INTERNATIONAL NETWORK FOR BAMBOO AND RATTAN

(INBAR)

TRANSFER OF TECHNOLOGY MODEL

(TOTEM)

BAMBOO FLOORING MANUFACTURING UNIT

by
Zhang QiSheng and Xu Bin

Bamboo Engineering and Research Center

Nanjing Forestry University
Nanjing, Jiangsu Province,
China
 CONTENTS

TRANSFER OF TECHNOLOGY MODELS (TOTEMs) 3

LAMINATED BAMBOO FLOORING AT-A-GLANCE 5

PART ONE: INTRODUCTION

1. Introduction 7
2. General development attributes and advantages 7
3. Suitable agro-ecological regions 7
4. Target groups 8
5. Requirements for success 8

Concluding remarks 8

PART TWO: THE BAMBOO FLOORING MANUFACTURING UNIT

1. Introduction 10

2. Production of bamboo flooring 10

2.1 Raw materials 11
2.2 Manufacturing bamboo sheets 11
2.3 Laying up and hot pressing 11
2.4 Planing, moulding and sanding 12
2.5 Painting 12

Appendices 14

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
 TRANSFER OF TECHNOLOGY MODELS (TOTEMS)

Transfer of Technology Models (TOTEMs) are focussed educational tools providing relevant
information and distance training on one specific area of bamboo/rattan management, processing
or utilization. They are a means of technology transfer between similar regions throughout the
world, with the emphasis on South-South transfer for livelihood development. They enable those
involved in the management and use of bamboo and rattan resources to more efficiently and
effectively develop and use skills relating to these resources.

TOTEMs are primarily intended as practical information resources and teaching aids for those at
the local extension level in their communities, who can utilize them to assist local community
development. Each TOTEM consists of a detailed written report of the technology, a PowerPoint
presentation, a film, and, where relevant, a set of technical photographs. They also include
information on target users, financial analyses of sample set-ups from the partner country
preparing the report and information on where to source particular technologies (such as
equipment). The TOTEM thus provides all the information required for establishing similar
technologies within interested countries and regions.

• The report contains all the technical details of the particular processes involved, as well as
other relevant information for establishing the technology such as costs of business
establishment, running costs and cash flows.

• The PowerPoint presentation contains details of the relevant technologies and their
applications, and is intended to provide an overview of the potential of the technology for
development.

• The film provides a visual guide to the processes involved and helps to bring them alive in
the minds of the learners.

The different parts of the TOTEM are targeted at slightly different audiences, via the local
extension workers. The report and film are intended to be the main means of extension to the
individuals and communities who will implement the technology and who will directly benefit
from it. The PowerPoint presentation is primarily intended as a tool for the extension worker to
sell the technology and its role in development to those who provide the infrastructural, policy
and financial support for its implementation, such as government departments, donors and NGOs.
There is considerable flexibility, however. Local extension workers will be able to incorporate the
TOTEMs in their own work as they wish and adapt and develop them to suit their particular
requirements and conditions.

This TOTEM on the bamboo flooring manufacturing unit has been produced by Zhang
QiSheng and Xu Bin at Nanjing Forestry University, Nanjing, China. The report part of this
TOTEM describes the technology for producing and establishing shoot-producing plantations for
rural development in regions where bamboo is available as a raw material. It is intended to be
used in conjunction with the illustrative film included in this TOTEM package

The first part of the report introduces the technology, discusses its development attributes, its
benefits and its applicability. The second part of the report provides detailed information on the

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
technical aspects of manufacturing laminated bamboo flooring. Appendix I gives details of the
main features of laminated bamboo flooring, including geometry and quality standards.
Appendix II gives the initial equipment costs of a unit producing 40, 000 m2 of flooring per year.
Appendix III costs consumables and the production cost per square metre.

This TOTEM is one of the first to be produced by INBAR/ NFU and your feedback is most
welcome - kindly contact INBAR or NFU with your comments or suggestions.

© International Network for Bamboo and Rattan 2001

Note: This TOTEM has been edited at INBAR and differs slightly from the form in which it was received
from the authors.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
 LAMINATED BAMBOO FLOORING AT-A-GLANCE

What is laminated bamboo flooring?

