PureBond Plywood Evaluation

PureBond refers to the technology used by Columbia Forest Products to manufacture urea formaldehyde-free plywood by replacing the bonding agents with a non-toxic, soy-based alternative.  Columbia is North America’s largest manufacturer of hardwood plywood and hardwood veneer.

utilitycollective.com

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This adhesive is derived from food-grade soy flour and a wet strength resin used in printed currency and milk cartons.  Columbia's formaldehyde-free decorative panels are also compliant with the U.S. Green Building Council's Leadership in Energy and Environmental Design (LEED) standards, earning one point for LEED's EQ Credit 4.4 for Low-Emitting Materials: Composite Wood, and satisfy the emissions standards of the California Air Resources Board (CARB) Phase 2 regulations.  PureBond plywood is  cost-competitive with the standard UF construction of most decorative veneer-core hardwood plywood that are available and in some cases PureBond is less expensive than many other no-added-formaldehyde alternatives currently available.  Additionally, PureBond is even more water resistant than UF panels – approaching the requirements for Type I, or waterproof performance.  PureBond panels have also out-performed UF bonded panels in all moisture degradation tests.

 

Columbia Forest Products states that they use "sustainable harvesting practices" to help ensure the "long-term health of forested property", recycle scrap for fuel in their furnaces, and sell residual material to others who use it for mulch or other products.
The Green Parent List, a network of scientists and engineers who are also parents, have endorsed this product as Volatile Organic Compound (VOC) remains the main culprit for childhood asthma.  By eliminating added formaldehyde families can reduce their VOC exposure in the home.  Also, as the first building product to receive the Green Parents’ List Healthy Home check mark, the PureBond Plywood has zero VOC, especially no formaldehyde, a well known respiratory and skin irritant, especially to children.

In terms of obtaining PureBond plywood locally there is wide availability as Home Depot is one of the distributors for many varieties of the product.  Transportation of materials within the United States is lessened due to harvesting and manufacture occurring exclusively in the U.S.  Additional 825 cabinet shops and furniture manufacturer have partnered with Columbia Forest Products to provide that option in their services.

There are a wide range of wood species utilized as veneer for the hardwood plywood product including exotic species native to countries throughout the world.  While domestic species represent a more sustainable choice, veneers do lessen the impact of harvesting.  While not implemented with all of the Columbia harvesting practices certain hardwood veneer options can also be specified to use Forest Stewardship Council (FSC) Certified materials.  Thus far, and quite possibly for the foreseeable future, bamboo has arisen as a very sustainable "hardwood" material.  This grass is highly renewable and can be grown in many areas of the world.  It is extremely durable as well and therefore is an ideal choice for flooring or many other applications.  Due to the variety of sub-species of bamboo there are also some very interesting options for coloration and grain patterning.

An evaluation of the actual sustainability of this product can be assessed using the following set of generally accepted criteria:

Transportation:   

Because the product's content is grown and produced in the Pacific Northwest of the U.S. its transportation distance is limited somewhat.  It does require transportation to distribution centers across the country but because it is sold by Home Depot it is easily obtained by many consumers.  

Pre-Consumer Recycled Content:

Wood pulp and scrap wood are somewhat utilized in the production of the plywood and scrap wood waste is used to fuel manufacturing furnaces.

Post-Consumer Recycled Content:

In some applications, such as cabinetry and wall paneling, the material can be strategically removed to be repurposed and due to its composition of natural materials it can be recycled into base materials for new wood products.

CO2 (Greenhouse Gas) Emission:

This may be one of the least effective aspects of this particular material.  CO2 outputs continue to be realized through harvesting, transportation, and manufacture of the product.

Toxicity:

Off-gassing of this type of material is greatly reduced, if not negated by the use of natural materials (soybeans and wood components) although some wood species inherently emit low level toxins.

Durability:

I see no reason why there would be any short term degradation of quality if implemented correctly.  Flooring application would be most susceptible to deterioration.  Its water resistant characteristics would make it a more durable alternative to conventional plywoods.

