COIRWOOD/COIRPLY & IT’S IMPORTANCE

COMPARING TO OTHER CONVENTIONAL

WOOD SUBSTITUTES

JESIYA FRANCIS
Presenter Name
S9 - 17
 INTRODUCTION

- It is important to find sustainable, alternative building materials

as the natural resources are depleting and therefore coir is an
excellent option.
- Coir is one of the thickest and toughest natural durable fiber. Coir
is an abundant and renewable natural resource as it is a
byproduct of coconut pressing.
- The expanding utilization of green and ripe coconuts and the
industrialization of coconut water have prompted increasing
production of solid wastes formed by the fibrous outer covering.
AIM
To find out the importance of using coir wood as a natural wood substitute and it’s uses in the
construction industry

OBJECTIVES
• To study about the history and characteristics of coir, coir fiber and coir wood.

• To study about its properties in relevance to other wood substitutes.

• To find out it’s significance and possibility in architecture and construction comparing
to normal wood and other wood substitutes.

• Identifying it’s benefits over other conventional materials.

SCOPE
• Provide new ideas of developing a sustainable building material that can be an alternative material for conventional building materials in future.
• Can be effectively utilized to minimize the huge investments in the construction industry.

LIMITATION
• The study is limited to mainly literature data only.
• Focused on researches and experimental data and therefore case study data are limited.

RESEARCH QUESTIONS
• What is coir wood / coir ply?

• How do materials like coir provide sustainable and effective solutions comparing to normal

• wood?

• What are the different ways of using coir wood in the construction industry?

• Can coir wood be used like any other wood substitute?

METHODOLOGY
 WHAT IS COIR ?
▪ Coir is a versatile natural fiber derived from mesocarp tissue, or husk of the coconut fruit.

▪ The outer layers covering the coconut seed are processed and spun into fibers commonly known as coir.

▪ Commonly, fiber is of golden color when cleaned after removing from coconut husk; and hence the name " The
Golden Fiber".

▪ Coir is the hairy husk of the coconut shell.

▪ The fibre is very valuable in the making of different kinds of materials.(History of coir, 2014)
STRUCTURE OF COIR FIBRE
• The individual fiber cells are narrow and hollow, with thick walls made from cellulose.
• They are pale when immature but later become hardened and yellowed with deposition of
lignin layer on their walls.
• Mature brown coir fibres contain more lignin and less cellulose than fibres, for example, flax
and cotton as are more stronger yet less flexible.
• White fiber is smoother and better, yet additionally more fragile. - The longitudinal and transverse views of

• The coir fiber is moderately waterproof and is the only natural fiber impervious to harm by coir are shown in figures.

salt water.
- The cross section shows many cavities
within the fiber, and about a third of the
fiber is mostly filled with air.

- This entangled air increases the yarn's

elasticity (resilience) markedly, its ability to
float in water, and increases the time it
takes for water to penetrate the fiber.
 COIRPLY / COIRWOOD

▪ Coir plywood (or coir ply) has become a popular plywood alternative.

▪ As forests continue to be depleted of their timber, it is becoming even more important to find sustainable,
alternative building materials.

▪ As the thickest and toughest natural commercial fiber, coir is an excellent choice for durable textiles.

▪ It has become more popular as a wood alternative as consumers look for more sustainable and eco-friendly
options.

▪ As a byproduct of coconut processing, coir is an abundant and renewable natural resource.

▪ The typical coconut tree produces 50 to 100 coconuts per year. After being harvested, coconuts are
separated into their parts (the kernel and the husk), leaving what was once considered waste — the coconut
coir.

▪ This coir is then combined with a polymeric matrix, such as phenol, polyester, or epoxy, and processed
under a controlled pressure and temperature.

▪ It is an eco-friendly, sustainable, and sensible alternative to wood.

Top face layer: Irregular and oriented jute with
CONSTRUCTION OF COIRPLY
phenolic resol on resinized paper carrier.

