Title of Technology: Coconut Fiber-Cement Board ... - Ecocoboard.net

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, spathes
or 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-coirwood
board
with 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.

COCONUT FIBER-CEMENT BOARD
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.

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. Equipment
The 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

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

PRODUCTION PROCESS
Extract fiber from husks

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
1” x 2’ x 4’ 800-1200
kg/cu.m.
Density Application
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

. Roofing System

c. Flooring System

Formwork and flooring for upper-level

d. Ceiling/Partitions
Rivet

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 MATERIAL
COCONUT FIBER-CEMENT BOARDS AS CONSTRUCTION MATERIAL
Roof Sheathing
Base Support
for upper-level
flooring
Basic Properties of CFB
Board Density = 550 -650 kg/cu.m.
Water Absorption = 32%
Thickness Swelling = 4.2%
Bending Strength (MOR)= 8.30kg/cm 2
Thermal Conductivity = 0.090W/m-k
Component of
furniture
(tables, chairs,
etc.), cabinets,
boxes and vases
Internal & exterior
walls, partitions and
ceilings

FINANCIAL ASPECTS

I. INVESTMENT REQUIREMENTS
ITEM NUMBE
R &
UNIT
I. Land 500m 3
Building 200 m 3
TYPE YEAR
ACQUIR
ED/
Plant/
storage
house
VALUE/AC
QUISITION
COST
(PhP)
ESTIMATE
D LIFE
(YEARS)
400,000 20
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
TOTAL 2,280,000

II. OPERATING EXPENSES
Item
A. Supplies/Raw Materials (please
itemize)
Unit & Number
Per Month
Cost/Unit
(PhP)
Total Value
(PhP)
Coconut fiber 22425 kg 1.5 33,638
Portland Cement 1308 bags 180 235,440
Flat steel 25 pc 450 11,250
Lumber fillet 83 pc 25 2,075
Plastic sheets 167 pc 25 4,175
Wooden moulds 01 pc 450 450
Bolts and nuts 4 pairs 75 300
Wooden cauls 17 bd ft 25 425
B. Miscellaneous Expenses
Electricity 1,500 kwh 3 4,500
Water 80 m 3 2 160
TOTAL 200,103

III. LABOR REQUIREMENTS
Type Of Labor
A. Direct Labor
Number
Man-
Days/Month
Wage
Rate/Month
Total
Value
Machine Operators 12 6,000/mo 72,000
Truck Driver/Lifter
Operator
B. Indirect Labor
1 6,000/mo 6,000
Manager 1 20,000 20,000
Bookkeeper/Encoder 1 6,000 6,000
TOTAL 104,000

IV. PRODUCTION
Item
Production
Fiber-cement
boards
Unit Quantity Price/Unit
Total
Value
8 mm pieces 1667 pcs 180 300,060
12 mm pieces 833 pcs 210 174,930
25 mm pieces 625 pcs 285 178,125
By-Products
Coir dust kilogra
ms
16,667
kgs
2.5
41,668
TOTAL 694,792

Gross Income
Cash Income
COST AND RETURN
ITEM VALUE (PHP)*
- Sales from cementbonded
boards
PER MONTH PER YEAR
653,125 7,837,500
- Sales from coir dust 41,667 500,000
Total Cash Income 694,792 8,337,500
Total Gross Income 694,792 8,337,500
*Currency Exchange Rate : 1 US$ = 46.5 Philippine Pesos

Expenses
Variable Cost
Hired labor 104,000 1,248,000
Supplies and materials
Coconut fiber residues 33,638 403,650
Cement 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 83,347
Interest on Operating Capital
(12% p.a.) 35.090 421.075
Total Variable Cost 438,450 5,260,555

Fixed Cost
Fixed 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 8,081,396
Gross 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. Palomar
Agency Affiliation: PCA-Zamboanga Research Center,San
Ramon, Zamboanga City
Telephone Nos.: (062) 982-0302
Fax Nos.: (062)9820302
Email Address: pca_zrc@pldtdsl.net