Mr. c.n. pandey

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Bamboo based composites

Transcript of Mr. c.n. pandey

  • 1.INDIAN PLYWOOD INDUSTRIES RESEARCH & TRAINING INSTITUTEBANGALOREDr. C. N. PANDEYDIRECTOR

2. CONSERVATION OF NATURAL FORESTSTHROUGH RESEARCH & DEVELOPMENT ANDADOPTION OF EFFICIENT TECHNOLOGIESIN THE FIELD OF WOOD AND PANEL PRODUCTSFROM RENEWABLE FIBERS INCLUDINGPLANTATION TIMBERS AND BAMBOOWHILE MEETING THE VITAL NEEDS OF THEDEVELOPING SOCIETY.VISION 3. INFORMATION & EXTENSIONTESTING & STANDARDIZATIONTRAINING & EDUCATIONRESEARCH & DEVELOPMENTMANDATERELATING TO PANEL PRODUCTS FROM WOOD, BAMBOO ANDOTHER RENEWABLE FIBRES INCLUDING AGRO AND FORESTRESIDUES 4. INTRODUCTION TO BAMBOO & BAMBOO BASEDCOMPOSITES IN INDIA BAMBOO IS ENDURING , VERSATILE & RENEWABLE THERE ARE 125 SPECIES OF BAMBOO IN INDIA SPREAD ACROSS18 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 INBAMBOO BASED COMPOSITES BAMBOO BASED COMPOSITES PROVIDE PROMISING LINKAGESBETWEEN ORGANISED SECTOR(RESIN BONDED BOARDS) ANDUNORGANISED SECTOR(HAND WOVEN MATS) PROVIDES POTENTIAL FOR EMPLOYMENT OPPORTUNITIES INRURAL AND TRIBAL AREAS ( COTTAGE SECTOR) 5. BAMBOO RESOURCES1250 known SpeciesWORLD DISTRIBUTION 6. DISTRIBUTION OF BAMBOO IN INDIAMAJORBAMBOO GROWINGREGIONS / STATESMAIN SPECIESD. strictus 45%M.bamboosoides 20%B.arundenacia 13%D.hamiltonii 7%B.tulda 5%B.pallida 4%AREA GS(percent)North East 28 66Madhya pradesh 20 12Maharashtra 10 5Orissa 9 7Andhra Pradesh 7 2Karnataka 5.5 3 7. GROWS 3 TIMES AS FAST & CAN BE HARVESTED 4 TIMES ASOFTEN AS EUCALYPTUSYIELDS 6 TIMES MORE CELLULOSE THAN FAST GROWING TREESFOUND EXTENSIVELY IN NATURAL FORESTS ANDCan be grown on degraded and deforested landSuitable for plantation or home garden cultivationGrows in different rain fed climatic conditionsMAXIMUM BIOMASS PER UNIT AREASUITABLE FOR ENGINEERING AND STRUCTURAL APPLICATIONSBAMBOO IN PANEL FORM IS WELL SUITED TO SUBSTITUTEPLYWOODWIDELY DISTRIBUTED, NATURALLY OCCURING & EASILYAVAILABLEBAMBOO A WONDER GRASS 8. BAMBOO - PHYSICAL PROPERTIESPROPERTIES OF BAMBOO VARY GREATLY FROM SPECIES TOSPECIES, AND TO SOME EXTENT WITH IN A SPECIESCULMS ARE GENERALLY LONG & STRAIGHT AND THE HOLLOWINTERNODES MAKE IT COMPARATIVELY LIGHTSTRENGTH VARIES WITH THE SPECIES, AGE OF CULM, MOISTURECONTENT AND PORTION OF CULM AND GENERALLY INCREASES UNTIL ITREACHES MATURITY.TENSILE STRENGTH IS HIGH PARALLEL TO THE GRAINBAMBOO FAILS IN SHEAR BEFORE IT FAILS IN TENSION & THEREFOREMODULUS OF RUPTURE IS USED TO CALCULATE STRENGTHDUE TO WEAK TRANSVERSE BONDS BETWEEN FIBRES, IT CAN BESPLIT EASILY ALONG THE LENGTH(RADIAL OR TANGENTIAL) 9. Specific gravity 0.575 to 0.655Average weight 0.625 kg/mFibre stress at elastic limit 390 to 1000 kg/cm2Modulus of rigidity 610 to 1600 kg/cm2Modulus of elasticity 1.5 to 2.0 x 105kg/cm2Ultimate crushing stress 320 to 720 kg/cm2Average tensile stress @ yield point 1400 to 2800 kg/cm2Ultimate compressive stress 794 to 864 kg/cm2Safe working stress in compression 105 kg/cm2Safe working stress in tension 160 to 350 kg/cm2Safe working stress in shear 115 to 180 kg/cm2Bond stress 5.6 kg/cm2(which can be increasedup to 10 kg/cm2i.e. equal to that ofsteel with concrete after suitabletreatment)BAMBOO - MECHANICAL PROPERTIES 10. SEASONING OF BAMBOOESSENTIAL PRE-REQUISITE FOR MAINTAINING SHAPEAND STRENGTH OF BAMBOOMETHODSAIR SEASONINGMODIFIED AIR SEASONINGCHEMICAL SEASONINGBAKING OVER OPEN FIREKILN SEASONING 11. BAMBOO - PRESERVATIVE TREATMENTBoucherie ProcessDip DiffusionInter nodal Injection MethodHot & Cold 12. BAMBOO PROCESSING INVOLVES TWO STEPS(a) PRIMARY PROCESSING(b) INDUSTRIAL PROCESSINGBAMBOO PROCESSING 13. PRIMARY PROCESSING MACHINESCross- Cutting m/c Splitting m/cKnot Removing, Width sizing &Planing m/cSlab Making m/c 14. MAT WEAVING 15. BAMBOO PRIMARY PROCESSING UNIT IN THEINSTITUTE 16. Growing stock in natural forest 3-4 tonnes/ha/yrGrowing stock in Plantation 5-12 tonnes/ha/yrNo. of bamboo required for CFCper year of 20 ft length3,00,000 Nos.Quantity of Bamboo 1000 tonnesLand requirement of bamboo (5tonnes per ha)200 ha.No. of mats of size 2.5m x 1.3m 1,50,000 mats/yrCapital investment $120 thousandBamboo required per day 3.33 tonnesCost of Bamboo $40/- per tonnecost of raw material per day $130/-COMMON FACILITY CENTRE FORPRIMARY BAMBOO PROCESSINGA Birds Eye View 17. (a) Operation of machinery and quality control 40 persons(b) Mat weaving 500 mats per day 200 personsLabourMechanic cum Quality control operator $1.6 / per day $64Mat weaver $1 per day $200$264Electricity, water, maintenance, advertisement,depreciation and other contingencies 40% of raw materialcost$53TOTAL $450Cost of production per mat $0.9Selling price $1.2Net Profit per day $151Net profit per year $45360B/C ratio 1:1.34EMPLOYMENT GENERATION AT CFC 18. INDUSTRIAL PRODUCTS DEVELOPED AT IPIRTI1. 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 CAP2. BAMBOO STRIP BASED PRODUCTS2. BAMBOO STRIP BASED PRODUCTS BAMBOO-WOOD (LAMINATES) FROM INDIAN BAMBOOS DEVELOPMENT OF TRANSPORT VEHICLE FLOORING3. BAMBOO IN ROUND / SPLIT / COMPOSITE FROM3. BAMBOO IN ROUND / SPLIT / COMPOSITE FROM BAMBOO BASED HOUSING SYSTEM Bamboo Match Sticks 19. Bamboo Mat Board HIGH MODULUS OF RIGIDITY COMPARED TOPLYWOOD HIGH INPLANE RIGIDITY HIGH RACKING STRENGTH MORE FLEXIBLE THAN EQUILAVENTPLYWOOD ECONOMICAL COMPARED TO PLYWOOD INSTITUTE IS INSTRUMENTAL IN THEFORMATION OF SPECIFICATION IS:13598BAMBOO MAT BOARD FOR GENERALPURPOSES BMB CAN BE UTILIZED FOR SHEATHINGMATERIAL IN STRUCTURAL AND SEMISTRUCTURAL PURPOSES SUCH AS WALLPANELING, PARTITIONS, ROOF SHEETHING,DOOR SKINS, BOX FURNITURE, BUILT UPHOLLOW BEAMS, GUSSETS, ANDCONTAINERSBAMBOO MAT BOARDIS:13598 20. BMB - STRENGTH PROPERTIESSl.No. Property1 Thickness of the panels 3mm 6mm 6mm 8mm 9mm2 Density, kg/m3 766 711 935 790 8923 I.B. Strength N/mm2DryWet2.181.982.422.140.820. 611.971.732.21.84 Surface Strength N/mm2DryWet11.4211.4211.2310.474.93.479.479.1013.1010.55 Tensile strength N/mm2 22.69 26.59 89.19 29.54 31.46 Compressive strength N/mm2 16.77 30.35 50.60 35.30 57.57 Mod. of Rupture N/mm2 50.74 56.31 102.57 59.35 68.88 Mod. of Elasticity, N/mm2 3678 3220 12033 3114 39309 Mod. of Rigidity, N/mm2 5881 6050 3527 6066 5750Physical & Mechanical Properties of BMB of different thickness 21. USE OF VENEERS FROM PLANTATION TIMBERALONG WITH BAMBOO MATS FORMANUFACTURE OF HIGHER GRADES OFPLYWOOD. AN ALTERNATIVE TO STRUCTURAL ANDSHUTTERING GRADE PLYWOOD