Laminated bamboo flooring is a unique flooring material. The natural grain of the
bamboo shows up clearly and is very attractive. The flooring is resistant to moisture,
pressure and damage. It is flexible, lasts longer than wood flooring and is cheaper. It also
acts as a sound insulator.

How is it produced?
Laminated bamboo flooring is produced by splitting bamboo culms into thick sections or
sheets. These are then coated with resin, assembled into units three layers thick and then
pressed firmly together in a hot press. After curing the pieces are trimmed to shape and
painted or varnished.

What is the market for bamboo flooring?

Bamboo flooring boards are very popular worldwide and markets are developing in
Japan, Europe and North America. In China there are over 100 manufacturers producing
about 10 million square metres per year (ten square kilometres!).

What is the role of a bamboo flooring manufacturing unit in

rural development?
The unit will provide employment for unskilled, semi-skilled and technically trained
people in the rural communities in which it is established. The unit will also promote the
further use of bamboo resources and the sustainable management of bamboo plantations
and natural bamboo stands.

How do I establish a bamboo flooring manufacturing unit?

The machinery for a unit producing 40, 000 m2 of bamboo floor per year will cost
approximately USD $366, 000 and each square metre costs $12.4 to manufacture. In
addition to the substantial start-up capital required a sustainable supply of bamboo culms
will be required, along with a stable workforce.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
 PART ONE

INTRODUCTION

DEVELOPMENT ATTRIBUTES, TARGET GROUPS and

BENEFITS of a

BAMBOO FLOORING MANUFACTURING UNIT

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
1. Introduction
Sympodial bamboo flooring is a type of decorative flooring. It is a high quality product
that can be used widely and has a large consumer market. It has many advantages, such
as its smoothness, stability, resistance to wear, sound insulation, resistance to dampness,
pressure resistance, and flexibility. The bamboo floor has a soft and natural lustre, and
maintains the natural gloss and grain of the bamboo culm. Bamboo flooring is
exceptional and unique and very attractive.

In order to meet increasing demands for wood-based products, many forests have been
over-harvested in recent years. Developing non-tree wood alternatives is one means of
solving the problem. Sympodial bamboos grow fast, produce a high yield and can
become fully rejuvenated within a few years of cutting. Bamboo is a perfect substitute for
some wood based products. Bamboo is highly suited to the production of flooring.
Bamboo flooring has some excellent advantages over wood flooring, such as its high
strength and size stability, and its special decorative effects, so it is popular and has a
large market potential in China, Europe, Japan and North America.

2. General development attributes and advantages

The main development attributes of the technology are as follows:

• Provides employment and income generation for rural people

• Increases the use of natural bamboo resources and promotes timber substitution
• Improves living standards of the rural communities in which it is established

The main advantages of the technology are:

• Bamboo flooring is more attractive than wood flooring

• It is cheaper to produce and hence the retail price is cheaper
• Bamboo flooring is more marketable due to its production from renewable bamboo
resources.

3. Suitable agro-ecological regions

There are rich sympodial bamboo resources in the tropics and subtropics and the unit may
be established anywhere throughout these regions. Once the bamboo forest is mature
culms can be harvested every year. The unit is especially suitable for areas where
bamboo plantations are desirable for the restoration of degraded forests or wastelands
such as abandoned shifting cultivation areas, or where bamboos can be grown to reduce
soil erosion, particularly on steep slopes in high rainfall areas. Bamboo can thus play an

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
important role in raising the productivity of degraded land and in protecting the
environment and forest ecology.

4. Target groups
The main target group are the people that will be employed by the unit. The unit will
require unskilled, semi-skilled and technically trained personnel and these can all be
recruited from the community in which the unit is established. If established as a
community cooperative then all members of the community will benefit. Another target
group are the local bamboo cultivators who will benefit from the increased area of
plantations and demand for bamboo culms that the unit will generate.

