LOOKS LIKE WOOD, BETTER THAN WOOD
Wood Polymer Composite Sheet
It is an intelligent solution which has emerged as a substitute of wood and wood,plywood products, fulfilling the demands that are not in the scope of wood.
WPC is a modern and ecological composite material which is made of60% PVC, 30% rice & wheat husk and 10% calcium carbonate and additives. It is the best substitute of Plywood because of its strength and durability. The major advantage of WPC lies in the fact that it retains the best properties of wood while eliminating all the downsides which one may face with woods.
For decades we have been cutting down trees to fulfil our need and demand of building products. The cost of the products made from plywood is too high. Along with the cost constraint there is limitation of colours available as well and the durability is also low. It is a versatile material with multitude application area. We can make all types of furniture using WPC like Modular furnishing, Bathroom vanities ,kitchen , cabinets , interior, partitioning ,shoe rack,wardrobes, cupboards, tables, chairs and any type of interior and exterior furniture.
- Production method
- Technical information
Why Wood Polymer Composite is the best replacement of
Plywood and Wood Products :
WPC is a revolutionary replacement for the wooden home construction products: It’s made up of wood polymer Composite Material. The Wood deteriorates, cracks, rots fall under the category of organic material, which automatically makes it a breeding ground for bacteria and a hearty meal for the termites to latch on. The other reason why wood must be avoided is due to the fact that wood cannot be recycled, and cutting down of trees is harmful for our environment and leads to deforestation. WPC on the other hand, combines the properties of wood and Plastic, making it a highly durable and malleable material. Along with other advantages, WPC is resistant to moisture, rotting, corrosion, aging, acid and chemical. It can both be polished and painted to match the shade of the door and wall well. The frames are available in different length and width.
Switching to wood polymer composite sheet is a
sustainable and lucrative alternate:
- It is a complete substitute of Plywood and Water Proof Ply.
- It is an environment-friendly option, since no cutting down of trees is required which essentially saves home of plenty of birds and animals.
- WPC is a low maintenance product. The furniture prepared from WPC don’t require waxing, oil-coating or any other treatment. They are color-fast and do not change their shape over time.
- WPC loves water and is moisture proof, durable and firm. They are environment friendly and fully recyclable. They are the perfect substitutes for wood.
The material can be well machined with utilizing standard processing equipment, making it as versatile as wood. Like plastic, the sheets are suitable for thermo processing i.e. they combine the benefits of both materials in a single product.
Alstone WPC is resistant to external influences, like snow, rain, salt water, sun, etc. It is a famous and very well used alternative to the tropical timber, this means it stands in line as the protection of valuable natural resource. The material used in Alstone Industries shows no sign of swelling, unlike conventional wood. The product is a well-known UV-resistant product which makes it very useful.
Due to the unique properties of the base material, Alstone WPC offers advantages as compared to wood:
- The material doesn’t administer any discoloration of the surface.
- There happens to be no resin discharge of any form.
- No surface erosion takes place due to any environmental influences.
- No cracks are administered due to shrinkage or swelling.
- No front-face capillary action
Alstone WPC is primarily based on natural raw materials. As a result of the special production method and composition of Alstone WPC Sheet some tiny air pockets may be formed. The differences in coloration and surface finish of individual sheets is very much possible. This color difference has no effect on the quality of the product. Due to the durability as well as the reduction of maintenance which is aided by Alstone Industries makes it recyclable and easy to use. It offers a significant advantage as compared to the conventional building materials. Alstone WPC is the perfect choice for projects in which the key requirement holds as sustainability.
AREAS OF APPLICATION
Alstone Industries is particularly suited to areas of application that rely on durable, sustainable and weather-proof materials with a wood like appearance.
The area of application is found in various domains:
- Outdoor furniture
- Wall and façade elements
- Store fit-outs
- Exhibition stands
Advantage of using WPC
- 100% water Proof
- 100% Termite Proof
- 100% Fire Retardant
- Durably water and weather resistant. It doesn’t swell and can be installed in water as well.
