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Published on: 7/1/2003
Last Visited: 8/1/2003
"While there is still a lot of potential for growth in decking, the market may be becoming saturated with capacity and competition," said professor Don Bender, Washington State University.He said new research and development is ready to push WPC products into largely untapped, non-traditional areas such as structural, industrial, marine and low-rise construction markets.
STRUCTURAL AND MARINE APPLICATIONS SHOW PROMISE
Traditional plastic lumber has lower stiffness and flexural modulus compared with natural wood, which has generally limited the applications of these materials in structural applications.New grades of compounded WPC lumber, as well as innovative designs and tooling, are getting around these limitations.
The U.S. Navy has recently granted Bender and his colleague, WSU professor Mike Wolcott, funds to demonstrate the commercial feasibility of manufacturing code-conforming products for marine structural applications, such as load-bearing marine decking and fendering or chocking, the wall portion of a pier against which boats dock.
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Bender says that unlike residential decking, the initial cost of marine decking and timber is a less important factor in determining what type of decking system is eventually installed at a marina or port.Long-term reduction of maintenance and replacement costs of dock and pier decking structures in the harsh marine environment is more important for operators of these facilities.The market for replacement of degraded marine timber is estimated to be 7,000 to 8,000 tons/yr, worth about US$250 million.
In order to demonstrate the suitability of WPC materials in these applications, Bender's group designed, tested and manufactured deck boards installed at a U.S. Navy facility in Rhode Island.The boards were extruded into hollow, 4 in. x 6 in. sections on a Milacron 86-mm in-line conical twin-screw extruder at Washington State's engineering lab.The PVC boards were filled with 50% pine wood flour.
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Standards can sometimes be used to exclude new products from the marketplace, Don Bender, professor, Wood Materials & Engineering Lab, Washington State University, told the audience at the 7th International Conference on Woodfiber-Plastic Composites.This can happen when testing and other standards for new products have yet to be developed, making buyers more inclined to use old products for which standards exist.
Bender said three ASTM testing standards for structural wood- and natural-fiber plastic composites are currently in draft form and being balloted for final approval in ASTM committees.