Modern Composite Material1

MODERN COMPOSITE MATERIAL A composite material (also called a composition material or shortened to composite, which is the common name) is a material made from two or more constituent materials with significantly different physical or chemical properties that, when combined, produce a material with characteristics different from the individual components

MODERN COMPOSITE MATERIAL The new material may be preferred for many reasons: common examples include materials which are stronger, lighter, or less expensive when compared to traditional materials. The most advanced examples perform routinely on spacecraft and aircraft in demanding environments •Reinforced concrete and masonry •Composite wood such as plywood •Reinforced plastics, such as fibre-reinforced polymer or fiberglass •Ceramic matrix composites (composite ceramic and metal matrices) •Metal matrix composites

POLY CARBONATES • Polycarbonates (PC) are a group of thermoplastic polymers containing carbonate groups in their chemical structures. Polycarbonates used in engineering are strong, tough materials, and some grades are optically transparent. • They are easily worked, molded, and thermoformed. Because of these properties, polycarbonates find many applications. Polycarbonates do not have a unique resin identification code (RIC) and are identified as "Other", 7 on the RIC lis

Polycarbonate in Building and Construction. Polycarbonate is a high-performing thermoplastic that is widely used in building and construction products, from windows and skylights to wall panels and roof domes to exterior elements for LED lighting.

PVC • Economical, versatile polyvinyl chloride (PVC, or vinyl) is used in a variety of applications in the building and construction, health care, electronics, automobile and other sectors, in products ranging from piping and siding, blood bags and tubing, to wire and cable insulation, windshield system components and more.

PVC Uses and benefits: Vinyl is versatile: it can be as rigid as industrial pipes, as pliable as plastic wrap, and as thin and flexible as wallcovering. It can also be completely clear or matched to any color desired. Building construction About three-quarters of all vinyl produced goes into long-lasting building and construction applications.  Life-cycle studies show PVC/vinyl is effective in protecting the environment, in terms of low greenhouse gas emissions and conservation of resources and energy.

PVC • Siding and Windows Vinyl helps produce siding and window frames that are extremely durable, affordable, and help conserve energy when heating and cooling homes. In fact, vinyl windows have three times the heat insulation of aluminum windows. • Wiring and Cables Vinyl is able to withstand tough conditions behind building walls – such as exposure to changing temperatures and dampness – for the life of the building. As a result, it is one of the most prevalent and trusted materials used in electrical wiring and cables.

PVC • Water Pipes • PVC helps conserve energy and water by creating virtually leak-free pipes that are not prone to corrosion and resist environmental stress. PVC breakage rates are as low as one percent of the breakage rates of cast metal systems. The lack of build-up in PVC piping improves functionality and increases energy efficiency. • Packaging • Because it is durable, dependable and light weight, flexible PVC helps packaging do its job to maintain the integrity of the products inside, including medicines. Clear vinyl is used in tamper-resistant over-the-counter medications and shrinkwrap for consumer products. Rigid vinyl film is used in blister and clamshell packaging to protect medicines, personal care products and other household goods.

INDUSTRIAL TIMBER BOARDS

• Industrial timber is nothing but timber product manufactured scientifically in factories. Because of its scientific nature, it is stronger and durable than ordinary timber materials. It also contains desired shape and size •Veneers

•Hard boards

•Plywood

•Glulam

•Fiber boards

•Chip board

•Impreg timbers

•Block board

•Compreg timbers

•Flush door shutters

veneers • Thin sheets or slices of wood of superior quality • Thickness: 0.4mm-6mm or more • Obtained by rotating a log of wood against a sharp knife or rotary cutter or saw • Veneers after being removed- dried in kilns to remove moisture • Indian timbers suitable for veneers- mahogany, oak, rosewood, teak ,etc. • Veneers used for- plywood, batten boards, lamin boards • Glued to surface of inferior wood with adhesives

plywood • Ply means thin. • Plywood is a board obtained by adding thin layers of wood or veneers on one above each other. The joining of successive layers is done by suitable adhesives. • The layers are glued and pressed with some pressure either in hot or cold condition. In hot conditions 150 to 200oC temperature and hydraulic press is used to press the layers. In cold conditions, room temperature is maintained and 0.7 to 1.4 N/mm2 pressure is applied.

