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Particleboard and Medium-Density Fiberboard OCTOBER 2001 PARTICLEBOARD AND MEDIUM-DENSITY FIBERBOARD ince U.S. production of particleboard began after World REPORT S War II, this practical and inexpensive alternative to solid wood has become one of the nation’s leading building materials. The floor you walk on, your workstation at the office, your household cabinets, and the walls and doors of your home may well contain particleboard (PB) or medium-density fiberboard (MDF), a similar product whose manufacture began in the United States in the mid-1960s. Production and use of PB and waste paper MDF have grown dramatically in and the past decade, replacing more agricultural and more solid wood lumber and residues as plywood products. In fact, the raw combined production of PB and materials. MDF in North America during Use of these 1999 was approximately 10.7 materials can million cubic meters␣ (over 12 divert wastes 3 billion square feet of /8-inch thick The amount of from panel). landfilling or agricultural burning. Though easy to produce and waste fiber far These well-suited for a host of uses, most exceeds present alternative PB and MDF, as currently materials and future fiber manufactured, use formaldehyde- include straw based resins, which emit requirements for residue, which formaldehyde gas from factories, production of PB is the stem of into the workplace, and into the a grain crop, and MDF. home. Formaldehyde is considered such as rice or a probable human carcinogen, and wheat, and inhalation of even small amounts bagasse, the residue from sugar of the gas can increase risks of cane processing. The amount of SEAL’S cancer. Some manufacturers are agricultural waste fiber far now turning to more benign resins exceeds present and future fiber to bind the wood products. requirements for production of PB and MDF. Most residual straw and Meanwhile, though PB and MDF bagasse is now burned, which are currently manufactured contributes to air pollution and primarily from wood residues from global warming. production of lumber and plywood, there is the opportunity to utilize From an environmental post-consumer waste wood and standpoint it is also important to GREEN make sure that the recycled content of wood-fiber-based PB WHAT’S WHAT: SOME KEY DEFINITIONS and MDF is as high as possible and that little, if any, virgin wood is Post-consumer Materials: Materials or finished products that have used. Recycled content saves trees. served their intended use, been diverted or recovered from waste This report evaluates various destined for disposal, and formed into useful consumer items. Post- methods of producing PB and MDF consumer materials are part of the broader category of recovered and the associated environmental and health impacts. It also makes materials. recommendations that will inform consumers and guide them to Pre-consumer Materials: Materials generated by manufacturing and environmentally preferable—and converting processes, such as manufacturing scrap and trimmings/ safer—PB and MDF products. cuttings. Also called post-industrial materials. Recovered Materials: Waste materials and byproducts that have been PB and MDF: recovered or diverted from solid-waste streams; this category does not Hard-Pressed and include materials and byproducts generated from, and commonly Bonded for Life reused within, an original manufacturing process. Particleboard (PB) is a panel product made of sawdust and Resin: The chemical material that binds the fibers together to produce wood shavings bonded together by particleboard or medium density fiberboard. Also called “binder.” urea formaldehyde or other synthetic resin and pressed into sheets. Used primarily as core veneer or another surface finish. The manufacture of PB in the material for doors, furniture, and In housing construction, particle- United States began on a large cabinets, particleboard often is board is used under carpet or scale after World War II as a low- covered on one or both sides with other finished surfaces as floor cost replacement for lumber and underlayment and stair treads; it plywood in furniture and The Choose Green Report is published is also used as floor decking in cabinetry. Some twenty years later, for Green Seal Environmental Partners. mobile homes. in 1966, the first North American To become an Environmental Partner, MDF plant began production in or to receive a copy of this report, contact Green Seal at (202) 872-6400 or Medium-density fiberboard New York. Demand for PB and greenseal@ greenseal.org. (MDF), a composite board made of MDF has grown dramatically in Green Seal President and CEO, wood fibers bonded with urea the past decade, replacing more Arthur B. Weissman, Ph.D. formaldehyde or other synthetic and more solid wood lumber and Editor, Mark Petruzzi resin, has a smooth surface and plywood products. good machinability. MDF is used as Researchers and Writers, Gary Davis, Rajive Dhingra, University of Tennessee a replacement for wood boards in While demand for PB and MDF Center for Clean Products and Clean furniture, cabinets, moldings, and is increasing, there are concerns Technologies picture