Kebony Per Brynildsen Karin Hjelmtvedt Kebony ASA September 2010 Contents 1. The principles 2. Product testing & documentation 3. Environmental performance 4. Summing up: Why Kebony? 2 Wood Modification Fundamentals • Wood cells’ composition makes the cell walls capable of absorbing high amounts of water. • When the cell wall structure absorbs water it will swell. This is a basic feature of the wood cell wall. G.I Vestøl www.umb.no • The water content of the wood affects its strength and durability • A permanent change of the wood cell wall structure is termed WOOD MODIFICATION 3 G.I Vestøl www.umb.no Wood Modification concepts Wood modification can be obtained by physical or chemical methods : • Heat applied to wood changes the cell walls’ chemistry. Products: ThermoWood; PlatoWood; Thermoholz;Perdure; • Polymer “grafting” to cell walls Kebonization => Kebony • Chemical reactions with wood cell wall cellulose, hemicellulose and lignins: Acetylation = > Accoya (TitanWood) Crosslinking with DMDHU => Belmadur (BASF) 4 Technology at the wood cell level • The Kebony method is a process where furan polymers are “grafted” to wood cell walls. • These polymers are very stable, and will not degrade or leach out of the wood. Furfuryl alcohol (FA) is a simple liquid produced from furfural, which again is derived from hemicellulose, a plant constituent. In our case, the FA is produced from bagasse, a waste product from cane sugar • Section of Radiata pine; cell walls containing furan polymer, image through fluorescence microscopy (L. Garbrecht Thygesen, RVAU, Copenhagen, 2006). • Fluorescence caused by furan polymer • Cell walls are invisible in this system without the fluorescence from the polymer 5 Background 1920s The principle of forming furan polymers 1950s Early attempts of wood furfurylation 1990s Prof. M. Schneider’s inventions 6 2004 Kebony production start in semiindustrial plant 2007 Financing of new Kebony plant 2008 New plant with commercial scale capacity 2009 Establishing representation in Spain, Italy, UK 2010 Doubling sales from 2009 The process steps • Extended lifetime READILY AVAILABLE WOOD • Biodegradable • Mostly soft (European Species) • • • Impregnation Curing Drying • Enhanced mechanical properties • Consistent quality & supply • Moisture sensitive • Inconsistent quality • Environmentally friendly RENEWABLE CHEMICALS processed from plant waste • Sugar canes • Corn cobs • Wood Technology Chemical from Biomass 7 Customer Fundamental Product Factors Affected by the Kebony process 8 Decay resistance => Resistance to rot (fungi), insects, larvae Dimensional Stability => Stability against swelling and shrinkage caused by moisture variations Hardness => Important for resistance to wear Bending Strength => Improved stiffness against elastic bending Increased density => Increased weight per volume unit Altered colour => The formed furan polymer is dark brown 1. The principles 2. Product testing & documentation 3. Environmental performance 4. Summing up: Why Kebony? 9 Kebony product testing & documentation • Durability against fungi and insects SP (Sweden); SHR (Netherlands); BRE (UK); Forest & Landscape Inst. (Norway); University of Gent (Belgium); Christian August Universität (Germany); Louisiana State University (USA); Danish Technological Institute. • Weathering, coating and gluing SP (Sweden); SHR (Netherlands); Dynea (Norway); Norwegian Inst. Of Wood Technology; Jotun AS (Norway) • Environmental Impact - Smoke gas testing, fire testing, leaching, eco-tox, emissions: SP (Sweden); SHR (Netherlands); AnalyCen (Norway), Forest & Landscape Inst. (Norway); Toxicon (Sweden); Danish Technological Institute. • Physical / Mechanical properties SP (Sweden); SHR (Netherlands); Virginia Tech (USA); Norwegian Inst. Of Wood Technology • Human health – chemical risk assessment IVAM (Netherlands) 10 Kebony Pine – Product Performance 11 Kebony Pine – Product Performance EN 113, Brown rot (Coniophora puteana; Gloeophyllum trabeum; Poria placenta) White rot (Coriolus versicolor) Kebony SYP and Kebony Radiata: Class 1 Durability EN 113, Brown rot (Coniophora puteana; Gloeophyllum trabeum; Poria placenta) White rot (Coriolus versicolor) Kebony SYP Durability Class 1 for all fungi except Poria (DC 2) 12 Product performance Hardness Brinell hardness (SP, Sweden): Control Kebony (M) Kebony (H) 13 Kebony Pine - Product performance Formosan Subterranean Termite Test AWPA E1-97 Independent Rating AWPA E1-97 9 R a n k in g 1 - 1 0 b y L S U 8,6 2,6 Untreated Control SYP ACQ .25 ACQ treated SYP F30 Kebony SYP (M) Sample Type • Kebony pine was the only product ranked “excellent” and ranked better than ACQ treated pine against Termites by researchers at LSU 14 Product performance Dimensional stability Vol. swelling @ 20% - 85% RH (SP, Sweden): In general : Anti-swelling efficiency (ASE) between 40 and 60 % 15 Kebony Pine - Product Performance Fastener withdrawal load Fastener withdrawal load pine sapwood - Kebony Pine 2500 Load (N) 2000 Galvanized nail 1500 Deck screw 1000 500 0 Untreated Radial Treatment Study by SP Trätek • Hot dip galvanised, 2.3 * 60 • Decking screw, 3.0 * 50 16 Tangential Kebony Pine - Product performance Modulus of Elasticity (MOE) ASTM D-143 MOE (psi) Control Mean ACQ MEAN FA MEAN 3000000 2,704,338 2500000 2,382,782 2,229,847 MOE (ps)i 2000000 1500000 1000000 500000 0 Control Mean Control SYP ACQ MEAN Treatment ACQ treated SYP FA MEAN Kebony SYP (M) • Kebony pine exhibited near the same rupture point as untreated and copper treated pine. • Kebony pine (yellow column) exhibited more stiffness (MOE) than untreated and copper treated pine • This MOE score means that Kebony pine will perform more consistently under loads. 17 Kebony Pine - Product Performance Fastener corrosion AWPA E12 Mils of Corrosion Compared to Control of untreated wood ACQ Control Control SYP Kebony SYP FA ACQ treated SYP 1,312 1,08 0,961 mils corrosion 0,873 0,602 0,332 0,308 0,221 0,152 0,156 0,068 0,067 0 Screw Plain Steel SAE1010 Screw Hot dip Zinc Galv. 0 0 0 Screw 316 Stainless Steel 0 Coupons Aluminum 2024-T3 0 Coupons Hot dip Zinc galv. 0 0,1 0 Coupons 316 Stainless Steel Coupons Copper Fastener/Coupon Type • Because of residues of minor amounts of organic acid, Kebony is weakly acidic. • Still, Kebony pine is overall less corrosive than ACQ treated pine 18 Kebony Maple – Product Performance 19 Kebony Maple – Product Performance AWPA E10, Brown rot (Coniophora puteana; Irpex lacteus; Poria placenta) White rot (Coriolus versicolor) Kebony SYP Durability Class 1 (calculated according to EN-350) 20 Product performance Hardness Brinell hardness (SP, Sweden): Control Kebony (M) Kebony (H) 21 Product performance Dimensional stability Vol. swelling @ 20% 85% RH (SP, Sweden): In general : Anti-swelling efficiency (ASE) between 40 and 60 % 22 Product Characteristics Appearance •Kebony 24 Before exposure is patinated by sunshine, rain and wind 1. The principles 2. Product testing & documentation 3. Environmental performance 4. Summing up: Why Kebony? 