Knock it Down - Bring the bamboo home

Preface

For all of us who have been through and education in ‘Design’, the word means many different things. We understand its
nature and its implications. We apply and we observe. We gather and we collate. We instill in and imbibe from myriad spaces
of thought, culture, society and environment. We all feel a sense of belonging when we hear the word ‘design’. The beauty
of it all lies in the fact that we all understand it differently. We define its purposes differently. It is almost as though we all
constantly seek to find our own missions, once empowered to ‘think like designers’.
Through two years of a study in Product Design I have learnt much. I have spent a lot of time trying to get to the bottom
of it all, to define Product Design. Along the line, my notions have constantly undergone change. It has been an adventur-
ous but steady ride. A fluctuating but enriching experience. This project is another such adventure. I no longer wish to define
Product Design. I have instead developed an apatite for the mysteries it has to offer.
During my study in Product Design, somewhere down the line I became acquainted with a new medium, one which took me
by surprise and instantly filled my frame of vision. Being very intrigued by this medium, I dove right in and began taking a
shot every opportunity I found. In the process I discovered amazing things and found a large scope for this medium. I took
the unconventional way in, starting at the top and tumbling my way down to the basics. With this project, I started again, at
the basics, with a fresh new angle. The attempt has been to find a new way up, learning as much as I possibly can along the
way.

Acknowledgements

I would like to convey my gratitude to a number of I would specially like to thank David at the workshop or ‘in-
people and parties, all of whom have contributed in novation station’ as he and I like to call it, for providing me
some way or the other towards bringing this project with his full cooperation and taking interest in my work.
home...
A big thank you is also due to Matthew at the workshop for
A special thank you to Sangaru Design Objects Pvt. constantly making himself available to us all.
ltd.
Their involvement has been integral and key to the Finally, I would like to thank the home team, my family, for
completion of this project their undying faith and unconditional support, and my fellow
batch mates and friends for sharing their energy and occa-
A heartfelt thank you to Jackson Poretta and the sionally boosting my ego!
Green Chakra group for their undying enthusiasm
and support. Jackie Bhai and the boys never fail to
synergize and energize !

A special thank you to my review panel, Janak Mis-
try, Bani Singh and Jackson Poretta for their con-
stant guidance and support.

A big thank you to Prof. M. P. Ranjan and Susanth.
C. S. at NID for their guidence.

A big thank you to Sudipto Dasgupta, Naga Nandini
Dasgupta and Gopal Bengeri.
Thank you all for your valuable feedback and ‘ever
ready’ attitude.

Contents

Synopsis....................................................................................................................................1

Initiatives

Green Chakra..........................................................................................................................3

Bamboo - the material...........................................................................................................6

The Project

Introduction.............. ................................................................................................................................13

Methodology..............................................................................................................................................14

Concept 1 - Strip Arch..,........................................................................................................................19
Concept 2 - Knockables, Satackables and Bamboo.......................................................................47

Prototype production............................................................................................................54

Critique....................................................................................................................................89

Conclusion..............................................................................................................................91

Bibliography............................................................................................................................92

Synopsis

Towards the end of my two year study in Product Design, I got an opportunity to do a self initiated project. By this time, I
had begun thinking about the field of natural building as an area of design. I decided to generate my project in the field of
natural building. At this point I got in touch with Jackson Poretta and the Green Chakra group, who were working with natu-
ral building techniques at the time. A large part of their activity was taking place at Drishya Kalika Kendra in Bayappanahalli,
Bangalore. After some discussion, it was decided that I would come in and contribute a shelter structure to the Drishya
campus. The designs I created incorporated bamboo as the prime material. This would be my first time working with bam-
boo. The structure required multiple bamboo poles to be bent into similar curves. With no prior experience and too much
research to process in the given time, we jumped right into an experimental exercise, mixing techniques and learning as we
went along. It was here that I first felt an urge to learn more about bamboo.
Following the Drishya project, I took up an internship at the Center for Bamboo Research, Auroville. During the course
of the internship I worked on a real time project - designing public furniture for the Pondicherry marine drive, in Bamboo.
I undertook design development and coordination of prototype production. Working with scant facilities and only a few
hours of electricity a day, I ended up doing a lot of work manually and got real up close with the material. I was exposed to
new techniques and methods using bamboo. It was here that I became acquainted with the issues and challenges related to
bamboo, with relation to furniture production. I understood the qualities of the material; Qualities that make it unique and
those that hold it back from full exploitation of its capabilities. I found myself asking - so what ? why not ? there must be a
better way. It is here that I found my inspiration for this project. Following this I got in touch with many professionals with
varied experience, gathered data, and jumped in!

