WOOD SUBSTITUTES.pdf

WOOD SUBSTITUTES

1. WOOD SUBSTITUTES
MODULE-1
BUILDING MATERIALS AND CONSTRUCTION TECHNIQUES -V

3. ? WOOD SUBSTITUTES
INDUSTRIAL PRODUCTS AS SUBSTITUES FOR NATURAL HARD WOOD.
1.VENEER AND VENEER PLYWOOD
2.PARTICLE BOARD
3.HARD BOARD
4.FIBER BOARD
5.BLOCK BOARD
6.LAMINA-BOARDS
7.GLULAM
8.LAMINATES
9.CEMENT PARTICLE BOARD
10.E-BOARD
11.BAMBOO PLY etc.

4. ADVANTAGES OF WOOD SUBSTITUTES
Advantages of wood
substitutes
Environmental benefits
Stronger than wood
Weather resistant, durable
Corrosion-resistant
Termite fungus, rot, rodent-resistant
Fire retardant, self-extinguishing nature
Cost-effective than teakwood, GRP, PC
products and maintenance-free
Use in variety of applications: doors,
ceilings, flooring, partition, furniture.

5. 1. VENEER PLYWOOD
•Veneerplywoodiscommonlyreferredsimplyas
plywood.Formakingplywood,roundlogsarefirst
cutintologsof1.5to2.5mlengths.
Veneer/
Plywood
Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply
•Theyarethensteamedandveneersarecutfrom
thesepieceswithawidesharpknifeextendingthe
fulllengthofthelog.
•Theseveneersaregluedtogethertoform
plywood.
•Glueispositionedbetweeneachlayerandeach
layerispositionedat90º.
•Generally,threeormoreveneersareglued
togetherwiththegrainscrossingeachother.This
crossgrainingincreasesthestrengthofplywood.
•Therearemanytypesofclassificationofplywood.
Inthemainclassification,therearethreegrades:
ordinarygrade,exteriorgradeandmarinegrade.

6. MANUFACTURING PROCESS
•Thelogsarefirstdebarkedandthencut
intopeelerblocks.Inordertocutthe
blocksintostripsofveneer,theyarefirst
soakedandthenpeeledintostrips.
•Thewetstripsofveneerarewoundintoa
roll,whileanopticalscannerdetectsany
unacceptabledefectsinthewood.
•Oncedriedtheveneerisgradedand
stacked.Selectedsectionsofveneerare
gluedtogether.
•Ahotpressisusedtosealtheveneerinto
onesolidpieceofplywood,whichwillbe
trimmedandsandedbeforebeing
stampedwithitsappropriategrade.
Veneer/
Plywood
Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

7. 2.PARTICLE BOARDS
•Theseboardsaremadewithparticlesof
wood(orothermaterialslikericehuskor
bagasseobtainedfromsugarcanes
aftercrushing)embedded insynthetic
resinsandsubjectedtoheatwith
pressure.
•Particleboardshavemanydesirable
propertiessuchashighdensity,high
surfacehardness,abrasionresistance,
highdurability,ETC
•Particleboard isheavierthan
comparablesolidwoodorplywoodbut
itprovidesbroadandstablepanelsof
reasonablestrength.
•Itiscommonlyusedforfurnituremaking.
•Theyareavailableinthicknessof5-50
mm
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

8. Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

9. 3.HARD BOARD
•Hardboardismadefromwoodthatis
pulpedandcompressedtomakesheets
usually3mmthick.
•Thefacesurfaceissmoothandhardand
theoppositesideisroughwithpatternor
crosslines.
•ItisclassifiedinCPWDspecificationsinto
threefollowingtypes:
(1)Mediumhardboard(density480-800
kg/m)availablein6mm,8mm.10mm
and12mmnominalthickness
(2)Normalhardboard(density800-1200
kg/m°)
(3)Temperedhardboard.(Hardboard
speciallytreatedforstrength,density
andwaterresistance)
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