25 Sustainability ● ● Certification of wood starting material – sustainably managed forests (Pine, Southern Yellow Pine; Maple) Documentation of environmental impacts : - “Carbon Footprint” – Global Warming Potential - Other Environmental impacts 26 Sustainability – Carbon Footprint Kebony Approach : ● ● ● 27 EMPA Life Cycle Analysis of Kebony Window Frame In-house research in combination with other consultants, for comparison of Kebony with teak and ACQ treated pine Product certification Sustainability – Carbon Footprint EMPA Study: ● 28 GWP of Kebony compared to PVC and Aluminium Sustainability – Carbon Footprint Kebony Maple compared to teak Estimated carbon release of Kebony compared to Burma teak over their entire life span 29 Sustainability – Carbon Footprint Kebony SYP compared to ipê Estimated carbon release of Kebony compared to Burma teak over their entire life span 30 Kebony v ThermoWood and Accoya Parameter ThermoWood Accoya Modification principle Furan polymer Heat treatment Acetylation Appearance Brown, greying on weathering Brown, greying on weathering Pale, good colour stability on weathering but vulnerable to staining fungi. Strength parameters Improved stiffness. Reduced bending strength Bending strength unchanged from parent wood *** * ** ** ** *** Fastener holding strength *** * ** Durability *** ** *** Hardness Dimensional Stability 31 Kebony 1. The principles 2. Product testing & documentation 3. Environmental performance 4. Summing up: Why Kebony? 32 Total economy • Durability • Dimensional stability • Hardness • Bending strength 33 • Low demands on maintenance • Good service life economy Kebony – projects 34 Kebony organisasjon 35 Hvorfor velger markedet Kebony? • Kebony er tidsriktig – Estetisk vakkert – Brukt av mange ledende arkitektbyråer i Skandinavia, og internasjonalt • Kebony er miljøvennlig – Vår prosess har ingen miljømessige konsekvenser – ingen skadelige stoffer – Impregneringsmassen som brukes er basert på bioavfall – Kebony er Svane merket – Kebony bruker bærekraftige råmaterialer som også kan erstatte truede tropiske regnskog-arter, avhengig av applikasjon • Minimalt vedlikehold, og varig – Kebony krever minimalt med vedlikehold – lav livsløpskostnad – Lang varighet – Kebony gir prosjektgaranti på 30 år – Beskyttelse mot sopp, råte, innsekter, o.s.v. 36 – God formstabilitet, slitestyrke, stivhet, bruddstyrke, hardhet Hvorfor velger markedet Kebony? • Kebony Furu – Største produkt i Norge (fasadekledning, dekke, tak). Velges av byggherrer som vil ha et rustikt utseende, og ønsker seg vekk fra store livsløpskostnader for periodisk vedlikehold (maling, beising). – Investeringskostnaden for en ferdig Kebony Furu -kledning er konkurransedyktig med tradisjonelle alternativer (gran, furu) som må grunnes og males. • Kebony SYP – Største produkt (primært dekke) i europeiske markeder som UK, Spania, Italia og Tyskland. – Velges av byggherrer som ønsker alternativ til tropiske treslag. Fordeler Kebony SYP: lange leveringslengder, forutsigbare ledetider, konsistent fuktighet i produktene, ”solide” produkter, ingen overflatebehandling nødvendig. • Kebony Lønn – Til båtdekk som substitutt for Burma-teak. Velges av båt- og båtdekksprodusenter fordi det er hardere enn teak og utvikles som teak utseendemessig. 37 Kebony har produkter som løser behov Tropisk trevirke under press Betydelig press til å redusere avskoging av tropisk trevirke Produsenter og konsumenter arbeider for å finne alternativer Markedet for trebeskyttelse er i endring Miljøfarlige og giftige impregneringsmetoder forbys og vil forsvinne Offentlig/priv. innkjøp beveger seg i retning av miljøvennlige produkter Markedet ønsker høy ytelse og redusert vedlikehold Kombinasjonen av funksjonalitet, miljø og estetikk skaper trivsel 38 Modifisert trevirke med forbedrede egenskaper Lang holdbarhet Formstabilt Fin estetikk Lite vedlikehold Styrke og hardhet Miljøvennlig Kebony blir lagt merke til Extracts of recent media coverage In total, Kebony has had ~50 articles in international media since summer 2009, with coverage ranging from business newspapers as The Economist to branch magazines. 39 Oppsummering 40