Inner layers: Alternate layers of coir with phenolic

resol (first layer being coir) and rubber timber
veneer coated with phenolic resol. Total layers
should be odd and minimum three.

Bottom face layer: Resinised paper carrier with

Irregular or oriented jute with phenolic resol

• Coir wood composites belong to the fiber reinforced plastics.

• In the fibre-reinforced plastics, the fibers are embedded in a
polymer matrix so that the former form a discontinuous phase in
the continuous phase of the latter. The resinous matrix in the
material used to envelop the reinforcement.
MANUFACTURING PROCESS OF COIRPLY

RAW MATERIALS FOR COIR

WOOD COMPOSITE :

• Coir needled felt

• coir matting

• coir rope, resin

• veneer

• kraft paper

• coir ply of desired

thickness

• wood veneer.
 COIR NEEDLED FELT
It is a non-woven fabric made up of decorticated coir fibre.

In the manufacturing process, the well cleaned coir fibre of good staple length passes through the cleaning machines by pneumatic suction and is the needled
by the needle loom on one side to evolve felts of various density, punching intensity, needle penetration and thickness.

The fibre is mechanically bonded (interlocked) to make endless length of sheet.

No bonding material is employed within the manufacture of coir needled felt.

It can be manufactured in thickness ranging from 10 mm to 20 mm with a density varying from 500 to 1500 g/sq.metre.

The coir felt is available in the form of rolls of 4 ft. width and 25 meter length.
 SELECTION OF RESIN

- Plywood, as we all know, is made from thin sheets of wood that are
bonded together with an adhesive.

- Manufacturers use phenol formaldehyde resin as the binder to

give structural strength and resistance to moisture. BIO-RESINS
While bio-resins are a completely safe
- However, formaldehyde is toxic when inhaled, swallowed, and in and eco-friendly alternative to PF
contact with skin or eyes. adhesives.

Replacement of phenol in plywood resin

- Phenolic resin is reactive with lignocellulosic and they have good - with lignin.
bond between fiber and polymer.
This new lignin-based adhesive
- Phenolic water-based plywood laminating resin was chosen as the significantly reduces the carbon
ideal resin for coir polymer composites due to its viscosity and footprint of plywood products from
production to final application without
solids content.
compromising on technical
performance.

PROPERTIES OF PHENOLIC RESINS

- Phenolic resin is reactive with ligno cellulosics and they have good bond between fiber
and polymer.
- Phenolic water-based plywood laminating resin was chosen as the ideal resin for coir
polymer composites due to its viscosity and solids content.
- FABRICATION PROCESS OF THE NEEDLED FELT : Fabrication of coir felt is made in Needled felt plant.

The opened coir is passed through the feeding system consisting

Bale opener opens the coir available in bale form.
of more openers, distributors and conveyors.

The fibres form loops below the web bottom surface by which the It is then needle punched with a needle-punching machine
fibres are mechanically entangled. consisting of reciprocating needle board, stripper plates and base
plates.

After needling, the edges are trimmed and if required cuts are
made by adjustable rotating cutters

Is rolled by winder, which always maintain constant speed in

winding in spite of continuous increase in roll diameter.

When a particular length is damaged, the roll is removed from the This needled felt is then coated with resin by polymer
winder and core of the next roll is put. impregnation process to form the coirply
 PRE-IMPREGNATED SHEET RESIN COATING
PROCESS FOR COIR WOOD COMPOSITE

• The addition of the right amount of resin to

the coir needled felt is achieved by polymer
impregnation process, where a resin carrier
fabric is pressed against the needled felt so
that a part of the resin is instantaneously
transferred to the needled felt from the resin
carrier fabric.

• Composite products from prepreg sheets

are prepared by hot press molding.

• It is a polymer impregnated coir fiber mat.