Maintenance:

Should not require much, if any, maintenance for most applications.

Packaging:

Packaging of product to be shipped is most likely minimal although when I requested sample pieces to be sent they arrived individually wrapped in cellophane and boxed fairly elaborately.

Environmentally Responsible Company:

While Columbia Forest Products is a major manufacturing company with some environmental responsibility challenges to address by the nature of their size, they should probably be given credit for taking a lead on pursuing this technology.  They could have easily not confronted this but in doing so will have a significant impact on responsible forestry and harvesting techniques.  Also, by offering the product at a cost-effective price it will hopefully become the standard for this type of material.

Learning Outcomes

Through studies completed in response to a sustainable building materials exploration course, I have become more knowledgeable in these areas:

• Materials research in identifying categories (LEED/CSI) of design and construction uses such as masonry, wood/plastics/composites, concrete, metals, thermal & moisture protection, finishes, etc.     

• Determining general materials that correspond to these categories and how they can contribute and be integrated into a complete building system.  Accomplished by accessing the LEED and CSI specifications and understanding how they segregate materials and with LEED, then assign a points rating.

• Determining specific materials and products that are available within these general materials groups by accessing various websites.  These included: greenbuildingpages.com, greenbuildingsupply.com, the National Institute of Building Sciences, jetsongreen.com, buildinggreen.com, as well as blogs and other sites that explore possibilities for reclaiming and/or salvaging materials to be repurposed.

• Understanding how to establish a criteria for evaluating materials for their sustainability.  By looking at various established systems for analyzing "green" materials I was able to identify the most significant characteristics that were valued.  These appear to be pre-consumer recycled content, post-consumer recycled content, toxicity, packaging, transportation, durability, maintenance, and greenhouse gas emissions.  Most all of these factors can be evaluated in the various stages of the materials life cycle.  From natural resource and mineral extraction, transportation to production facility, the manufacturing energy needed and emissions produced, transportation to distribution locations, transportation to building sites, machinery needed to install, lifespan of materials, recycling of used materials, and waste produced.  There are many ways to evaluate and interpret the sustainability of building materials.  There seems to almost always be a cost/benefit relationship with an individual material and even more so when multiple materials are being used in the same application and their characteristics can work for and against each other.

• Established a format for evaluation of materials criteria in order to quantify information gathered.  By inputting all data into a spreadsheet document findings could be more easily understood and graded by parameters listed.

• Identified established furnishings that have an interesting design concept but may not utilize sustainable materials in their construction.  Documented materials used in these items and successes and failures where applicable.  Proposed alternative solutions for the implementation of materials to execute the chosen designs.

Furniture Design: Material Alternatives

Products offered by Design Within Reach include: a media credenza (solid walnut frame, walnut veneer over masonite); a 5-drawer cabinet (ebony & oak veneer); and a coffee table (solid walnut frame; solid ply tabletop with walnut veneer).

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In looking at the sustainability and environmental impact of the materials used in these products, here is an itemized analysis:

• solid walnut - Good material choice in terms of minimal off-gassing and/or toxicity. Can be a sustainable material if farmed/harvested responsibly or reclaimed from another use, which I'm guessing isn't the case here.
• walnut veneer - Same environmental and sustainability characteristics, although an ever better alternative to solid walnut in that there is less material needed to accomplish a similar look. This can only be a better alternative though if the substrate used is a green product.
• masonite - I can't seem to located any reliable information of sustainable qualities that it might have or its composition. It does contain formaldehyde which is a health risk. It is not recyclable or easily reusable and therefore contributes to landfill waste.
• ebony & oak veneer - Same qualities of all veneers in using less wood resources although oak is relatively plentiful, especially when farmed for harvesting purposes. Ebony is a much more endangered species, so even used in a veneer application is unsustainable.
• plywood - Unless otherwise specified this most likely contains formaldehyde. Plywood is in another sense fairly sustainable as it is comprised of scrap wood and pulp.