1

Initiatives

Green Chakra
Any design process must be as ‘inclusive’ as possible. Includ-
ing multiple parties, within reason of course, increases the
number of beneficiaries and adds collective synergy to any
design process and here lies the true value of design as an
exercise.
I now had an opportunity to act upon this belief, by orient-
ing my project such as to include more people, for whom
this can be a valuable learning exercise.

The Green Chakra group :
Jackson Poretta is a natural builder and an ecological artist
who has undertaken the tutorship of six young men from
Byappanhalli and Sanyasikunte, with a goal to train them
in the field of natural building, in order to equip them with
the knowledge to make a difference in their own homes
and the skills to generate employability. Together they
are“GreenChakra”.

All material experiments and basic prototyping for the
Knock It Down project, would be carried out in collabora-
tion with the Green Chakra group.
This would be a new area of work for Green Chakra. It
would be a valuable learning exercise for them and would
help expand their workspace to include new production
techniques with Bamboo. Simultaneously, it would serve the
purpose of material tests and explorations for the Knock It
Down project.

3

bamboo
the material

5

About Bamboo
the material

The culm consists of tissues which have vessels for carrying
the culm is usually hol- watery sap, conducting food solutions, and the thick walled
low, but in few species fibres. The cells store starch and all cells are vertically
it is solid or has small oriented. All these together make up the fibrovascular
bundles which run vertically in the internodes. The bundles
are smaller, more in number and compact towards the
branch periphery. Also, the maximum number of fibrovascular
clum bundles is found towards the base of the culm. This is
because as they ascend some of them pass into the branches
node and leaves at the nodes. There is no branching of the vessels
or fibres along the internodes, resulting in weak transverse
Sheath or bonds. The fibres constitute 60 to 70 percent by weight of
culm leaf the bamboo, while the vessels make up about 15 percent.1
The transverse section of a culm shows a much higher
concentration of
culm shoot fibres towards the periphery than the inner wall. Near the
or sprout base of the culm, the outer one third portions contain the
most fibres. The longest and most mature fibres are found
between one-fourth to half the height of the culm. Above
this the fibres tend to get smaller and less mature

6

About Bamboo
the material culm

internode
of the whole culm, the top part is
the strongest in compression, and
bending strength in most cases

in the internode the shortest
ﬁbres are located near the nodes
and the longest are in the centre
of the internode

of the whole culm the central
part of the culm is the strongest
in tension

the lower part of the culm
inspite of its largest diameter
and wall thickness has the lowest
mechanical characteristics of the
whole culm.

the thickness of the wall culm
decreases from the base to the top

7

About Bamboo
the material

Bamboo culms are tall cylindrical stems which taper at
the top with the maximum diameter at the base. They are
usually hollow with few exceptional species. All culms are
rhythmically divided by transverse walls at nodes which
appear as a slight swelling on the surface of the cylinder.
The parts between the nodes are called the internodes and
the hollow space within is called the lumen. Branches and
leaves grow out of the nodes, generally towards the upper
part of the culm. Culms of different species of bamboo
are characterized by varying physical properties . These are
reflected in the variations in diameter of culm, height of
Diverse physical characteristics of bamboo culms of different species. culm, wall thickness of internodes, size of lumen, length
(a) variation in diamter (b) variations in internode length of internodes, branching pattern, and so on. The most
significant variation seems to lie in the shapes of the culm
sheaths which are attached to the nodes till the culm attains
maturity.

