New OSB Product Formulation Test

Nick Gierc

January 7, 2010

Presentation Overview

Resin overview Test proposition Plant testing procedure Quality assurance testing Conclusions & results

Resin Overview

Two most common resins for OSB production:

Phenol formaldehyde (PF) Diphenylmethane diisocyanate (pMDI)

Both PF and pMDI are derivatives of Benzene which is by-products from petroleum industry.

Resin Overview Continued

Phenol Formaldehyde (PF) Dominant resin used for both plywood and osb

adhesion. Cured PF is considered “water proof”. Produces “mechanical” bonds to wood substrate Formulation:

Phenol + Formaldehyde + additives/extenders. Reaction carried out in high pH water solution. Resin reaction is uncompleted to allow for short-chain

molecule bonding to the wood substrate to completion.

Resin Overview Continued

Diphenylmethane diisocyanate (pMDI) Produces “chemical bonds” with the wood

substrate . Chemical bonds are stronger with pMDI vs the

mechanical bonds of PF. Reaction occurs with between the hydroxyl groups

on the wood substrate and the isocyanate groups (-N=C=0) forming solid, insoluble, polyureas.

Polyureas are stable to chemical attack and insoluble

Resin Overview Continued

Application resins used to make OSB are supplied to manufacturers as

short polymer chains, which are not capable of functioning as an adhesive without further polymerization.

Resin applied as either: water-based solutions – sprayed onto wood non-aqueous solutions – sprayed onto wood powder – mechanically blended with wood

Resins are chemically active before application to wood but are controlled when added in the factory through temperature, and other factors.

Test Proposition

Due to the Mountain pine beetle (Mpb) epidemic in British Columbia, and now passing into regions of Alberta, there are millions of m3 of Lodge pole pine which have become economically unfeasible to produce due to deteriorated lumber grade recovery.

This test will investigate how different blends of MPB fiber with the current Aspen blend affect internal bond, thickness swell, MOR, MOE properties of our OSB product.

This test will also investigate the different bonding strengths of both PF and pMDI resins and how it affects internal bond, thickness swell, MOR, MOE properties of our OSB product.

Hypothesis !

Lower MC on the MPB fiber could yield lower drying cost to the OSB process as compared to Aspen.

The residuals (sawdust, bark etc) might require less BTU’s to heat as compared to Aspen residuals.

MPB fiber usually displays a much lower moisture content (20% MC) as compared to green Aspen (30%+ MC).

Pine might have superior mechanical properties as compared to aspen or there might be an advantage to create a highbred specie (combination pine + aspen) to maximize the benefits of both species.

Potential increase in cost/ton to transport MPB vs Aspen species for both log deliveries and panel shipments.

It is EXTREMELY IMPORTANT that the new product meets or exceeds the customers expectations of the current Aspen product!

Testing Procedure

Testing Procedure Continued

The test will consist of 16 boards of varying characteristics. Due to the specie difference, the test will probably need to be conducted in 3 downtime sessions First session – Aspen Test (boards 1-4) Second session – Pine Test (boards 5-8) Third session – Hybrid Test (boards 9-16)*

* In the event that Pine and Aspen can’t be separated in the production flow, the test will be condensed to a uniform mix of Pine & Aspen blend instead of separate core and surface blend (boards 9-12)

Testing Procedure Continued One board will be produced for each test

Board formulation will be changed each time at the blender and press per board

Board will be tracked through press, trimmed to size and identified (1-16) at the sizing station.

Sized test boards will then be allowed to cool in accordance to Quality Management System

Boards will them be tested following APA Quality Assurance Policies for Structural – Use Panels Qualified to PRP-108*

Quality Assurance Testing

APA Test Method D-7 Moisture Cycles for Quality Assurance Bending Test

APA Test Method S-14 Quality Assurance Bending Test

APA Test Method P-1 Linear Expansion and thickness swell measure from oven dry OR 50% relative humidity to vacuum pressure soak

Quality Assurance Testing

APA Test Method D-7 Moisture Cycles for Quality Assurance Bending Test

Specimen cut in accordance to ASTM D-3043 section 8.2, except that the specimen width shall be 4 ½” by 14” long

Used to evaluate bond performance Specimens placed in vacuum pressure vessel with water at

65+/-10F. Vacuum of 27+/-2 Hg applied for 30 minutes Specimens then soaked for 30 minutes at atmospheric

pressure Specimens are removed from the cylinder and tested wet. Compare to Table 4 in APA PRP 108* book

Quality Assurance Testing

APA Test Method S-14 Quality Assurance Bending Test

Specimen cut in accordance to ASTM D-3043 section 8.2, except that the specimen width shall be 4 ½” by 14” long

Used to evaluate bond performance Specimens are tested dry Compare to Table 3 in APA PRP 108* book

Quality Assurance Testing

APA Test Method P-1 Linear Expansion and thickness swell measure from oven dry OR 50% relative humidity to vacuum pressure soak.

This test provides a quick evaluation of a panel’s dimensional stability.

Specimens at cut at least 3” with and at least 12” long. Specimens selected to avoid large characteristics such as

knotholes, knots, splits etc. Testing apparatus is added to the test specimens. Specimens conditioned at 50% (+/-5%) RH and 70 F (+/-6 F)

until a constant weight is achieved.

Quality Assurance Testing

APA Test Method P-1 Linear Expansion and thickness swell measure from oven dry OR 50% relative humidity to vacuum pressure soak.

Constant weight is achieved when 2 samples, 24 hrs apart agree within 0.2%.

Preconditioned length and thickness is measured and recorded. Specimens are now placed in a pressure cylinder and flooded

with 65+/-10 F tap water and subject to a vacuum of 27+/-2 Hg for 1 hour.

Specimens then subject to 2 hours of pressure of 100 lbs/in2 After exposure specimens are measured for length and thickness. % change = ((Lw – Lpc) / Lpc ) * 100 Lw = dimension saturated Lpc = dimension pre-conditioned

Process Control Information

Additional information to collect during test. Final weight of each sample boards prior to specimens being

removed. Weight of each resin consumed per test board Final moisture content of sample boards Sample of flake distribution of each sample board to determine %

pins, fines, accepts, over. % furnish recovery per log BTU’s required to dry furnish to target furnish moisture content. Press cycle time per board sample

All this information is required to determine financial feasibility in conjunction with the quality testing data.

Data Analysis All quality control and process control data

needs to be analyzed.

Summarize the quantitative characteristics of the Pine vs. Aspen vs. Hybrid.

Summarize the quantitative characteristics of PF vs pMDI.

Look for trends in the testing by graphing data and running statistical functions.

Determine other characteristics such as weight per panel, BTU usage/Msqft of species etc.

Conclusions

Quality Testing Conclusions? Is the product better? Will the customer accept the new product? Will the customer pay more for a superior product?

Financial Conclusions?

At the end of the day, will the change make the

plant more revenue?!

Thanks for your timePresented by:Nick Gierc

Reference Material:- APA Quality Assurance Policies for Structural – Use Panels Qualified to PRP-108*

- http://www.entrepreneur.com/tradejournals/article/199193624.html - Evaluation of oriented strandboard and plywood subjected to severe relative humidity and temperature conditions.

- Phenolic resins: chemistry, applications, standardization, safety, and ecology by Arno Gardziella, Louis Pilato, André Knop

- Understanding Properties of Commercial OSB Products by Siqun Wang, Hongmei Gu and Trairat Neimsuwan