Title of Technology: Coconut Fiber (Coir)-Cement Board Production and Application

Years Developed: 1992-2005

Target Clients:

• Small-scale entrepreneurs = P3M - P15M

DEFINITION

• Coconut fiber-cement board (CFB) is a product manufactured from fibrous materials like coconut coir, fronds, spathesor shredded wood

• Fiber is mixed with Portland cement at a predetermined ratio of 70% cement and 30 fiber by weight.

• The cement-fiber mixture is formed into mats and pressed to the desired thickness

Two types of coir - cement boards

1. Three-layered wood-coir-wood boardwith density ranging from 650-800 kg/m3. Coir fiber is at the core.

Two types of coir - cement boards

2. Single homogenous layer coir fiber-cement board with density ranging from -800 kg/m3-1200 kg/m3.

PRODUCT SPECIFICATION• Thickness = 8 mm, 12.5 mm, 25 mm• Width = 0.6 m• Length = 1.22m and 2.3 m • Density = 650 to 1200 kg/cu.m.

PRODUCT SPECIFICATION• Thickness = 8 mm, 12.5 mm, 25 mm• Width = 0.6 m• Length = 1.22m and 2.3 m • Density = 650 to 1200 kg/cu.m.

COCONUT FIBER-CEMENT BOARD

Basic Properties of CFB as a Construction Material

Basic Properties of CFB as a Construction Material

• Water Absorption = 32% • Thickness Swelling= 4.2%• Heat Conductivity = 0.090W/m.K (DIN 52612,

Part 1)• Bending Strength (Modulus of Rupture) =

8.30 kg/cm2

• Water Absorption = 32% • Thickness Swelling= 4.2%• Heat Conductivity = 0.090W/m.K (DIN 52612,

Part 1)• Bending Strength (Modulus of Rupture) =

8.30 kg/cm2

CFB STANDARD MANUFACTURING PROCEDURE

1. EquipmentThe basic machines needed in the production of

fiber-cement boards are as follows:• Decorticating machine• Wood shredding machine (optional)• Cement-fiber blender• Hydraulic cold press• Trimmer

2. Accessory equipment and tools• Dipping vat• Weighing scale• Form boxes• Wood fillets• Plastic sheets• Steel bolts

CFB STANDARD MANUFACTURING PROCEDURE

Extract fiber from husks

PRODUCTION PROCESS

Soak the fiber in tap water for at least 18 hrs

Weigh the fiber and cement separately

Mix/Blend the pre-weighed cement & coir

Form the mixture into mat using the wooden moulder

Press the matted fiber-cement blend. Maintain pressure for 24 hrs

Trim the boards to the final dimension

Dry and condition boards for about 28 days

Paint-coated boards ready for use

CONSTRUCTION APPLICATIONS

Board Dimension

Density Application

1” x 2’ x 4’ 800-1200 kg/cu.m.

Flooring/External Walls

1” x 2’ x 4’ 650 kg/cu.m. Partitions/Ceiling

3/8” x 2’ x 3’ 650-800 kg/cu.m. Roofing

3/8” x 2’ x 4’ 800 kg/cu.m. Furniture component

2. Specific Applications

a. Wall Panel System

Installation of wall panels

b. Roofing System

c. Flooring System

Formwork and flooring for upper-level

Rivetd. Ceiling/Partitions

COIR HOLLOW BOARDS

CORRUGATED COIR ROOF BOARDS

EXPOSURE TEST OF ROOF BOARDS

e. Furniture/boxes components

COIR CEMENT BOARDS CHAIRS WITH COCOWOOD FRAME

CFB TABLE WITH COCOWOOD FRAME

COCONUT FIBER-CEMENT BOARDS AS CONSTRUCTION MATERIALCOCONUT FIBER-CEMENT BOARDS AS CONSTRUCTION MATERIAL

Roof Sheathing

Base Support for upper-level

flooring

Internal & exterior walls, partitions and

ceilings

Component of furniture

(tables, chairs, etc.), cabinets, boxes and vases

Basic Properties of CFBBoard Density = 550 -650 kg/cu.m.Water Absorption = 32%Thickness Swelling = 4.2%Bending Strength (MOR)= 8.30kg/cm2

Thermal Conductivity = 0.090W/m-k

FINANCIAL ASPECTS

ITEM NUMBER &

UNIT

TYPE YEAR ACQUIR

ED/

VALUE/ACQUISITION

COST(PhP)

ESTIMATED LIFE

(YEARS)