 An armoire offered by Copenhagen Furniture is apparently constructed of either teak or cherry wood veneer over an unspecified backing material with an acrylic lacquer finish.

http://copenhagen.dyndns.org/

In looking at the sustainability and environmental impact of the materials used in this product, here is an itemized analysis:

• teak & cherry wood veneer - Again, veneers in general are a good choice but these two species of wood are not the most sustainable option, especially teak wood.
• acrylic lacquer finish - Most likely a high VOC based finish and therefore will off-gas for a considerable amount of time and release toxic chemicals affecting indoor air quality.

 Products offered by IKEA include: a bed frame (particleboard, fiberboard, ash veneer, and acrylic paint); kitchen cabinetry (solid pine, stain, clear polyurethane/acrylic lacquer, particleboard, melamine foil, fiberboard, and acrylic paint); and a children's table (solid pine, stain, clear acrylic lacquer).

http://www.ikea.com/

http://www.ikea.com/

http://www.ikea.com/

In looking at the sustainability and environmental impact of the materials used in these products, here is an itemized analysis:

• particle board - Not a good choice at all, full of formaldehyde, very high indoor toxicity, and not recyclable.
• fiberboard - Again, generally full of formaldehyde as a binding agent, but certain types of fiberboard can be considered "green" building products. Consisting of bio-based, secondary raw materials (wood chip or sugarcane fibers) recovered from within 100 miles (160 km) of manufacturing facilities, the binding agent used in this type of fiberboard is an all-natural product, consisting of vegetable starch containing no added formaldehydes.
• ash veneer - A good choice for a veneer species. Highly abundant and easily accepts stains.
• acrylic paint - A synthetic product that requires heavy reliance on natural resources and produces much waste. Relatively high VOC ratings which affect indoor air quality.
• solid pine - Abundant species of wood but can produce low level off-gassing of toxins.
• polyurethane - Most likely an oil-based urethane and therefore has a high VOC rating. 
• melamine - A formaldehyde-based resin used as a laminate generally over particle board or fiber board. Not good.

Materials that might serve as more sustainable and environmentally sound alternatives to the ones used in the furnishings listed are:

• Any hardwood listed as "FSC-Certified" and therefore grown and harvested sustainably. Most U.S. domestic hardwoods have no to low levels of off-gassing. Veneers do consume less wood but the trade-off might be in the production energy needed to manufacture it. As with all products, keeping the production and transportation needs close to the farms is a better option.
• Formaldehyde-free plywoods that use soy-based or other organic binders are now becoming more readily available and the cost of these products is in some instances competitive with conventional plywood. There are FSC-Certified hardwood species that can be applied as veneers and bamboo in particular is a very sustainable grass/wood that can be used. Bamboo is also available in a variety of sub-species that are unique and attractive.
• Water-based urethanes and natural polymerized finishes are becoming more available also. Drawbacks are that the price of these products is quite a bit more than oil-based substitutes and the curing times can be significantly longer.
• Textile options were not shown above but there are good, sustainable options for those applications as well. There are fabrics for upholstery, fibers for lattice, and carpeting and flooring options that can be much more environmentally friendly. Many use high percentages of post-consumer recycled content and have a lessened impact on natural resources.

Spreadsheet Evaluation of Materials Researched

Terratex Flooring Fabric

These products are offered by Interface, which specializes in the design, production and sales of environmentally-responsible modular carpet for commercial, institutional, and residential markets.  Interface has been recognized for its environmental policies and practices that include: providing employee seminars and workshops to educate and involve employees in the company's environmental policies and goals; sponsors educational newsletters, education seminars for the general public regarding environmental issues; published policies in production & manufacture, product disposal, installation use and maintenance, and a company social profile; and has a facility recycling waste program in place.  They also have a stated goal of achieving a zero environmental footprint by 2020.  By all appearances this is a really environmentally responsible company that produces attractive, contemporary designs for their stated purpose.

The Terratex flooring fabrics in particular are made from 100% recyclable or renewable material, manufactured using sustainable processes, and are recyclable or compostable at the end of it's life.  There are also LEED Credit-Opportunity Contributions in: Rapidly Renewable Materials, Recycled Content categories. 

