GREEN SEAL’S

REPORT the mid-1960s.the in a similarproduct States United whosemanufacture beganinthe (PB)ormedium-densityfiberboard (MDF), contain particleboard wallshousehold cabinets,andthe anddoors ofyour homemaywell youThe floor walk your on,your office, workstation atthe wood nation’s hasbecomeoneofthe leadingbuildingmaterials. MEDIUM-DENSITY FIBERBOARD MEDIUM-DENSITY PARTICLEBOARD AND billion squarefeetof (over12 million cubicmeters␣ 1999 wasapproximately10.7 MDF inNorthAmericaduring combined productionofPBand plywood products.Infact,the and moresolidwoodlumber the pastdecade,replacingmore MDF havegrowndramaticallyin post-consumer wastewoodand there istheopportunity toutilize production oflumberandplywood, primarily fromwoodresidues from are currentlymanufactured to bindthewoodproducts. now turningtomorebenignresins cancer. Somemanufacturersare of thegascanincreaserisks inhalation ofevensmallamounts a probablehumancarcinogen,and home. Formaldehydeisconsidered into theworkplace,and formaldehyde gasfromfactories, based resins,whichemit manufactured, useformaldehyde- PB andMDF, ascurrently well-suited forahostofuses,most panel). Production anduseofPB Meanwhile, thoughPBand MDF Though easytoproduceand S War II,thispractical andinexpensive alternative tosolid Worldince U.S.production after began ofparticleboard 3 / 8 -inch thick standpoint itis alsoimportantto global warming. contributes toairpollution and bagasse isnowburned,which and MDF. requirements forproductionofPB exceeds presentandfuturefiber agricultural wastefiberfar cane processing.Theamountof bagasse, theresiduefromsugar requirements for production ofPB exceeds present and futurefiber waste fiberfar The amountof From anenvironmental agricultural and MDF.

Most residualstrawand OCTOBER 2001 wheat, and such asriceor a graincrop, is thestemof residue, which include straw materials alternative burning. landfilling or from divert wastes materials can Use ofthese These waste paper and materials. agricultural raw residues as 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. In fact, the amount of tests developed by the American health concern even at these lower residual straw generated by U.S. National Standards Institute or the levels. agriculture (estimated at over 100 American Society for Testing and million metric tons) far exceeds Materials), are equal to or better present and future fiber than wood-based PB and MDF. Greener Choices requirements for PB and MDF And, because formaldehyde-based manufacture. resins are not used with board Alternative Fiber Sources made from straw and bagasse, the Clear the Air, Clear the Fields Bagasse, another source of fiber resulting product does not carry by Using Agricultural Waste for PB and MDF, is the residue the health risks associated with Fiber from the processing of sugar cane formaldehyde. Straw is the stem of a small- for sugar production. This waste grain cereal plant, such as wheat product is currently disposed of in Currently, six plants in the or rice, or the shaft left after the large quantities in Louisiana, United States produce PB and MDF growing of grass for grass seed. Florida, and Hawaii. In fact, more from straw and bagasse. These While some straw is left to than 4.5 million tons of bagasse include strawboard plants in North condition the soil, in many places generated each year in the United Dakota (Primeboard, Inc.), it is cleared from fields after grain States is typically burned in steam Minnesota (Isoboard Enterprises), harvest by boilers, which creates more air California (Fiber Tech), and Idaho burning, which Some 500,000 emissions than other energy (Pacific Northwest Fiber) and has caused acres of rice sources, such as natural gas. sugar cane bagasse plants in serious air Louisiana (Acadia Board) and pollution fields in Using straw or bagasse as the Hawaii (Hawaiian DuraGreen). problems. For California’s fiber for PB and MDF provides an Another strawboard plant, which example, some Sacramento alternative to burning straw in will use rice straw, is under 500,000 acres fields or disposing of bagasse by construction in California. These of rice fields in Valley produce burning it in steam boilers. plants are located near the sources California’s about 1.5 million Although processing straw into PB of the straw or bagasse to keep Sacramento tons of rice and MDF is similar to processing transportation to a minimum. Valley produce wood residues, breaking straw into about 1.5 straw that fibers requires less processing and Reduce the Waste Stream million tons of traditionally less drying, therefore less energy through Use of Post-Consumer rice straw that Wood and Paper was burned in use. traditionally The solid-waste stream in the was burned in the field each United States contains the field each year. approximately 16 million tons of year. Such recoverable solid wood waste from burning was creating 56,000 tons the municipal, construction, and of carbon monoxide annually in demolition solid-waste streams. In California alone, along with addition, 79 million tons of waste particulate matter, carbon dioxide, paper disposed of each year could and other air pollutants. provide another source of fiber for Because of adverse health PB and MDF. Using post-consumer effects associated with such wood and paper waste for PB and pollution, California is phasing out MDF could potentially divert some straw burning and is requiring rice 95 million tons from landfills and growers to find alternative means decrease the harvesting of trees. of straw disposal. Meanwhile, Locating PB and MDF plants near wheat production in the Midwest urban areas would provide access and the cultivation of bluegrass for to wood and paper wastes and

