Composite decking
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WPC began in the late 1980s as an alternative to pressure treated wood for outdoor applications. It has since grown to around 10-12% of the US decking market. WPC production involves mixing recycled wood flour with polymers like polyethylene or PVC in an extruder to form solid composite boards, rails, and fences. The composites resist rotting, require no staining or painting, and provide a realistic wood-like appearance without the environmental impacts of harvesting natural wood.
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Composite decking
- 1. Wood/Plastic Composites (WPC)Wood/Plastic Composites (WPC) for Outdoor Livingfor Outdoor Living
- 2. WPC: Where did it start? • Subsidiary of BB&S Treated Lumber Co. • Use of CCA (Chromated Copper Arsenate) • Late 1980’s/early 90’s WPC began • WPC natural direction
- 4. The Market (US) Acceptance of pressure treated wood in early 1980's WPC products about 10%-12% of the market (46 million square meters) with market value of about $1 billion. 1980 - 1996 market for PT wood grew at annual rate of 20%. It is now a 5 billion feet market (460 million square meters). Until 2009 downturn, WPC decking, railing, & fencing market growing in excess of 20% per year. The European market is estimated to be 2.6 million sqm with majority coming from European producers along with imports from U.S. & China.
- 5. Use of wood molders to create surface effects for better appearance. Fiber Composites became known - innovative products. True tropical hardwood colour effects. Capstock on decking to improve scratch, stain and fade resistance. New techniques for coextruded rail products. Double embossing techniques for “rough sawn” appearances.
- 6. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing Fiberon LLC registered in 2010 1 of 3 largest producers of WPC in US
- 7. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing Raw materials US producers use primarily Polyethylene/Wood for decking & PVC/Wood for railings. The wood species used varies by regional location of producer & the types of wood available. European market ~ Polypropylene/Wood or PVC/Wood compounds to extrude the decking or other WPC products
- 8. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing UK/European trend “The market in Europe is expected to increase from virtually nothing at the moment to somewhere in the region of £500 million to £1 billion over the next five years. In volume terms, this equates to up to 1.3 million tonnes of WPC material. It has even been suggested that the European market for WPCs will eventually exceed that in the USA …..” ~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003
- 9. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing UK/European trend “Although there are conflicting views as to which application will offer the greatest opportunity for WPC manufacturers in the UK and the rest of Europe, the applications most likely to emerge and achieve significant growth in the short to medium term are outdoor products (decking, fencing and garden/outdoor furniture), doorframe profiles and window profiles.” ~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003
- 10. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing UK/European trend “It is generally accepted that the lower-value, outdoor products will be the first to make an impact on the UK market …...” ~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003
- 11. One and one-half acres of rainforest are lost every second with tragic consequences for both developing and industrial countries ~ http://www.rain-tree.com/facts.htm
- 12. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing Use of Recycled materials “ (Outdoor products) will, however, be very important in introducing the consumer to WPC materials and the benefits that they can offer over competing materials.” ~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003
- 13. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing UK/European trend “There is, however, a general reluctance amongst potential manufacturers and end-users, in the UK especially, to consider plastic recyclate as a feedstock for WPC materials…. the preference would be to use virgin polymer and wood flour or fibre from traceable sources….. These will have an impact on the cost of the final product.” ~ Wood Plastic Composites study – Technologies & UK market opportunities, published by WRAP, 2003
- 14. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing Solid Core Board No pest gets in No water trapped within No end caps needed
- 15. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing No staining or painting ever needed Benefits compared to wood Deck not slippery when wet No splitting or splintering Use of recycled materials No rot or decay
- 16. How is it made? Recycled Wood in flour form HDPE or PVC in pellet form Dried from 6% moisture to 2% Hoppers Hoppers Extruder Transported via bulk trucks (20 MT) or bulk rail cars (100 MT) The wood arrives every 4 hours and the polymers on a similar schedule.
- 17. Both the eastern (North Carolina) & western (Idaho) plants run 24 hr/7 days for 360 days per year. Lubricants, color, moldicides, and aging stabilizers are also added directly to the extruder. The extruder mixes the materials together dispersing & distributing the wood and minor ingredients into the polymer matrix. At the end of the extruder is a die that gives the WPC its desired profile. The profile is cooled in a series of water baths, sawn to length, molded to give a surface appearance, and embossed to get a grain effect. The boards, rails, & fence products are stacked into bundles, packaged, & moved to the storage area.
- 20. Best Decking & Fencing Solutions Composite Decking, Railing & Fencing Hidden Fasteners for Stunning Finish
Editor's Notes
- Introduce yourself & subject.
- Fiber Composites was founded as a grass roots start-up venture. It started with 6,000 sq.m. of factory space in 1998. The initial output capacity was 900 lb./hr. of WPC Over the next 10 years consistent growth allowed the increase in production space to grow to the current 36,000 sq.m. Similarly the capacity now exceeds 30,000 lb./hr.
- The U.S. dominates the WPC market for Outdoor Living applications, because it was the place that first embraced the idea of wood decks. Wood decks came into vogue with the acceptance of pressure treated wood in the early 1980's. From 1980 through 1996 the market for PT wood grew in the U.S. at an annual rate of 20%. It is now a 5 billion feet market (460 million square meters). Of that the WPC products have about 10%-12% of the market (46 million square meters) with a market value of about $1 billion. Until the 2009 downturn, the WPC decking, railing, and fencing market was growing in excess of 20% per year. The European market is estimated to be 2.6 million square meters with the majority coming from European producers along with imports from the U.S. and China. Source of figures?
- Name was changed to Fiberon LLC in 2010 to reflect a successful branding campaign. Fiberon is now one of the three largest producers of WPC in the U.S. market. (Who are the other 2?)
- WRAP – Waste & Resource Action Prog
- Cost of Staining oil. B&Q: £ per litre Slippery index not tested but in due time. Warranty also for stain & fade.
- The major raw materials, recycled wood in flour form and HDPE or PVC in pellet form, arrive at the plant in bulk trucks (20 MT) or bulk rail cars (100 MT). The wood arrives every 4 hours and the polymers on a similar schedule. The wood is dried from 6% moisture content to 25 moisture content.??? Once dried the wood is transferred to hoppers above the extruder where it is fed to the extruder at a predetermined rate. Similarly the polymer is transferred to the extruders to be added to the extruder blend. How is the solid core encapsulated?
- Minor ingredients such as lubricants, color, moldicides, and aging stabilizers are also added directly to the extruder. The feeder system is extremely accurate as some of the ingredients are added at a fraction of a per cent. The extruder mixes the materials together dispersing and distributing the wood and minor ingredients into the polymer matrix. At the end of the extruder is a die that gives the WPC its desired profile. The profile is cooled in a series of water baths, sawn to length, molded to give a surface appearance, and embossed to get a grain effect. The boards, rails, and fence products are then stacked into bundles, packaged, and moved to the storage area. Both the eastern (North Carolina) and western (Idaho) plants run 24 hr./7 days for 360 days per year.