This product has been recognized for excellence in the following categories: little or no extraction impact, 50% post-consumer recycled content, 50% post-industrial recycled, no toxic or carcinogenic materials or chemicals used, 100% disclosure of input materials; no greenhouse gas emissions, no ozone-depleting gases used or emitted; no machinery required for maintenance; no off-gassing during installation, use and maintenance; product can be easily disassembled for alternative disposal, product reclamation program in place; 100% of product can be reused, 100% of product can be recycled; exceeds OSHA standards in all facilities; company compiles and publishes an annual Sustainability Report available to the public; no animals or animal by-products used in any product or process; 100% sustainable on-site energy, green energy provider; and company occupies three LEED certified buildings (1 LEED silver,  1 LEED platinum, & 1 LEED gold).

 

 

 

Old Fashioned Milk Paint

Made by The Old Fashioned Milk Paint Co., Inc., these paints are certified USDA Bio-based and offer LEED Credit-Opportunity Contributions in: Regional Materials, Rapidly Renewable Materials, IAQ Performance, Low-Emitting Materials - Paints and Coatings.  It is an all natural, biodegradable paint in powder form containing no preservatives and zero VOC's.  As in originally produced home-made milk paint, they use milk protein, lime, clay, and earth pigments such as ochre, umber, iron oxide, lampblack, etc.  The lime is alkaline but becomes totally inert when mixed with the slightly acid milk.  They use no lead, no chemical preservatives, and no fungicides.  Also, this milk paint contains no hydrocarbons or any other petroleum derivatives.  It is environmentally safe and non-toxic.  There is a slight milky odor when it is applied, but it is completely odorless when dry.  The paint is safe for childrens furniture and toys, and can also be used for interiors of homes of people who are allergic to modern paints. 

This product was a 2009 Green Building Pages award winner while excelling in the following areas: little or no extraction impact, 100% renewable resource content, no toxic or carcinogenic materials or chemicals used; no outputs on Toxic Chemicals Lists; water conservation/no water used; no greenhouse gas emissions, no ozone-depleting gases used or emitted; packaging is less than 5% of purchased product volume, 50% post-industrial content packaging, 100% non-toxic, non-carcinogenic, biodegradable packaging; average distance from supplier to manufacturer is less than 50 miles, average distance from manufacturer to distribution is l01-500 miles; no off-gassing during installation, use and maintenance; life expectancy of product is greater than 50 years or 100% biodegradable after product renewal, no diminution of performance over time; 100% of product can be recycled, 100% of product is non-toxic, biodegradable.

 (image borrowed from: http://www.milkpaint.com/prod_mp.html)

ThermaSteel Panels

These pre-insulated, light guage steel framing panels are 100% recyclable (galvanized steel and expanded polystyrene) and are utilized in foundation, floor, wall, roof and ceiling applications for residential, commercial and industrial projects as well as infill or curtain for high-rise construction.  They are Energy Star certified and provide LEED Credit-Opportunity Contributions for Energy Performance, ControlLability of Systems - Thermal, Thermal Comfort - Design, Recycled Content, and Innovation & Design.  Due to the prefabricated nature of their construction the panels complete four functions at once: framing, insulation, sheathing, and vapor barrier.  Window and door rough openings can be pre-molded as well.  They have higher "R" values due to greater thermal efficiency, are quickly installed, have good wind resistance, and produce very little job site material waste.

This product, manufactured by ThermaSteel Corporation, was deemed a 2009 award winner by Green Building Pages and rated highly in the following areas: no outputs on toxic chemicals lists, no ozone-depleting gases used or emitted, no off-gassing during installation, use and maintenance, no packaging used, no machinery required for installation, no toxic or carcinogenic materials required for installation, life expectancy of product is greater than 50 years or 100% biodegradable after product renewal, no diminution of performance over time, 71% of product can be reused, and 100% of product can be recycled.