The nodes are swollen and more lignified than the
internodes. The transverse membrane completely separates
each internode. The vessels and fibres that are unconnected
in the internodes pass through the transverse wall, cross
connecting the wall of the culm.. The nodes, therefore,
provide the only connection from one end of the culm to
another. The slenderness ratio of bamboo culms is very high
which could make the structure of the plant unstable. Nodes
play an important role of the axial crack arrester. It prevents
the cylinder from structural buckling and increases bamboo’s
rigidity.
Variations in wall thickness in different species of bamboo

8

About Bamboo
the material

The term ‘bamboo’ describes all tree or bush-like grasses
having a durable woody or branched stem. The lignifying cross - weight failure at
cell structure of the bamboo tissue and its technological section (kg) tensile load
properties are similar to the wood tissue. Bamboo may, (cm.sq.) (kp.)
therefore, also be termed ‘wood’. However, bamboo has the
most rapid growth amongst all plants (up to 1.2m in 24hrs).1 Steel St. 37 1 0.785 4

Bamboo is extremely resistant to tensile stresses, has high Wood 13.5 0.785 8
resistance to bending and buckling stresses. It fails in shear
before it fails in tension. The bottom portion of the culm is Bamboo 12 0.785 24
more resistant to shear due to its greater wall thickness. As
far as size, lightness and strength are concerned, bamboo With regard to its mechanical/ technological properties
is one of nature’s extreme products. Other products, such bamboo is superior to constructional timber (softwood)
as reed, cane, and rod timber, are practically its equal, since and also to constructional steel in terms of the ratio of live
almost all them constitute light weight constructions. load/ deadweight. Bamboo as a plant is a phenomenon;
and possesses fascinating material properties. Because of
All types of rods – in particular grasses (bamboo, reeds and the hard silicate layer of the outer surface, bamboo is highly
straw) and straight - growing coniferous trees (fi r, spruce) resistant to chemical, insect and mechanical exposure.
are not only effective from a structural point of view, but
also very economical. Effective transmission of forces over
a particular length makes bamboo extremely inexpensive
compared to other rods.

Young culms with high moisture content show a greater
increase in strength when dried than older culms. The
difference between old and new culms gradually diminishes
by about 2 ½ years. The moisture content of bamboo causes
it to behave like wood in relation to its compressive strength
which almost doubles when the green culm is air-dried.

9

About Bamboo
the material

A variety of sections or splits that are extracted from the culm, each
to suit a speciﬁ c purpose.

The capacity of the bamboo wall to be split longitudinally within its segment results from the parallel orientation of the
constituent fibres. In the nodes, however, these fi bres cross each other in all directions. These reinforcement nodes with
their highly silicified diaphragms thus increase the resistance to splitting or bending. The bamboo tissue has no radial fibre
orientation. This is why there is no increase in diameter above ground unlike timber structures. The whole section of
bamboo becomes a single annual ring. From mechanics we know that, cylindrical tubes containing the same amount of
material as a solid round bar has four times the rigidity of that bar.

10

knock it down
Bring the bamboo home
Diploma Project
Nishant Wazir

12

Introduction
scenario

Bamboo up till now...
As a result, the access points for purchase/exchange of
Bamboo, a versatile grass, often referred to as ’won- these products are few, and highly specialized, predominantly
der grass’, is found in most parts of India. For ages, – lifestyle brands, NGOs etc.
this material has been used to meet day to day living So, in most cases, the product range is high-end, highly priced.
needs, with diverse applications. Up till now, bam- Bamboo has the potential to cater to markets which are larger,
boo handicrafts and products have existed in very wide-spread, economically viable and utility based.
niche-spaces of the urban market. Most people, be
it, manufacturers or consumers, are not fully aware
of the potential and versatility of this material. This The Opportunity
limit’s the spectrum of possible applications relevant
to One of the most well established applications for bamboo
the urban scenario. is that of lifestyle products. Of this, furniture holds a very
small segment. Bamboo furniture products are not accessible
to most people, due the reasons stated above.
The Problem Bamboo has now come into the limelight as a sustainable
material resource, hence ‘the way forward’. The material is
In the urban scenario, bamboo products occupy being more widely accepted across industries and markets.
segments largely in lifestyle product markets. The This is a growing sector where new technologies and market-
material has been well established as more than ing methods are being researched, to cater to future industry
appropriate for the existing product range. However, and market conditions, while consumers are becoming more
for some time now, the furniture market has aware of ways in which bamboo can cater to their different
remained small, disproportionate to the potential lifestyles.
held country wide, both in terms of material What the industry needs now, is innovative production tech-
diversity and skill types. niques and marketing methodologies, to expand the bamboo
Few manufacturers enterprise bamboo products, as market, catering to all socio – economic levels.
the market is small. This in turn leads to monopolis-
tic market conditions.

