Sustainable Composite Wood Products

Formaldehyde-Based Resins for
Sustainable Composite Wood Products

Informed by LCI data and achieved through proven low-emitting
technology
Wood Adhesives 2013

Toronto, Canada
October 9, 2013
Jeff Swartzentruber
North American Technical Service Leader, Momentive Specialty Chemicals

What is Sustainability?
1987 United Nations Bruntland Commission
defined Sustainability
Development that meets the needs of the
present, without compromising the ability of
future generations to meet their own needs.
There are a myriad of other definitions and

descriptions of sustainability
Most have three basic dimensions
Environmental
Social
Economic
The differences in most definitions is on how these

three dimensions are measured and weighted
Wood Adhesives 2013 Toronto June 2013

2013 Momentive Specialty Chemicals Inc. All rights reserved.

Composite Wood Products are positive in all three areas
Environmental
Wood is a preferred material environmentally
Composite wood products increase the utilization rate of wood resources
Economic
Composite wood products provide jobs and directly impact local economies
Social
Composite wood products improve the quality of life through the wide variety of products
made from them to improve utility, functionality, performance and aesthetics of everyday life

Wood Is A Preferred Material
Source: Tackle Climate ChangeUse Wood

Composite Wood Products Increase Wood Utilization

35-39% processed
into lumber
20% for
energy
37-38% processed
into lumber
23% as raw
materials
41% processed into

lumber
25% as raw
materials
52% processed into lumber
41-45% as waste
16% for
energy
23% for
energy
36% as raw
materials
Source: Utilization of Harvested Wood by the North American Forest Products Industry, Dovetail Partners, Inc., 2012

23-24% as
waste
11% as
waste
12% for
energy
1940
1970
1985
2005
Composite Wood Products Increase Wood Utilization

Milestones on the Pathway to Zero-Wood-Waste
1930s: Wood waste at 50-60%
1955: Particleboard commercially produced in the United States
1968: Patent issued for laminated veneer lumber (LVL).
1970: Wood waste at 38%.

1971: Patent issued for wood structural I-beams.
1978: Oriented strandboad (OSB) manufactured commercially.
1981: Wood waste at 17%

Early-1990s: Parallel Strand Lumber (PSL) developed in Canada.
Mid to late 1990s: Finger-jointed lumber accepted for structural uses by all major building codes in the U.S. and Canada
2005: Wood utilization reaches 90%, and productivity has grown 29% since 1965 and 14% since 1985 .
2012: Wood waste at 0.14% - 1.5%.
Formaldehyde-based resins were essential in the development of the composite wood products
that have increased utilization rates. It wasnt until the late 1970s and early 1980s that focus
was given to formaldehyde emissions from those products.
Source: Utilization of Harvested Wood by the North American Forest Products Industry, Dovetail Partners, Inc., 2012

LCI Data Supports Composite Wood Products Carbon Storage

Life Cycle Inventory (LCI) Data has been collected for Composite Wood Products
Examples include Consortium for Research on Renewable Industrial Materials
(CORRIM)
Softwood Plywood (2005)

I-Joists (2005)
Laminated Veneer Lumber (2005)
Oriented Strand Board (2005)
Particleboard (2008)
Medium Density Fiberboard (2008)
Formaldehyde based resins (2008)
Data shows that carbon stored in composite wood products exceeds that generated in
the extraction and production of the composite wood products
Life Cycle Analysis (LCA) reports have also been completed for many of these products or
in the process of being completed.

LCA / LCI Energy for Common Resins Systems
GHG- Green house gases

Song, Y.S, et. al. Composites: Part A 40(2009) 1257-1265
Wilson James B. Wood and Fiber Science 42(X) 2010, pp. 1-19
http//www3/abe.lastate.edubiobased/LCAreview.pdf
Good LCA values for Formaldehyde

based resins.

One Example Tying It All Together

ECC Certification is available to individual manufacturing plants and requires an on-site qualification audit and
subsequent annual audits. Unfinished composite panel products must first comply with the stringent California
Air Resources Board (CARB) formaldehyde emissions regulation before being considered for other ECC
criteria.
Qualified plants must then meet at least three of the following requirements:
Carbon Footprint
Local and Renewable Resource
Recycled/Recovered
Sustainability
Wood Sourcing
Source: ECC Sustainability Standard & Certification Program Brochure

Composite Panel Association

How can the worlds largest

formaldehyde producer
embrace sustainability?