It also uses 90% post-consumer recycled content in its production, the average distance from supplier to manufacturer is l01-500 miles, the average distance from manufacturer to distribution is 501-1000 miles, the product can be easily disassembled for alternative disposal, and no animals or animal by-products used in any product or process.

Steel framing can also provide the following benefits over traditional wood framing: warranty call-backs are minimized because steel does not shrink, split, or warp and as a result, there are no nail pops or drywall cracks to fix after the structure is completed.  Consistent quality of material means that scrap is drastically reduced (2% for steel versus 20% for wood).  Steel framing is easier to handle because steel studs weigh 1/3less than wood studs, and can be installed at 24” on center.  Long term maintenance costs are reduced because steel is resistant to rot, mold, termite and insect infestation and provides good indoor air quality because steel does not emit volatile organic compounds (VOCs).  Also, in most residential applications, additional plywood or OSB is added as sheathing. With steel panels sheathing is not required on the exterior walls.  Any exterior cladding can be used which reduces material costs for items that are not needed.  Steel panels also reduce the time it takes to build as it is lighter and you can move the material around easier.  With most stick framing, a builder has to cut the lumber to size, frame, drill holes for wiring, insulate, and sheath.  Steel panels are custom made based on a set of architectural drawings and arrive at the job site cut to the correct heights, framed, have pre-molded wire chases, and are pre-insulated.  Many steps are eliminated lowering the cost of labor and time needed to construct.  Additionally, using EPS (expanded polystyrene) as an insulator reduces air leaks and is recyclable.  Using a steel insulated panel with EPS has its own built in vapor barrier which allows the panel to breathe but also eliminates the cause of molding.  Also, there is no wood for the invitation of termites and other wood-boring insects.

(images borrowed from: http://www.thermasteelcorp.com/scouten1.html)

 

PaperStone & RainStone composite surface material

This interior surfacing material can be used in many applications: conference tabletops, counter tops, signs and plaques, window sills, restroom partitions, cabinets, indoor wall cladding, as well as cutting boards and cutlery handles.  It is extremely hard, practically impervious to water, scratch resistant, highly resistant to staining, and can bear temperatures to 350 degrees.  Also, both products are made from sustainable sources containing 100% post-consumer recycled cardboard or 100% recycled standard office paper.  Additionally, there are LEED Credit-Opportunity Contributions in the following categories:  Materials Reuse, Recycled Content , Low-Emitting Materials - Composite Wood, Agrifiber & Laminate. These two products were rated using specific criteria to grade its "life-cycle" attributes by a public, web resource guide, Green Building Pages.  They scored highly in various categories and well enough overall to be deemed a 2009 award winner based on the Green Building Pages evaluation.  

Areas that were judged to to be exceedingly sustainable in their characteristics were:  a zero-impact carbon footprint (99% reduction of greenhouse gas emissions/no ozone-depleting gases used or emitted); packaging (packaging is less than 5% of purchased product volume, 50% post-consumer content packaging, 10% post-industrial content packaging, 100% non-toxic, non-carcinogenic, biodegradable packaging, steps taken to reduce packaging); no off-gassing during installation, use and maintenance; living wage policies are available to the public and the CEO (or highest paid employee) salary is less than 10 times lowest wage; company has publicly-accessible human rights policy and a publicly-accessible child labor policy; product certifications include: FSC, Smartwood; no animals or animal by-products used in any product or process and products have been independently tested. 

Areas that did not score as well and/or showed room for improvement were:  transportation (the average distance from supplier to manufacturer is 501-1000 miles), durability & performance (life expectancy of the product is 20-29 years); just 60% renewable resource content; product reclamation & reincarnation (cannot be easily disassembled for alternative disposal and only 46% of product can be reused).

Overall, it appears to be a really sustainable, multi-use material choice that earns LEED credits.  There are 9 color options, 3 panel sizes, and thicknesses ranging from 1/4" to almost 3".  More information can be found at the PaperStone website.

(images borrowed from: http://www.paperstoneproducts.com/)

 








Rating criteria?

