Presentation on Wood Composites

Course Teacher

By

Dr.I.Sekar
Associate Professor

A.Maheshwaran
BSF-04-012

Wood Plastic Composites

Wood plastic
Plastic ranging from polypropylene to PVC Binders/Fillers Wood flour to Wax Wood saw dust & scrap wood products

Benefits
True hybrid materials & combine best features of wood & plastics Use low cost & plentiful raw materials Competitively priced Easily produced & easily fabricated Available in broad range of finishes & appearance Easily recycled after use No further processing is needed Weather, water, & mould resistant

Properties

Properties
High resistance to moisture (0.7% compared to 17.2% in Pine) Moisture not transmitted across plastic boundaries Good stiffness & impact resistance Dimensional stability Resistance to rot Excellent thermal properties

Environmental Benefits
Negligible waste & that produced is reused No volatile organic compound Recycled & reused after their service life Disposed using standard methods Increase efficiency up to 40% compared to traditional wood

Processing

 Mix of wood & plastic - modified with process & additives - to improve processing / final properties of WPC Compatibiliser/coupling agent Improve blending Basic wood product fine saw dust(40-60mesh range) Simple die can be used even for most complex profile

Wood filler

Wood putty or Plastic wood wood dust combined with a binder that dries and a diluent and a pigment fill imperfections, nail holes or pores in wood Wood putty or plastic wood - thicker version Wood filler - thinner version

Plastic wood

The base product -100% recycled High-Density Polyethylene (HDPE) shampoo and detergent bottles, to milk jugs Some, entirely of HDPE recycled HDPE + with wood fibers, rubber, fiberglass, or other plastics

Like Natural wood, Plastic lumber is

expand & contract with heat (Magnitude varies) cut and shaped with traditional wood working tools

Plastic wood will not:

Rot (seawalls, docks) crack warp splinter degrade

Plastic wood is:

denser than wood virtually maintenance free long lasting stain resistant waterproof UV resistant aesthetically pleasing impervious to insects not affected by exposure to most substances

Plastic wood also:

works with any deck fastener requires no painting or sealing used in composite extruded panel plastic wood for flooring Provides a good shock-absorbing surface for pedestrian traffic, such as runners and hikers.

Plastic lumber and Wood-plastic composites - difference

fiber plastic lumber can have less than 50% wood fiber. balloted in ASTM by Committee D20 Standard Test Method for Shear Properties of Plastic Lumber and Plastic Lumber Shapes.

Wood-plastic composites have at least 50% or more wood balloted in ASTM by committee D07 Standard Test Methods for Evaluating the Mechanical and Physical Properties of Wood-Plastic Composite Products

New technology in plastic composite lumber

post-consumer plastics such as high density polyethylene (HDPE) mixed environmental wastes and plastic material into extruded composite lumber 65% recycled Cellulostics materials and 30% recycled plastic materials.

CATEGORIES
1. 2. 3. 4. 5. 6. Material Preparation Extruder Design Screw Design Cooling Technology Die technology Fillers

Wood cement

Wood cement

wood wool cement boards (WWCB) cement bonded particleboard (CBPB)

General Properties

durable and resistant to frost/thaw, fire, moisture, rot, vermin, fungus and termites easy workability

MANUFACTURING PROCESSES
Manufacture
Manufacture

of Wood Wool Cement Board

of Cement Bonded Particle

Boards
Manufacture

of Cement Bonded Fibre

Boards

Manufacture of WWCB

Long wood + cement wool strands (or excelsior) - cut from debarked logs

400-500mm length prior to cutting the wood wool treated to prevent blue-staining

The logs stored on racks a month to reduce the moisture & sugar content

Manufacture of WWCB

wood is shredded
salt (CaCl2) solution + Portland cement (2:1 ratio) spread onto plywood moulds & stacked The mats pressed at room temperature under 10 psi. stack is clamped under pressure for another 24 hours then removed from the moulds & cured for 2-3 weeks. They are subsequently trimmed and finished.

Workers collecting sawn logs for shredding

Logs being shredded into wood wool

The wood wool is then soaked in a salt solution

Eltomation Rotating Wood Wool Machine Boards

The pressed and finished boards

Manufacture of CBPC

wood is in particle rather than strand form softwood logs debarked & stored to reduce moisture and sugar content Portland cement: wood: water in ratio 3:1:1 Water evaporation is monitored CaCl2 added - cement setting The mixture fed to a conveyor

Manufacture of CBPC

mat subsequently cut These stacked & compressed together to 1/3rd of its original height over a 2-3 minute period. The mats are clamped and heated in a chamber at 70-80 degrees Celsius for 6-8 hours. boards dried, trimmed and stored for 12-18 days until the cement cures.

Modern CBPB plant

Manufacture of CBFB

wood pulped cellulose fibre (with an air-dry moisture content of 12-16%) Silica + alumina + water + pulped cellulose Binders added water removed and mixture is rolled onto mats, cut, and sized, or moulded

Properties

Properties of WWCB

insulation fire retardation water resistance resistance to organism attack mechanical properties

Insulation

WWCB provides very good insulation, both thermally and acoustically. Acoustic Insulation Resistance of a plastered wall of 5cm Wood Wool Cement Boards 36-40dB Resistance of a plastered double wall with air space between WWCBs 53-57dB Resistance of a permanent shuttered wall with 12cm concrete core 354-56dB Noise Reduction Coefficient for 2.5cm board 0.7 Thermal Insulation (Evans,1996) Thermal resistance (R) for 2.5cm board 5

Fire Resistance

5cm boards 1 hour resistance 10cm boards 2 hours resistance

Water Resistance
Dimensional change after soaking in water for 48 hours: 0.84% thickness swelling 0.21% linear expansion 22% water absorption

Resistance to Organism Attack

WWCB is highly resistant to dry rot and other fungal growth as well as to termites.

