WOOD-PLASTIC COMPOSITE PANEL

BRIEF HISTORY OF WOOD-PLASTIC COMPOSITE PANELS

The company that invented and patented the process to create WPC
was Covema of Milan in 1960, founded by Terragni brothers (Dino and Marco). Covema
called WPC under the tradename Plastic-Wood. After a few years from the invention of
the Plastic-Wood the company Icma San Giorgio patented the first process to add wood
fiber/wood flour to the thermoplastics (WPCs).
As a relatively new material, WPC is still quite rare in some industries. But many,
especially those trading in outdoor products, have seen huge benefits to switching to
WPC from timber. By the end of the 80s WPC was becoming more popular for products
such as door and window frames, park benches, and indoor furniture. In the early 1990s
WPC composites were introduced into the decking market, while WPC for fencing and
cladding solutions continued to gain popularity.

The popularity of WPC and its gradual replacement of timber can be attributed to its
longevity and weather resistance, as it will never rot away due to water damage as
timber does, and its environmentally friendly use of recycled materials. WPC products
can also be produced with simulated wood grain, and with pigments to perfectly mimic a
natural timber effect, so consumers are able to maintain the aesthetic of timber
products, with the additional benefits of WPC.

WHAT IS WOOD-PLASTIC COMPOSITE PANELS

Wood-plastic composite (WPC) is a blanket term for a range of composite materials
which are primarily created using wood fibres, wood flour, or wood pulp, along with
thermoplastics like polypropylene (PP), polythene (PE), and polyvinyl chloride (PVC).
Additives can be included to improve the bond, structure, or pigment of the final WPC
product. WPC wall panels or wood plastic composite panels are a compound building
and interior design material that combines lumber product such as wood fibers and
wood particles with recycled plastic.

WPCs are produced by thoroughly mixing ground wood particles and

heated thermoplastic resin. The most common method of production is to extrude the
material into the desired shape, though injection molding is also used. an innovative
building material that combines the natural look and texture of wood with the durability and low-
maintenance properties of plastic.

WPC wall panels offer a unique combination of aesthetic appeal, durability, and
sustainability, making them a popular choice for architects, builders, and homeowners
looking for an innovative and eco-friendly building material
 HOW IT IS MADE

Wood plastic composite is a new class of composite materials in recent years. It is

made of a unique blend of natural wood and plastic fibers. Sawdust, pulp, bamboo,
peanut hulls, and unused woodworking materials, like bark, from a variety of projects,
are combined with polyethylene, polypropylene, polyvinyl chloride, etc. to form this new
material WPC

WPCs are produced by thoroughly mixing ground wood particles and

heated thermoplastic resin. The most common method of production is to extrude the
material into the desired shape, though injection molding is also used.

Main production steps and properties of WPC

 In general, manufacturing of WPC is a two-step process. Combination of wood

and thermoplastic such as high density polyethylene (HDPE), low density
polyethylene (LDPE) and polyvinyl chloride (PVC) are mixed together dough-like-
consistency called compounding. Mixing can be handled by either batch or
continuous process.
 In addition to the main ingredient wood with grain size ranging from 20
to 60 mesh, plastic coupling agents, stabilizer, foaming agents or dyes
also are added to enhance properties of the final product for a particular
use.
 The most common method used in producing wood-plastic composite
panels is the extrusion method. The Extrusion method forces molten
composite through a die, is shown in Figure 1. In the case of injection
molding method, molten composite is forced into a cold mold. The third
one presses molten composite between mold halves

Figure 1. Extrusion manufacturing process of wood plastic composite. The majority of

WPC is produced by extrusion process, which uses variety of extruder types such as
single screw or double screw to form final shape of the material. Figures 2, 3 and 4
illustrate examples of WPC products and a flowchart of a typical manufacturing process,
respectively.

 Figure 2. Different types of wood composite products.

 Figure 3. Application of wood plastic composites as decking.

  Figure 4. A typical production flowchart of wood plastic composite.

Due to the addition of organic material, WPCs are usually processed at far lower
temperatures than traditional plastics during extrusion and injection molding. WPCs
tend to process at temperatures of about 28 °C (50 °F) lower than the same, unfilled
material, for instance. Most will begin to burn at temperatures around 204 °C
(400 °F). Processing WPCs at excessively high temperatures increases the risk of
shearing, or burning and discoloration resulting from pushing a material that is too hot
through a gate which is too small, during injection molding.

CHARACTERISTICS

WPC products have taken many industries by storm in recent decades for their
strength, weather resistance, and lack of required maintenance when compared to
timber product, especially for outdoor installations like composite decking, composite
cladding, or composite fencing.
WPC panels stand for Wood-Plastic Composite panels. These are a type of building
material used in construction and interior design. WPC panels are made by combining
wood fibers or wood flour with thermoplastics like polyethylene, polypropylene, or
polyvinyl chloride (PVC). The result is a composite material that combines the natural
appearance and texture of wood with the durability and low maintenance of plastic.

WPC panels have gained popularity as an alternative to traditional wood panels and
other building materials for several reasons:

1. *Durability:* WPC panels are resistant to rot, decay, and insects, which are common
issues with natural wood.

2. *Low Maintenance:* They require minimal maintenance, such as periodic cleaning,

and do not need staining or painting.

3. *Environmental Benefits:* WPC panels often contain recycled materials, making them
more environmentally friendly than pure wood products. Additionally, they reduce the
demand for virgin wood.