Plyboo: Bamboo Plywood & Flooring

In 2008 PlybooPure FSC-certified bamboo flooring was selected as a "Top-10 Green Building Product" by BuildingGreen, publisher of Environmental Building News, the architecture and design industry's most respected source of information on sustainable building and design.  The line of products are available from Smith & Fong, who originally started in 1989 as designers and manufacturers of art-craft quality bamboo pieces.  Smith & Fong's bamboo forests require no pesticides, fertilizers or irrigation, and an average of 20 percent of the bamboo forest is harvested in any given year, thereby leaving 80 percent of the forest standing at all times.  Their certified Plyboo products qualify for the FSC Pure designation, as they are 100% FSC material from an FSC-certified forest and have been sold and/or processed by an FSC chain-of-custody certified company.  Additionally, all the wood for the Sideways flooring line is domestically sourced, FSC Pure, and made in the U.S..  The manufacturing processes use 100% formaldehyde-free adhesives to ensure indoor air quality.  The resulting finish and appearance of the engineered hardwood flooring comes from a proprietary thermal treatment process that requires no added stains, dyes or toxic chemicals to achieve its look.  The Smith & Fong website also provides corresponding LEED credits available for the individual products that they offer.  Smith & Fong maintains a direct relationship with their bamboo farmers, ensuring responsible harvesting practices and a level of quality control not found in bamboo on the open market.  Their bamboo stalks are selected by hand, resulting in the harvest of mature bamboo and ensuring that the bamboo canopy is evenly culled (left about 80% intact every year).  100% of the forest can be sustainably harvested over a five- or six-year period, as moso bamboo ("timber bamboo") matures at 5 - 6 years of age.  Bamboo should not be harvested until after it matures and hardens into a reliable product.  The range of products offered could be used in a variety of applications; including cabinetry, furniture, gym floors, commercial and residential flooring, and other creative architectural purposes.

 

(images borrowed from: http://www.plyboo.com/)

Non-Toxic Wood Finishes

Tried & True Traditional Finishes are made using traditional 18th-century production techniques.  Unlike most finishes being sold they don't contain petroleum distillates, solvents or heavy metal drier additives.  Produced largely from polymerized linseed oil with other natural-product additives, the finishes strictly adhere to the standards established by the FDA (Food and Drug Administration) and qualify as non-toxic and safe for food-contact surfaces in both their uncured and cured (wet and dry) states.  Types of finishes available include their Original Wood Finish, Danish Oil and Varnish Oil.  I have personally used the Danish Oil and find it to be very effective with a high-yield of coverage.  The company that manufactures the finishes sells them directly via their website but I found the cost to be a little cheaper through the Lee Valley Tools website which is a great place to find lots of things related to woodworking and otherwise.  

 

(image borrowed from http://www.leevalley.com/us/wood/page.aspx?c=&p=45105&cat=1,190,42942)

Formaldehyde-free Hardwood Plywood

Purebond formaldehyde-free hardwood plywood is a relatively new product being offered by Columbia Forest Products.  This plywood is advertised as non-toxic and utilizes a formaldehyde-free, soy-based adhesive.  It is also compliant with the U.S. Green Building Council's Leadership in Energy and Environmental Design (LEED®) standards.  I have found that it is really cost-competitive with other, existing hardwood plywood and is offered with either a veneer or composite core.  It is apparently very water-resistant and the hardwood components can be specified as "FSC-certified", meaning the wood is sustainably grown and harvested.  They offer a fairly wide range of species, including Bamboo, which is a very sustainable option and really attractive.  I purchased the Birch, veneer-core for a project and have been really satisfied.  The 3/4" sheets are really light-weight and it routs surprisingly well for a plywood.  The more "exotic" domestic wood species (Walnut, Cherry, Maple, etc.) increase significantly in price but the Birch is a real bargain.  There are distributors scattered around the U.S. and some Home Depot stores carry it as well.  More information, including the option to order (free of charge) can be found at Columbia's website.

 










  
   

(images borrowed from http://www.columbiaforestproducts.com/PureBond.aspx)