BASED COMPOSITES, THEREFORE CAN BE
THE MATERIAL FOR THE FUTURE
CONCLUSION contd..