4 Choose Green Report place the finished product in certified by independent well-managed forestry carefully proximity to users. certification organizations. Most balance ecosystem health with the producers of PB and MDF with amount of timber harvested from One company, Homasote, pre-consumer recycled wood the forest. Invasive management produces an MDF-like board from content, however, use techniques, like clear-cutting and post-consumer recycled waste formaldehyde resins in the board. biocide use are minimized. Non- paper, recycling approximately invasive management practices 80,000 tons per year. Homasote Promote Sustainable Forest such as riparian buffer zones, uses a formaldehyde-free wax Practices by Using Sustainably balanced-age distribution, and emulsion as the binder and a Managed Wood Sources integrated pest management are closed-loop manufacturing process Even if the wood fiber for PB always preferred over invasive that recycles all water used. and MDF is pre-consumer recycled techniques. PB is available Unfortunately, while and recovered containing wood fiber derived there are PB material, by from sustainable forestry, but products available demanding that these products currently use that are made from this wood fiber be formaldehyde-based resins. recycled wood from trees grown products, such as and harvested in a Alternative Resins waste pallets, they sustainable manner, builders Methylenediphenyl Isocyanate use formaldehyde- (MDI) can reduce the based resins. The most widely used overall impacts of alternative to urea formaldehyde forestry practices Reduce the Waste for PB and MDF is methylene- for lumber and Stream by Using diphenyl isocyanate (MDI). Unlike Pre-consumer plywood products. most wood-based PB and MDF Recycled and There are products that are made with Recovered Wood organizations that Residues formaldehyde-based adhesives, certify wood Most PB and MDF products made with MDI do not products that have contains wood emit a toxic gas during use. While been produced with wood from residues from lumber and plywood MDI has other advantages, such as sustainably managed forests. For production. The PB and MDF the ability to bond to wood instance, the Forest Stewardship industries, along with other panel particles with higher moisture Council and its independent industries, consume approximately content and requiring less dryer certifiers apply criteria to certify 10 million metric tons of these energy and lower press that the source of wood for wood residues per year. Depending temperatures (which may lower products is a “well-managed” on the plant and the process, these air emissions), there are concerns forest: one that maintains the raw materials may be considered about MDI toxicity for workers essential characteristics of a pre-consumer recycled content or exposed during PB and MDF natural forest before and after a recovered materials. manufacturing. MDI can be used timber harvest. FSC standards of

Pre-consumer and recovered materials are those that otherwise MDI TOXICITY would end up in the solid waste stream. PB and MDF with high MDI is a hazard for workers in PB and MDF plants, although controls content of pre-consumer and to prevent exposure are generally in place. MDI can cause dermatitis recovered materials divert wood and respiratory diseases in workers and may alter the immune system, waste from disposal and is an indication that little or no wood resulting in sensitization of the respiratory system and asthma-like fiber was produced and harvested reactions. It is not considered a carcinogen in humans, but there is for direct use in the product. Some limited evidence of tumors in animals. While OSHA’s Permissible manufacturers have had the pre- Exposure Limit for MDI in the workplace is less than that for consumer and recovered material content of their PB and MDF formaldehyde (0.02 ppm versus 0.75 ppm), MDI does not present an exposure risk in the finished PB and MDF products.

Choose Green Report 5 for wood-based PB and MDF and manufacturers of PB and MDF. A 1. Agricultural Waste Fiber, for products made with strawboard, available in the Formaldehyde-Free: agricultural agricultural residues, for which United Kingdom under the name residues that would have been formaldehyde-based adhesives are Stramit, uses the natural lignin in burned, bonded with a generally not suitable. straw, together with high formaldehyde-free resin; temperatures and pressures, to Naturally Derived Adhesives bind the straw fiber; this type of 2. Post-Consumer Waste Fiber, Environmental and human strawboard is not currently Formaldehyde-Free: post- health concerns have prompted manufactured in the United States. consumer paper waste, bonded researchers to develop naturally with a formaldehyde-free resin; derived adhesives and resins for Market Survey: wood products. While alternatives, What’s Available 3. Recovered Wood Fiber and such as resins manufactured from Formaldehyde-Free: pre- furfuryl alcohol or lignin There are three categories of consumer wood residues, bonded chemicals, have been greener PB and MDF available on with a formaldehyde-free resin. demonstrated in the laboratory, the market: they have not been embraced by

Recommended Particleboard and Fiberboard Products h AGRICULTURAL WASTE FIBER, FORMALDEHYDE-FREE

RENEWABLE/ MANUFACTURER PRODUCT SUSTAINABLY PRODUCT (BRAND) DEESCRIPTION FIBER SOURC HARVESTED ASVAILABILITY PERFORMANCE STANDARD

Isoboard Swtrawboard Wyheat Stra Annuall Home Depot, Meets ANSI-M3 (particleboard) (Isoboard, renewable Lowe's, standards at Guaranteed StorageBord, Isobord's Global Property Performance Levels ShelfBord and Sales Office IsoUnderlay)

