Coconut Wood-Fiber Cement Boards

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PRODUCTION AND APPLICATION OF COCONUT WOOD-FIBER-CEMENT
BOARDS
Target Clients:
· Cottage/Village-level entrepreneurs
· Micro-scale entrepreneurs
· Small-scale entrepreneurs
· Medium-scale entrepreneurs
Descriptin ! t"e Tec"nlg#:
Coconut fiber-cement board (CFB) is a product manufactured from
fibrous materials like coconut ood! coir! fronds! spat"es! and s"redded ood
t"at are mi#ed it" $ortland cement at a predetermined ratio of %&' cement
to (& ' fiber b) eig"t* CFB is made b) forming t"e cement-fiber mi#ture into
mats and pressing t"em to t"e desired t"ickness* CFB panels "ave good
strengt" properties and "ig" dimensional stabilit) "en soaked in ater
(ater absorption of (+' and t"ickness selling of ,*+') surpassing t"e
minimum re-uirements set b) $./0S1-Standard 2&3-24%3* /t "as lo t"ermal
conductivit) (k-value of &*&4& 5/mk) "ic" indicates its e#cellent insulation
properties! t"us it can be used as roofing materials even it"out t"e provision
of ceiling* Flame test s"oed t"at "ile t"e board can be burned! it is rat"er
slo it" minimal smoke emission*
6#posure test of paint-coated CFB roof s"eets "as demonstrated t"e
capabilit) of t"e material to it"stand t"e deleterious effect of eat"ering
found in actual service condition*
CFB is no being used as alternative building construction materials for
suc" application as pre-fabricated components in modular alls and partition
panels as a tec"ni-ue of reducing cost and time of manufacturing and
construction*
7"e ma8or e-uipment/mac"ineries needed to produce CFB include
decorticating mac"ine! blending mac"ine! ")draulic press! trimmer! and lifter*
Production Process
7"ere are to ma8or components in t"e production of coconut ood-fiber-
cement board namel)! (a) coconut ood! coir fiber produced from suc"
sources as "usks! spat"es! peduncles! petioles and leafs"eat"es! and (b)
cement* 7"e production of cement-bonded boards involves t"e folloing
steps9
2* S"red t"e top lo densit) portion or t"e coconut tops logs using t"e
ood s"redding mac"ine* :ecorticate/6#tract coconut fiber from "usks
using t"e decorticating mac"ine* Fiber can also be taken from ot"er
parts of t"e coconut tree suc" as spat"es! petioles! etc*
+* Soak t"e coconut ood and t"e fiber separatel) in dipping tank full of
ater for to da)s to leac" out e#tractives and sugars*
(* Collect t"e coconut ood and fiber from t"e dipping tanks and allo
ater to drain from t"e residues for about 3 minutes*
,* 5eig" separatel) t"e coconut ood! fiber and cement it" a ratio of
(&' coconut fiber and %&' cement*
3* Mi# separatel) t"e re-uired amount of coconut ood and fiber it"
cement in a blending mac"ine*
;* Form mat using ooden forming bo#es and flat steel cauls lined it"
pol)et")lene s"eets*
%* $ress t"e mat to t"e desired t"ickness it" t"e use of guide bars!
")draulic press and clamping apparatus*
<* =emove t"e fastened/clamped boards from t"e ")draulic press*
4* 1fter 2< to +& "ours under pressure! remove t"e boards from t"e clamping
apparatus and properl) pile using +3 cm # +3 cm # ;& cm ooden sticks
to provide air circulation (fillet-stacking) during t"e initial +,-"our air
dr)ing and conditioning*
2&* 7rim t"e edges of t"e boards to t"e desired dimensions*
22* Fillet-stack for furt"er dr)ing and conditioning for about one eek*
Fig $% Prcess Fl& in t"e Pr'(ctin ! Ccn(t &'-!i)er-Ce*ent
Bar's
Cocofiber produced
b) decorticating
Soaking
Cocofiber in tap
ater
5eig"ing of Cocofiber
and cement component
Mi#ing of Cocofiber!
cement and ater
Mat forming of t"e cement-
fiber mi#ture
$ressing of t"e boards
Conditio
ning of
CFB
S"redding of
coconut ood
T"e Pr'(ct9
Coconut 5ood-Fiber-Cement Board (CFB) > medium densit) panel
manufactured b) t"e mi#ture of fibrous materials like coconut ood-coir and
$ortland cement at ratio of %&9(& cement ?ood-fiber b) eig"t*
• 7"ickness > < mm! 2+*3 mm! +3 mm
• 5idt" > &*; m
• 0engt" > +*( m
• :ensit) range > ;3& to 2+&& kg/m
(
Basic $roperties of CFB
• 5ater 1bsorption > (+'
• 7"ickness Selling> ,*+'
• .eat Conductivit) > &*&4&5/m@ (DIN 52612, Part 1)
• Bending Strengt" > <*(& kg/cm+
$% Cnstr(ctin Applicatins
Board :imension :ensit) 1pplication
2A # +B # ,B <&&-2+&& kg/m
(
Flooring/
6#ternal 5alls
2A # +B # ,B ;3& kg m
(
/ $artitions/
Ceiling
(/<A # +B # (B ;3&-<&& kg/ m
(
=oofing
(/<A # +B # ,B ;3& kg/ m
(
Furniture component
+% Speci!ic Applicatins
5alling S)stem =oofing S)stem Flooring S)stem
$% In,est*ent Re-(ire*ents . In P"ilippine Pess/ .$ US0 1 23 P"il Pess/
/tem
Cumber
D Enit
7)pe
Fear
1c-uired
/
Construc
ted
Value/1c-uisi
tion Cost
(peso per
unit)
6stimate
d 0ife
(/n )ears)
1* 0and D
Building(s)