frames. Like PB, the wood that the availability of wood residues used to manufacture MDF residues is not keeping pace with Design, Cutting Edge Graphics come from sawdust and shavings this demand and that the price is Printed on Green Seal-certified from lumber and plywood increasing. This has led some Mohawk Satin Cool White Recycled manufacturing processes. producers to look toward paper, 30% postconsumer content alternative sources of fiber, such This Choose Green Report was produced as agricultural waste products and with assistance from the U.S. Environmental Protection Agency’s wood and paper waste. Aside from Pollution Prevention Division. any economic advantage, these alternatives also present Copyright © 2001, Green Seal, Inc. www.greenseal.org environmental benefits such as diversion of waste from landfills or GREEN SEAL burning. Environmental Partner 2 Choose Green Report The type of resin used to bind continue to If These Walls Because no Could Talk the wood fibers determines the release small type of air emissions released threshold has amounts of Environmental Impacts of during the pressing process; been determined formaldehyde PB and MDF typically these emissions include gas. Producers below which A portion of the trees cut for formaldehyde compounds, such as have generally lumber and plywood production urea formaldehyde. Primary exposures do not met industry become sawdust and trimmings finishing steps for PB and MDF increase the risk standards and that are used in PB and MDF. If include cooling or hot stacking, have reduced of cancer, trees are harvested for direct use grading, trimming/cutting, and formaldehyde in these products, then the impacts sanding. Secondary finishing steps formaldehyde emissions from from growing and harvesting these include filling, painting, remains a health PB an average trees must be considered as part of laminating, and edge finishing. of 80 percent concern even at the environmental profile of PB below 1980 and MDF. Information obtained When used in the home in lower levels. levels, from industry sources shows that furniture, subflooring, or stair primarily by approximately 25% of the treads, PB and MDF made with reducing the ratio of formaldehyde production capacity in the U.S. and formaldehyde-based resins to urea in resin formulations. Canada uses some virgin wood in their products, ranging from 1 to 80% virgin content, averaging FORMALDEHYDE TOXICITY 34%. According to the EPA, formaldehyde is a probable human carcinogen The wood residues are either when inhaled or ingested. In fact: ground into particles (for PB) or ■ Breathing even small amounts of formaldehyde may increase the risk steam heated to break down the residues into fibers (for MDF), then of contracting lung and nasal cancer. dried to lower moisture content. ■ Chronic formaldehyde exposure can cause menstrual disorders and Many dryers are directly heated by pregnancy problems in women workers exposed to higher levels. combustion of a portion of the ■ Short-term inhalation exposure can result in eye, nose, and throat wood residues; others are heated by burning oil or natural gas. irritation and respiratory symptoms. Dryers release wood dust, carbon monoxide, carbon dioxide, Standards have been set by industry for formaldehyde emissions from nitrogen oxides, fly ash, volatile all wood products and by the U.S. Department of Housing and Urban organic compounds—such as terpenes, resin, and fatty acids— Development for wood products in manufactured homes. that evaporate from the wood, and combustion and pyrolysis American National Standards Institute (ANSI) standards for products, such as methanol, acetic particleboard flooring products restrict formaldehyde gas emissions to acid, ethanol, formaldehyde, and furfural. 0.2 parts per million (ppm) as measured in the American Society for Testing and Materials (ASTM) large chamber test. All other materials After the fiber is dried, it is must emit less than 0.3 ppm to meet the ANSI blended with wax, a synthetic standard. HUD regulations for materials used resin such as urea formaldehyde, and other additives and formed in mobile homes limit emissions to 0.3 into mats. The mats are processed ppm. According to EPA’s Integrated Risk in large presses that use heat and Information System, if these levels pressure to cure the resin and were to occur in indoor air, and an form the product into sheets or boards. Presses are usually heated individual had lifetime exposure, by steam, which is generated by a the risk of cancer would be higher boiler that burns wood residues. than generally considered acceptable. Choose Green Report 3 However, because formaldehyde is grass seed in the Northwest are In addition, the properties of believed to cause cancer, and producing large amounts of straw. strawboard, such as internal bond because no threshold has been For PB and MDF manufacturers, strength, resistance to rupture, determined below which this is a case of one industry’s moisture resistance, and screw- exposures do not increase the risk trash being another industry’s holding strength (as measured by of cancer, formaldehyde remains a treasure.
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