PdrimeBoard Swtrawboar Wyheat Stra Annuall Multiple Meets ANSI-M3 standards renewable distributors

Pacific Northwest Swtrawboard Byluegrass Stra Anuall Available for Moisture-resistant; laboratory Fiber renewable immediate tests conducted by company (PacificBoard) shipment show superior strength, campared to wood-based particleboard

FriberTech Agrifibe Ryice Straw Annuall Door cores sold Meets ANSI standards for composite panel renewable to door particleboard and fiberboard (Mainly door manufacturers cores; also some industrial board and underlayments)

Acadia Pearticleboard Byagass Annuall Available directly Excellent moisture resistance, (DuraCane) renewable from the high hardness and moduli of company rupture (MOR) and elasticity (MOE); exceeds MDF standards

Hawaiian Pearticleboard Byagass Annuall Panel Source Highly moisture-resistant; DuraGreen renewable International is internal bond values greater than the exclusive 200 psi; tight screw holding sales agent (contact company for details) © 2001, Green Seal, Inc. Use of this Information in this confirmed purposes Green wit is prohibited. table was table for commercial © 2001, the manufacturer. It has not been independently verified by Green Seal unless otherwise Green by It has not been independently verified Seal certified. identified as Green the manufacturer.

6 Choose Green Report Recommended Particleboard and Fiberboard Products

POST-CONSUMER WASTE FIBER, FORMALDEHYDE-FREE

RENEWABLE/ MANUFACTURER PRODUCT SUSTAINABLY PRODUCT (BRAND) DEESCRIPTION FIBER SOURC HARVESTED ASVAILABILITY PERFORMANCE STANDARD

Hdomasote F-iberboar 100% post Post-consumer Most lumber and Products comply with building consumer newsprint supply home center codes for various applications recycled exceeds current locations; network (contact comapny for details) newsprint demand of dealers

RECOVERED WOOD FIBER, FORMALDEHYDE-FREE

RENEWABLE/ MANUFACTURER PRODUCT SUSTAINABLY PRODUCT (BRAND) DEESCRIPTION FIBER SOURC HARVESTED ASVAILABILITY PERFORMANCE STANDARD

SierraPine Medium-density 100% Ne.A. Multipl Meets ANSI 208.2-1994 (Medex, Medite II Fiberboard recovered and distributors standards for MDF and Medite-FR) preconsumer recycled wood fiber © 2001, Green Seal, Inc. Use of this purposes is table Green for commercial © 2001, It has Information confirmed in this tableprohibited. with the was manufacturer. Seal unless otherwise Green verified by not been independently identified as Seal certified.Green

MANUFACTURER CONTACT INFORMATION

Isoboard...... http://www.isoboardenterprises.com ...... 503-242-7345

Primeboard...... http://www.primeboard.com ...... 701-642-1152

PacificBoard ...... http://www.pacificfiber.com ...... 208-686-6800

FiberTech ...... 530-458-4547

Acadia ...... 727-393-9668

Hawaiian DuraGreen .... http://www.hawaiianduragreen.com ...... 808-877-2942

Homasote ...... http://www.homasote.com ...... 800-257-9491

SierraPine ...... http://www.sierrapine.com ...... 800-334-2250

Choose Green Report 7 NON-PROFIT ORG. US POSTAGE PAID WASHINGTON, DC 1001 CONNECTICUT AVE., NW PERMIT NO. 5515 SUITE 827 WASHINGTON, D.C. 20036

IN THIS ISSUE

— Recommended Particleboard & Medium-Density Fiberboard — Environmental Impacts — Greener Choices — Alternative Fibers — Alternative Resins — Market Survey

Guidelines and Standards purchase products meeting this several performance standards for EPA Comprehensive guideline. See http://www.epa.gov/ PB and MDF. If you are purchasing cpg/products/fiberbrd.htm. PB and MDF, you should determine Procurement Guideline for the level of performance you need Fiberboard U.S. Department of (a waterproof product, for EPA has adopted a Agriculture Biobased example) and inquire as to Comprehensive Procurement Products List whether the product meets those Guideline for Structural performance standards. For PB Fiberboard containing recovered A 1998 Executive Order directs and MDF made from agricultural materials (80–100% recovered the U.S. Department of Agriculture fiber, specifying the performance material required). Structural to develop a list of biobased characteristics required may yield fiberboard is a panel made from products that can guide agencies more eligible products than just wood, cane, or paper fibers matted in their purchasing policies. Once referencing test methods, since together which is used for the list is published, it may also be many of the test methods for PB sheathing, structural, and a useful reference. See http:// and MDF were developed with insulating purposes. Examples of www.usda-biobasedproducts.net. wood fiber products in mind. The these products include building recommended products table board, insulating formboard, and Performance Standards provides available information sheathing. Any Federal agency, or The American National about performance standards met any state agency that is using Standards Institute (ANSI) and the by the individual products. appropriated Federal funds for American Society for Testing and procurement, is required to Materials (ASTM) have adopted