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What are long fiber composites?

Long fiber thermoplastics (LFT) are bulk molding materials that feature continuous fiber filaments
running the full length of the pellet allowing these materials to exhibit simultaneous improvements in
strength, stiffness, and impact resistance over a wide temperature range.

Heralded as an exciting growth area in thermoplastics, LFT composites are widely accepted as a
viable alternative to traditional reinforced thermoplastics and metals for a vast array of applications.
What process is used to make long fiber composites?

Pultrusion process is used to manufacture long fiber thermoplastics (LFT), which entails pulling
continuous fiber rovings through a polymer melt in a specialized processing die. The resulting
composite strands are cooled and chopped into pellets.

Pultrusion is dramatically different than the process used to manufacture short fiber thermoplastics
(SFT) where chopped fiber is melt-blended with plastic resin using conventional extrusion
compounding methods. The fiber length in a SFT pellets is typically less than 1 mm while in LFT
pellets fiber length is up to 1/2 inch.

What is "wet-out" and why is it important?

Wet-out refers to the impregnation of the fiber rovings with thermoplastic resin during the pultrusion
manufacturing process. Successful wet-out completely coats the individual filaments and results in
pellets that are free of loose fibers or other debris which can cause problems during conveying.
[ Return ]

How long are long fiber composite pellets?

Standard pellet length for long fiber composites at RTP Company is 7/16 inch, or 11mm, although
other lengths can be specified in the 6 to 12 mm range. Experience has shown that this length
provides optimal properties while still allowing processing in standard injection molding equipment.
 [ Return ]

Why is fiber length important in reinforced plastics?

The fiber is the structural component of long fiber composites. The longer the fiber, the more
effectively the polymer is able to "grab on" and transfer stress to the fiber. At lengths around 1/2 inch
the strength of the fiber is fully attained, and longer lengths provide no significant improvement in
physical properties while making the material more difficult to process.
[ Return ]

Are fibers other than glass available?

Long fiber thermoplastic (LFT) composites are available with glass, aramid, stainless steel, or
carbon fiber reinforcement at loadings up to 60% by weight.
 Glass fiber is the most popular and cost effective reinforcement used for LFT composites
 Aramid fiber is utilized for its excellent wear resistant properties
 Sainless steel fiber for its electrostatic dissipation (ESD) and electromagnetic interference (EMI) shielding
properties
 Carbon fiber provides additional enhancements in flexural modulus and potential weight reductions while also
providing ESD properties
[ Return ]

What are typical long fiber loading levels?

Available fiber loading levels for most thermoplastic resins are 20, 30, 40, 50, and 60% by weight.
Balancing performance, cost, and weight are critical criteria in selecting a correct polymer to fiber
ratio. In general, 40 and 50% loading levels are most common.
[ Return ]

What polymers are long fiber composites available in?

long fiber thermoplastics (LFT) are available with polypropylene (PP), nylon 6 (polyamide 6), nylon
6/6 (polyimide 6/6), PPA, PBT, polyurethane elastomer (TPUR), PC/ABS alloy, PPS, and PEEK.
Other semi-crystalline engineering resin systems offer potential for development if appropriate end-
use applications present themselves.
[ Return ]

What performance characteristics make long fiber composites unique?

Long fiber thermoplastic (LFT) composites bridge the price-to-performance gap between short fiber
thermoplastic (SFT) materials and advanced composite materials while still being processable via
efficient injection molding methods.

Successful end-uses often require greater performance than is attainable with SFT products and
where metal is not a desirable option due to weight or per part costs. LFT composites have gained
rapid acceptance as a viable alternative to die castings, metal assemblies, and traditional plastic
materials in a vast array of markets, including: industrial equipment, automotive, consumer goods,
sports and leisure, and information technology.
[ Return ]
 What are the typical properties and benefits of long fiber composites?

The benefits of long fiber thermoplastic (LFT) composites can be

easily understood by examining the entangled long fiber matrix formed in a finished part. Exposing a
molded part to pyrolysis conditions, commonly referred to as burn-off, removes the polymer and
leaves behind the glass reinforcing fibers allowing visual examination. The fiber network that is
formed by an LFT material retains the shape of the molded part and resembles a fiber preform with
well and evenly distributed fibers.