• The prepreg sheet are cut into the
required size and stacked over. • By prepreg sheet molding process, more than 60% weight of coir
fibre can be incorporated in the composite.

• Non-woven coir needled mat is used for impregnation with resin to

prepare prepreg sheets.

• The non-woven coir needled mat is preferred as it is comparatively

more economic.
• Coir ply has all the properties of phenol-bonded ply with the added strength
of fiber reinforced phenol bonding.

• Manufacturing process gives it a natural, smooth, glossy finish on both

sides. Can be used without surface treatment.

• The board has the lowest consumption rating per square foot, on paints and
varnishes.

• Has both vertical and horizontal load bearing strengths. The best
compression / strength ratios among phenol- bonded boards.
GENERAL PROPERTIES
• Can be form-cut in to virtually any shape, with minimum wastage and low OF COIRWOOD
labor costs.

• Has high degrees of surface abrasion resistance.

• Does not flake-off dust as in ordinary particle boards and asbestos.

• Resists contraction/ expansion due to temperature variations.

• Does not absorb water or moisture.

• Termite / insect resistant. Also has a high fire retardant property.

DENSITY 700-800kg/m3

MODULUS OF ELASTICITY 35-40N/mm2

MODULUS OF RUPTURE 3000-3500N/mm2

SHEAR STRENGTH 20-25N/mm2

SCREW HOLDING CAPACITY >2000N

NAIL HOLDING CAPACITY >1500N

MOISTURE 10-15%

PROPERTIES OF COIRWOOD
 COIRPLY PLYWOOD MEDIUM PARTICLE
DENSITY FIBRE BOARD
BOARD

Tested as per IS - 1734 IS-1734 IS- 2380 IS- 2380

Density(kg/mcu) 748 400-700 750-850 700-800

Moisture(%) 6.50% 5-15% 5-15% 5-15%

Glue shear strength 1720 1200-1750 - -

(N/mm2)

Water resistance No declamation No declamation Disintegrate Disintegrate

(8hrs boiling)

Tensile strength
(N/mm2)
23.6 35.55 7-8 4-4.5
On comparing it’s strength with other
Compressive 51.02 29.24 - -
wood substitutes coirply has relatively
strength(N/mm2)
good strength making it fit for
Modulus of elasticity
(N/mm2)
6440 3500-7400 - -
constructional purposes and several
Modulus of rupture 47.5 29.49 25.28 12.5-15
other uses
(N/mm2)

Nail holding power 50 40-100 - -

(in Kg)

Screw holding 245 200-300 125-150 8-125

power(in kg)

Surface strength 30 - 30 30
(kg/cm2)

COMPARISON OF COIRPLY WITH OTHER WOOD SUBSTITUTES

 COMPARISON TO WOOD

LIGNIN CONTENT

where, Lignin – It is a complex organic polymer that, with cellulose, forms the
45.84% 38-40% chief constituent of wood. It is second to cellulose as the most abundant
organic material. They lend to give rigidity and do not rot easily.

COIR FIBRE NORMAL WOOD

A normal tropical tree of 15m height would give lumber of 3.5 cubic meters.
60% timber recover would be 2.25cubic meters. Further 20% of wastage is
produced during conversion. Hence total recovery would be around 1.80 One unit of coir composite
cubic meters. building materials would
produce 40 cubic meters a Coir is renewable every 45
day, where by 22 tropical days as against 60 years for
trees could be saved every a tree.
single day.
Specifications :
Standard board sizes - 2.4m x 1.2m
Thickness options - 4mm, 6 mm, 8mm, 12mm, 18mm and 19mm.