4. *Versatility:* WPC panels can be used for a variety of applications, including wall
cladding, flooring, fencing, decking, and furniture.

5. *Appearance:* They can mimic the look of real wood, providing a natural aesthetic
while maintaining their durability.

6. *Moisture Resistance:* WPC panels are less susceptible to water damage compared
to natural wood, making them suitable for use in damp or humid environments.

7. *Dimensional Stability:* They are less prone to warping or cracking due to changes in
temperature and humidity.

Overall, WPC panels are a versatile and eco-friendly choice for a range of construction
and design projects where the appearance of wood is desired, but the practical benefits
of plastic are necessary.

ADVANTAGES AND DISADVANTAGES

Advantages of WPC Panels

i).Aesthetics & Visual Appeal

WPC panels successfully imitate & mimic the appearance of natural wood,,
offering an attractive option for multiple uses. They come in an extensive
assortment & variety of colors, textures, and finishes, enabling customization to
fit individual design preferences,which makes them a versatile option for a range
of design styles.hey can be used in both modern and traditional settings, and
they can be customized to fit any design concept.

ii).Durability & Long Lasting

WPC wall panels are highly durable and long-lasting. These panels are highly
resistant to moisture, insects, and decay. They can withstand extreme weather
conditions, such as heavy rainfall, high temperatures, and strong winds.They do
not warp, splinter, or rot like traditional wood, making them a long-lasting and
low-maintenance option and also resistant to pests, termites, and fungal decay,
which makes them an ideal choice for outdoor applications. Additionally, their
high resistance to UV radiation and extreme weather conditions contributes to
their extended lifespan & longevity.

iii).Eco-Friendliness

WPC panels are made from recycled materials, such as wood waste and plastic,
which help decrease the demand for new resources & makes them an
environmentally friendly option.They do not require the cutting down of trees,
also fully recyclable at the end of their lifespan, reducing their environmental
impact.

iv).Low Maintenance

WPC wall panels require very little maintenance. Unlike traditional wood that
require regular painting, staining, or sealing. WPC panels are resistant to fading,
cracking, and warping.They are easy to clean and maintain, needing only periodic
washing with soap and water to maintain their appearance.

v).Resistance To Insects And Mold:

WPC panels are highly resistant to termites and other wood-destroying insects,
as well as mold and mildew. This reduces the need for chemical treatments and
prolongs their lifespan.

vi).Easy To Install

WPC panels are light and easy to handle, making installation faster and more
cost-effective than traditional wood panels which makes them a popular choice
for DIY projects. They can be installed using simple tools and do not require
specialized skills or equipment.
Disdvantages of WPC Panels

i).Thermal Expansion And Contraction

WPC panels can expand and contract due to temperature changes. This may
result in gaps or buckling if not adequately addressed during installation.

ii).Limited Structural Applications

WPC panels are unsuitable for load-bearing applications because they lack the
structural strength of conventional wood. They are most appropriate for non-
structural uses, such as exterior cladding, decking, and fencing.

iii).Vulnerability To Scratches And Stains

While WPC panels are resistant to various types of damage, they can be
susceptible to scratches and stains. Care should be taken when moving heavy
objects or using abrasive cleaning products.

iii).Environmental Concerns & Ecological Concern

Although WPC panels are created from recycled materials, the production
process still consumes energy and produces waste. Additionally, the use of non-
biodegradable plastic in their composition may raise questions about their long-
term ecological impact.

iv).May Be Less Aesthetically Pleasing

While WPC wall panels come in a range of colors and textures, some people may
find them less aesthetically pleasing than traditional wood panels. They may not
have the same natural wood grain or texture, which can make them less
appealing to some homeowners.

v).May Require Additional Support

WPC wall panels may require additional support during installation, especially if
they are being installed on a curved or uneven surface. This can add to the cost
of installation and make them less suitable for DIY projects.

vi).Limited Availability

WPC wall panels are not as widely available as traditional wood panels. They may
be harder to find in some areas, which can make them a less convenient option
for some homeowners.
vii).Prone To Fading

WPC wall panels are prone to fading over time, especially when exposed to direct
sunlight. Although they are resistant to UV rays, prolonged exposure can cause
them to lose their color and become dull.

viii).Limited Temperature Range

WPC wall panels may expand or contract with changes in temperature, which can
cause them to warp or buckle. They have a limited temperature range, and they
may not be suitable for use in extremely cold or hot climates.

ix).Not As Strong As Wood

While WPC wall panels are strong and durable, they are not as strong as
traditional wood panels. They may be prone to cracking or breaking under heavy
loads or impact, which makes them less suitable for high-traffic areas.

x).Cost

One of the main drawback & disadvantages of WPC panels is their higher initial
cost compared to traditional wood panels. However, their low maintenance and
extended lifespan may balance the initial investment over time.

EXAMPLES OF WPC uses ON BUILDING

(where to use)

External applications
The following are the external uses of WPC panels:

 facades,
 decking of swimming pools
 garden furniture, landscape components
 park benches
 planter boxes
 outdoor panelling,doors
 windows
  outdoor deck floors
 railings
 fences
 landscaping timbers
 cladding
 siding park benches
 molding and trim
 Exterior cladding

Interior applications
The following are the interior uses of WPC panels:

 interior ceiling
 kitchen cabinets
 bathroom vanities
 interior partitions
 modular furnishing
 household furniture
 doors
 windows railing
 wall panellings
 Interior cladding

REFERENCES