plywood Plywood has so many uses. It is used for doors, partition walls, ceilings, paneling walls, formwork for concrete etc. Due to its decorative appearance, it is used for buildings like theaters, auditoriums, temples, churches, restaurants etc. in architectural purpose.

Block board Block board is a board containing core made of wood strips. The wood strips are generally obtained from the leftovers from solid timber conversion etc. These strips are glued and made into solid form. Veneers are used as faces to cover this solid core. The width of core should not exceed 25mm. If the width of core is less than 7mm then it is called as lamin board. Block boards are generally used for partitions, paneling, marine and river crafts, railway carriages etc.

Particle board/ chipboard • Chip boards are another type of industrial timber which are made of wood particles or rice husk ash or bagasse. These are dissolved in resins for some time and heated. • After then it is pressed with some pressure and boards are made. These are also called particle boards • Manufactured by extrusion pressing (orient wood particles in direction at right angles to the plane of board) or by pressing in parallel plates (parallelly orient particles to plane of board) • Heavier than solid wood or plywood- can be sawn like wood • Mainly used for furniture making

Hard Boards • Hard board is usually 3 mm thick and made from wood pulp. Wood pulp(Pulp is a lignocellulosic fibrous material prepared by chemically or mechanically separating cellulose fibres from wood, fiber crops, waste paper, or rags) is compressed with some pressure and made into

solid boards. The top surface of board is smooth and hard while the bottom surface is rough. Hard boards are generally classified as three types as follows:

Fibre Boards • Fiber boards are made of wood fibers, vegetable fibers etc. They are rigid boards and called as reconstructed wood. • The collected fibers are boiled in hot water and then transferred into closed vessel. Steam with low pressure is pumped into the vessel and pressure increased suddenly. • Technology used to make fibre board – combination of particle board and hard board • Wood chips- steamed to separate the fibres from each other • Fibres blended with resin and wax- turned into sheets by passing through a pressing machine under controlled heat, pressure • Thickness- 25mm- 32mm, as sheets 2.44mX1.22m • Medium density fibre boards-MDF particle boards- mass production of furniture, cabinets, etc. and flush doors

Laminated wood flooring Laminated wooden flooring is a compressed fibre board planks covered by a photographic image of wood stone or tile with a protective overlay It laid in living areas ,studies and play rooms .

Tech Wood • TECHWOOD is made from natural organic fiber & PVC in extruded from, creating the next generation of composite building material. TECHWOOD is user-friendly and it substitutes other traditional wood or plastic building materials. TECHWOOD products are designed for Outdoor & Indoor applications including decking, railing, cladding, false-ceiling and other decoration work. Techwood TECHWOOD products are free from conventional wood problems such as splitting, warping, decay and are 100% waterproof and termite proof. TECHWOOD is a revolutionary product, very apt for exterior cladding and has been widely used in Western countries. It is most suitable for renovation of old fashioned exterior. It gives the elegant look of wood and apt for those who want to upgrade from conventional ACP/Metal/Glass cladding. .

Tech Wood

TECHWOOD is very easy to install and to revamp the exterior & interior of showrooms, as it can be readily covered on metal partition, front fascia, rooftop, gate fascia etc. It doesn’t even need frame work as it can be directly nailed, screwed or pasted on walls & use metal channels for false-ceiling. The TECHWOOD products has got a lifetime guarantee for its quality. The colour shades are guaranteed against extreme weather Conditions TECHWOOD profiles are most suitable for Swimming pool floors, Garden pathways, Shower/Toilet flooring, Wet area floors, Staircase steps, Automobile floors and many kinds of anti skid applications. TECHWOOD provides user friendly Handiclip system to install the decking / flooring to strong and solid installation by not having those unsightly nail/screw heads showing.