13

Knock it down
project methodology

The Approach

This project will work towards development of new
production methods and process for bamboo furni-
ture products.
Increasing marketability – by incorporating modular-
ity for ease of stocking and shipment/delivery, while
keeping production costs to a minimum. This will
enable manufacturer-consumer interaction to take
place remotely through a select and order exchange
channel.

Why Knock-down furniture
Knock-down furniture has certain key qualities that
favour the goals set by this project :

A knock-down piece of furniture comes in parts. This means
that different components are manufactured separately and
eventually packaged together. This allows for production chains
to flexible and optimized.

A knock-down piece of furniture is received in parts and as-
sembled into full form by the user. This allows the end user to
have some ﬁrst hand tactile interaction with the material. This
feature will help helps to instill a basic understanding of and
awarness about the material used, accross a large user base.

14

Knock it down
project methodology

The Challenge

As versatile a material as bamboo is, it comes with A production process of this nature is labour intensive, with
its own set of challenges, arising from its unique a considerable margin of material wastage. Hence we can
characteristics. Traditionally used materials like wood deduce...
and various metals are standardised to a large extent 1. Bamboo as a raw material is almost impossible to
before being translated to furniture or other prod- standardize. Standardization is the first step towards cost
ucts. This makes standardization easy, which in turn reduction. It is safe to say that every piece of bamboo is
helps mass manufacture, organized and optimized different from the other.
production units and also helps reduce costs.
2. For the very same reason, easily 80% - 85% of the work
Unlike wood and metal, bamboo, as a raw material, has to be done manually, by skilled labour. With a process
is near impossible to standardize. It is safe to say that that is labour intensive and time intensive to this degree,
every single piece of bamboo is different from the costs are bound to be high.
other. This also depends, to a large extent, on the
type or species of bamboo. For the reasons explained above, the profit margin for
Such irregularities have to be manually tackled, every bamboo product, furniture in this case, is high. Since
making the process time consuming and labour the margins cannot be compromised much for the above
intensive. This also often results in wastage of reasons, the only way to allow lowering of profit margin per
material as not all pieces turn out to be suitable and piece, is by producing in larger volumes, such that a even
have to be discarded. a smaller profit margin per piece will collectively bring in a
reasonable amount.

The main questions :

1. To what extent can this material be standardized ?
2. How can this standardised avatar of the material be used
to produce volumes?

15

Bamboo splitting machine Bamboo knot removal machine

Bending bamboo splits by applying heat and pressure Bending bamboo splits by applying heat and pressure

16

Knock it down
project methodology

The Approach

1. Bring the material to a form that can be stan-
dardised :

The bamboo poles are converted into bamboo
strips, by splitting and planing to achieve a standard
width, thickness and length.

These process can be carried out mechanically, ma-
chines do exist for this purpose.

2. The bamboo strips are bent (using heat) and
laminated (using suitable adhesives), into the desir-
able form. These forms are simplified and easy to
replicate using identical steel Jigs.

17

Knock it down
initial exploration

Exploring ‘knock - down’ in general

Knock down stool comprises 5 main pieces, assembled using bamboo pins or screws

Knock down bench comprises 5 main pieces, assembled using bamboo pins or screws

18

Knock it down
split arch concept

First set of sketches for the SPLIT ARCH concept

The split-arch concept incorporates two modules :

1. An arch like structure made from laminated bamboo splits
2. A supporting structure, a truss-like frame on which to mount the arches

Several arches mounted in a row-like arrangement would form a seat.

19

Knock it down
with the artisans

Furniture workshop at NID R&D, Bangalore : Joinery

20

Knock it down
with the artisans

Furniture workshop at NID R&D, Bangalore : Joinery

21

Knock it down
material tests

Splitting + bending

22

Knock it down
material tests

Splitting + bending

23

Knock it down
material tests

Splitting + bending

24

Knock it down
material tests

Using rigidtsteel Jig

The steel Jigs evidently provide a well defined shape
and form.
The extra space between the two strips is cause by
irregularity in level and volume at the nodal points. It
turns out that the particular species of bamboo used
here is not suitable for this process as it comes with
many irregularities. The ideal species of bamboo to
be used in order to get a good finish is the Balcooa
species. Balcooa poles are almost completely straight
with a regular surface and almost standard inter-nod-
al lengths, as opposed to Bambos, which we are cur-
rently using. However, Balcooa will have to sourced
from Katlamara plantations in the north east. This
is not feasible for the project at this stage as time
does not allow it. Also, the material requirement
is too small to place an order. For the purpose of
prototyping for this project, we will be using Bambos
itself. Carefully selected pieces, which are reasonably
straight and consistent should do the job in terms of
finish consistency.