0and 2&&& m
+
$lant
and
stora
ge
,&&!&&& +&
Building +&& m
+
2&&!&&
B* 6-uipment/Mac
"iner)

:ecorticating
mac"ine 2
,3&!&&& 2&
Blending mac"ine 2 +&&!&&& 2&
.)draulic press 2 33&!&&& 2&
7rimming
mac"ine 2
23&!&&& 2&
0ifter 2 ,(&!&&& 2&
:ripping tank + ,&!&&& 2&
.auler truck + ,3&!&&& 2&

II% Operating E4penses
/tem
Enit D
Cumber
$er Mont"
Cost/Enit
($"$)
7otal Value
($"$)
1* Supplies/=a Materials
(please itemiGe)

Coconut ood/fiber ++,+3 kg 2*3 ((!;(<
$ortland Cement 2(&< bags 22& 2,(!<<&
Flat steel +3 pc ,3& 22!+3&
0umber fillet <( pc +3 +!&%3
$lastic s"eets 2;% pc +3 ,!2%3
5ooden moulds &2 pc ,3& ,3&
Bolts and nuts , pairs %3 (&&
5ooden cauls 2% bd ft +3 ,+3
B* Miscellaneous 6#penses
6lectricit) 2!3&& k" ( (!%3&
5ater <& m
(
+ 2;&

