Module 3
Wood Substitutes for Natural Hard Wood
Industrial wood substitutes, often called engineered wood or composite wood
products, are building materials made by binding strands, particles, fibers, or
veneers of wood together with adhesives or other materials (like cement or plastic)
under heat and pressure. They offer key benefits over natural hard wood, such as
greater uniformity, resistance to warping, and better utilization of wood resources.
1. Veneers and Veneer Plywoods
Physical Areas of Available Forms
Product Characteristics
Properties Application & Sizes
Provides a
Thin sheets of natural wood Surface finishing Standard panel
wood, thinner than finish with for furniture, sizes, typically
Veneers 3mm. Can be minimal solid doors, panels, available in
rotary cut (peeled) wood. Flexible decorative wall thickness $ < 3
or sliced. (especially coverings. \text{ mm}$.
rotary cut).
Interior
Grade/MR
High strength (Moisture
and stiffness Resistant):
Manufactured Indoor furniture,
in both
from multiple Panels/Sheets
directions (due partitions.
layers (plies) of Exterior typically $4 \text{
to cross-
thin veneers Grade/BWR mm}$ to $25
lamination).
cross-laminated (Boiling Water \text{ mm}$ in
Veneer Improved
(grains at Resistant): thickness.
Plywoods dimensional
$90^\circ$ to Standard sheet
(Plywood) stability, resists Kitchen furniture,
adjacent layers) bathroom sizes like $1220
warping.
and bonded with paneling. Marine \text{ mm} \times
Lightweight
durable adhesives Grade: Boat 2440 \text{ mm}$
compared to
under ( $4' \times 8'$).
solid wood of building,
heat/pressure. applications
equivalent
strength. subjected to
prolonged water
exposure.
Structural
Plywood:
Physical Areas of Available Forms
Product Characteristics
Properties Application & Sizes
Construction
applications
requiring stability
(shear walls,
roofing,
subfloors).
2. Particle Board
Physical Areas of Available Forms &
Characteristics
Properties Application Sizes
High density, high
surface hardness,
abrasion resistance.
Made from small Heavier than Furniture making
Sheets/Panels
particles of wood comparable solid (e.g., cabinets,
typically $5 \text{
(or other materials wood or plywood. ready-to-assemble
mm}$ to $50 \text{
like rice Provides broad, furniture),
mm}$ in thickness.
husk/bagasse) stable panels of underlayment,
Standard sheet
embedded in reasonable strength. floor leveling, core
sizes, often $1220
synthetic resins Cost-effective. material for
\text{ mm} \times
and subjected to Susceptible to veneering or
2440 \text{ mm}$.
heat and pressure. swelling and laminating.
damage from
moisture if not
protected.
3. Hardboard and Fiberboard
Physical Areas of Available Forms
Product Characteristics
Properties Application & Sizes
Made from pulped Very high Door skins, Sheets/Panels.
Hardboard
wood fibers (or density ($800 perforated Common
(High-
chips, plant fibers, - 1200 \text{ boards thicknesses 3mm
Density
sawdust, recycled kg/m}^3$). (pegboards), to 12 mm
Physical Areas of Available Forms
Product Characteristics
Properties Application & Sizes
Fiberboard - materials) Good flexural furniture Standard width
HDF) compressed under strength, backing, typically
high heat and highly drawer
pressure, often durable. bottoms,
without added Tempered temporary wall
adhesives (relying hardboard coverings,
on wood's lignin). has better concrete
Smooth, hard face strength and formwork
surface and a water (shuttering).
rough screen- resistance.
patterned back.
Smooth
surface,
excellent for
painting and
Engineered wood machining
Furniture,
wallboard made (routing, Sheets/Panels.
Fiberboard cabinets,
from wood fibers carving). Common
(Medium- shelves,
(blended with wax Density is thicknesses from
Density decorative
and synthetic resin) generally 3 mm to 30 mm
Fiberboard - moldings,
compressed into lower than or more.
MDF is a speaker
rigid sheets. hardboard. Standard sheet
common boxes,
Uniform density Better screw- sizes, often 1200
type) architectural
throughout the holding than mm, 240 mm.
millwork.
panel. particle board,
but can be
susceptible to
moisture
damage.