5. Requirement for success

The essential requirements for a successful bamboo flooring manufacturing unit are:

• Start-up capital
• Source of raw bamboo materials
• Secure workforce
• Market access

Concluding remarks
The bamboo flooring unit is a commercially and socially effective means of processing
bamboo into quality flooring materials. It has significant potential for income and welfare
improvement for poor rural people both in the unit itself and in its forward and backward
linkages. In addition, by using bamboo as a substitute for wood timber it reduces
environmental degradation due to the overharvesting of timber trees. The unit requires
considerable start-up capital and may be best established with the guidance of state
agencies or NGOs.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
 PART TWO

THE BAMBOO FLOORING MANUFACTURING UNIT

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
1. Introduction
Laminated bamboo flooring is produced by the following basic steps

• Production of longitudinal bamboo sheets (sections)

• Bleaching sheets
• Drying, sanding and selecting sheets
• Applying glue to sheets and allowing them to dry
• Hot pressing sheets together into floorboards
• Shaping floorboards
• Sanding and painting floorboards

2. Production of bamboo flooring

The detailed process is as follows:

Cross cutting Packaging

Sawbuck Checking

Force planing Painting

Boiling Sanding

Drying Transverse tongue groove moulding

Finish-planing Longitudinal tongue groove moulding

Selecting Side planing

Glue spreading Surface planing

Laying up Hot pressing

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
There are two types of floor based on the colour: naturally-coloured floor, and coffee-
coloured floor and two types based on the arrangement of bamboo sheets: horizontal
and vertical.

The processing procedure is as follows:

2.1. Raw materials

Sympodial bamboos with large diameter culms are suitable for manufacturing flooring
(e.g. Dendrocalamus giganteus Munro. D. barbatus Hsueh et D.Z. Li and D.
membranaceus Munro). Culms with a diameter at breast height of over 10 cm should be
harvested when four years old. The culms are first crosscut into sections of the desired
length (the floor length plus an additional 11-13.5cm) and the sections are then cut into
slips of the same width (25 cm, 30 cm or 35 cm). Bamboo sheet is produced after planing
the slips to the same width, thickness and length.

2.2. Manufacturing bamboo sheets

Because bamboo can not be cut in some seasons (eg. spring), the factory should store
some dried bamboo sheets according to its manufacturing capability. Boiling is a key
procedure in the manufacturing of floors. It removes some water-soluble extracts and at
the same time can add insecticides and preservatives if these are included in the boiling
mixture. Bamboos are usually boiled for about 3-4 hours.

After being boiled all the bamboo sheets are piled up in the drying kiln (800C) for 4-5
days. If the sheets have been carbonised, they are removed when the moisture content
reaches 14-25%. The moisture content of other dried sheets is reduced to 5-8%.

At present, there are the two main ways for color treatment: bleaching and light
carbonisation. In bleaching, the bleaching agent solution can be brushed onto the surface
of the bamboo sheets, and the bleaching agent, such as H2O2, can be added to the water
during boiling. In carbonization, high temperature and moisture are required to treat
bamboo sheets in a closed container. Steam at 0.3 MPa is passed into the container for
40-120 minutes. Then the sheets are taken out and piled up to dry to 5-8% moisture
content. After finishing the sheets are planed to a thickness variation allowance of
0.2mm.

Sheets are then selected to weed out faulty sheets and to reduce the colour differences
among the sheets, so that finished floor has an even colour.

2.3. Laying up and hot pressing

Urea-formaldehyde (UF) adhesive is usually used to bond bamboo sheets. The solid
content of UF adhesive is above 60%, the viscosity is 30-50 Pa.S and the free

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
formaldehyde content is below 0.5%. Modifiers can be added to UF adhesive to improve
its properties, or an alternative adhesive can be used.

Usually floors are made of 3 layers. There are two kinds of flooring: one in which the
three layers are parallel to each other, and the other in which the outer layer and the
central layer are vertically orientated. The two edges of the bamboo sheet and both
surfaces of the central sheet should be spread with liquid adhesive at about 150g/m2 per
surface. Sheets of the same color should be placed on the upper face and those of
different colours may be used for the lower and central layers. String is used to tie the
sheets after laying up. UF adhesive should be spread on both surfaces of each sheet for a
vertical floor at a similar rate. The inner and outer surface layers of adjoining sheets
should face one-another. Two pieces of string should be used to tie up the two sides after
laying-up to the desired width.

