Corrugated cardboard
From MaterialProject.org, the free architectural material catalog
Contents |
Material analysis
MasterFormat Number: 12 50 00 Furniture
History and Traditional uses
- Packing and shipping are the most common uses of corrugated cardboard.
- Corrugated cardboard is a cellulosic fiber containing recycled materials, however traditional made by mixing sawdust and bark.
- Originally used as cushioning for packaging during the 19th Century, but patented in 1856 in England for the inside construction of top hats. Patented again in the U.S. in 1871 for bottle packaging, it was Oliver Jones however adding a second side (sheet) to give it extra support.
- This fiberboard has been designed for sophistication as it is used for "branded packaging", e.g Starbucks coffee cup sleeve.
Emerging uses / trends
- Used in stack construction or applied to existing surfaces.
- New uses include sculpture, interior surface applications, and graphic displays.
- Corrugated cardboard can be constructed into furniture: tables, chairs, bookshelves, filing cabinets, and other decorative accent pieces.
- Used even in architectural structures in stacked construction.
- Pre- fabricated homes made from corrugated cardboard have been constructed in Australia back in 2004. The roofing is weatherproofed, and it can be broken down and easily assembled. The homes fully functional with a kithcen and a bathroom as part of an exhibition.
Finish and aesthetic qualities
- Most often produced in shades of brown, though the linerboard can be produced in any color or even preprinted.
- Custom colored fiberboard is available, most successfully done with a water based paint that adds to the sustainability of the piece.
- Commonly made in five different fluting profiles, A, B, C, E, and F, though both larger and smaller profiles are still emerging. The different fluting sizes can be combined in one board by layering the various sizes between linerboard.
- Can be treated with wax coating to provide moisture and vapor protection.
Surface forms / shapes
- Produced in large sheets or rolls.
- Comes as flat panels or flute profiles varying in thickness.
- Can be glued and carved in any form.
- The fluting arches run in one-direction, and on their vertical side, they provide great compression strength.
- Corrugated cardboard has an infinite amount of shapes and forms, as long as there is a utility knife to cut through. Using basic principles of construction (post and lintel) any shape can be supportive.
Cost analysis
- A pricless and sustainable approach is reusing fiberboard costing a designer $0.
- Average cost: $.17 for 6’x6’x1/8”, $.32 for 14’x14’x5/32”, $7 for 40’x48’x1”, and $29 for 48’x92’x2”.
Material properties
Primary structural use
- Compressed together to form stronger surface areas.
- Top and side compression.
Material performance
- The fluting resists bending and folding from all directions.
- Lacquering furniture corrugated cardboard protects it from scratches or marks.
- Easy to assemble and take apart.
- Stiff, Stable, and springiness.
- Systematic sound transmission.
- Excellent thermal properties.
- Waterproof and fire resistant applications are requirements.
- Additives are mixed in the pulp during early stages to give it durability in times of high humidity.
Dimensional and opening restriction
- Length and width cut to size
- Most common flute sizes are A 3/16", B - 1/8", C - 5/32", E - 1/16", and F 1/32".
- Flute sizes are the number of flutes per linear foot, which roughly translates to width.
Acoustic property
- High acoustical value and used for sound absorption.
- Air gaps between flutes or honeycomb structure allows for great acoustical insulation. These air pockets have a greater area for sound to travel which softens the sound transmission.
Manufacturing process and assembly
- Corrugated cardboard is a cellulosic fiber containing recycled materials, however it can be mixed with sawdust and bark pulp.
- Construction of the flutes start with single sheets that are heated and moistened then put through a patterned gear wheel and let to cure. Once dry, bonded to one (single wall) or two sheets (double wall) for durability
- Arches, known as flutes, are anchored to liner boards by a starch based adhesive.
- Another liner board is placed on top of the exposed side of the fluting, adding more strength to the cardboard.
Environment and Life Safety
Environmental impact
- More than 70% of corrugated cardboards are recycled and 65% of them have recycled contents from various post-consumer materials. Most corrugated cardboard is made from recycled paper, corrugated boxes, sawdust, wood chips. No heavy metals or ozone depleting substances are used in the production process. Wax coatings cannot be recycled.
- Up to three LEED points under the Materials and Resource section can be obtained. Using reusable materials designers can receive one point, while the recycling content of the material can give the designer one to two LEED points.
- Corrugated cardboard is sustainable since it has a never ending life cycle with the “cradle to cradle” approach to design and functionality of a space. It is as simple as reusing a shoe box as a storage container.
- It is biodegradable.
Flammability rating
- Very flammable.
- Untreated 34 seconds ignition time, ASTM E1354.
- Codes require cardboard to be fire retardant. A safe application of intumescent paint produces high fire resistance. While other forms of fire resistant coatings are dangerous for the environment, SafeCoat® Latex is manufactured with sustainability in mind, allowing the cardboard to be easily recycled.
References
Student contributions
- Hanna Kim-Seda, Fall 2005
- Amanda J Davidson, Spring 2008
- Ashley Pearson, Spring 2010
See also
Similar materials
References
- Ini Ani Cafe, 105 Stanton Street, between Ludlow and Essex Streets in the Lower East Side area of Manhattan
- USGBC: LEED Rating System
