Manufacture of “Opium” Bamboo Mat board

In the same principle as the flattened bamboo, stems should be split and then be flattened.

Zoom - Opium Bamboo Mat Board

The difference for “Opium” Bamboo Mat, the stem is split very carefully and fully to manufacture thin bamboo strips which are then drilled in their thickness and connected together by an invisible thread.
Traditionally, this mat used by opium smokers, they lay on the ground on the bamboo mat. The mat could be so completely rolled and unrolled for storage or travel. These mats have been intelligently designed to allow air to circulate under the body of the smoker to help him stay cool and comfortable while smoking.
Now considered a product of antiquity, these mats are very rare.
In partnership with a local company which patented the manufacturing process, we can provide you this unique product.
Arranged and pasted to be pressed on a “smart” board, a panel of synthetic fiber and cellulose (water resistant). “Opium” Bamboo Mat board has a slightly unique "grain" with a strikingly elegant appearance. Perfect for your indoor decorations.

Manufacture of flattened bamboo panels

Flattened Bamboo Board - Wall and Ceiling

To make panels flattened bamboo, the bamboo pole has to be flattened. It is crucial to use freshly cut stems.
The first step is to break all the nodes of the bamboo stalk and along its entire periphery. This is done entirely by hand using a knife or hatchet. Then the interior knots are completely split to facilitate manual opening of the stem. The bamboo is then opened and flattened.

The interior nodes are then removed.
It is this stage that flattened bamboo stalks receive preventive treatment against fungi and insects and then dried.
Once dried, flattened bamboo will be planed to make flat surfaces. They will then be sized, arranged and be glued and pressed on a “smart” board made of synthetic fibers and cellulose (water resistant).
These panels, with very pronounced nodes make this material a very distinctive rugged looking element, and are ready for walls and ceilings.

Manufacture of woven bamboo plywood

In the same way as for the bamboo flooring, the bamboo pole to the manufacture of woven bamboo plywood, is cut lengthwise to desired length, the outer knots are removed and the poles are split or sawn into slats, the internal knots are removed and the slats are then planed.

The green outer skin is removed by planing.

It is at this stage that the slats will receive preventive treatment against fungi and insects.

The strips are then dried.

Zoom - Woven Bamboo Plywood

After drying, the slats are cut into thin strips. These are calibrated and weaved to form single sheet. After gluing, the panels are pressed at high temperature.

Several sheets of woven bamboo can be pressed to one another under high temperature until the required thickness of plywood. A part from its decorative aspect, board of woven bamboo plywood is stronger and more flexible than ordinary plywood. Woven bamboo plywood offers no deformation under the action of water or changing temperatures. This is not the case with the regular plywood made from wood.

These panels of woven bamboo plywood are also very effective as a concrete form.

Reuse is 3 times higher than regular plywood (for the same thickness and same quantity of concrete).

Manufacture of Strand Woven Bamboo

Unlike other bamboo products, if the bamboo is used for making Strand Woven Bamboo, all species and sizes of bamboo can be used since the plant is mature. However, it is important to begin manufacturing within the days following of harvest.

Outdoor Strand Woven Bamboo Decking

The outer knots are removed and the pole is split into slats, the interior knots are removed and the slats are then planed.

Indeed, it is necessary to remove the outer skin and the knots inside that are not appropriate in the manufacturing process: The protective skin of the bamboo is too fat and the internal knots are too soft.

The slats are then cut into strands. More the strands of bamboo are thinner, more the finished product will be better.

The strands of bamboo are then treated by boiling in an antifungal and insecticide solution (for natural color) or carbonized (for the color of coffee).

The strands are then dried. After drying, they are dipped in glue. This process ensures that the glue is linked to the strands of bamboo.

The strands are prepared together in a mold and are press under very high pressure at high temperature.

This process results in a solid bamboo board that is almost twice the density of regular bamboo flooring. In terms of sustainability, high density created by this process allows Strand Woven Bamboo to be used in exterior and appropriate for use in high traffic public spaces.

The density of Strand Woven Bamboo is very important up to 1200 kg / m3.

One advantage of this method is that it produces no waste, indeed all of the bamboo plant and the small pieces can be used when only the biggest part of the stem of bamboo can be used for traditional solid hardwood floor.