The extensive fiber network in an LFT part serves to improve most all performance characteristics
and also inhibit crack propagation. Often referred to as "stiff and tough," LFT composites exhibit a
wide range of performance advantages:
 Better impact resistance and rigidity at elevated and sub-zero temperature ranges (up to 5 times that achieved
with short fiber thermoplastics)
 Modulus retention at elevated temperatures
 Creep resistance under constant load in severe environments
 Dimensional stability and resistance to warpage resulting from reduced shrinkage ² which occurs as
thermoplastic materials solidify during molding
[ Return ]

How much do long fiber composites cost, relative to other reinforced materials?

Relative to short fiber materials long fiber thermoplastic (LFT) composites are slightly more
expensive, but yield price-to-performance advantages that make them attractive for end-use
applications that need an engineered material solution. Due to the efficiencies of the injection
molding manufacturing process LFT composites result in a lower per piece cost when replacing
metal and provide a significant reduction in weight.
[ Return ]

Are long fiber composites really better than short fiber?

Each class of material has unique benefits. Polymers reinforced with long fiber offer elevated
performance at levels unattainable by similarly reinforced short fiber materials. The physical
requirements of individual applications should dictate which material is best positioned to provide a
solution. Modulus is nearly equivalent between short and long fiber products, remaining more
dependent on filler content than fiber length.
[ Return ]

Why should I use long fiber composites?

Reasons for using long fiber thermoplastics (LFT) vary, but a perennial conclusion is that the
application would not be feasible using any other plastic material. LFT composites have opened
possibilities for plastics to displace traditional materials and gain improved performance, design
freedom, corrosion resistance, and weight reduction.
[ Return ]

man plastics replace metals?

Reinforced plastic compounds have replaced metal in many applications by providing better
aesthetics, corrosion resistance, and opportunities for part consolidation. When choosing long fiber
composite materials designers can now exploit these benefits when confronting demanding load
requirements of structural components.
[ Return ]

Is metal replacement common with long fiber composites?

Die castings and metal assemblies are opportunities to apply the advantages of long fiber
thermoplastic (LFT) composites to new applications. To bring new designs to reality, while avoiding
typical metal concerns (corrosion, painting, recycling, etc.), designers regularly choose reinforced
plastic compounds. In instances where other reinforced plastics do not fulfill performance
requirements of complex parts, LFT composites are the logical choice.
[ Return ]

man long fiber composites replace short fiber reinforced thermoplastics?

Use of longer reinforcing fibers elevate the performance of thermoplastics to such a high degree that
cheaper resins begin to provide the properties of more expensive engineering polymers. In many
instances, long fiber composites have proven themselves to be an economically viable alternative to
other reinforced plastics. Contact any of our sales engineers for assistance in examining the
differences between available reinforcing technologies.
[ Return ]

What application development support is available?

RTP Company's global Technical Service team is available to provide expertise regarding design
analysis, mold construction, pre-production trials and trouble-shooting. A wide variety of Computer
Aided Design analysis and metal replacement tutorial services are also available.
[ Return ]

man I convert a die cast tool to evaluate long fiber composites?

Many die cast tools can easily be modified to allow them to be used for plastic injection molding.
Often, this is a convenient first step in creating a meaningful prototype to measure success potential
for changing materials.
[ Return ]

man long fiber composites be air conveyed?

Yes, the 1/2 inch size of long fiber compoiste pellets can be easily accommodated by most air
conveyance systems. Full "wet-out" of long fiber composites minimizes loose fibers and other fines
that cause problems in air conveying systems. Use of abrasion resistant elbows is recommended.
 [ Return ]

Are long fiber composites molded similar to other thermoplastics?

Yes, care should be taken to maximize fiber length in the molded article to maintain physical
properties. Typical accommodations include: use of free flowing check-rings and general purpose
screws; generous mold gates and runners; and radiused corners and direction changes. A detailed
Long Fiber Molding Guide is available to reference.
[ Return ]

Are long fiber composites abrasive to tools and molding equipment?

All reinforced plastics, particularly those with fiber ends, are more abrasive to molding machinery
than unfilled resins. Since long fiber composites have fewer fiber ends than an equal loading by
weight of short fiber material, it wears less on equipment.
[ Return ]

Is special equipment needed to mold long fiber composites?

