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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


1.Rafters & purlins Dip diffusion

22

3.Columns

Internodal injection or Boucherie

33

11

2.Grid Dip diffusion

Treatment


Roof covering: corrugated bamboo mat board

Doors and windows: frames of sawn plantation timber with bamboo mat

board infill panels.


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


PLASTERING

FIXING OF TRUSSFLOORING FIXING OF PURLINS


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..

http://www.ipirti.gov.in, http://www.bamboocomposites.com

E-mail: [email protected]

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