APPLICATIONS :

• It can be used as furniture for doorways, kitchen cabinets, tables and

chairs and offices, bedroom, dining room and also as
• solid composite panels,
• sheet metal shutters,
• panel shutters,
• insulation panels,
• foam composite panels,
• roofing systems,
• wall and floor cladding systems,
• particle boards,
• for disaster management
COIR WOOD IN THERMAL INSULATION

Kerala state coir corporation limited manufactures various coir products for thermal insulation, products
such as coir needle felts and coirply boards can be used as pads made by interlocking coir fibre through
needling; these coir felt pads an boards can be used for low cost acoustic control, air and water filtration,
thermal insulation and also for soil erosion control.
The sizes available are 60*40 and 90*45; density is 174 kg/m3 and heat capacity is 2600 J/kg. which varies
for different coir based insulation products. (A Conspectus on Serviceability of Coir Fibres in Civil
Engineering, 2016).

COMPOSITE FOAM PANELS

Coir fibre in a randomly distributed manner has been used in

polyurethane foam panels by 51.5% to decrease its weight and
increase its mechanical properties by a considerable note. (A
Conspectus on Serviceability of Coir Fibres in Civil Engineering,
2016)
ROOFING MATERIAL

Roofing materials which are considered as a low cost alternative to corrugated galvanized iron and asbestos cement sheeting, can also been
made from short randomly distributed coir fibres in a cement matrix or corrugated roofply.

Testing has been done on corrugated coir roofing where it shows that it is not only
comparable to other roofing materials, but it is even better. It has a low thermal
conductivity, provides good insulation, and can even be used in a house without a ceiling.
It even stays stable when soaked in water, and it burns slower than other wood-based
materials.

WALL PANELLING SYSTEM

Wall panels can be made of gypsum and cement as binder and coir fiber as the reinforcement. Bending
strength, compressive strength, moisture content, density, and absorption were investigated.
Coconut fibres did not contribute to bending strength of the tested wall panels.
Compressive strength increased with the addition of coconut fibres, but the compressive strength
decreased with an increase in water content and density was increased. There was no significant change
of moisture content with coconut fibres.
COIRWOOD COMPOSITE FOR FLUSH DOOR
SHUTTER

Flush door shutters can be used in the making of

every types of doors. It is ideally suited for bathroom COIRWOOD COMPOSITE FOR PANEL DOOR SHUTTER
and kitchen doors because it is water resistant and
fire retardant. CONSTRUCTION

CONSTRUCTION FRAME :The main frame is made of coir laminated

veneer lumber (CLVL). Coir laminated veneer lumber
Top face layer: Random or oriented jute with phenolic is made of properly oriented jute face layer/coir with
phenolic resol/resin coated rubber timber veneer/
resol on resinised paper carrier.
Coir with phenolic resol/oriented jute face layer.
Inner layers : PANEL : The panel is either made of normal coirply
(a) Coir with phenolic resol/treated rubber timber or NFRP.
blocks with phenolic resol coating/coir with phenolic
resol.
Or
(b) Coir with phenolic resol/rubber timber frame made
with veneer and filled with coir with resol/coir with
phenolic resol.

Bottom face layer: Resinised paper carrier with

random or oriented jute with phenolic resol.
USE OF COIR COMPOSITIES IN DISASTER MANAGEMENTS.

In 2001, in Bhuj (Gujarat / India) 500 shelters were built to assist within the
relief from an earthquake.

The walls and roofs were made from coir ply and guarded from UV rays by
weather coat paints, respectively tiles.

The boards having good insulation properties have shown a temperature

difference of 5 to 8 degrees in comparison to the surface temperature.
In spite of the acute climate in Gujarat they are said to remain without
defects until today.

Coir ply is essentially a substitute for plywood, the foremost popular wood-
based panel in India. (Coir -Traditionally Used Fibres For New Construction
Applications, 2015)
 ▪ Coir can be easily made into sheets of wood.

▪ Therefore it can be easily constructed during times of need. i.e, during disasters when a large
amount of people needs shelter.

▪ Since coirwood is an excellent insulator during both hot and cd conditions, it can be effectively
used as wall panels.

▪ It is also water resistant and termite resistant.