- Resistant against salt and chlorinated-water
- UV-resistant, WPC won’t fade away or turn yellow under the influence of sun.
- Skid-resistant, it is ideal for pool decks and terraces.
- Free from cracks and splinters.
- Resistance against fungal and mold decay.
- Resistance against termites and other parasites.
- Products partially fulfil very high fire classes
- Sustainable and recyclable.
Alstone Industries sheets are made to look and feel just like wood. The material can be machined with standard processing equipment,making it as versatile as wood. What is more, like plastic,the sheets are suitable for thermoprocessing i.e. they combine the benefits of both materials in a single product.
Alstone Industries is highly resistant to external influences such as sun,rain,snow or salt water, and as an alternative to tropical timber it also contributes to the protection of valuable natural resources. In contrast to conventional wood or wood based products, the material used in Alstone WPC Sheet shows no sign of swelling. Furthermore it is UV resistant.
unique properties of the base material, Alstone Industries offers many advantages compared to wood:
- No discolouration of surfaces due to chemical decomposition or leaching of timber components.
- No resin disc harge
- No surface erosion due to environmental inf luences.
- No cracks due to swelling or shrinkage.
- No front-face capillary action
Alstone Industries is primarily based on natural raw materials. As a result of the special production method and composition of Alstone WPC Sheet some tiny air pockets may be formed. Differences in the colouration and surface finish of individual sheets are also possible, but this has no effect on the quality of the product. Due to its specific material properties and durability as well as associated reduction in maintenance and servicing cost stogether with its recyclability ,Alstone WPC Sheet offers significant advantages compared to conventional building materials when it comes to life cycle costs (‘cradle to cradle”). This makes Alstone Industries the perfect choice with regard to projects in which sustainability is a key requirement.
AREAS OF APPLICATION
Alstone WPC is particularly suited to areas of application that rely on durable, sustainable and weather-proof materials with a wood like appearance.
Possible areas of use:
- Outdoor furniture
- Wall and facade elements
- Store fit-outs
- Exhibition stands
Alstone WPC sheets are produced by means of the extrusion method. Sheet extrusion is a thermoplastic processing method.
A sheet extrusion plant consists of an extruder,a tool sometimes referred to as a die with a fishtail design for shaping purposes, a triple roller calendar to smooth the extruded material, a cooling section, a haul-off and a separating unit (saw or cutting device) and a destacker.
By applying heat, shearing and pressure, the raw material is heated during the extrusion process to convert it into a viscious fluid form. A rotating screw presses this molten material through a shaping tool-fishtail nozzle. The surface of the calendar rollers generally has a highgloss finish. It essentially determines the surface quality of the sheet. The shaping process is complete once the calendar has performed its smoothening task. After the extruded material has cooled down on the roller conveyor, sheets are produced by being cut to the desired length in the separating unit before being off-loaded onto transport pallets by the destacker. As the material meets the aforementioned requirements, Alstone Industries IM is suitable for boat- and ship building purposes and can be used on bulkheads, walls, ceilings, linings or floor coverings. In the event of a fire, hydrogen chloride gas and other broken down byproducts may be released. For this reason, Alstone WPC sheets should not be burnt without taking suitable emission control precautions. Offcuts and/or sanding dust, as with any other thermo plastic material,should be properly disposed of. Please follow the instructions of your local disposal expert.
Performance in outdoor use
Alstone WPC is extremely resistant to external influences such as sun,rain, snow or salt water. As the AlstoneWPC Hybrid material is also UV resistant ,Alstone Industries is suitable for outdoor use. For optimal protection and to avoid bleaching of the material due to natural causes, we generally recommend application of a varnish or sealant.
Temperature changes can alter the dimensions of any material. For this reason, the thermal expansion coefficient should be taken Into account when cutting and assembling Alstone WPC sheets.The thermal expansion coefficient of plastics is signifi cantly greater than that of metal or wood and must therefore- be taken Into account when Alstone WPC is used in areas that are subject to a high degree of temperature f luctuation.
