Abstract
The mechanical properties and fire resistance of medium-density fibreboard (MDF) consisting of empty fruit bunch fibre (EFB) and palm-based pre-polyurethane (pPU) as the green binder were investigated. The EFB was in the size range of 300 to 500 μm with ATH varied at 5, 10, and 15%w/w of the total mass of the resin and was added into the pPU matrix at a ratio of 65:35 of the EFB to pPU. This study discovered the significant of mixing sequence to the strength enhancement of the fibreboard. A direct proportionality was noted between the Shore D hardness and the amount of ATH with an increase up to 17% with increasing ATH content. Furthermore, this is contributed to well-disperse ATH in the pPU matrix which also increased the impact and flexural strengths. An increase in impact strength of 13, 20 and 33%, with increasing ATH loading percentage was observed. The maximum increase in flexural strength was 33%, which was associated to ATH content of 15%. On the other hand, the burning rate decreased from 6.0 to 3.2 mm·s−1 with increasing ATH content.