25

Knock it down
split arch concept

Variations

Assembly of split arch stool

Variable assembly depending on the form and arrangement of the supporting frame and arch dimensions

26

Knock it down
split arch concept

The Problem : Stability

The above depictions assume stability of the arch
structure. However, on close observation, one can
see that at the junction of joining with the arch, the
pole frame behaves like a pivot for the otherwise
support-less arch to ‘rock’ or ‘sway‘. The arch is
rendered unstable.

The next step will be to devise a better structure for
the supporting frame, one which provides stability to
the arch.

27

Knock it down
split arch concept

Sketches



28

Knock it down
split arch concept

Sketches



29

Knock it down
split arch concept

Revised support frame

A two piece support frame, where bamboo arches would be inserted between spacers to prevent ‘sway‘

A small scale mock up.

30

Knock it down
split arch concept

The Problem : consistency

This support frame relies on spacers to provide the
structure with rigidity. This structure assumes that
all the bamboo arches will be of exactly the same in
terms of size, thickness and surface properties.

To achieve this level of precision and consistency in
an irregular material like bamboo is not possible.

The next step will be to incorporate spacers as com-
ponents providing rigidity, without requiring too high
a level of precision or consistency.

31

Knock it down
split arch concept

Revised support frame

A support frame using poles as well as splits

Here the arches would snap into place onto the pole frame and would have split sections for spacers

32

Knock it down
split arch concept

The Problem : cumbersome assembly

This design reverts to the pole frame as seen in the
first design. However, this pole frame incorporates
two penetrating tie members instead of one (top
right). This greatly reduces the ‘pivot‘ effect. This
design also incorporates flat split bamboo sections as
spacers (left), which would fit into grooves created
along the edge of the arch.

This design has too many components assemble.
There are too many detailed components. The
‘consistency‘ persists.

33

Knock it down
split arch concept

Revised modules

Arch module incorporating 3 arches clubbed together.

Here the three arches are permanently fixed together, held by a flat bamboo split section

34

Knock it down
split arch concept

The new module

This design addresses the basic problem that has
been recurring through the previous designs
i.e. stability
This design incorporates a revised arch module.
Here, three arches are clubbed together as one mod-
ule. The expansion that occurs in the base (x3)
not only provides rigidity and stability, but also re-
duces the impact and load borne by each arch when
used as furniture to sit on.
All designs from hereon will use the new (x3) three
arch module.

35

Knock it down
split arch concept

Revised (x3) design

Three arch module. Incorporates solid bamboo poles as tie members and hollow bamboo sections as spacers

Add-ons can be incorporated, e.g. arm rest, back rest. The add-ons would be fixed in place of spacers

36

Knock it down
split arch concept

New features : add-ons
The Problem : consistency, stability

Though this design does incorporate the new
add-on feature, the additional loops on the arches
pose a problem regarding consistency.

The absence of a tie member between the two ‘arms‘
of the arches creates the possibility of the arms
sliding/growing apart with repeated use, with the
load and impact coming from above. This poses a
problem with stability.

37

Knock it down
split arch concept

Solid pole frame + (x3) arch module

One piece rigid pole frame

Arch arms are forced closer and pushed into frame from above. When released, the arms snap into place.

38

Knock it down
split arch concept

The Problem : bulky components, tension in arches not contained

This design attempts a simplified approach - using
fixed solid bamboo pole frames on which to mount
the arch modules.
The solid bamboo frame is too bulky. This defeats
the purpose of knock down furniture, as it does not
aid optimized utility of space.
The arch arms experience a high ‘push and pull’ ten-
sion between the top and bottom of the frame.
After a point, the slightest shift or force from be-
neath or sliding of arches on the top section may
cause the arches to be launched off the frame.