10. •Thenormalandtempered
hardboardsareavailablein3
mm,4mm,5mm,6mm
and9mm,and12mm
thicknesses.
•Thewidthofhardboardsis
usually1.2mandlengths1.2
m.1.8m,2.4m,3.0m,3.6m.
4.8mand5.5m.
•Thetoleranceallowedis+3
mm.Onlytemperedquality
asmentionedaboveshould
beusedfordoorshutters,etc.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

11. 4.FIBER BOARD
•Thetechnologyusedtomake
fibreboardisacombinationofthose
usedformakingparticleboardand
hardboard.
•Formakingfibreboards,woodchips
aresteamedtoseparatethefibres
fromeachother.
•Thesefibresareblendedwithresin
andwaxandturnedintosheetsby
passingthroughapressingmachine
undercontrolledheat,andpressure.
•Theseboardsareavailablein
thicknessof25mmto32mmandas
sheets2.44mx1.22m.
•Mediumdensityfibreboardsarecalled
MDFparticleboards.Theyaresuited
formassproductionoffurniture,
cabinets,etc.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

12. Woodchips,shavings,andsawdusttypicallymakeupthe
rawmaterialsforfiberboard.However,withrecyclingand
environmentalissuesbecomingthenorm,wastepaper,corn
silk,bagasse(fibersfromsugarcane),cardboard,cardboard
drinkcontainerscontainingplasticsandmetals,telephone
directories,andoldnewspapers arebeingused.
Panelscanundergoavarietyoffinishingstepsdepending
onthefinalproduct.Awidevarietyoflacquercolours
canbeapplied,aswellasvariouswood-grainpatterns.
Forexample,laminatingmachinesareusedtoapplyvinyl,
foil,and othermaterialstothesurface.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

13. 5.BLOCK BOARD
•Blockboardisalsoknownasbatten
boardorsolid-coreplywood.
•Blockboardsarethickerthanmostof
theplywoodsandhaveacoremade
ofstripsofwoodeachnotexceeding
25mminwidth,laidseparatelyor
gluedorotherwisejointedtoforma
slabwiththedirectionofthegrainsof
thecoreblocksrunningatrightangles
tothatoftheadjacentblock.
•Theslabisthengluedbetweentwoor
moreouterveneersoneitherside.
•Thicknessesarefromabout19mm
upwards.
•Theyaresuitableforitemsliketable
tops,doorpanelandsimilarpiecesof
largeareas
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

14. Followingsarethestepsofblockboardprocessing:
1.Slicing
Thelogsoftimberare
slicedatfirstfor
makingtherawof
blocks.Stripsmaybe
25mm.
2. Rotary Cutting
Forouterlayer,logs
arecutatrotary
cutting.Thusveneer
for coating is
obtained.
3. Gluing
Toattachtheslicesglueoradhesivesareused
eg:Ureaformaldehyde,Phenolformaldehyde
whichiscalledplasticresin.Exteriorgradeblock
boardrequiresphenolformaldehyde.Gluingis
doneunderhighpressure.
4. Drying
Theblocksaredriedtoreducethe
moistureaswellaswatercontentleft
insideblocks.Fordryingtheblocks
arekeptbeforethesun.Themoisture
contentisreducedto10-12%.After
properdrying,theyarereadyfor
makingasandwich.
5. Attaching
Blocksareattachedtogether
usedsoftwoodorhardwoodas
requiredforinteriororexterior
graderequired.
6. Finishing
Finalfinishinggiving
lamination,acoating
isdone
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

15. 6.LAMINA-BOARD
•Whenthecorestrips
consistofacoremade
upoflargepiecesof80
mmwidth,itiscalled
blockboardorbatten
boards.
•Ontheotherhand,ifthe
coreconsistsofstrips
eachnotexceeding7
mminthickness,itis
calledlaminaboards
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