III% La)r Re-(ire*ents
7)pe Hf 0abor Cumber
Man-
:a)s/Mont"
5age
=ate/Mont"
7otal
Value
1* :irect 0abor
Mac"ine
Hperators/tec"nicians
2+ ;!&&&/mo %+!&&&
7ruck :river/0ifter
Hperator
2 ;!&&&/mo ;!&&&
B* /ndirect 0abor
Manager 2 +&!&&& +&!&&&
Bookkeeper/6ncoder 2 ;!&&& ;!&&&
I5% Pr'(ctin
/tem Enit Iuantit) $rice/Enit 7otal Value
Production
Fiber-cement boards
< mm pieces 2;;% pc 2<& (&&!&;&
2+ mm pieces <(( pc +2& 2%,!4(&
+3 mm pieces ;+3 pc +<3 2%<!2+3
By-Products
Coir dust kilograms 2;!;;% kg +*3 ,2!;;<
Cst an' Ret(rn Anal#sis
/76M V10E6 ($.$)
$6= MHC7. $6= F61=
Jross /ncome
Cas" /ncome
- Sales from cement-bonded boards
;3(!2+3 %!<(%!3&&
- Sales from coir dust
,2!;;% 3&&!&&&
7otal Cas" /ncome
;4,!%4+ <!((%!3&&
Ttal 6rss Inc*e
;4,!%4+ <!((%!3&&
6#penses
Variable Cost
.ired labor 2&,!&&& 2!+,<!&&&
Supplies and materials
Coconut fiber residues ((!;(< ,&(!;3&
Cement 2,(!42% 2!%+%!&&&
Flat steel 22!+3& 2(3!&&&
0umber fillet +!&%3 +3!&&&
$lastic s"eets ,!2%3 3&!&&&
5ooden moulds ,3& ,!3&&
Bolts and nuts (&& (!%3&
5ooden cauls ,+3 3!&&&
5ater 2!;&&
3&!&&&
6lectricit) (!%3&
+&!&&&
Marketing and Selling Cost 2&!%&< 2+<!3&&
/nterest on Hperating Capital (2+') +,!&2+ +<<!2,,
Ttal 5aria)le Cst 7289788 298339:22
Fi#ed Cost
Fi#ed Cas" Costs
/nterest on fi#ed capital /nvestment 2(!&4& 23%!&<&
Ttal Fi4e' Cas" Csts $798;8 $:<9838
Fi#ed-Con Cas" Costs
:epreciation 2,!2&& 2;4!+&&
Ttal Fi4e'-Nn Cas" Csts $29$88 $=;9+88
Ttal Fi4e' Csts +<9$;8 7+=9+38
Ttal Csts 7=<92;8 292$293+2
Cet Cas" /ncome =3$9<8$%=< 39$3892+8%88
Jross Margin 7:292;+%:8 29+239;:=%88
Net Inc*e 7+<978+%:8 79;++9=<=%88
Mar>et:
Commercial production of CFB is e#pected to contribute to t"e
governmentKs national s"elter program! specificall) on socialiGed and lo-cost
"ousing* 7"e demand for building materials is e#pected to increase due to t"e
continuous increase in t"e number of private and government "ousing pro8ects*
CFB can replace construction materials suc" as tiles! bricks! pl)ood!
asbestos and cement "ollo blocks* /t is used for internal and e#terior alls!
partitions and ceiling* /t can also be used as a component in t"e fabrication of
furniture! cabinets! bo#es and vases! among ot"ers*
$otential market outlets are construction material suppliers! building
contractors and government/private agencies involved in lo-cost "ousing
pro8ects* Ht"er target markets are t"e lo and middle-income "ouse"olds "o
ould like to on "ouses at affordable prices*
Lgistics:
• 1vailabilit) of Coconut Farm =esidues
for Commercial $roduction of Cement-Bonded Boards
6stimates s"oed t"at a full) bearing coconut plantation could generate
2+*%3 tons of coconut residues per "ectare per )ear* Hf t"ese! t"e petiole
accounts for ,%*(' of t"e total eig"t it" 2%*(+' for leaves including midribs!
2;*,,' for "usk! 2&*(;' for peduncle! ,*++' for spat"e! and 2*%&' for
leafs"eat"*
Combining t"e coconut residues and ot"er cellulosic materials found in
coconut plantation ould provide appro#imatel) 2%*%3 tons per "ectare of dr)
biomass per )ear* /f 3&' of t"ese biomass or farm residues ill be processed
and utiliGe to manufacture cement-bonded boards "ile t"e remaining 3&' ill
be left to decompose in t"e field for t"e purpose of soil conservation! a
processing plant could be establis"ed ever) fort) five (,3) "ectares of full)
bearing coconut plantation* 7"e said area can sustain t"e annual ra materials
of +%4!(;& kg dr) coconut residues and 22+!3&& kg dr) ood biomass needed b)
t"e processing plant it" a capacit) of not less t"an (%!3&& boards per )ear
/n t"e $"ilippines! t"ere are more t"an t"ree (() million "ectares of land
planted to coconut* /f 3&' of t"e total coconut farm residues are converted into
construction materials! about (&!&&& processing plants could be establis"ed in
t"e different coconut provinces of t"e countr)* Based on t"e estimates! around
nine (4) million units of +-bedroom bungalo-t)pe "ouses could be built )earl)
utiliGing coconut farm residues as ra materials in t"e fabrication of needed
e#terior alls! interior partition panels! ceiling and corrugated roofing of t"e
buildings*
Reg(latr# Re-(ire*ents:
$./0S1 S71C:1=: 2&3-24%3 provides minimum product specification for
cement-bonded boards*
Ris>s:
:ecorticating of coconut "usks and t"e disposal of aste ater being used for
soaking t"e fibers can cause environmental problem* $roper attention s"ould be
taken to minimiGe if not totall) eliminate t"is perceived problem*
S(rce ! Tec"nlg#:
1genc) 9 $C1-Lamboanga =esearc" Center! San =amon!
Lamboanga Cit)
=esearc"ers9 0uisito M* $eNamora and Ceil M* Melencion
7elep"one Cos*9 (&;+) 4<+-&(&+
Fa# Cos*9 (&;+)4<+&(&+
6mail 1ddress9 pcaOGrcPpldtdsl*net
=eferences9
$10HM1=! =* C* and 0*M* $6Q1MH=1 +&&&* :evelopment in t"e use of
coconut farm residues for t"e manufacture of coir-ood-cement board
as alternative construction material* Coconut =esearc" and
:evelopment (CH=:) Mournal! 2;(+)93;-;;*

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