39

Knock it down
split arch concept

Solid pole and split frame + (x3) arch module

Support frame using solid bamboo poles as well as bent laminated bamboo splits


40

Knock it down
split arch concept

The Problem : complex forms, tension in arched not contained

Though this design is aesthetically exciting, it uses
very complex forms. These forms are possible to
achieve using bamboo splits, but again demand too
high a level of consistency. This will also be labour
intensive.
The arch arms experience a high ‘push and pull’ ten-
sion between the top and bottom of the frame.
After a point, the slightest shift or force from
beneath or sliding of arches on the top section may
cause the arches to be launched off the frame.

41

Knock it down
split arch concept

Collapsible pole frame + (x3) arch module with locks

Collapsible solid bamboo pole frame with modified (x3) arch module, incorporating locks


42

Knock it down
split arch concept

This design uses a collapsible X frame made using
solid bamboo poles.
This design uses a modified version of the (x3) arch
module, incorporating solid bamboo pole sections
as locks. The arches are force fitted from above.
When released, the solid pole sections on the arch
arms, find their place between the lower middle tie
members of the X frame. This locking mechanism
ensures that the arches will not be launched off the
frame, unless forced manually, with the same action
as applied when assembling.

43

Knock it down
split arch concept

Collapsible pole frame + (x3) arch module with locks

Collapsible solid bamboo pole frame can be varied in length

Add-ons like a back rest can be installed using an additional lock

44

Knock it down
split arch concept

Added feature : customization

This design also has a new provision for add-on
features such as a back rest.
The add on can be installed by manually force-fitting
from the top. The bottom locks in using the same
mechanism as the arch modules. An additional lock is
installed on the top section of the X frame, running
across the length, above the arch modules.

45

Knock it down
split arch concept

The verdict

The ‘strip arch’ concept aimed at creating designs for knock down furniture which is modular in nature, to be assembled
using a few simple steps. The ‘strip arch + support frame’ designs went through various stages, constantly tackling flaws and
problem areas as they arose along the way. Eventually, the technical problems were all solved and the design was theoretically
‘working’. However, in the process, the design lost its simplicity and the desired aesthetics had been compromised to a large
extent. Simplicity of assembly, form appeal and approachability of the design were key criteria to determine the feasibility
of investing time, labour and funds in prototyping and production. Since it failed to sufficiently satisfy these criteria, it was
decided that the ‘strip arch’ concept would not be taken forward to the prototyping stage.

46

Knock it down
knockables, stackables and bamboo

First set of sketches for the ‘knockable, stackables and bamboo’ concept

Knock - down Furniture : A piece of furniture which is received in parts (components) and assembled by the user. Once as-
sembled, the final piece of furniture is permanently fixed. It is not necessarily “collapsible“. The furniture can be dismantled,
with the use of a basic and common tool like a screwdriver.
This concept emphasized on creating knock-down furniture using forms that are easy to integrate into an ‘assembly line’ type
of production method.
All finished components will be stackable - for ease of stocking and transportation.
These components can come together in different configurations to form a complete piece of furniture which too will be
stackable as a whole.
The designs will incorporate modularity and scalability as integral qualities to aid expansive production and marketing meth-
ods.

47

Knock it down

Further exploring form

Stackable assembled furniture

Easy to replicate, stackable forms

48

Knock it down

Further exploring form



49

Knock it down

Finalized form



50

Knock it down

Finalized form

51

Knock it down

Finalized form

All details of joints and joiner depicted here are
subject to change.
While working with hands-on with the material, deci-
sions will be taken regarding suitability of joinery.

52

prototype
production

53

Knock it down
prototype production

Treatment

Proper treatment of bamboo is essential for longevity of the material, making it immune to insects and fungus (the prime
reasons for decay and short lifespan)
The method of treatment used here involves soaking the bamboo poles / splits in a solution of water and boric acid for a
period of 3 to 4 days.
This process rids the bamboo of all sugar and lactose content, making it immune to fungus and insects such as termites and
ants. After soaking, the bamboo must be naturally dried in the sun before it is ready for use.