The hot pressing method is used to seal the sheets together as floorboards. A two-
dimensional single open hot press is required with heat provided by steam or high
frequency heating. Place the laid-up sheets in the hot press, add a few press stops
between each lay-up and then apply the heated pressure. If the heat source is steam a
steam pressure of 1.0MPa is required. The pressure of the hot press should be 1.5-
2.0MPa, the temperature of the hot press plates should be 105-1100C, and the pressing
time required is 1.1-1.2 minutes per millimeter of thickness of lay-up. If high-frequency
heating is used, 5-minutes is sufficient.

2.4. Planing, moulding and sanding process

The following procedures are the same as for the manufacture of wood floors. The back
and one side of the blank of bamboo floor should be manufactured to be the datums plane
from which all measurements will be taken. Then the longitudinal tongue-groove and the
back slots should be moulded. The next process is manufacturing the transverse tongue-
groove.

Initial sanding is done with an 80 grit belt sander. Final sanding is with a 180 or 240 grit
belt sander so the blank surface is smooth and level. All these procedures are in
preparation for painting.

2.5. Painting

UV-cured paint is usually used for painting. Several undercoats are painted on the upper
face of the floor with one final topcoat. The sides and the rear receive only one coat.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
 APPENDICES

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
Appendix I

PART III
Main Features of Sympodial Bamboo Floors.
1. Geometry standard of bamboo floor (Table-1)

Table 1. The geometry standard of bamboo floor.

Name Sign Dimension (mm) Allowance

+0.5
Floor board length L 450, 610, 760, 915
0
0
Floor board width B 76, 91, 100
- 0.3
Floor board thickness H 9, 12, 15, 18 0.2

Face layer thickness h1 4, 4.5, 5, 6 0.1

+ 0.2
Groove width h2 3, 4, 5, 6
0
+ 0.3
Groove height b1 6
0
.0
Tongue width h3 3, 4, 5, 6
- 0.2
+0.3
Tongue height b2 5
0
Black slot width s 15 25 1

Black slot height h6 1 0.5

Tongue and groove corner radius r 0.5 1 0.2

Tongue back low depressed
f 1 0.2
height
Tongue surface corner angle ( ) 3 30’

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
2. Surface qualities standard (Table 2 3)

Table 2 Quality standards for bamboo floor faces

Degree
Name Note
Grade A Grade B Grade C
Decay Prohibited
Color difference Allow little Allow chromatism
Less than one Less than one
Splits Prohibited width <0.2mm width <0.5mm
length <10% 0f floor length <20% 0f floor
Worm holes Prohibited
Wavy grain Prohibited Allow little
Floor’s wane Prohibited
Less than one
Open joint Prohibited Width < 0.5mm
Length < 30% of floor
Discoloration Prohibited Area <5% of floor
Less than 10 per floor
Blisters Prohibited Allow little Painted floor
Diameter <1mm
Less than 10 per floor
Pinholes Prohibited Allow little Painted floor
Diameter <1mm
Wrinkling Prohibited Area < 5% of floor Painted floor
Prohibited Area <5% of floor Painted floor
Other defects Prohibited

Table 3. Quality standards for floor backs and sides

Degree
Name Note
Grade A Grade B Grade C
Decay Prohibited
Color
Allow chromatism
difference
Split Width < 1mm Width < 2mm
Worm holes Prohibited Diameter < 2mm
Wavy grain Allow

Length < 20% of floor Length < 30% of floor Length < 40% of floor
Floor’s wane Width < 10% of floor Width < 20% of floor Width < 30% of floor
Depth < 1mm Depth < 1.5mm Depth < 2mm

Less than one Less than 2 every floor

Open joint Prohibited
Width < 1mm width < 1mm
Less than 10 every floor Painted
Blisters Prohibited
diameter < 2mm floor
Less than 10 every floor Painted
Pinholes Allow little
diameter < 2mm floor
Painted
Wrinkling Area < 5% of floor Area < 10% of floor
floor
Painted
No paint Area < 5% of floor Area < 10% of floor
floor

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
4. Physical and chemical properties of bamboo floors (Table 4 ).