4. Block Board
Areas of
Characteristics Physical Properties Available Forms & Sizes
Application
Lightweight (due
Core is made of
to the core) but
strips of solid
with good Long shelves,
wood (blocks)
strength and large table tops, Sheets/Panels. Common
placed edge-to-
stability. Less partitions, thicknesses 16 mm to
edge,
prone to paneling, furniture 30mm. Standard sheet
sandwiched
warping/cupping where long, stable sizes, often 1200 mm
between outer
than solid wood lengths are 2400 mm
veneers of wood
boards. Good required.
or thin layers of
screw-holding
plywood.
strength.
5. Other Advanced & Specialized Substitutes
Product Characteristics & Physical Properties Areas of Application
Structural timber members made of
several layers of dimensioned lumber Structural beams,
Glulam (Glued bonded together with durable, moisture- arches, columns,
Laminated resistant structural adhesives. High headers, and framing in
Timber) strength-to-weight ratio, aesthetic residential, commercial,
appeal. Can be manufactured in curved and public buildings.
shapes and long spans.
Thin sheets made by pressing layers of Surface finishing for
paper and resin (e.g., phenolic resin for particle board, MDF,
Laminates
core, melamine resin for decorative and plywood to create
(Decorative
surface) under high heat and pressure. counter tops, furniture
Laminates)
Extremely hard, durable, scratch- surfaces, wall paneling,
resistant, and easy to clean. and flooring.
Cement A composite material made from wood
Exterior cladding,
Particle Board particles (fibers or chips) mixed with subfloors, fire-rated
cement and other mineralizing agents.
walls, wet areas
Excellent fire resistance, termite
Product Characteristics & Physical Properties Areas of Application
resistance, and weather resistance. (bathrooms, laundries),
High density and acoustic insulation permanent formwork.
properties.
Often refers to boards with a non-wood
E-Board
core (like EPS or XPS foam) Insulated panels for
(Expanded
sandwiched between two thin sheets of walls and roofing, non-
Polystyrene -
wood-based material, cement particle structural partitions, cold
EPS core
board, or other rigid facings. Very storage construction.
boards)
lightweight, excellent thermal insulation.
Manufactured from bamboo strips cut,
processed, and laminated together under Furniture, cabinetry,
Bamboo Ply high pressure, similar to wood plywood flooring, counter tops,
(Bamboo or block board, but using renewable decorative paneling,
Plywood) bamboo grass. Extremely hard, due to its durability and
durable, and highly sustainable. unique appearance.
Distinct natural grain pattern.
studying and analyzing different wood substitutes, material selection
criterias, specifications, application
These notes are structured for quick revision, focusing on definitions, key
characteristics, and application distinctions of major wood substitutes.
1. Veneer-Based Engineered Products (High Strength & Stability)
Definition & Key Key Primary
Product
Process Characteristics Application
Layers of wood veneer High dimensional Structural sheathing
bonded with the grain stability (resists (roofs/subfloors),
Plywood of adjacent layers warping). Balanced concrete formwork,
perpendicular strength in two durable furniture
($\mathbf{90^\circ}$). directions. Graded (cabinets).
by glue type (e.g.,
Definition & Key Key Primary
Product
Process Characteristics Application
BWP for
exterior/wet use).
High linear Load-bearing
Laminated Layers of veneer strength and headers, floor
Veneer bonded with all grains stiffness (like a joists, and
Lumber parallel to the long beam). Uniform structural beams
(LVL) axis. and predictable where high bending
strength. strength is required.
Structural capacity
over long spans.
Can be fabricated Large structural
Glued Layers of
into custom beams, arches,
Laminated dimensioned lumber
curved shapes. columns in
Timber bonded with all grains
Superior fire commercial/public
(Glulam) parallel.
performance buildings.
(predictable char
rate).
2. Particle and Fiber-Based Boards (Uniformity & Machinability)
These are made from re-constituted wood fragments bound by resins.
Composition & Primary
Product Key Characteristics
Density Application
Smooth surface
Cabinet doors,
(excellent for painting).
decorative
Medium- Superior
moldings,
Density Fine wood fibers + machinability (routing,
furniture requiring
Fiberboard resin. High density. profiling). Poor
a smooth
(MDF) resistance to moisture
painted finish or
and edge screw-
intricate routing.
holding.