MULTIWOOD

Multiwood Is Made Up Of ‘U’ Pvc Polyester Resin & Is Made In An Extruded Polymer Profile Form. Multiwood Is 100% Waterproof, Termite & Borer Proof, Corrosion Free & Fire Retardent. Multiwood Is Mainly Used For Wet Area Applications. Multiwood Sheets Are Pure White In Colour And Has A Glossy And Finished Surface. Multiwood Has Unique Features And Long-lasting Properties, That Can Withstand In Any Climatic Conditions. Multiwood Because Of The Comprehensive Applications Of Multiwood, It Has Already Been Used In Building Decoration And Renovation Work. The Water, Acid And Stain Resistant Features, Environment Protective Aspects And The Comprehensive And Diversified Applications Makes It As A Real Substitute For Wood. The Uniqueness And Specialty Use Of This Wonder Sheet, Leads Us To Name It Multiwood.

glulam • GLUed and LAMinated wood • Solid wood- glued to large sections • Support for long span roofs for sports stadiums, indoor swimming pools, sheds for chemical factories, etc. where other materials like steel cannot last long • Can be sued as beams of many shapes including curved members • Fabrication difficult- not so popular in India

Wooden Flush Doors Wooden flush door shutters: A door shutter is an important building element that must possess qualities like strength, rigidity, resistance A flush door is a solid core door with block board core, cross band and veneer faces on either side. The timber is strengthened with vacuum pressed chemical treatment. The moisture is reduced through the seasoning process at an automatic kiln plant.

Wooden flush door shutters • Interior door work • Available in thickness of 25mm, 30mm, 35mm • CPWD- 3 tests to test quality of doors • End immersion test: end of door shutter immersed in water at room temperature for a height of 30cm for 24 hours and then allowed to dry for 24 hours. Repeated 8 times- no delamination at end of test • Knife test: a thin knife inserted below outer veneer and raised upwards. A good specimen should give considerable resistance for insertion and raising of knife • Glue adhesion test: for this test, a 150mmX150mm piece is cut and immersed in boiling water for 4 hours and cooled for 24 hours. At the end, no delamination- good quality

Laminates: Lamination is a process of pasting a laminated sheet with heat and pressure.It is intended to give a long life to the ply or the material beneath. The substance used for the process increases the features as well as durability of the door.

The door undergo the process of lamination with equal mechanic pressure and bonding against the traditional time consuming manual processes.

THICKNESS : 25, 30, 32, 35, 38, 40, 45, 50 & 55mm in double or single leaf construction.

laminates • Laminates are products made- bonding together 2 or more layers of materials • Plywood, glass laminates, composite glass laminates, plastic laminates- all come under this class • Can be glued to wood to make surface aesthetic & heat resistant • Furniture like table tops- made of joined wood pieces- covered with laminate to give appearance of one piece of furniture

Decorative laminates • High pressure decorative laminate on plywood- used for surfacing of large areas- tables, cabinets, etc. • Available in thicknesses of 0.8mm, 1.0mm, 1.5mm • Their backside- suitable for adhesive bonding to surfaces • Standard sizes of a HPL sheet- 1.22mX 2.44m • Decorative laminates- manufactured by assembly of impregnated papers • Kraft paper impregnated with phenol formaldehyde forms the core of laminate • Below kraft paper- barrier paper and a base or design paper • Overlay of tissue paper impregnated with melamine formaldehyde resin- provided over kraft paper • Melamine paper given as a protection and also to enhance abrasion resistance • Pressed in a hot press between stainless steel plates to ensure good finish

Decorative laminates are laminated products primarily used as furniture surface materials or wall paneling. It can be manufactured as either high- or low-pressure laminate, with the two processes not much different from each other except for the pressure applied in the pressing process.