▪ It can be used for panelling of roofs, floors and in making the frames of doors and windows.

▪ It can be easily cut, therefore can be used in making furnitures and cabinets for offices too.

▪ It can be easily nailed and screwed and so provides excellent base for shelves and desks.

▪ It’s natural grain pattern provides aesthetic appeal and therefore it need not be painted.

COIRWOOD – It’s uses in the construction of houses.

1. COIR WOOD HOME, ALAPPUZHA, KERALA

Developed by Central Institute of Coir Technologies

Project type: Residence (model)
Area: 340 sq.ft
Total Construction cost: 4 lakh
Material:Coir wood

COSTRUCTION OF HOUSES USING COIRWOOD

2. COIR WOOD HOUSES, COIR BOARD,COIMBATORE

In an effort to recycle coir waste, Coir Board is looking at eco-friendly

shelters that will replace tents for security guards and defence personnel in
high altitudes. The Coir Research Centre in Bengaluru has developed a
model house made out of coir wood and it was displayed at the coir fair.

As part of its marketing initiatives, Coir Board will build six model houses
made out of coir wood and supply it free of cost to some of the Central
Government ministries.

This house has withstood the changes of nature for two and a half years in
Bengaluru. It is a modular structure and can be disassembled in three to
four hours.

Different accessories can be easily attached to it. Therefore, it can be used

in the building of temporary shelters in the event of a disaster. It can be used
to build shelters for security personnel or armed forces.

COSTRUCTION OF HOUSES USING COIRWOOD

3.COIR WOOD HOUSES, UPCOMING PROJECT IN
POLLACHI,TAMILNADU

The coir board,is setting up the houses at Pollachi. These homes would be
much cheaper than a brick and mortar house or even a plywood house,
because it cost only around 90 per sqft.

This house will be 100% environment-friendly because it is built only out of a

byproduct of coconut and does not involve felling or exploitation of coconut
trees at all. The house has been designed by Bengaluru-based Coir
Research Center, which has previously set up a house in their campus.

Model houses will be built by using coirwood alone . Their house has already
proven that coir wood can withstand heat, rain and the cold. Because, they
have five different types of coir boards for different conditions, and they are
also conditioning them in such a way that they don’t catch fire easily, stand
strong, don’t start seeing leakages or break down.

COSTRUCTION OF HOUSES USING COIRWOOD

4. HOUSE CONSTRUCTION USING CFB, PHILIPPINES

Zamboanga Research Center, San Ramon, Zamboanga city invented

coconut fiber boards (CFB) for different applications. According to them,

CFB can replace building materials such as tiles, bricks, plywood and hollow

blocks made of asbestos and cement. It is used for interior and exterior

walls, partitions and ceilings. It can also be used as an ingredient in the

manufacture of furniture, cabinets, boxes and flowerpots, among others.

COSTRUCTION OF HOUSES USING COIRWOOD

COST COMPARISON OF COIRWOOD PRODUCTS TO NORMAL
CONVENTIONAL WOOD PRODUCTS
COST COMPARISON OF COIRWOOD PRODUCTS TO NORMAL
CONVENTIONAL WOOD PRODUCTS
COST COMPARISON OF COIRWOOD PRODUCTS TO NORMAL
CONVENTIONAL WOOD PRODUCTS
 ANALYSIS & INFERENCE

In recent years the application of coir fibre in construction industry is

increasing and revealing new ways of using coir. Studies showing that it
can be a good alternative to conventional materials in several ways. Initial
stages of using coir as a building material can be seen from the history.

It shows that coirwood can be effectively used as a construction material

just like other substitutes. Being a natural resource material with huge
amount of annual production in many countries. It is also economical
comparing to other wood substitutes.

From case studies it is clear that, Coir can be effectively used as a building
material and it is infinitude. Construction materials from coir are also
showing that, the potentiality of coir, since it is being a sustainable material.

2/8/20XX 32
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