Sustainability at Momentive is an Integrated Business Approach
At Momentive, sustainability creates long-term stakeholder value through responsible

stewardship of our assets, the environment, our products and our social responsibility.

Sustainability the Momentive Way
Our sustainability initiatives grouped into 3 broad categories:

Operational excellence programs
Product innovation efforts
Our focus on being good corporate citizens
http://www.momentive.com/sustainability/

Housing/Construction Industries & Formaldehyde Based Resins

Formaldehyde Based Resins Offer Performance Attributes

PF resins for OSB
Lower cost solution for surface resins
Does not adhere to metal
Does not require a release agent
Durable and creep resistant

Easy to manage for safe handling at the panel manufacturer


Amino Resins for HWPW
Higher solids
Less water means reduced issues with wood regarding checking
and blows or blisters
Thermosetting
better heat resistance
rigid glue lines
In making curved plywood this is critical to hold the curve
and not have any springback.
Provides impact resistance for paper laminating
Will not soften under the heat of embossing
Heat cured amino resins are faster setting than thermoplastic
systems
Light color cure

No bleed through with thin veneers
Tack for layup time


Amino Resins for PB/MDF
Cure speed customizable to enhance productivity
Buffers
Catalysts
Ability to develop tack for process flexibility

Dry tack
Wet tack
Water based for ease of cleanup/line flushing

Excellent machinability and paintability
Light color cure

Low-Emitting Composite Wood Products Is The Goal

Primary Focus On Resins Used for Interior Products
Indoor Air Quality the driving force
Focus on formaldehyde as an indoor air pollutant result of several factors
HUD standard for PB and HWPW implemented in 1984
ANSI Standards for PB and MDF lowered the levels further
California Air Resources Board Composite Wood Rule pushed the levels down closer
to the levels of natural wood
Outside of North America, similar push for lower emissions in EU, AU/NZ and Japan

Formaldehyde Bioassay Results (Rats)

Nasal tumor data that initiated investigations
Levels of formaldehyde given
to rats that had an effect
60
50
Monticello et al., 1991
40
30
20
10
0
700
2,000
6,000
10,000
15,000
Exposure Concentration (ppb parts per billion)

Tumor Response
(%)
Kerns et al., 1983
PPB
Formaldehyde Emissions in Particleboard UF Resin (NA)
Year
Interior Panel Emission Standards
F*** and F**** are 6 month average results,

maximum individual tests at 120 ppb and 70 ppb
respectively
ULEF RT and Exempt are 90%

of QC and all quarterly certification limits,
10% of QC tests are allowed up to a higher limit.
ULEF RT max is 80 ppb and 90 ppb for PB and MDF not applicable for HWPW
ULEF Exempt max is 50 ppb for HWPW and 60 ppb for PB/MDF
Typical Formaldehyde Indoor Air Levels

are Already Very Low (ppb levels)
EPA Informal
Level of Concern
WHO Guideline
Source: CARB

How Did We Get There?

It is not resin technology alone
Panel producers play an important role
Increased emphasis on process control
Furnish moisture control
Weight control
Pressing strategies
Catalyst strategies
Scavenger strategies
Important no matter which resin technology
is utilized
http://evergreengroup.com.my/pop.php?view=MDF_Particleboard_Process&mid=1931

How Did We Get There?

But particleboard resin molar ratios (formaldehyde:urea*) have changed
*Mole Ratios are expressed as an approximate F/U
dramatically
Prior to HUD
1.20 1.40
After HUD pre CARB
1.10 1.20 surface layer
1.15 1.40 core layer
CARB phase 1
1.00 1.10 surface layer
1.10 1.25 core layer
CARB phase 2
0.75-0.90 surface layer
1.00-1.20 core layer
ULEF
0.65-0.80 surface layer
0.80-1.00 core layer
equivalent to account for melamine
Consistent with what has been

found for E0/F*** and SE0/F****
in Europe and AU/NZ

Resin Technology Modifications

Multiple methods of achieving target molar ratios
Specific to an individual plants need for flexibility and required molar ratio range
Incorporation of melamine at the lowest molar ratios (1-4% typical) has become more
common
Cook strategies
Internal buffers/catalysts

One Size Does Not Fit All

The same molar ratio, or even the exact same resin formulation does not result in the
same formaldehyde emissions when used at different manufacturing locations
Some differences have been observed on different production lines within the same
site when making the same products!
Old relationships still apply
Thicker panels vs. thinner panels
PB vs. MDF
High density vs. low density
Customization of formulation to
manufacturing process is needed!