This means that Strand Woven Bamboo are not only more sustainable, but could be considered more environmentally friendly than other types of bamboo flooring.

Rather than losing the wastes of bamboo in the process of making slats for flooring, they are immediately recycled by Strand Woven Bamboo.

Manufacturing of bamboo flooring:

Horizontal Bamboo Flooring

If the bamboo is to be used to manufacture flooring, the external knots are removed and the pole is split or sawn into slats, the interior knots are then removed and the slats are then planed.

The green outer skin is removed by planing.

It is at this stage that the slats will receive the preventive treatment against fungi and insects.

The slats of bamboo can be kept clear in their original color, or they may be colored in an autoclave oven at high temperature, it is the process of carbonization.

The slats are then dried.

The slats are again planed, calibrated and sorted according to their colors in order to homogenize the tint of the future floorboards.

The bamboo slats are glued at high pressure and high temperature, with an environmentally adhesive conforms to the standard E1.

The bamboo slats are pressed next to each other horizontally. This produces a panel or board having the characteristics of bamboo nodes (called here plain pressed or Horizontal)

Or, instead of being pressed to the horizontal sections can also be pressed laterally onto the edge. The panel then has finer lines and nodes of the bamboo are slightly less visible (in this case side pressed or Vertical).

The resulting panels are sanded and cut to the required dimensions for floor boards, panels, accessories.

Then the final step is to make the tongues and grooves.

A final quality control is performed during packaging.

Density of bamboo flooring is 750 kg / m3.

Do you know how we manufacture our Bamboo products?

There are different stages of processing bamboo according to the final product that is desired:
The havest of the bamboo culm.
From the plant to the bamboo poles or fence.

Harvesting:

All products are made from carefully selected bamboo. The bamboo must be mature to provide the best strength, stability and durability.

Therefore, great attention should be paid to the location where bamboo is grown and how it is harvested. Determine the origin and age of bamboo is very important to ensure the right hardness and color.

The sugar content in almost all plants varies with the seasons. The dry season is the period of dormancy. During this period, the bamboo plant uses its nutrient reserves for the next growing season, sugar content and moisture content is lower, which reduces the chances of insect attack and the possibility of further cracking.

During the rainy season, starch and moisture content in the bamboo is higher. It is also the time when new shoots emerge and culling operations could damage or destroy the shoots. It is therefore not recommended to harvest the bamboo during the rainy season.

In a bamboo plant, only the main stem of bamboo is used for our products.
The bamboo is cut lengthwise to desired length.

Bamboo Pole for building:

If the stem of bamboo is to stay as pole for construction or to make fences, the knots will be drilled to facilitate infiltration of the solution for preservation treatment against insects and fungi in the stem.
Immediately afterwards, we will proceed to treatment. It is a very important step to ensure the sustainability of our products.
It is important to treat bamboo within a few days after harvest to prevent insect attacks.

In this regard, the season of harvest is also important as we have seen above.

After treatment, the poles are dried.

Following in a forthcoming article or on our webiste 

Other alternatives methods of bamboo's treatment

Treatment in boiling linseed oil / oleo-thermal process:
The culms or slats of bamboo are soaked in linseed oil heated to between 100 and 120 ° C.
The treatment of bamboo by oleo-thermal process is to our knowledge not developed mainly due to the excessive cost of energy to boil the oil in large basins.

Thermo-treatment:
The principle of the process is to heat the bamboo in an autoclave at a temperature high enough (for bamboo between 150 and 200 ° C), in anoxic condition and to regularly inject steam to avoid the bamboo to ignite. Bamboo is "cooked" in some way and stabilized while remaining solid. Its ability to absorb water is reduced by half.

The technique thermo-treatment of bamboo is an alternative to preservative treatment with use of insecticides and chemicals. However, heating the bamboo at high temperatures makes it stable and virtually rot-proof. It thus makes naturally resistant to borers, termites, fungi and moisture.

Vacuum High Temperature

Bamboo products treated by this method can also be used as a structural element of a building. But bamboo from thermo-treated tends to reduce strength and flexibility, and their implementation in structure requires special precautions (such as use of larger section).
They are also ideal for flooring, decks, exterior, siding etc.

The bamboo processing under high temperatures is to our knowledge not yet developed. Chalet & Bamboo seriously considers this method of treatment but requires a significant investment.