Cutting and assembly of Alstone WPC sheets should be com pleted under stable temperature conditions. It is recommended that the material is stored in the shade or in areas with no direct sunlight before being cut or assembled, as the material can signif icantly heat up in the sun and expand accordingly. We recommend storing the product for at least 24 hours at a consistent temperature that corresponds to that of the sub sequent area of application. Apart from its composition, the processing method, handling conditions and design of the finished product, as well as the resultant tension exerted on it, will have an effect on the lifespan of the material. The latter is also influenced by ambient conditions as well as strains and stresses exerted during installation and processing.
Due to the smooth surface, the organic consituents on the surface of the product can never absorb moisture. However water can penetrate into open pores. Water absorbed in this way does not initiate any rotting processes; it can be released again during drying.
ALSTONE WPC is based on a thermoplastic material and therefore displays the usual properties of a thermoplastic when exposed to higher temperatures. In the case of parts not subject to mechanical wear and tear, we therefore recommend a maximum operating temperature of 65 Degree Celsius. Depending on the level of wear and tear, the maximum operating temperature may be lower than 65 degree Celsius.
RESISTANCE TO MICRO ORGANISMS AND INSECTSAlstone Indsutries does not act as a food source for:
- Mould (fungi that discolours or destroys wood)
- Gnawing insects
Depending on the environment in which it is used, organic residues may be deposited on Alstone WPC Sheet. These are the ideal breeding ground for the kind of fungal spores naturally present in the ambient air and may lead to staining. However, the material itself will not deteriorate as a result. For optimal protection, we recommend cleaning Alstone wpc where required and removing any organic residues ( eg. Leaves or foliage)
Alstone Industries offcuts and /or sanding dust should be properly disposed of, as with any other thermoplastics. Please follow the insructions of your local disposal expert. In the event of a fire, hydrogen chloride gas and broken down by-products may be released. For this reason, Alstone WPC Sheet should not be burnt without taking suitable emission control precautions.
Alstone WPC Sheet can be drilled using standard spiral drills. No special grinding Is gene rally required. However, we do recom mend the use of drill bits with relief ground cutting edges and small twist angles. if the rake angle of the bit has been nega tively ground for drilling holes, it prevents the bit from jamming and the material from breaking.This Is recommended up to a drill hole depth of approx. 15 mm. If the drill hole Is longer than 5 x a, it is advisable to withdraw the bit from the hole a number of times in order to extract the shavings efflciently. If the drill hole is more than 10 mm in diameter, pre-drilling is to be recommended. Drill holes exceeding 20mm in diameter can be created more efficiently using double –edged bits with a pilot, while drill holes exceeding 40mm in diameter are best made with circle cutters. The use of Forstner bits is also possible.
Cutting speed and forward feed depend on the depth of the drill hole. If the proper processing parameters are observed, no smearing of the material will occur.
All standard milling machines used in metal machining and designed for high speeds are suitable. High cutting speeds and small cutting depths are recommended.
The edges can be planed with the usual tools and conventional planning and thickness planning machines. Manual files and handheld electric planers can also be used to dress the sheets.MILLING CHART
Alstone WPC sheet can be cut lengthwise and crosswise with all the usual sawing equipment.
To achieve clean cutting edges, the saw blade should only project slightly beyond the Alstone WPC sheet in each case. Use of carbide-tipped saw blades improves cutting performance and quality, while also considerably extending the tool life of the saw blade. We recommend using saw blades with small tooth pitches to cut through Alstone WPC sheet (eg. Saw blade 220mm 0. , with approx. 88 teeth) Circular saws table
Due to its rotating saw band, heat dissipation is more efficient when a band saw is used. The saw bands must be sharp and set correctly in order to achieve a clean cut.Band saws table
Alstone WPC sheet comes smooth on both side as standard. To give the look and feel of wood, sanding of the finished product is necessary. Sanding may be done by hand or with suitable sanding machines (e.g. belt sanders), but in any event the sheets should always be sanded In the same direction (cross-wise or lengthwise). Depending on the desired surface finish, we recommend the use of sandpaper w ith a grain of 24 to 60. It Is best to begin with a coarse grain paper, followed by progressively finer sand paper until a smooth surface is achieved. Finer sandpaper should only be used to remove surface dirt. The look and feel of wood may not be achieved if the sand paper is too fine or the product is sanded using a circular motion. However, this will have no adverse effect on the quality of the product. For optimal protection of the finished surface, we recommend application of a sealant.