No special equipment is required to injection mold long fiber thermoplastic (LFT) composites.
However, to produce quality parts care should be taken to minimize fiber breakage and maximize
fiber distribution and packing. A detailed Long Fiber Molding Guide is available to reference which
discusses these and other issues related to molding LFT composites.
[ Return ]

What are the most important things to remember when molding long fiber composites?

Use low shear conditions to minimize unnecessary fiber filament breakage and maintain maximum
physical properties in finished parts. Low shear conditions commonly include: proper barrel
temperatures, slower screw rotation, minimal back pressure, and moderate injection speeds.
[ Return ]

What is typical fiber breakage during molding and how does it affect properties?

Even with the utmost care, some fiber breakage will occur during the molding process - this is to be
expected. Successful molding practices minimize broken fibers and result in a normal bell-curve
distribution of complete long and broken fibers.

If excessive fiber breakage occurs molded articles will not have the high stiffness and toughness
associated with well made long fiber composite parts. Consult our Long Fiber Molding Guide for
details on maintaining optimum physical properties during molding.
[ Return ]

How do I check if fiber length is maintained?

Look for evidence of long fibers protruding from the sprue entry. Conducting a pyrolysis, where the
polymer is burned away leaving the fiber matrix intact, allows fiber distribution, packing, and
breakage to be visually examined.
 [ Return ]

man long fiber composites be molded in very thin walls?

Long fiber thermoplastic (LFT) composites exhibit excellent flow characteristics, even at high fiber
loadings of 60% by weight. Not only can LFT composites flow long distances, they routinely fill
intricate and thin wall sections with remarkable ease. Evaluation of any material in its end-use
design should always be conducted to ensure appropriate properties are maintained.
[ Return ]

Are long fiber composites suitable for molding large parts?

Long fiber thermoplastic (LFT) composites are regularly molded into parts weighing in excess of 10
pounds and with surface areas comparable to doorways. The limiting factor is not LFT composites,
but the availability of large injection or compression molding equipment.
[ Return ]

Why should I buy long fiber composite pellets instead of using direct in-line compounding
(D-ILm or D-LFT)?

To be economically viable, direct in-line compounding demands large numbers of large parts to be
molded on a single machine. Deploying a direct in-line compounding system also requires a
significant investment in specialized equipment that must be kept continuously in operation along
with the development of in-house compounding expertise. For many applications and molders
purchasing long fiber composites as precompounded pellets is a better option because of its
flexibility and reduced capital investment.
[ Return ]

Why should I buy long fiber composites from RTP mompany

Supplier selection criteria vary, but most customers rely on RTP Company because of our broad
portfolio of specialty compound products and the engineering expertise to support them during
development and production. All RTP Company manufacturing facilities are registered to ISO
9001:2000 quality standards and are located across the globe allowing consistent and timely
delivery no matter where you do business

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With the advent of modern civilization and development of scientific knowledge, there has
been an upsurge in demand for developing newer materials for novel applications. In fact,
with the technological leaps in recent times, focus has been on developing the materials
required to perform in stringent conditions - high temperature & pressure, highly corrosive
environment, higher strength but without much weight implications etc. which the
conventional materials failed to service. This ushered in 'engineered material', devising
material properties catering to the application needs. And the innovation was not limited to
developing materials with novel properties alone but it also addressed the method of
manufacturing - improved processing techniques, effective use of energy while processing
and more importantly with the least environmental impact. Advanced materials with
combination of properties for specific end uses became a reality.

Over the last thirty years composite materials, plastics, and ceramics have been the
dominant emerging materials. The volume and number of applications of composite
materials has grown steadily, penetrating and conquering new markets relentlessly. Modern
composite materials constitute a significant proportion of the engineered materials market
ranging from everyday products to sophisticated niche applications.