Mechanical Properties

Specific Gravity

light boards for insulation only 360kg per cubic metre denser boards for roofs and permanent shuttering 450kg per cubic metre

Bending Strength = 20-30kg per cubic centimeter Design load for 2cm board = 50psf Ultimate load for 2cm board = 200psf Allowable span for 2cm board = 122cm Deflection at design load = 0.2cm

Properties of CBPB

insulation machinability water resistance mechanical properties

Insulation

Thermal Insulation

Thermal conductivity (k value) = 0.35W/m.K Linear thermal expansion = 0.01W/m.K

Electrical Insulation

CBPB is resistant to tracking and does not build up static charges, thus be used as backing panelling for electrical appliances.

Acoustic Insulation

The sound reduction for boards of various thicknesses is as follows:

6mm - 28dB 10mm - 31dB 20mm - 33dB 30mm - 36.5dB 40mm - 38dB

Machinability

working - CBPB can be worked using hard tipped tools in a similar manner to timber,plywood or chipboard. sawing - can be sawn with handsaws, jigsaws with suitable blades or power saws with tungstentipped blades.

drilling - use hand drill or high speed power drill

sanding - manual sanding or mechanical sander preferably applied to both sides of board simultaneously.

fixing - drilling of pilot holes for nails and screws is recommended for most board thicknesses.

Water Resistance

Thickness swelling

<1.0% after 2 hours soaking <1.5% after 24 hours soaking <2.0% after >24 hours soaking

Longitudinal and Transverse Swelling

2.7mm/m from air dry to water saturated 0.1mm/m for each 1% change in moisture content of the board 1.4mm/m for each 30% change in relative humidity of ambient air

Mechanical Properties

modulus of elasticity = 4500N per cubic mm bending strength = 10-15N per cubic mm (depending on density and raw materials) compressive strength = 15N per cu mm density = 1250kg per cubic metre

APPLICATIONS

Applications of CBPB

External Applications
flat roofing prefabricated structures(including housing) mobile homes permanent formwork balcony parapets and floors cladding for industrial and warehouse buildings tunnel linings

External Applications
sound barrier walls on highways fire barriers pavillions separating and party walls soffits agricultural buildings swimming pool surroundings and paving

Internal Applications
sound insulation and fire resistant partitions and doors linings for timber frame housing fire resistant doors, walls and ceilings built-in furniture column and beam casings

Internal Applications
lift shaft and duct linings back boards for electrical and gas appliances glue laminated structural members flooring in greenhouses linings for bathrooms and laundries

Applications of WWCB

Most important applications

thermal and acoustic insulation for low-cost housing

thermal and acoustic insulation

basements floor units permanent shuttering partitioning sound insulation in walls, ceilings and floors roofs sound barriers thermal insulation (often combined with other insulation products such as polystyrene and polyurethane)

Applications for Low-Cost Housing

relative low price of products since wood wool can be produced from inferior quality wood which is unsuitable for sawmills

simple technology required to produce boards, etc see photograph below of plant in the Philippines
in most countries in the world wood and the components of cement are readily available low enough weight to allow handling panels without the use of cranes or heavy machinery

Applications for Low-Cost Housing

highly skilled labourers are not required for board manufacture or building construction which allows boards to be made and buildings to be constructed locally and cheaply the construction process is quite fast and simple high insulation value easy handling and workability important properties such as fire, water, termite and fungi resistance

References:
http://www.umeciv.maine.edu/rla/images/DSC00088.JPG http://www.tangram.co.uk/TI-Polymer-Plastic&Composite_Windows.html http://www.tangram.co.uk/TI-Wood_Plastic_Composites.html

http://www.tangram.co.uk/TI-Wood_Plastic_Composites_Review.pdf
http://www.cis.tennessee.edu/EPAMACT/other/Plywood/pcwpVT1.shtml http://www.renewresources.com http://www.machinerydata.com/HowToMakePlasticWood.htm http://www.cierraindustries.com/plasticlumber.asp http://en.wikipedia.org/wiki/Wood-plastic_composite

http://www.awc.org/Publications/download.html http://www.awc.org/HelpOutreach/faq/FAQfiles/Plastic_Wood-Lumber.html http://www.panelworldmag.com/vserver/hb/display.cfm?MagazineKey=6&IssueKey=4 61&SectionKey=389&ArticleKey=620 http://www.fpl.fs.fed.us/documnts/pdf1997/wolfe97a.pdf#search=%22wood%20cement %20products%22 http://www.ccaconference.org/pre/pdf/Gong.pdf#search=%22wood%20cement%20prod ucts%22 http://www.anu.edu.au/Forestry/wood/cfb/contents.html http://www.fpl.fs.fed.us/documnts/pdf1996/geime96b.pdf#search=%22cement%20wood %22 http://www.aciar.gov.au/web.nsf/doc/JFRN-5J47AH http://www.anu.edu.au/Forestry/wood/nwfp/woodwool/woodwoolphil.html http://www.toolbase.org/Technology-Inventory/walls/wood-fiber-composite-forms

Thank you