Unit of
Item Degree
measurement

Moisture content 90 6.0-14.0

Thickness <15mm 98.0

Strength MOR MPa
Thickness > 15mm 90.0

Every adhesive
Immersion test adhesive bond mm
open length = 25

Hardness MPa 55.0

Circle r 400

Paint resistance
Surface information Left 50% of face
To abrasion

Lost weight g/100r 0.08

Paint stain NO stain

Allow intersect of
knifecut paint scars to leave;
Paint adherence
allow paint scar left by a
knifecut to leave a little

Paint gloss % 85

Formaldehyde emission from floor mg/100g 50

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
Appendix II. Equipment required for the bamboo flooring unit (yearly output: 40, 000M2) (Table 5)

Quantity of Power of
Price Sub-total Operators Sub-total Sub-total cost
Number Type, name and specification of machine machine machine
(US dollar) power (kw) (person/Table) operators (US dollar)
(Table/set) (kw/Table)
1. Trim saw for bamboo 130 2 2.2 4.4 1 2 260
2 Ripsaw for bamboo tube (single operator L=1350mm) 400 2 2.2 4.4 1 2 800
3. Ripsaw for bamboo tube (double operators L=1350mm) 680 1 4.4 8.8 2 2 680
4. Ripsaw for bamboo tube (single operators L=2250mm) 680 4 4.4 17.6 2 8 2720
5. Force planer for bamboo slip 4300 5 10.4 52 1 5 21500
6. Boiler. (2T) 14500 1 2 2 14500
7. Single stringer crane (2T) (span: 9—12m) 1200 1 1 1 1200
8. hot—water vats 2400 2 1 1 4800
Drying room (20M3/single kiln) eight overhead fan vapor
9. 16300 4 15 60 1 4 65200
dryer kilns (not including ground works)
10. Finishing planer of bamboo 4700 5 12 60 1 5 23500
11. Two—dimensional single open press 31300 1 9.5 9.5 1 1 31300
12. Auto—feed platform bamboo slip 2400 1 1.5 1.5 2 2 2400
13. Two—dimensional sing open press 50600 1 13 13 1 1 50600
14. Auto—feed platform for bamboo slip 4800 1 1.5 1.5 2 2 4800
15. Slashing saw for bamboo board 7200 1 15 15 1 1 7200
16. Single head trimmer 100 2 3 6 1 2 200
17. Planer saw bamboo board 4400 2 10.7 21.4 1 2 8800
18. Scraping machine for bamboo sheet 4650 2 10.7 21.4 1 2 9300
19. Transverse slot mortiser for bamboo sheet 1 (200—600) 6800 1 8.95 8.95 1 1 6800
20. Transverse slot mortiser for bamboo sheet 2 (200—1200) 7200 1 8.95 8.95 1 1 7200
21. Longitudinal slot mortiser for bamboo sheet 6000 2 9.6 19.2 1 2 7200
22. Ultraviolet infrared film and curing apparatus 15700 1 2 2 15700
23. Three heads wide belt sander 7900 2 12.5 25 1 2555 15800
24. Universal wood working grinding machine 3000 1 0.41 0.41 1 2 300
25. Center gathering collector 21700 2 27.5 55 43400
26. Carbonization container 14400 1 14400
27. Sanding belt; knife tool and other tools 6000 6000
Total 414 55 366560
Note: the above information has been collected from an anonymous manufacturer in South China.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit
Appendix III

Quantity of Raw Material Consumed (Table 6)

Material Quantity required annually (tonnes)

Bamboo 5000

UF adhesive 12

Polyvinyl acetate emulsion adhesive 0.5

Ammonium chloride (NH4Cl) 0.12

Paint 8

Other chemical materials 0.4

Note: about 50% of the bamboo will be wasted and may be used for other uses.

Cost of per Square Meter of Manufactured floor (Table 7)

Cost
Item
(US dollar)
Bamboo materials 6.5

Chemicals 2.5

Water and power 0.7

Wages 1.4

Manufacturing costs 0.8

Other materials 0.5

Total 12.4

Note: the above data are from an anonymous manufacturer in South China.

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Transfer of Technology Model: Bamboo Flooring Manufacturing Unit