Today high performance fibre reinforced plastics (FRP) are starting to challenge those
ubiquitous materials such as steel & aluminium in everyday applications as diverse as
automobile bodies and civil infrastructure. It would be naive to suggest that FRP will
dislodge those materials from their dominant roles. However, continuous advances in the
manufacturing technologies and performance of FRP have intensified the competition in a
growing range of applications leading to significant growth in its market acceptance. For any
given application and industry sector, the final choice is often a competitive outcome of
alternative solutions, including advances in alternative materials such as aluminium alloys
and metal-composite hybrids. Each type of composite brings its own performance
characteristics that are typically suited for specific applications.

Increasingly enabled by the introduction of newer polymer resin matrix materials and high
performance reinforcement fibres of glass, carbon and aramid, the penetration of these
advanced material forms has witnessed a steady expansion in usage. The increased
consumption has reduced the product cost. High performance FRP can now be found in such
diverse applications as composite armouring designed to resist explosive impacts, fuel
cylinders for natural gas vehicles, windmill blades, industrial drive shafts, support beams of
highway bridges and even paper making rollers. An examination of the diversity of some of
these newer applications and the socio-commercial considerations that underpin their
introduction gives an instructive insight into the future place of high performance FRP.

The development of a composite component involves both material and structural design.
Unlike conventional materials, the properties of the composite material can be varied
considering the end application. Properties (stiffness, thermal expansion etc.) can be varied
continuously over a broad range of values by suitable selection of resin, fibre, their ratio,
additives etc.

Commonly used polymer matrix composites comprise a thermosetting resin matrix in

combination with a fibrous reinforcement. Some advanced thermoplastic resins are also
used, whilst some composites employ mineral filler reinforcements, either alone or in
combination with fibrous types. Cellular reinforcements (foams and honeycombs) are also
used to impart stiffness in conjunction with ultra lightweight. Whilst the use of composites
will be a clear choice in many instances, material selection in others will depend on factors
such as working lifetime requirements, number of items to be produced (run length),
complexity of product shape, possible savings in assembly costs and on the experience &
skills of the designer in tapping the optimum potential of composites.

Lightweight corrosion resistant materials such as FRP could provide an important

contribution to the safe, economical development of resources. The need for new markets
has spurred renewed efforts in reducing the cost of both raw materials and manufacturing
processes, making composites more competitive to use in civil infrastructure applications.
The mechanical properties of composite laminates are listed in Table-I.

Indian efforts centre around developing cost effective building materials as well as for
catering to the housing needs of urban & rural poor. In this context, certain developments
concerning glass fibre reinforced polymer composites, natural fibre composites, industrial
waste based composites have assumed importance. The key restricting factors in the
application of composites are initial costs due to raw materials and also inefficient
conventional moulding processes.

Various key product applications being developed in the building & construction industry are
prefabricated, portable & modular buildings, exterior cladding panels, interior decorations,
furniture, bridges and architecture mouldings. Various proven composite products being
used in the housing sector are bathtubs & basins, drainage channels, manhole covers, pits,
farm buildings, doors, door frames & windows, cabinets, housing modular, sheeting roof and
flat, structural members, portable toilets, ponds & fountains, water storage tanks etc.

m
 

    


Composites have long been used in the construction industry. Applications range from non-
structural gratings and claddings to full structural systems for industrial supports, buildings,
long span roof structures, tanks, bridge components and complete bridge systems. Their
benefits of corrosion resistance and light weight have proven attractive in many low stress
applications. Composites present immense opportunities to play increasing role as an
alternate material to replace timber, steel, aluminium and concrete in buildings.

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Bridges account for a major sector of the construction industry and have attracted strong
interest for the utilization of high performance FRP. FRP has been found quite suitable for
repair, seismic retrofitting and upgrading of concrete bridges as a way to extend the service
life of existing structures. FRP is also being considered as an economic solution for new
bridge structures. Design approaches and manufacturing efficiencies developed for road
bridge applications will benefit their introduction into a broader range of civil construction
fields.

Decks for both pedestrian and vehicle bridges across waterways, railways and roadways are
now a commercial reality in both North America and Europe, with some pedestrian bridges
being built entirely from composites. Because of the superior durability of composite, only
cosmetic maintenance requirements are expected for at least 50 years. The composite
bridge decks are quite suitable for replacing conventional/old bridge decks having super
structure intact. The replacement can be carried out in a short time with minimal
disturbance to the traffic.