Coarse wood Lowest cost EWP. Core material for
Particle chips/shavings + Least strength and laminates,
Board (PB) resin. Lowest lowest resistance to budget/RTA
density/cost. moisture and sag. (Ready-to-
Composition & Primary
Product Key Characteristics
Density Application
Assemble)
furniture, low-load
shelving.
Furniture backing,
Highly compressed Very hard and thin. drawer bottoms,
Hardboard
wood fibers. Very One side is smooth, door skins,
(HDF)
high density. the other textured. display boards
(pegboards).
Core of solid
Lightweight but highly
wood strips Long shelves,
resistant to warping
(blocks) doors, partitions,
Block Board over long lengths.
sandwiched and large flat
Good screw-holding in
between outer panel furniture.
the core.
veneers.
3. Specialized & Composite Boards (Performance Driven)
These materials are chosen for specific durability or environmental needs.
• Laminates (HPL):
o Composition: Paper layers saturated with phenolic/melamine resins, pressed at
high pressure.
o Characteristics: Extremely hard, scratch-resistant, non-porous surface. Must be
bonded to a core board.
o Application: Kitchen countertops, cabinet faces, high-traffic furniture surfaces.
• Cement Particle Board:
o Composition: Wood particles mixed with Portland cement and mineral additives.
o Characteristics: Excellent fire resistance, termite resistance, and moisture
resistance. Very dense and heavy.
o Application: Exterior cladding, fire-rated walls, backer board for wet areas
(bathrooms/laundries).
• Bamboo Plywood:
o Composition: Laminated strips of the bamboo grass (highly renewable).
o Characteristics: Very hard and durable. Highly sustainable. Unique aesthetic.
o Application: Flooring, high-end furniture, countertops.
4. Material Selection Criteria (Exam Focus)
When answering questions about material choice, emphasize these four factors:
1. Application Environment (Moisture/Pest):
o Criterion: Does the product require protection from water or pests?
o Choice: BWP Plywood or Cement Particle Board for wet/exterior use.
2. Structural Requirement (Load-Bearing):
o Criterion: Will the material bear significant weight or shear forces?
o Choice: Glulam or LVL for beams; Plywood for sheathing. Avoid MDF/PB for
structural loads.
3. Finish & Machinability:
o Criterion: Does the design require a smooth finish or intricate routing/carving?
o Choice: MDF for flawless painting and detailed cutting.
4. Cost and Sustainability:
o Criterion: Budget constraints and environmental goals (low-formaldehyde, renewable
source).
o Choice: Particle Board (lowest cost). Bamboo Ply (high sustainability). Look for
E1/E0 grades (low formaldehyde).
Study of Industrial Wood Substitutes the specifications from relevant
BIS Codes.
The Bureau of Indian Standards (BIS) establishes the quality and safety benchmarks
for industrial wood substitutes in the Indian market. Adherence to these Indian
Standards (IS) often leads to the granting of the ISI Mark, which is mandatory for
several major wood-based panel products under the Quality Control Order (QCO).
1. Plywood and Block Board
BIS standards for plywood and block board primarily focus on bond strength
(moisture resistance) and appearance/grade.
Relevant Mandatory Tests
Product Key Specifications & Grades
BIS Code(s) (Examples)
Water Resistance Test:
Grades based on Adhesive Bond
To verify bond strength
Strength: <ul><li>MR (Moisture
after exposure to
Resistant): For interior, dry
water/boiling water. Glue
use.</li><li>BWR (Boiling Water
Plywood Shear Strength:
IS 303: 1989 Resistant): Better bond strength,
(General Measures the bond
(Mandatory) suitable for humid
Purposes) quality between veneers.
conditions.</li><li>BWP (Boiling
Mycological Test (for
Water Proof): Highest bond strength
certain types).
(e.g., Marine Grade uses Phenolic
Formaldehyde Class
resin).</li></ul>
($\mathbf{E1, E2}$).
Specifically for load-bearing and
Bending Strength
structural applications. Specifies
IS 10701: (MOR), Dimensional
Structural higher requirements for bending
2012 Stability, Bonding
Plywood strength, Modulus of Elasticity
(Mandatory) Quality, and Load-
(MOE), and load-bearing capacity
Bearing Capacity tests.
compared to IS 303.