54

Knock it down

The Tools

Left to Right : The Dao, Chisels, Files, Hacksaw

Left to Right :
LPG flame blower,
G-Clamps

55

Knock it down

Splitting

The splitting of bamboo poles and thinning of splits here is done manually using basic tools like the hatchet and the dao

56

Knock it down

Bending

Bending of splits is done by applying heat and pressure simultaneously, along a profile with the help of jigs

The Jigs :
A modular system of JIgs has been used here.
This includes steel rings of varying diameters and a board on which to arrange them

Mild (MS) steel rings An MS ring held to plywood board using a screw

57

Knock it down

Bending

Arranging MS rings to create Jig :

The steel rings are placed on top of a full scale drawing of the bending profile, and checked for selection of the correct
sizes, suitable for achieving an accurate bend along the specific bending radius (as depicted in the profile)

Selecting the right sized rings aginst full scale bend- Arranging the MS rings in a configuration suitable to
ing profile achieve the required curve

58

Knock it down

Bending

Bending along the Jigs

The bamboo splits are bent by applying heat and pressure simultaneously, to key sections, along the layout of the Jig.
G-clamps are used to hold bent section in place to avoid warping.
Using this method of bending, several splits can be bent in to a similar profile using fixed Jigs, making replication easy.

Applying heat while pulling the split to bend along G-Clamps being used to hold the bent segment in
the Jig place while it cools

59

Knock it down

Smoothing

Cleaning charred skin :

After bending, the surface of the split is cleaned and smoothened using simple tools like the file, the dao and the chicsel.
This procedure can also be carried out on a rotating sanding machine.

Smoothing the inside surface using a file Removing the burnt skin using a dao

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Knock it down

Lamination

Clubbing multiple splits together

The process of lamination involves the application of epoxy glue (e.g. areldite) and clamping the bent section together.
After clamping, this assembly left undisturbed for a period long enough to allow the adhesive to dry.

Bent splits being held together after application of Bent splits being held together after application of
epoxy glue - Areldite epoxy glue - Areldite

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Bending + Lamination

This particular Design incorporates 3 laminated splits for each individual component (for strength and rigidity)
The result of Bending and Lamination 3 splits each for all the profile is shown below :

Main profiles for lower section - each profile com- Main profiles for seat and backrest - each profile
prises 3 laminated splits - these are stackable comprises 3 laminated strips - these are stackable

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Bending + Lamination

Preparing profiles

This particular Design incorporates 3 laminated splits for each individual component (for strength and rigidity)
The result of Bending and Lamination 3 splits each for all the profile is shown below :

Main profiles for lower section - each profile com- Main profiles for seat and backrest - each profile
prises 3 laminated splits - these are stackable comprises 3 laminated strips - these are stackable

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Assembly

Attaching tie members for lower section arches

Creating hole for insertion of bamboo pin Applying adhesive

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Assembly


Preparing bamboo pin for insertion Inserting bamboo pin (force fit)

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Assembly


Fully inserted bamboo pin Fully inserted bamboo pin

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Assembly

Inserting tie-members for lower section arches

Creating slots for insertion of tie member

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Assembly


Slot for insertion of tie member

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Assembly


Junction being held by G-Clamps while adhesive
dries

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Assembly

Attaching tie members for backrest profiles

Creating half lap cuts in backrest
profile

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Assembly


profile

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Assembly


profile

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Assembly


Gluing backrest profiles to tie member

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Assembly


Joint reinforced with bamboo pin

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Assembly


Gluing backrest profiles to tie
member

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Assembly

Adjustments : spacing and alignment of backrest profiles

Temporary brace Checking measurements for spacing

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Assembly


Positioning external members for align- Clamping after application of adhesive
ment

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Assembly


Joint reinforced with bamboo pins

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Assembly

Adjustments : leveling

Leveling bottom end of backrest Leveling bottom end of backrest
profiles profiles

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Assembly

Adjustments : leveling

Positioning external member for align- Joint reinforced with bamboo pin
ment

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Assembly

Fixing screw inserts on bottom section frame

Screws with washers and inserts Screw insert to be embedded in tie
member

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Assembly


Creating holes to embed inserts Applying adhesive to insert

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Inserting screw-insert into the tie members while screwing from the top, through
the backrest tie member

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Finishing

Final touches

Final stage of smoothing using sandpaper and a handheld grinding machine

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Polishing

Final touches

Applying a coating of wax polish to lend a glossy texture, while maintaining the natural look

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The finished piece

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The finished piece

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Cost analysis

Raw material was sourced and sponsored by me

Bamboo Rs. 600

Bamboo procurement Rs. 800

Prototype production was carried out at Sangaru Design Objects Pvt. Ltd., Bangalore

Overheads:
Gas, adhesive, electricity Rs. 1500

Labour:
2 persons X Rs. 250/day X 10 days Rs. 5000

*As is evident from the difference in raw material cost and procurement cost, it is very important to have a good system in
place for sourcing and procurement of material

*The adhesive used here is ‘Areldite’. This costs approximately Rs. 200 per 100gms. For a larger scale of production, cheaper
alternatives can be used (epoxy glue of any kind)

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my critique

Aesthetics

Aesthetics seem to be nice on the whole

The chair appears to have good proportions

Tie members at the top and bottom ends of the
seat-backrest seem to be obstructing an otherwise
streamlined look

Some of the bamboo split ties members could per-
haps be replaced with steel pipes. This would give the
chair a more contemporary look.