JOINING - SCREW FIXING
We recommend appropriate pre-drilling for all screw diameters.To minimise the risk of breaking around the edges,the minimum distance of 20 mm from any edge should be maintained for all screws. As a rule, the use of flathead screws is recommended.When using flat-head screws, they should be countersunk so the material is not put under pressure. Lower-stress joining can be achieved with the help of special plastic screws. Here, too, pre-drilling is esse ntial. flor further info rmation, please refer to documentation provided by the respective suppliers of screws.
In application areas prone to tempe rature f luctuation, the thermal expansion coeff icient should be taken into account. In this case, a larger drill hole and the use of so-called plumber screws (screws with washers) may be advisable.
We do not recommend driving any /nails into Alstone WPC Sheet as this may lead to cracking or breaking of the sheets. Even predrilling the nail holes will not rule out the chance of tension cracks appearing. Depending on the specific field of application, we recommend testing the proposed method on sample sheets.
Alstone WPC sheet can be glued. Due to the host of different gluing agents available and the various options for gluing Alstone WPC to different kinds of surface materials, we recommend con ducting preliminary tests on sample sheets. Good results can be expected from glues (from various manufacturers) suitable for hard plastics (rigid PVC/PVC-U) .They include, for example, STPU (hybrid) adhesives, one-part adhesives and twocomponents PU/PUR adhesives as well as polyester and epoxy resins. When using adhesives it is also advisable in many cases to pre-treat the substrate with a cleaning agent or primer. For other material combinations, please speak to your pre ferred adhesive supplier or contact our Technical Service Centre. We work in close cooperation with other wellknown producers of adhesives and are committed to reviewing our knowledge continuously as regards Alstone WPC bonding by means of adhesives. Depending on the application area, the following points are important when gluing:
- Gluing of the sheets prior to mounting Application of
- Application of pressure to the adhesive seam
- Hydrolytic stability of the adhesive
- Temperature of application
- Pot life
- Thickness of the adhesive bond
- Clean and grease free surface
In all cases, please always refer to the technical data sheets of the respective manufacturers.
THERMAL PROCESSING WARM BENDING
The linear bending zone of an Alstone WPC sheet can be heated in various ways on one or both sides:
- Without contact
- With heaters (infrared or quartz heaters)
- With glow wires or heating rods
- With a hot air blower
General advice on storage of Alstone WPC Sheets Storage should be in a suitable building, free of any moisture, temperature swings or direct sunlight. Any packaging straps should be released as soon as possible after the delivery. If Alstone WPC is replaced, steel bands should be avoided wherever and whenever possible. Unilateral heating by any heat source must be avoided. Sufficient ventilation of the material must be ensured. To avoid foxing or mould stains, the material should not be wrapped in plastic film. The sheets must be stored on a stable level and on a well-supported pallet that is at least as large as the size of the sheets. Individual sheets should be stored flat and lying down. An intermediate layer (e.g. cardboard) between the pallet and the semi-finished plastic product is recommended. In case block storage of several pallets is involved, we recommend using one pallet ''head first'' as an interim layer between each pallet to ensure the weight is evenly distributed.
|Colors||Frosty White & Natural Wood|
|Thickness||4mm, 6mm, 8mm, 12mm , 16mm, 18mm , 25mm , 30mm , 35mm, 40mm, 45mm , 50mm, 60mm|
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