KØL Manufacturing Process

KØL High-Density Fiber Cement combines innovative manufacturing processes with a commitment to quality and environmental safety. Originating from a rich history of expertise in fiber cement production, KØL panels are crafted to meet the highest standards in architectural design and functionality. KØL manufacturing process, rooted in precision engineering and continuous research and development, results in a product that is not only aesthetically versatile but also exceptionally durable and reliable:

  • Durability and Strength: The high-density composition ensures long-lasting durability and resistance to environmental stressors.

  • Environmental Safety: Produced with a focus on environmental and workplace safety, aligning with sustainable practices.

  • Aesthetic Versatility: Available in a range of textures and colors, suitable for diverse design requirements.

  • Through-Colored Panels: Pigment is mixed into the material, ensuring consistent color throughout the panel, enhancing aesthetic integrity and reducing visible wear.

  • Water and Dirt Resistance: Treated with a water-repellent substance that reduces absorption and minimizes dirt spots, maintaining the panel's appearance.

  • Authenticity Preservation: The treatment accentuates the natural characteristics of the panels, preserving their authenticity over time.

Example of a KOL facade application with visible fasteners
KOL Sheets cut and stacked after manufacturing.

What is Fiber Cement?

Fiber cement is a durable and adaptable construction material composed of Portland cement, cellulose fibers, sand, and water. Today's fiber cement is appreciated for its strength, fire resistance, and versatility, making it a preferred choice for architectural facade cladding applications and exterior members of rainscreen systems.

Fiber cement is a durable and adaptable construction material composed of Portland cement, cellulose fibers, sand, and water.

History of Fiber Cement

The material's history extends to the late 19th century when Ludwig Hatschek, an Austrian industrialist, patented the first fiber cement in 1901. Initially, fiber cement contained a mix of 90% cement and 10% asbestos fibers, offering significant strength and fireproofing capabilities. However, due to the health risks associated with asbestos, its use in fiber cement was phased out by the mid-1980s. Manufacturers adapted by substituting asbestos with cellulose fibers, preserving the material's key qualities while enhancing safety.

As the 21st century unfolded, fiber cement saw further advancements. The modern iteration is not only safe but also boasts improved durability and resistance to the elements, aligning with sustainable manufacturing practices. This evolution reflects the industry's commitment to safety, sustainability, and innovation, ensuring fiber cement remains a mainstay in contemporary construction.

KØL Fiber Cement Panel Manufacturing Process

The Hatschek Process, with over a century of history, remains vital in fiber cement panel production, enhanced by contemporary technological advancements. This process starts with a sophisticated blend of Portland cement, ground sand, cellulose fibers, and water, meticulously mixed to create a slurry. The process can be broken down into four steps, each critical to the integrity and quality of KØL panels:

01. Slurry Preparation

The Hatschek process begins with the careful blending of Portland cement, ground sand, cellulose fibers, and water. This mixture is thoroughly combined to form a homogenous slurry, laying the foundation for high-quality fiber cement panels.

01. Slurry Preparation The Hatschek process begins with the careful blending of Portland cement, ground sand, cellulose fibers, and water. This mixture is thoroughly combined to form a homogenous slurry, laying the foundation for high-quality fiber

02. Sheet Formation

The prepared slurry is then fed onto a series of rotating cylindrical sieves. As these sieves turn, they collect layers of the slurry, building up sheets of the material. These sheets are subsequently transferred onto a conveyor belt, where they emerge as thin layers of fiber cement.

02. Sheet Formation The prepared slurry is then fed onto a series of rotating cylindrical sieves. As these sieves turn, they collect layers of the slurry, building up sheets of the material. These sheets are subsequently transferred onto a conveyor

03. Compression & Cutting

Next, the thin sheets are subjected to a rolling process, where they are pressed to form thicker, denser sheets. This compaction is crucial for achieving the desired strength and density. Once the required thickness is attained, the continuous sheet is cut into individual KØL panels, each tailored to specific dimensions.

03. Compression & Cutting Next, the thin sheets are subjected to a rolling process, where they are pressed to form thicker, denser sheets. This compaction is crucial for achieving the desired strength and density. Once the required thickness is atta

04. Drying & Finalization

KØL High-Density Fiber Cement panels undergo autoclaving, a rapid drying method. In this process, a pressurized steam chamber applies high temperatures and pressures to uniformly cure the panels, enhancing their strength and durability while ensuring timely delivery.

04. Drying & Finalization KØL High-Density Fiber Cement panels undergo autoclaving, a rapid drying method. In this process, a pressurized steam chamber applies high temperatures and pressures to uniformly cure the panels, enhancing their strength an