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Industrialized Bamboo in East Africa: Resource, Production Process and Market Entrance of a Novel Scrimber Composite

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Industrialized Bamboo in East Africa: Resource, Production Process and Market Entrance of a Novel Scrimber Composite Industrialized bamboo in East Africa: Resource, production process and market entrance of a novel scrimber composite D ISSERTATIO N with the aim of achieving the degree of Doctor rerum naturalium at University of Hamburg Faculty of Mathematics, Informatics, Natural Sciences Biology Department submitted by Goran Schmidt born in Magdeburg, Germany Hamburg 2020 II Advisor and examiner Prof. Dr. Jörg B. Ressel Universität Hamburg Department of Biology Institute of Wood Science Leuschnerstraße 91 Germany – 21031 Hamburg Co-Examiner Prof. Dr. Dr. Marius-Catalin Barbu Salzburg University of Applied Sciences Campus Kuchl Markt 136a Austria – 5431 Kuchl Type: Monography Title: Industrialized bamboo in East Africa: Resource, production process and market entrance of a novel scrimber composite Author: Goran Schmidt Matriculation: 6052138 Page count: 235 Date of submission: 28.08.2020 Date of defense: 28.10.2020 III Dedicated to my family IV Acknowledgements This thesis is a results of my studies at Universität Hamburg from 2014 to 2019. The practical works were carried out in different laboratories from 2015 to 2018. I wrote major parts of the monography while working part-time at Thünen Institute in 2019 and 2020. Looking back, this was not my wisest decision. But the experiences, lessons and impressions during this time are invaluable: First and foremost, I want to thank my advisor Prof. Dr. Jörg B. Ressel. It has been an outstanding opportunity to be one of your last doctoral students. I appreciate your contributions of time, ideas, and funds but especially the trust in my abilities. Though always reminding me to “Schreiben Sie zusammen!”, you have given me the freedom to find my own project and continue with bamboo research at the Institute of Wood Science. Until today I am not completely sure why you had asked me to become a doctoral student. I hope to investigate this last research question while having a drink after the disputation. My former lecturer Prof. Dr. Dr. Marius C. Barbu was so kind to take over the second examination of the thesis. I am aware of its extent and want to thank you very much for your willingness to support me on this endeavor. I am also thankful for the positive social atmosphere in my two working groups. Prof. Dr. Andreas Krause as well as Dr. Sebastian Rüter gave me the flexibility to work on my thesis on the job. Thank you, to the whole BioHome project team for your patience and comprehension during the last phase of my thesis writing. The group has been a source of friendship, advice and inspiration to me. Thomas Stute and Friederike Matthies, two former master students (UHH), contributed on a very professional level and we became good friends after some time. My three „wise men” (Dr.) Julius Gurr, Dr. Martin Nopens and Dr. Oliver Mertens made the journey a very special experience. During my “biology period”, Dr. Jan- Henning Blohm and Dr. Verena Becker discussed and laughed together with me. Without all of you I might have given up already. Special thanks and greetings. The process engineering and product quality parts of this thesis is built on results of a GIZ funded Fraunhofer WKI project which, thanks to the open-minded policy of department head Dr. Dirk Berthold, I took part in. For all the discussions, presentations, meetings and quality assurance I am very grateful to Mathias Belda (WKI) and colleagues. At Fraunhofer WKI, University Hamburg and Thünen Institute nothing works without technicians, sample preparation and handicraft labor. Thank you, Stefanie Warsow (TI), Richard Deetz (WKI), Frank Froning (WKI), Johannes Beruda (UHH), Dörte Bielenberg (UHH), Tanja Potsch (TI), Gabriele Circelli (TI), Sabrina Heldner (TI), Jens Schröder (TI) for your constant and accurate work. Additional thanks go to Marie Lenz (UHH) who worked with me on the fungal deterioration of bamboo scrimber. I very much appreciate your enthusiasm to conduct the long-lasting experiments together with Thomas and Dr. Eckard Melcher (TI). For the great photographic works, I would like to say thank you to Christina Waitkus (TI). In the parameter screening, there were major statistical problems. Thus, I consulted Bettina Steffen (TI) which led to the painful insight that the results would not change even when applying the ever more laborious ANOVA variants, I am thankful she shared her time with me. Unfortunately, the private industrial project in Ethiopia suffered one tragic drawback when our dear colleague Christopher Cleur (†) from Ghana died suddenly in 2017. He was always a competent partner, capable to discuss business issues from the technical view. Although we had some contradictions, I am very grateful to have met him. V Thanks to the mobility grant provided by the German Wood Science Association (Bund deutscher Holzwirte e.V.), I was able to present some preliminary