   
 


Among a wide array of composite products, pultruded profiles such as gratings, ladders,
cable trays, solid rods & other sections are used in many structural application with Class I
flame retardancy. Pultrusion is the most cost-effective method for the production of fibre-
reinforced composite structural profiles. It brings high performance composites down to
commercial applications such as lightweight corrosion-free structures, electrical non-
conductive systems, offshore platforms and many other innovative new products. Pultruded
sections are well-established alternative to steel, wood and aluminium in developed
countries and are fast catching up in other parts of the world. Structural sections have
ready markets in oil exploration rigs, chemical industries etc. The amount of energy
required to fabricate FRP composite materials for structural applications with respect to
conventional materials such as steel & aluminium is lower and would work for its economic
advantage in the end. The pultruded products are already being recognized as commodity in
the international market for construction.

In pursuit of developing advanced performance materials for building & construction,

railways, automobiles, bio-medical etc., the Advanced Composites Programme was launched
by Technology Information, Forecasting & Assessment Council (TIFAC), an autonomous
organization under the Department of Science & Technology (DST), Govt. of India. Under a
project of the aforesaid programme, FRP Pultruded profiles (industrial gratings, solid rods
for electrical insulation, cable-trays, ladders etc.) with excellent surface finish and flame
retardancy as per international standards have been developed by M/s. Sucro Filters Pvt.
Ltd., Pune. The profiles developed have met all the desired properties. Table II lists the
mechanical/ chemical properties of FRP pultruded sections vs. other structural materials.
Table III lists out the characteristics of the pultruded products.




 


Composite plates are successfully used to repair masonry beams, columns, buildings and
other structures damaged/weakened by impact, earthquake or subsidence and can usually
be adhered in place by hand without the need for heavy lifting equipment. Such repairs can
be carried out much more rapidly than traditional techniques.Composite reinforcing bars
may be used to replace steel in conventional reinforced concrete in order to prevent
"concrete cancer" problems resulting from internal corrosion of the reinforcement. The use
of composite rebars is justified where the nature of the construction would render possible
future repairs inaccessible or otherwise unduly costly.

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The composite is an ideal material for the manufacture of prefabricated, portable and
modular buildings as well as for exterior cladding panels, which can simulate masonry or
stone. The translucent roof sheeting is now supplied in a variety of colours and profiles to
suit both commercial and domestic building needs. In interior applications, composites are
used in the manufacture of shower enclosures and trays, baths, sinks, troughs and spas.
Cast composite products are widely used for the production of vanity units, bench tops and
basins. Realistic simulation of marble in various colours, onyx and granite can now be
achieved with cast composites using resin, filler and proper processing technology. The
availability of highly fire resistant phenolic composites opens up the opportunity for new,
safer and cost effective building techniques.

This area holds priority for the induction of composites in place of conventional materials
being used in doors & windows, paneling, furniture and other interiors. Components made
of composite materials find extensive applications in shuttering supports, special
architectural structures imparting aesthetic appearance, large signages etc. with the
advantages like longer life, low maintenance, ease in workability, fire retardancy etc. The
key restricting factors in the application of composites are initial costs due to raw materials
and also inefficient conventional moulding processes. Industry & design experts are of the
view that with the adoption of advanced technologies and some extent of standardization,
these problems could be easily taken care of.
|  |


With the scarcity of wood for building products, the alternative, which merits attention is to
promote the manufacturing of low cost FRP building materials to meet the demands of the
housing & building sectors. The doors made of FRP skins, sandwiched with core materials
such as rigid polyurethane foam, expanded polystyrene, paper honeycomb, jute/coir felt
etc. can have potential usage in residential buildings, offices, schools, hospitals, laboratories
etc. As structural sandwich construction has attained broad acceptance & usage for primary
load bearing structures, the FRP doors can be manufactured in various sizes & designs using
this technology.

The principal fabrication technique employed is contact moulding or hand lay-up process.
The front & back sheets of the doors are fabricated separately. Wooden inserts are placed
between two sheets for various fittings. The PU foam is sandwiched between the sheets by
in-situ foaming process followed by painting & polishing to meet aesthetic requirement.
Proper usage of additives imparts fire retardant properties to the doors. In addition, usage
of composite material for the doors makes them totally water & termite resistant. FRP doors
are much cheaper than the wooden ones. The FRP doorframes can also be fabricated by
contact moulding.