Grades: Classified into BWP Grade Resistance to Water
IS 1659: and MR Grade (based on adhesive test (for BWP grade).
Block
2004 and moisture resistance). Types: Adhesion of Plies and
Board
(Mandatory) Decorative Type (better face veneer Dimensional Changes
quality) and Commercial Type. caused by humidity.
Modulus of Rupture
Relevant Mandatory Tests
Product Key Specifications & Grades
BIS Code(s) (Examples)
(MOR) and Modulus of
Elasticity (MOE).
2. Fiber and Particle Boards
Standards for reconstituted boards emphasize uniform density, internal bond
strength, and formaldehyde content.
Relevant BIS Key Specifications & Mandatory Tests
Product
Code(s) Grades (Examples)
Density Range: Covers Internal Bond Strength
boards with density typically (critical test for fiberboards).
from $600 \text{ kg/m}^3$ to Modulus of Rupture (MOR)
Medium-
IS 12406: $900 \text{ kg/m}^3$. and Modulus of Elasticity
Density
2021 Formaldehyde Class: (MOE). Screw Withdrawal
Fiberboard
(Mandatory) Specifies limits for E1 and E2 Test (measures screw-
(MDF)
classes to regulate VOCs. holding power). Linear
Grade 1 / Grade 2 Expansion due to moisture
classifications. absorption.
Specifies requirements for
Transverse Tensile
wood particle board for
Strength (perpendicular to
Particle IS 3087: general purposes. (Note:
the surface). Swelling in
Board (PB) 2005 May also fall under broader
Water. Water Absorption.
lignocellulosic board
Bending Strength.
standards).
Relevant BIS Key Specifications & Mandatory Tests
Product
Code(s) Grades (Examples)
Specifies requirements for Tests cover both the core
Pre- MDF that has been factory- properties (density, strength)
IS 14587:
laminated laminated, covering both the and surface properties like
2023
MDF core board (MDF) and the abrasion, scratch, and stain
laminated surface. resistance.
3. Decorative and Structural Composites
Relevant BIS Key Specifications &
Product Focus Area
Code(s) Classification
Part 3 (Laminates $< 2 \text{ Surface Durability
mm}$ for bonding) & Part 4 (scratch and abrasion
Decorative (Compact Laminates $\geq 2 resistance).
Laminates IS 2046: 1995 (and \text{ mm}$). Classification Dimensional Stability
(High- revised Parts 1-8) based on decorative finish, (resistance to post-
Pressure) thickness, and intended use laminating warping).
(e.g., exterior grade, flooring Resistance to staining
grade). and heat.
BIS standards Specifies structural stress
generally reference grades (e.g., $24\text{F}, Allowable Stresses for
Glued or align with 28\text{F}$) based on the design (bending, shear,
Laminated international required Modulus of compression). Quality
Timber standards (ANSI Rupture (MOR) and of laminating lumber
(Glulam) A190.1) for Modulus of Elasticity and adhesive bond
structural wood (MOE). Specifies suitable integrity.
products. adhesives for structural use.
Key Specification Parameters in BIS Codes
For wood substitutes, the examination of specifications revolves around these critical
parameters:
1. Grade based on Adhesion/Moisture:
o MR (Moisture Resistant) / BWR (Boiling Water Resistant) / BWP
(Boiling Water Proof). This is verified by subjecting samples to varying
water/humidity tests and checking for delamination (failure of the
adhesive bond).
2. Mechanical Strength:
o Modulus of Rupture (MOR): The material's ultimate bending
strength. Critical for load-bearing products like structural plywood and
Glulam.
o Modulus of Elasticity (MOE): The material's stiffness, which
determines its deflection under load.
3. Internal Bond Strength (IB):
o Measures the tensile strength perpendicular to the board's surface.
This is crucial for MDF and Particle Board to ensure the material
doesn't crumble or split internally.
4. Formaldehyde Emission Class:
o E1 and E2 are classifications based on the amount of residual free
formaldehyde released (Volatile Organic Compounds or VOCs). E1
has lower emissions and is preferred for residential and indoor use.
BIS increasingly mandates strict control over this parameter.