results from the biodegradation study at the IUFRO Div. 5 conference in June 2017 in Vancouver. This travel additionally opened the opportunity to visit the original scrimber industry plant and the first commercial bamboo plantation in Alabama. Thanks to Walter Jarck and my friend Sebastian Roth for making the trip a great experience going back to the roots of scrimber technology. In 2015 my mother visited the wood and forestry research campus in Hamburg-Bergedorf and after hours of laboratory tours, she asked what the heck we did here the whole day. Former acting director Dr. Johannes Welling walked down the stairs and answered: We spend 50% of the time keeping the knowledge we have, 30% is administration and only one fifth goes to new research. The most important women in keeping this knowledge are the librarians Astrid Stilke and Ulrike Reupke (†). Thank you for your constant help. Though English is my working language, it has been challenging to write the monography in a foreign language. Big thank you to Vicki Marais for reading the manuscript and helping to improve the language. But Chinese and Amharic are far beyond my capabilities. Thank you very much Hanzhou Ye and Gebrewold Teklay for supporting me with the translation of my abstract to 汉语 and አማርኛ. Additionally, I would like to acknowledge honorary Prof. Dr. Dr. h.c. mult. Walter Liese who was the one awakening my passion for bamboo. I am now 34 years and though you were born 60 years earlier you impress me with an ever-curious mentality, a continuous working attitude, and your incredible vitality. Walter, you are an outstanding personality and example to me and the doors that you opened were not even visible to me a couple of years ago. Thank you. Academically formed families provide a context leading to ten times more doctoral degrees than non-academics. Statistically, I am one out of hundred children of non-academic parents trying to pursue a doctoral degree. I bow my head with gratitude especially before my parents Gudrun and Stefan, my whole family, but also my teachers, professors, colleagues and friends for the support during the many years of schooling and university. Thank you for the understanding, love, and encouragement. VI Abstract The presented work offers a research contribution to the promotion of the bamboo processing industry in East Africa. The trade deficit in wood products is growing steadily in the region and in the case of Ethiopia exceeded EUR 100 million. A structural analysis of the bamboo processing sector showed that there are promising prospects to develop an exportable building product based on bamboo scrimber. For this purpose, the native African highland bamboo was investigated morphologically, anatomically and mechanically, an industrial production process was developed and the technical product suitability for export as decking boards was tested. The raw material investigations showed that the merchantable volume of the single culm is rather small (0.005 m³) and the upper two thirds of the culm are better suited for processing due to its comparably constant inner and outer taper. The characteristic fiber density gradients were also found in highland bamboo and the anatomy of its vascular bundles and fiber cells were described. The fiber length (1.4 mm) in node and internode was found equal, though the latter were slenderer. For processing into bamboo scrimber, the scrim strands were then examined and density (0.66 to 0.75 g/cm³), fiber content (29.83 to 38.32 %), strength (between 50 and 215 N/mm² in compression and tensile tests) and modulus of elasticity (21 kN/mm²) were determined. As a presumed weak point in the composite material, it was found that nodes halve the bending and tensile strength, while compressive strength was not affected. Silica content was relatively low (< 1.5 %) regardless of location, altitude and age and was successfully reduced by simply washing the raw scrims. In contrast to other woody species highland bamboo was found well suited for processing to scrimber. A fabrication process was configured based on existing technologies and the production parameters were determined. A pre-selection of pressing temperature (130 °C), heat treatment of the scrim strands (3 h, 160 to 180 °C), adhesive (8 – 12 %, sprayed phenol resin) and additive (2 % wax) was found to be promising. The wide variation of the results from the laboratory panels however made it necessary to investigate the effect of raw material variants and adhesive distribution. The influence of the height sections in the bamboo culm on internal bond and thickness swelling was negligible but the properties could be steered via layered adhesive concentrations. However, nearly all properties followed a strong correlation with specimen density and strongly overlapped other factors which made densification the most important influencing one. Industrially upscaled experiments have revealed additional challenges for the implementation phase: The specific pressure in the multi-daylight hot press must not exceed 7 N/mm² which is why the input moisture of the fiber must be kept below 5 %.
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