The FRP doors & doorframes have been designed & developed using the aforesaid
technology by the RV-TIFAC Composite Design Centre (CDC), Bangalore under the
Advanced Composites Programme. The FRP doors developed by CDC conform to BIS
specifications (IS:4020). After successful field trials and users¶ feedback, the technology for
FRP door has been transferred to over 50 entrepreneurs for commercial exploitation.

The rapid expansion of the use of sandwich construction in many fields has yielded a more
precise knowledge of design methods, test procedures & manufacturing techniques of cost-
effective composite products. A low-density core made of honeycomb or foam materials
provides a structural performance with minimum weight. Other considerations such as
sound insulation, heat resistance, vibration-damping etc. dictate the particular choice of
material used as core material.

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The fibre glass veil facing used while moulding the panels for suspended ceilings increases
panel stiffness and resists puncturing. Due to their easy printability, the veil imparts good
panel aesthetics. The suspended ceilings are used to cover up electrical wiring, ducting,
piping and fittings. The veil with an optimum porosity contributes to improved acoustical
quality of the working or living space.

|  


 


FRP Modular Toilet Units for Railway Coaches were developed under a project of the
Advanced Composites Programme in partnership with Hindustan Fibreglass Works,
Vadodara with design and technology support from IIT-Bombay. The Industrial Design
Centre of IIT-B helped in design drawing, fabrication of modular toilets with improved
aesthetics & ergonomics. IIT-B also extended support in terms of structural design of FRP
toilets, reinforcement lay-up, mould design & fabrication, selection of suitable raw materials,
testing & mechanical characterization and quality assurance norms for fabrication. Three
types of FRP toilet units were developed as per the space availability in ICF coaches.

The FRP toilet unit consists of four parts : the flooring trough, one L-shaped side-wall, one
C-shaped side-wall & roof. These parts are fastened by self-tightening screws. The FRP
toilet is light in weight, corrosion resistant, fire retardant, has longer life with easy
maintainability. Due to its modular design, the whole toilet unit can be installed inside the
coach in a short timeframe. The following features were provided in the toilet .

 FRP sandwich door with rigid PUF core, lipped with pultruded FRP frame on all four
sides of the door
 Special PVC sheet with improved anti-skid and anti-abrasion properties for the
flooring
 Concealed type Ki-tech flexible conduits with aluminium core encased within two
HDPE layers

FRP toilet units are now fully operational in passenger coaches of Indian Railways. The
performance of four nos. FRP toilets, which were fitted to an AC-II tier coach of Mumbai
Rajdhani Express in October 2001, has been extremely satisfactory. Based on the initial field
trials, FRP toilets have been inducted by the Indian Railways for many important trains on
regular basis. The project bagged the Certificate of Merit under the National Award for
Excellence in Consultancy Services±2001 by DSIR, Govt. of India.

 |

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Natural fibres, as a substitute for glass fibres in composite components, have gained
interest in the last decade, especially in the housing sector. Fibres like flax, hemp or jute
are cheap, have better stiffness per unit weight and have a lower impact on the
environment. Structural applications are rare since existing production techniques are not
applicable and availability of semi-finished materials with constant quality is still a problem.

The moderate mechanical properties of natural fibres prevent them from being used in high-
performance applications (e.g. where carbon reinforced composites would be utilized), but
for many reasons they can compete with glass fibres. Advantages and disadvantages
determine the choice. Low specific weight, which results in a higher specific strength and
stiffness than glass is a benefit especially in parts designed for bending stiffness.

Natural fibre composites (NFC) can be used as a substitute for timber as well as for a
number of other applications. It can be moulded into sheets, boards, gratings, pallets,
frames, structural sections and many other shapes. They can be used as a substitute for
wood, metal or masonry for partitions, false ceilings, facades, barricades, fences, railings,
flooring, roofing, wall tiles etc. It can also be used in pre-fabricated housing, cubicles,
kiosks, awnings, sheds/shelters. Natural fibres due to their adequate tensile strength and
good specific modulus enjoy the right potential for usage in composites thus ensuring a
value-added application avenue. The maximum tensile, impact and flexural strengths for
natural fibre composites reported so far are 104.0 MN/m2 (jute-epoxy), 22.0 kJ/m2 (jute-
polyester) and 64.0 MN/m2 (banana-polyester) respectively.