WITHOUTWARPAGE MOE AND MOR OF BMVC ARE HIGHER THANEQUIVALENT PLYWOOD BMVC WILL BE ECONOMICAL IN HIGHERTHICKNESS AS COMPARED TO BMB FOR ALL PRACTICAL PURPOSES BMVC CAN BEUSED IN A SIMILAR WAY TO PLYWOOD. INSTITUTE IS INSTRUMENTAL IN THEFORMATION OF SPECIFICATION IS:14588BAMBOO MAT VENEER COMPOSITE FORGENERAL PURPOSESBAMBOO MAT VENEER COMPOSITE(BMVC)Bamboo MatVeneer CompositeIS:14588 22. REPLACEMENT OF HIGH PRICED IMPORTEDVENEERS WITH BAMBOO MAT RESIN FORMULATIONS OPTIMIZED FOR THEMANUFACTURE OF HIGH DENSITY SHUTTERINGGRADE PANELS. DENSITY OF THE PANELS ACHIEVED IS 1.1gm/cc TO1.2gm/cc PANELS WITH BAMBOO MATS ALONE AND INCOMBINATION OF BAMBOO MATS & VENEERS WEREMADE THE STRENGTH PROPERTIES MEETS THEREQUIREMENT OF IS: 4990 1993, SPECIFICATIONFOR SHUTTERING GRADE PLYWOOD IN ALLCONSTRUCTIONS. EASE THE PRESSURE ON IMPORT OF TIMBERBAMBOO MAT COMPREGHIGH DENSITY SHUTTERING GRADE PANELBamboo MatCompregBMC overlaid withPhenolic Film 23. BMCS IS A GREEN ROOFING MATERIAL COMPARED TO OTHERROOFING MATERIALS IN THE MARKET SUCH AS ACCS,CFRP,CAS,CGIS THE MANUFACTURE OF BMCS DOES NOT AFFECT THE HEALTH OFWORKERS AND ENVIRONMENT. ENERGY REQUIREMENT IS LOWHAS IMMENSE POTENTIAL AS AN ECOFRIENDLY ROOFING MATERIALIS HIGHLY RESILIENT,LOW WEIGHT,LOW THERMAL CONDUCTIVITY,GOOD AESTHETIC APPEARANCEINSTITUTE IS INSTRUMENTAL IN THE FORMATION OF INDIAN STANDARDSPECIFICATION IS:15476 BAMBOO MAT CORRUGATED SHEETSBAMBOO MAT CORRUGATED SHEET(BMCS)Bamboo Mat CorrugatedSheet IS:15476 24. ParticularsThicknessmmWidthin mmMaxLoadNLoad bearingcapacity inN/mmWeight of sheet(2.44m x1.05m)in kgsBMCS[4layers]3.7 400 1907 4.77 9.78GI Sheet 0.6 400 1937 4.84 10.43Aluminiumsheet0.6 405 669 1.67 3.92ACCS 6 330 1800 5.45 21.5STRENGTH PROPERTIES OF BMCS IN COMPARISONWITH OTHER EXISTING ROOFING SHEETS 25. BMRC IS COMPATIBLE FOR ROOFINGWITH BAMBOO MAT CORRUGATEDSHEETS SUITABLE FOR WIDE RANGE OF ROOFANGLES REPLACEMENT FOR THE PRESENTPRACTICE OF USING THIN FLAT BOARDSWHICH CAUSES PERFORATIONS DUE TOWEATHERING. DIMENSIONALLY STABLE, NONPERMEABLE , ANTI-TERMITE ANDWEATHER RESISTANT READY & EASY TO FIX FOR ROOFINGPURPOSE.BAMBOO MAT RIDGE CAP(BMRC)Bamboo Mat Ridge Cap 26. FLEXI- PLY WITH BAMBOO MAT AS CORE FLEXIPLY BASED ON BAMBOOMAT & WOOD VENEER IS A NEWENGINEERED PRODUCT HAS A GREAT POTENTIAL FORAPPLICATIONS IN MAKING CABINSOF HEMISPHERICAL SHAPES ANDARCHES WITH SHARP CURVATURESFlexi-PlyFlexi-Ply Centre Table 27. REDUCTION IN THE CONSUMPTIONOF TIMBER FOR MAKING DOORS ASTHEY ARE HOLLOW DOORSWITHOUT WOOD BATTENS SAVES ABOUT 1/3 QUANTITY OFTIMBER THEY ARE MORE STRONGER THANIMPORTED SKIN BOARDS MADEFROM HIGH DENSITY FIBRE BOARDBECAUSE OF ITS HIGH IMPACTRESISTANCE LEADS TO IMPORT SUBSTITUTIONBamboo Mat MouldedSkin BoardDoor with Bamboo MatMoulded Skin BoardBAMBOO MAT MOULDED SKIN BOARD(BMMSB) 28. Bamboo matchairBAMBOO MAT TRAY & CHAIR SEATS WATER RESISTANT HEAT RESISTANT SCRATCH RESISTANT UNBREAKABLE ECOFRIENDLY Bamboo Mat Tray 29. BAMBOO LAMINATESHorizontalLaminateVerticalLaminateSPECIES TESTED : Bambosa bamboose, B. nutan, Dendrocalamus hamiltoniiYIELD : ABOUT 15%Mfg.COST : Rs 650/ m2(approx.)/13 USDB/C ratio : 1.5STATUS : READY FOR COMMERCIALIZATIONLaminated productSUBSTITUTE FOR WOOD 30. Magazine holderLaminated BambooCe