Panel Emissions Decay Over Time
Source: Particleboard Formaldehyde Emissions and Decay under Elevated Temperature and Humidity
Conditions. 2012 Reidlinger et al

Beyond the Raw Panel
Source: VOC Emission Barrier Effects

Technical Bulletin, Composite Panel Association

Continuing into the Future

All adhesive systems have positives and negatives
Development efforts focused on improving formaldehyde based resin performance
Reduced resin usage
Improved property performance
Improved productivity
Improved moisture resistance
Incorporation of renewable raw materials
As technologies develop and become economical formaldehyde and urea from bio based
syn gas becomes possible
Enhances the sustainability message
All with low emission products as a prerequisite

Momentive Advocacy
Momentive continues to advocate for bringing value to the wood/forest industry
We continue to advocate vigilantly for:
The sustainability of the forest products industry
The sustainability of wood as a building/construction product
The sustainability of advanced formaldehyde technologies and its responsible use



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Formaldehyde-Based Resins for

Wood Adhesives 2013

Sustainable Composite Wood Products

There are a myriad of other definitions and

The differences in most definitions is on how these

Wood Adhesives 2013 Toronto June 2013

Sustainable Composite Wood Products

Wood Adhesives 2013 Toronto June 2013

Wood Is A Preferred Material

Source: Tackle Climate ChangeUse Wood

Wood Adhesives 2013 Toronto June 2013

Composite Wood Products Increase Wood Utilization

41% processed into

52% processed into lumber

Wood Adhesives 2013 Toronto June 2013

Composite Wood Products Increase Wood Utilization

1970: Wood waste at 38%.

1981: Wood waste at 17%

Wood Adhesives 2013 Toronto June 2013

LCI Data Supports Composite Wood Products Carbon Storage

Softwood Plywood (2005)

Wood Adhesives 2013 Toronto June 2013

LCA / LCI Energy for Common Resins Systems

GHG- Green house gases

Good LCA values for Formaldehyde

Wood Adhesives 2013 Toronto June 2013

One Example Tying It All Together

Source: ECC Sustainability Standard & Certification Program Brochure

Wood Adhesives 2013 Toronto June 2013

How can the worlds largest

Wood Adhesives 2013 Toronto June 2013

Sustainability at Momentive is an Integrated Business Approach

At Momentive, sustainability creates long-term stakeholder value through responsible

Wood Adhesives 2013 Toronto June 2013

Sustainability the Momentive Way

Our sustainability initiatives grouped into 3 broad categories:

Wood Adhesives 2013 Toronto June 2013

Housing/Construction Industries & Formaldehyde Based Resins

Wood Adhesives 2013 Toronto June 2013

Formaldehyde Based Resins Offer Performance Attributes

Durable and creep resistant

Wood Adhesives 2013 Toronto June 2013

Formaldehyde Based Resins Offer Performance Attributes

Light color cure

Tack for layup time

Wood Adhesives 2013 Toronto June 2013

Formaldehyde Based Resins Offer Performance Attributes

Ability to develop tack for process flexibility

Water based for ease of cleanup/line flushing

Wood Adhesives 2013 Toronto June 2013

Low-Emitting Composite Wood Products Is The Goal

Wood Adhesives 2013 Toronto June 2013

Formaldehyde Bioassay Results (Rats)

Monticello et al., 1991

Exposure Concentration (ppb parts per billion)

Wood Adhesives 2013 Toronto June 2013

Kerns et al., 1983

Formaldehyde Emissions in Particleboard UF Resin (NA)

Interior Panel Emission Standards

F*** and F**** are 6 month average results,

ULEF RT and Exempt are 90%

Typical Formaldehyde Indoor Air Levels

F* and F** are 6 month average results,