Although the tensile strength and Young¶s modulus of natural fibre like jute are lower than
those of glass fibres, the specific modulus of jute fibre is superior to that of glass and on a
modulus per cost basis, jute is far superior. The specific strength per unit cost of jute, too,
approaches that of glass. The need for using jute fibres in place of the traditional glass fibre
partly or fully as reinforcing agents in composites stems from its lower specific gravity
(1.29) and higher specific modulus (40 GPa) of jute compared with those of glass (2.5 & 30
GPa respectively). Apart from much lower cost and renewable nature of jute, much lower
energy requirement for the production of jute (only 2% of that for glass) makes it attractive
as a reinforcing fibre in composites. Table IV gives the properties of a few natural fibre.
  Tensile strength strongly depends on type of fibre, being a bundle or a single
filament

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Jute-coir composites provide an economic alternative to wood for the construction industry.
It involves the production of coir-ply boards with oriented jute as face veneer and coir plus
waste rubber wood inside. A very thin layer of jute fibres impregnated with phenolic resin is
used as the face veneer for improved aesthetics and to give a wood like finish.

The orientation & uniformity of jute fibre improve with carding and this also helps in better
penetration of resin into the fibre. The coir fibre contains 45.84% lignin as against 39% in
teakwood. Therefore, it is more resistant than teakwood against rotting under wet and dry
conditions and has better tensile strength. The composite boards namely, coir-ply boards
(jute + rubber wood + coir) as plywood substitute and natural fibre reinforced boards (jute
+ coir) as MDF substitute can be used in place of wood or MDF boards for partitioning, false
ceiling, surface paneling, roofing, furniture, cupboards, wardrobes etc. These boards have
been employed as doors & door frames as an alternate to conventional material like wood,
steel etc.

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Bamboo is one of the fastest renewable plant with a maturity cycle of 3-4 years, thus
making it a highly attractive natural resource compared to forest hardwoods. Bamboo offers
good potential for processing it into composites as a wood substitute. Bamboo laminates
could replace timber in many applications such as furniture, doors & windows and their
frames, partitions, wardrobes, cabinets, flooring etc.

Bamboo laminates are made from slivers milled out from the bamboo culm. After primary
processing comprising cross cutting, splitting and 2-side planing, the slivers are treated for
starch removal and prevention of termite/borer attack. The slivers are then subjected to hot
air drying followed by 4-side planing for attaining uniform thickness. These slivers are
coated with glue on the surface and are arranged systematically. They are subjected to a
curing in a hot press (6¶X4¶ 2-day light) at temp. ~ 70 0C using steam & pressure ~ 17
Kg/cm2. The pressed laminate (panels/tiles) is then put through trimming, sanding &
grooving machines to give a pre-finish shape. The flow chart & intermediate quality control
parameters for manufacturing bamboo composites are enclosed.

The project on production of bamboo composites & laminates is based on the following
premises.

 Value-added products from Bamboo

 Cost-effective compared to good solid wood sections for furniture
 Diversification from traditional plywood to bamboo based products
 Complete range of bamboo composite laminates for furniture, flooring tiles, boards,
door & window frames to replace the use of timber for domestic as well as
international market
 Expected Benefits
 Bamboo composite based flooring tiles, boards (used for partitions, cupboards,
racks, door & window panels) and blocks (used for furniture, rails & styles for doors
& windows etc.) as wood substitute would help develop & promote high value-added
products from bamboo
 Bamboo composite laminates with a low-temperature curing resin system for
reduced energy requirement
  Promotion of eco-friendly use of bamboo while building a sustainable infrastructure
for plant multiplication, propagation and cultivation
 Boosting the usage of bamboo based products in India towards generating good
employment & income opportunities at rural level

Towards an effective bamboo utilization and exploring the value-addition potential, the
project on development of bamboo composite laminates was launched by the Advanced
Composites Programme of TIFAC in partnership with M/s. Emmbee Forest Products Pvt.
Ltd., Manabari with technology support from the Department of Polymer Science &
Technology, University of Calcutta. The project aimed at developing value-added products
from bamboo with an innovative resin system for reduced processing energy requirement.
Bamboo based products such as flooring tiles, laminate boards, blocks (for door & window
frames, rails & styles, furniture etc.) as wood substitute are being developed under the
project.