I. Land 500m3 Plant/ storage house

400,000 20

Building 200 m3 storage 100,000 20

2. Deco. machine 1 150,000 10

Blending machine 1 200,000 10

Hydraulic press 1 550,000 10

Trimming machine 60,000 10

Lifter 1 430,000 10

Dipping tank 2 40,000 10

Hauler truck 1 450,000 10

I. INVESTMENT REQUIREMENTS

TOTAL 2,280,000

II. OPERATING EXPENSES

ItemUnit & Number

Per MonthCost/Unit

(PhP)Total Value

(PhP)A. Supplies/Raw Materials (please itemize)

Coconut fiber 22425 kg 1.5 33,638Portland Cement 1308 bags 180 235,440

Flat steel 25 pc 450 11,250Lumber fillet 83 pc 25 2,075Plastic sheets 167 pc 25 4,175Wooden moulds 01 pc 450 450Bolts and nuts 4 pairs 75 300Wooden cauls 17 bd ft 25 425

B. Miscellaneous Expenses

Electricity 1,500 kwh 3 4,500Water 80 m3 2 160

TOTAL 200,103

III. LABOR REQUIREMENTS

Type Of Labor Number Man-Days/Month

Wage Rate/Month

Total Value

A. Direct Labor

Machine Operators 12 6,000/mo 72,000

Truck Driver/Lifter Operator

1 6,000/mo 6,000

B. Indirect Labor

Manager 1 20,000 20,000

Bookkeeper/Encoder 1 6,000 6,000

TOTAL 104,000

IV. PRODUCTION

Item Unit Quantity Price/Unit Total Value

Production Fiber-cement

boards8 mm pieces 1667 pcs 180 300,06012 mm pieces 833 pcs 210 174,93025 mm pieces 625 pcs 285 178,125

By-ProductsCoir dust kilogra

ms16,667 kgs

2.541,668

TOTAL 694,792

COST AND RETURN

ITEM VALUE (PHP)*PER MONTH PER YEAR

Gross IncomeCash Income

- Sales from cement-bonded boards

653,125 7,837,500

- Sales from coir dust 41,667 500,000Total Cash Income 694,792 8,337,500

Total Gross Income 694,792 8,337,500

*Currency Exchange Rate : 1 US$ = 46.5 Philippine Pesos

ExpensesVariable Cost

Hired labor 104,000 1,248,000Supplies and materials

Coconut fiber residues 33,638 403,650Cement 235,440 2,825,280

Flat steel 11,250 135,000

Lumber fillet 2,075 24,900

Plastic sheets 4,175 50,100

Wooden moulds 450 5,400

Bolts and nuts 300 3,600

Wooden cauls 425 5,100

Water 1,600 1,920

Electricity 4,500 54,000

Marketing and Selling Cost 6,948 83,347Interest on Operating Capital (12% p.a.) 35.090 421.075

Total Variable Cost 438,450 5,260,555

Fixed CostFixed Cash Costs

Interest on fixed Capital Investment 13,090 157,080

Total Fixed Cash Costs 13,090 157,080 Fixed-Non Cash Costs

Depreciation 14,100 169,200 Total Fixed-Non Cash Costs 14,100 169,200 Total Fixed Costs 27,190 326,280 Total Costs 465,640 5,586,835

Net Cash Income 681,693 8,081,396Gross Margin 256,332 3,076,841

Net Income 229,142 2,750561

Market:Commercial production of CFB is expected to contribute to

the government's national shelter program, specifically on socialized and low-cost housing.

CFB can replace construction materials such as tiles, bricks, plywood, asbestos and cement hollow blocks. It is used for internal and exterior walls, partitions and ceiling. It can also be used as a component in the fabrication of furniture, cabinets, boxes and vases, among others.

Potential market outlets are construction material suppliers, building contractors and government/private agencies involved in low-cost housing projects.

Other target markets are the low and middle-income households who would like to own houses at affordable prices.

Regulatory Requirements:PHILSA STANDARD 105-1975 provides minimum

product specification for particle boards.

Risks:Decorticating of coconut husks and the disposal of waste

water being used for soaking the fibers can cause environmental problem. Proper attention should be taken to

minimize if the totally eliminate this perceived problem

Source of Technology:Researchers:, Luisito J. Peñamora, Neil J. Melencion and

Rolendio N. PalomarAgency Affiliation: PCA-Zamboanga Research Center,San

Ramon, Zamboanga CityTelephone Nos.: (062) 982-0302

Fax Nos.: (062)9820302Email Address: pca_zrc@pldtdsl.net