Making resin cast bamboo composite structures

[chetan gore]

hello everybody,
i,m looking forward to making composite structures of bamboo by casting bamboo with resins, can anybody let me know the process for the same ?
thanks,
chetan

[Mark Meckes]

Hi Chetan,
This is an extensive subject of which the ingredients used, processes employed, and products made are quite diverse.
Achieving a quality, durable, bond that is non-toxic during manufacture, and for end use may or may not be a primary objective, and opinions will vary as to which glue or resin is best and safest.

There's a lot of general info about glues and resins etc on the web, as the wood related industry is vast. But there is much less info when it pertains specifically to bamboo.

Is your interest general or specific?
regards,
Mark
---------------------------------------------
Here's several websites with related info...

* From the Digital Library and Archives of the Virginia Polytecnic Institute and State University (Website) (http://scholar.lib.vt.edu/)
Penetration of Liquid Adhesive (http://scholar.lib.vt.edu/theses/available/etd-08212000-10440027/unrestricted/Chapter6.pdf) .pdf upload
- Chapter 6 Penetration of Liquid Phenol Formaldehyde and Polymeric Diphenylmethane Diisocyanate Adhesive into Calcutta Bamboo

* Bamboo Panel Boards (http://www.inbar.int/publication/txt/INBAR_Technical_Report_No12.htm)
- a State of the Art Review INBAR Technical Report -International Network for Bamboo and Rattan Website (http://www.inbar.int/)

* Bamboo Composite Boards & Laminates (http://www.tifac.org.in/do/acm/case/laminates.htm)
- Advanced Composites Programme TIFAC Technology Information, Forecasting & Assessment Council,(Website) (http://www.tifac.org.in/) Technology Bhavan, New Mehrauli Road, New Delhi-110 016, India.

* Product materials specs. Teragren Material Safety Data Sheet (www.teragren.com/tera_press/misc_pdfs/ Teragren_LLC_MSDS_Panels_Veneer_07-04.pdf) .pdf upload - Bamboo Paneling Products Google html cache (http://64.233.161.104/search?q=cache:P-6N1S0Y8FcJ:www.teragren.com/tera_press/misc_pdfs/Teragren_LLC_MSDS_Panels_Veneer_07-04.pdf+bamboo+dust&hl=en[/url)

* Product materials specs.High Mountain Bamboo Flooring (http://www.bamboomountain.com/glue_specs.htm)
Glue spec for formaldehyde-free bamboo flooring
-POLYMAR ISOCYANATE ADHESIVE FOR WOOD
Specially developed for small dimension lamination and 3-ply parquet flooring. Two part adhesive system utilizing water based polymer (resin) and isocyanate (hardener)....

[chetan gore]

Dear Mr. Mark, thank you very much for immediate reply.
My interest is very specific.
I'm working in a rural part of India and trying to develop some kind of structures which can be used for producing manure by farmers, by degrading bio mass like dung and farm waste.
Similar structures can also be used in low cost housing for door / window
frames etc.
By using bamboo with resins, these things should be free from rusting and having good load bearing capacity, and longer life.

I've done some trials and want to know about the following:

1) Which resins should I use ? ( as branded resins mfgrd by companies like
siba etc. are very costly. I want to go for low cost things, hence have used
general purpose resins, with hardener and accelerator )

2) What will happen if bamboo gets further dried after casting got set ? (if
bamboo shrinks a bit and it may get released from resin ? )

3) We are removing the surface skin of bamboo to help it get good grip with resin, and we are not using long poles. max. length of bamboo will be around 3 Ft. how do I dry the same ?

4) how to judge or decide durability and strength of the end product, that
is casting of bamboo with resin ?

I request you to please guide me on above.
thanks and regards,

chetan

[Mark Meckes]

Hello Chetan,
Thanks for your participation at the bamboo forums!
Finding answers to some of your questions will take time and practical research.
I am not personally familiar with resin casting processes though I am interested in finding out more about it.

As you mentioned, the cost of resin is a big factor in whether this application would be economically feasible.
It is most certainly possible, so the question is...
What is the minimum ratio of resin to bamboo fiber content that would provide a durable adhesion and be waterproof, or impervious to liquid penetration.

In this respect, the role of the resin is primarily to adhere the fibers, and the bamboo fibers provide the structural elements.

Other considerations...
- Sizes and dimensions of receptacle ?
- Shape - cylindrical ? panels ?
- Would the bamboo/resin-cast cantainer be free standing?.. that is, without support of any structural surroundings, or could it be as a membrane or `liner' that was fit inside a wooden, or bamboo plyboard, mud/brick or other structure?

Whether it is free-standing or a sleeve type liner has a great bearing on how much bamboo fiber would be needed to make the reseptacle.

Regarding the bamboo... selection of materials, processing, design of, and directional alignment of the bamboo fibers is crucial.
Would the container be made from woven bamboo panels?
Can pulped bamboo fibers be blended with the resin?

Bescause of the cost of the resin glue, an approach of `less is more' must be employed. (The more bamboo you need to use, the more resin will be needed to adhere to the added surface areas)

In this respect, the bamboo should be evaluated to determine the highest quality and iniformity of strength that you can acheive..

Other woods or materials with known or satisfactory properties and characteristics can be used as a `benchmark guide', during evaluation.

Comparative evaluation is necessary to determine if the bamboo species that you use really is the most suitable option.

regards,
Mark