Double Corrugated Board Industrial Grade (BC Flute)

The Professional Standard for Structural Massing and Heavy Duty Prototyping

This double wall corrugated board is an industrial strength material engineered for applications requiring maximum stability and structural integrity. Featuring a multi layer BC Flute construction, the board combines a robust B flute and a thick C flute to provide exceptional compressive strength and superior shock absorption. With a high quality white Kraftliner top layer, it offers a professional, clean aesthetic that is highly receptive to technical markings and precision finishing.

Key Performance Features

• Five Layer Architecture: Built using three flat linerboard faces separated by two wavy fluted mediums to provide unparalleled puncture resistance and impact cushioning.
• Exceptional Rigidity: The rigid cross section prevents sagging in expansive models and easily supports heavy duty craft projects, architectural mock ups, and volumetric prototypes.
• Professional Finish: Features a bright white Kraftliner front face for crisp pencil work or laser etched layouts, paired with a reliable brown Testliner backing.
• Sustainable Composition: Made from high fibre technical paper that remains 100 percent recyclable and environmentally responsible.

Working with Double Corrugated Board

• Cutting Technique: Can be cut with a utility knife, snap off blades, craft knives, and most high quality blades. Due to the thickness, it is beneficial to avoid trying to cut through the material in a single stroke. For the cleanest results, score the material using a ruler and a sharp blade to cut through a single layer at a time, preventing the blade from slipping or tearing the inner corrugations.
• Advanced V Cutting: The 7mm profile is ideal for V cutting techniques. To make a clean 90 degree bend, use a v groove cutter or carefully slice out a 90 degree channel through one flute and one liner on the inside face of the board. Leave the outer liner completely intact to act as a living hinge for stable 3D geometric forms.
• Adhesives and Assembly: Easily stuck with PVA glue for strong, permanent structural bonds. Hot glue is ideal for quick, temporary holding during assembly, and painter's tape can be used to hold pieces temporarily at 90 degree angles while the PVA glue cures.
• Finishing and Effects: Edges can be neatly cleaned up using coarse grit sanding blocks, such as 120 grit. Additionally, inner structural elements can be exposed using a soaking method to dissolve the internal glue, allowing you to peel away the layers and reveal the aesthetic, wavy flutes inside.

Advanced Joining Methods

• Slot and Tab Joints: Create structural interlocking joints by cutting male tabs on one piece and matching slots on another. This mechanically locks the heavy board pieces firmly in place before applying glue.
• Pinning for Extra Strength: For end to end butt joints or right angles, you can reinforce the connection by pushing wooden skewers, toothpicks, or metal rods directly through the board junctions with a dab of hot glue.

Technical Specifications

• Material: Multi layer Technical Paper (High fibre content)
• Structure: 5 Layer (Liner, Fluting, Liner, Fluting, Liner)
• Flute Type: BC Flute (Approximately 6mm total thickness)
• Surface Finish: White Kraftliner (Front) / Brown Testliner (Back)
• Weight and Density: Heavy duty construction (Kraftliner: 140 g/m / Fluting: 115 g/m)
• Disposal: 100 percent Recyclable

Applications

• Architectural Model Making: The preferred substrate for large scale structural massing, site model bases, and topographical contouring.
• Industrial Prototyping: Ideal for full scale volumetric mock ups, ergonomic studies, and furniture prototypes.
• Exhibition and Set Design: Extensively used in scenography for constructing lightweight partitions, plinths, and oversized geometric props requiring interlocking slot and tab structures.
• Technical Packaging: A definitive choice for bespoke transport outers and protective intermediate layers for fragile, high value components in transit.

Comparison between Micro, Single, and Double Corrugated Board

Corrugated boards are classified by their layer thickness and flute sizes. Choosing the correct board depends on the balance required between intricate detail and structural strength for your project.

• Micro Corrugated Board: Ultra thin boards usually between 1.0mm and 2.0mm thick. This is the ultimate choice for visible, aesthetic models, intricate architectural details, consumer product packaging mock ups, precise laser cutting, and projects requiring fine, curved details.
• Single Corrugated Board: The industry standard single wall option. It is best for rapid architectural prototypes, large scale structural models, and heavy, unpainted model bases.
• Double Corrugated Board: Composed of a heavy duty, double wall fluted layer. This is best for large, weight bearing models, heavy topographical landscapes, or foundational blocks where maximum rigidity and puncture resistance are prioritised.