For preventing bamboo composites from any deterioration by moisture absorption and
imparting long-term storage life, a water based acrylic pre-coat has been developed. This
pre-coat would prevent any fungal attack during transit for the reconstituted wood sections
for furniture. Further, a UV cured melamine acrylate system as the finishing coat has also
been developed for flooring tiles made of bamboo composites. A water based PU resin
system has also been tried for final finish of the flooring tiles.

Various stages of bamboo processing starting from cross-cutting, parallel splitting, knot
removal, two-side planning, anti-fungal treatment, drying, four-side planning, glue
application and hot pressing were fine tuned. Products such as flooring tiles, furniture
sections, reconstituted wood, air locked sections, mat boards etc. have been developed
under the project.

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In the wake of disastrous damages by the earthquake in Gujarat, the Advanced Composites
Programme has contributed to the national efforts of re-building and rehabilitation. Under
the TIFAC Rehab Project for Kachchh, the following initiatives were taken up for the quake
affected people.

392 low-cost semi-permanent shelters (20¶x12¶) made of natural fibre composite

materials such as jute-coir composite boards and rice husk particle boards with bamboo mat
face veneer etc. were supported on MS angles & channels. For improved aesthetics and also
to augment the thermal insulation, natural fibre composite board roofing of the shelters was
covered with terracotta tiles.

In order to cater to the shelters, 128 community toilet blocks (4¶x4¶) made of modular FRP
section for walls & roof were constructed.Fifteen shops (12¶x8¶) were constructed in the
township along with a Post Office in the township, which has commenced its services. In
addition to the semi-permanent residential shelters constructed at Bhuj, 25 school blocks-
cum-community centres (24¶x 20¶) were also constructed at various locations in Kachchh.

The TIFAC Rehab Project was a model initiative of technology demonstration with novel
building materials with the delivery in the quickest possible time addressing the crucial need
for post-disaster relief.

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For augmenting the reception block of Technology Bhavan campus in Delhi, the Advanced
Composites Programme took initiatives by building a 3000 sq. ft. temporary structure for
post office, CR section, technology demonstration-cum -display area and additional office
space towards showcasing composite building materials. The array of products developed
under the programme such as jute-coir boards, FRP doors, bamboo composite flooring tiles
& rice husk particle boards for false ceiling were used in the construction of the shelter
towards technology demonstration. Jute-coir composite boards, made of coir felt & waste
rubber-wood as inside veneers and oriented jute as face veneer is a unique value-added
application for agro-wastes and positioned as an effective wood substitute building material.
While the shelter structure was fabricated out of standard steel sections, jute-coir boards
were used for double-wall construction ensuring excellent thermal insulation. They were also
used for roofing overlaid with terracotta tiles. Elegant looking bamboo composite tiles were
used for the flooring. The door shutters made of sandwich panels of glass fibre reinforced
polyester resin, have good aesthetic appeal with adequate mechanical strength and water
resistance.

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The most important feature governing the choice of material & form of construction for any
component is its structural integrity. Whereas high specific strength and lightweight were
often the dominant criteria to be achieved, particularly for aerospace applications, there is
today an increasing emphasis on other criteria such as environmental durability, embedded
energy, fire resistance.

Innovative thermoset and natural fibre composite products would go a long way in
developing new application areas thus enhancing its market reach. India with an excellent
knowledge-base in various resins, catalysts & curing systems coupled with an adequate
availability of various raw materials can certainly carve out a niche in the upcoming
technology of composite fabrication. Value-added novel applications of natural fibre
composites would also ensure international market for cheaper substitutes. The products
when locally manufactured would actually become cost competitive for other wood
substitutes.

The Advanced Composites programme has improved the laboratory-industry linkages

towards application development & commercialization by launching 30 projects across the
country. The programme has been quite instrumental in bridging the knowledge gaps and
bringing together the industries & the users for technology development, transfer &
subsequent commercialization