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my critique

Ergonomics

The backrest should be more inclined, the current
position is too up right. The current incline on the
back rest is 10 degrees. This could be increased to 20
degrees. Alternately, 2 instead of 3 laminated splits
could be used to create back rest profiles. This will
allow some flex and actions in the back rest.

The seat is too short. The current seating depth is
36cm. This should be increased to 40/42cm.

The seating height too is a little bit more than it ide-
ally should be. Perhaps 5cm lower would be more
comfortable.

The seat is currently straight, at almost 180 degrees.
A slight dip towards the back end of the seat will be
more comfortable.

The tie member in front of the bottom section is
hindering to the legs. Perhaps more rigid steel tie
members along the profile could allow us to do away
with the from tie member altogether.

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conclusion

Reflections

The final concept - knockables, stackables and bamboo, has achieved the goals set by this project. This concept uses bamboo
in an unconventional avatar, one that can be standardised to a large extent. This allows for mass production and cost control,
which in turn enables the contemporary bamboo markets to expand. An increased market space for these products has a
direct effect on craftsmen and artisan communities, providing them with more work and exposing them to a fresh approach
to the material. From hereon, they now have an extended workspace to translate their deep understanding and experience of
the material.
In working first hand with artisans, I find that design intervention has a catalytic effect. Working with designers, constantly
trying new approaches, craftsmen and artisans begin an exploratory phase themselves and knowingly or unknowingly begin
to apply design thinking. Given their strong foundation in the use of the material, this enables them to think on fresh lines,
evolving their traditions, perhaps even developing indigenous techniques and technology. All this contributes to the core
mission of propagating the use of bamboo in a way that its is socially, economically and ecologically viable, profitable and
progressive for all those involved.

This project has been carried out on a very small scale. The aim has been to set an example and showcase a few of the many
possibilities bamboo offers the urban industry, markets and lifestyles. The up scaling of such production methods can have a
strong impact on markets, livelihoods, traditions as well as the environment.
The production of the the prototype for this project has been labour intensive as one single product prototype is not motive
enough to encourage heavy investment in mechanized systems. However, most of the processes involved can be mechanized
using existing technology.

Responsible material sourcing is as important , if not more, than design application. Bamboo is a highly sustainable resource
with many environmental and ecological benefits. Using bamboo to replace other, less sustainable materials is a move for-
ward, but plantation exercises are all important. If we do not invest time money and energy in plantation, proportionately to
increase in applications, we will be back to naturally occurring forests for resources and all will be lost. As a designer, I have
taken the position of a small catalyst. With this project, I hope to provide a look into what I see as a bright future with main
streamed bamboo.

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Bibliography

Books Websites and blogs

• Bamboo- the gift of the gods - Oscar Hidalgo - • http://sandeepsangaru.com/
Lopez • http://www.idc.iitb.ac.in
• Bamboo and Cane crafts of Northeast India • http://www.ikea.com/
-Ranjan, M P., Iyer Nilam, Pandya Ghanshyam, • http://www.ipirti.gov.in
• http://studioalaya.com/
Project documents • http://www.ubfdb.org/
• http://www.wondergrass.in/
• Lifestyle accessory in Bamboo - Rajive Jassal • http://wondergrass.blogspot.com/
PGDPD, NID • http://design-for-india.blogspot.com/
• Furniture Design for Tripura Bamboo Mission
- Garima Aggarwal PGDPD, NID
• Bamboo Product Development for Tripua Bam-
boo Mission - Andrea Noronha PGDPD, NID
• Bamboo Product Development &
Entrepreneurial Workshops - Outreach
Programmes, Centre For Bamboo Initiatives, NID

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Knock it Down - Bring the bamboo home

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