16. 7.GLULAM
•Gluedandlaminatedwoodiscalled
"Glulam"(GLULAM).Itisnotmadeof
veneersbutwithsolidwood.
•Solidwoodisgluedtolargesections.
Componentsmadefromthisprocessare
especiallysuitableforsupportoflong
spanroofsforsportsstadiums,indoor
swimmingpools,shedsforchemical
factories,etc.,
•whereothermaterialslikesteelcannot
lastlong.Theycanbeusedasbeamsof
many shapes includingcurved
members.
•Thetimbersectionsarefirstdriedinakiln.
Theyarethenmachined toform
interlockingVcutsacrossthewidthand
theendsectionsofeachpiece.
•Suitablegluesarethenappliedandthe
piecesareforcedtogetherunder
longitudinalpressurewhiletheglue
cures.Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

17. Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

18. 8.LAMINATES
•Laminatesaretheproductsmade
bybondingtogetheroftwoor
morelayersofmaterials.
•Productssuchasplywood,glass
laminates, composite glass
laminatesallcomeunderthisclass
Speciallaminatesfromplasticsare
alsoavailableinthemarket.
•Thesecanbegluedtowoodto
makethesurfaceaestheticaswell
asheat-resistant.
•Astheselaminatescomeinlarge
widthfurniturelikelargetabletops
canbemadeofjoinedwood
piecesandcovered
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

19. Step 2: Drying the papersStep1:Soakingthepaperin
resins
Thebrownpaper(suchasthe
oneusedforbrownpaperbags)
thatisgoingtoformthebottom
sideorbaseofthelaminateis
soakedinatubthatisfilledwith
phenolicresin.
Thisisfollowedbyadrying
processinwhichthesoaked
papersareallowedtodry.After
thedryingiscomplete,the
paperwhichearlierwaseasyto
tearacquiresnewphysical
properties.Itbecomesstiffand
brittle.
Step 3: Cutting
Thehardenedrollsofpaperare
thencuttothedesiredsizesby
thecuttingmachines.InIndia,
thestandardormostcommon
sizeforlaminatesheetsis8'x4'(8
feetby4feet).
Hard pressthesepapers
togetherunderhighpressure
andtemperature.Itisthereason
whydecorativelaminatesare
oftenreferredtoasHPLand
HPDL(High-pressuredecorative
laminates).
Step 4: High-pressure pressing
and bonding
Step 5: Sanding the
non-decorative side
Inthefinalstepoftheprocess,
the bottom side(non-
decorativeside)isuniformly
sandedbyasandingmachine.
Samples ofthefinished
productsmaybesubjected
tostandardqualitytestsfor
laminatesaspernorms
Step 6: Testing, Packing
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

20. 9.CEMENT PARTICLE BOARD
•CementParticleBoardsarealsoknownas
CPBoards
•Itismadefromamixtureofwoodparticles
andcement.
•Cementboardaddsimpactresistanceand
strengthtothewallsurface.
•Itisnotactuallywaterproof,butitishighly
resistanttoabsorbingmoistureandhas
excellentdryingproperties
•Suitableforexternalandinternaluse,andit
isidealforceilings,floors,insulationandwall
partitioning.
•composed ofwood chips,Portland
cement,additivesandwaterandcanbe
manufactured in6mm upto24mm
thicknesses.
•Allboardsoffersoundinsulation,waterand
frostresistancealongwitheasyinstallation.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

21. Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

22. 10.E-BOARD
•Anotherformofcementboard.
•Eboardisacementcellulosefibreboardused
forfalseceilingpartition.
•composedofcement,silicasandandwood
pulp.Reinforcedfibercementproductssuchas
fibercementboardaremanufacturedusing
the‘HatscheckProcess.
•Usedinsteadofgypsumboard.Thiskindoffalse
ceilingdoneatwetandceilingdamaged
areas.
•Fibercementboardisacompositeofcement
reinforcedwithcellulosefibers.Thisisalsoknown
asWaterprooffalseceiling.
•ThismaterialusedtocoverandInteriorand
exteriorofabuildinginbothresidentialand
commercialApplications.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

23. 11.BAMBOO PLY
•Bambooplywoodisastrongbuildingmaterialthatisincreasinglyusedasanalternative
tomoretraditionalhardwood.
•engineeredbamboocanbedividedintotwomaingroups;"laminatedbamboo"and
"strandwovenbamboo“PanelssimilartoOSB,MDF,particleboard,matboardsetc.
Laminatedbambooplywoodismadefromflatrectangularbamboostripsthatarecutfrom
thebamboostem.Thesestripsor"slats"arethengluedtogethereitherhorizontally(plain
pressed)orvertically(sidepressed).
1)LAMINATED BAMBOO
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

24. LAMINATED BAMBOO MANUFACTURING PROCESS
1)Selecting bamboo poles
Bamboopoleswithan
averagediameterof9
cmareselectedforthe
production of
engineered bamboo
products.Thesearecut
intolengthsof250cm.
2)Splitting bamboo poles
Thebamboo polesare
placed inaspecial
machinewhichconverts
themintoroughbamboo
slats.
3) Planing bamboo slats
Thebamboo slatsare
initiallystillveryirregular
inshapeandstructure.
Toeliminatetheirgreen
outerlayerandinternal
nodes,theslatsare
planed in the
dimensions22x6mm.
4)Boiling bamboo slats
Toprotectbamboo from
futureinsectsattacksor
fungi,theslatsareboiledin
hydrogenperoxidefor±7
hours.Thistreatmenthas
theaddedadvantagethat
itbleachesthestripswhich
resultsinauniformnatural
colour.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

25. 5)Carbonizing
Bamboostripsarecarbonizedinahigh-
pressuretankforseveralhours.The
combinationofheatandpressurereleases
naturalstarchinbamboostripswhichgives
itatypicalbrowncaramelcolour.
6)Drying and sanding
Aftertheboiling/carbonizingtreatment,
bamboostripsaredriedinakilnforabout5
daysuntiltheyreachamoisturecontentof
approximately8-10%.Oncedry,thebamboo
stripsaresandedtotheirfinal20x5mm
dimensions.
Plain pressed
7)Plain pressed
Afterqualitycheckingtheyareprocessed
intopanels.Ina"plainpressed"panelthe
bamboostripsarepressedtogetherfacing
up.Thisresultsina1-plywherethepattern
andcharacteristicofthebamboonodesare
clearlyvisible.Plainpressedbamboo
plywoodhasathicknessof5mm.
Plain pressed
8)Side pressed
Ina"sidepressed"panelthebamboostrips
arepressedtogethervertically.Thisresultsin
a1-plywherethepatternandcharacteristic
ofthebamboonodesarenotclearlyvisible.
Sidepressedbamboo plywoodhasa
thicknessof20mm.
Plain pressed Plain pressed
9)Cutting to size
Abandsawisusedtoconvert20mmside
pressedplywoodintothinnerpanels.Thisway
theindividualsheetscanbeusedtobuild3-5-7
or9-plybamboopanels.
10)Sanding
Sandingisthefinalstepintheproduction
processtoaccomplishaperfectlyflata
smoothsurface.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

26. Forstrandwovenbamboolargelythesamestepsapplyaswithlaminatedbambooexcept
thatthestripsarenotgluedtogetherhorizontallyorvertically.Instead,rawbamboostrandsare
usedwhicharecompressedunderhighpressuretocreateanew"composite"material.
STRAND WOVEN BAMBOO
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply

27. STRAND WOVEN BAMBOO MANUFACTURING PROCESS
From strips to strands
1)From strips to strands
Afterboilingorcarbonizingthebamboo stripsaspreviously
describedinstep5-6,thestripsarecrushedintoroughfibrous
bamboostrands
2)Adding glue to bamboo strands
Thebamboostrandsaresoakedwithgluebeforeputtingthemin
thepress.
From strips to strands
Thebamboostrandsareplacedinamassiveindustrialpress
andcompressedwithapressureof2,500tons.
to strands
3) Compressing 4)Cutting to size
Strandwovenbamboo panelsareavailableinamaximum
thicknessof20mm,otherwisetheywouldbecometooheavy.30-40
mmthickpanelsaresawnintosmallerboardsofmax10-30cm
wide.Thesebambooplankscanthenbeprocessedintobamboo
flooring,deckingorsiding.
Veneer/
Plywood
Particle Hard Fiber Block Lamina Glulam Laminate
Cement
Particle
E-board
Bamboo
Ply