IMPROVING UTILIZATION AND VALUE ADDING OF PLANTATION TIMBERS FROM SUSTAINABLE SOURCES IN MALAYSIA

Executing agencies: Forest Research Institute

Malaysia (FRIM) Timber Research and

Technical Training Centre

(TRTTC), Sarawak Forest Research Center

(FRC), Sabah

Collaborating agency Forestry and Forest

Products Research Institute

(FFPRI), Tsukuba, Japan

MS ISO 9001 : 2000MS ISO 9001 : 2000

INTERNATIONAL TROPICAL TIMBER ORGANISATION (ITTO)

PROJECT APPROVAL (2004); IMPLEMENTATION (Sept 06 – Sept 09)

Paper presented at the IUFRO ALL DIV. 5 meeting @TAIPEI 2007 by:

Y. E. TAN (FRIM)

N. LIM (TRTTC)

J. JOSUE (FRC)

K. S. GAN (FRIM)

MS ISO 9001 : 2000MS ISO 9001 : 2000

1.1. Depleting Raw Materials supplyDepleting Raw Materials supply Depletion in quality timber (from natural & second Depletion in quality timber (from natural & second

growth forest) & rubberwood growth forest) & rubberwood

Recycling of wood wastes, agricultural by-products Recycling of wood wastes, agricultural by-products

Maximise utilisation of lesser utilised wood species,Maximise utilisation of lesser utilised wood species, plantationplantation & other lignocellulosic resources. & other lignocellulosic resources.

2. Cost of production increased 2. Cost of production increased (Cost of resin, wood resources & labor increased) (Cost of resin, wood resources & labor increased) Minimise wastageMinimise wastage IImprovement in machines efficiencymprovement in machines efficiency Enhancement in process optimisationEnhancement in process optimisation

MOTIVATION:Issues in Forest Products sector

3. Stricter competition due to globalisation 3. Stricter competition due to globalisation Improvement in product quality & technical content Improvement in product quality & technical content

CE marking CE marking

JAS/ JIS accreditation schemeJAS/ JIS accreditation scheme

Standards harmonizationStandards harmonization of products quality of products quality

4. Environmental issue 4. Environmental issue Sustainable forest managementSustainable forest management policy policy Minimise air/ water pollution Minimise air/ water pollution Moving towards environmental-friendly processMoving towards environmental-friendly process

Issues in Forest Product Sector

MS ISO 9001 : 2000MS ISO 9001 : 2000

Logs Production & Consumption in Peninsular Malaysia

-

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Year

Cubic meter

Production Consumption

Sharp downward trend!

Total value : RM 23.4 billion (USD 6.9 bil.)Total value : RM 23.4 billion (USD 6.9 bil.)

EXPORTS OF MAJOR TIMBER PRODUCTS2006 (RM, Million)

9%

1%

3%4%5%

25%

1%

14%9%

29%

Logs Plywood Veneer Mouldings BJC

Fibreboard Furniture Particleboard Sawn Timber Others

Source: MTIB

(Plywood)

(Furniture)

US35%

EU19%

Japan9%

Australia8%

Canada4%

Others25%

Total Furniture Exports RM 6.3 billion (USD 1.9 billion) Source: MTIB

Hence, there is a room for plantation Hence, there is a room for plantation forests in Malaysia, of which the current forests in Malaysia, of which the current level of area of plantation is low by any level of area of plantation is low by any standards.standards.

to supplement current shortage of wood to supplement current shortage of wood supply;supply;

as raw materials for booming furniture as raw materials for booming furniture industry in the country;industry in the country;

Other socio-ecological reasons.Other socio-ecological reasons.

DEVELOPMENT OBJECTIVEDEVELOPMENT OBJECTIVE

to improve end-uses and value-adding of Malaysian forest plantation resources through systematic evaluation of their basic physical and mechanical properties in order to contribute to the development of the sustainable wood-based industries.

SPECIFIC OBJECTIVESSPECIFIC OBJECTIVES

Objective 1: To produce technical data on wood characteristics of

selected plantation grown species from Malaysia based on harmonised set of procedures developed; and

Benefits Permits comparison of results, essential for Permits comparison of results, essential for

establishing effects of site, clones, silvicultural establishing effects of site, clones, silvicultural treatment, etc;treatment, etc;

Not just using rate of growth as the main Not just using rate of growth as the main criterion;criterion;

Proposed approach to be adopted by all ITTO Proposed approach to be adopted by all ITTO countries if possible countries if possible <Hence, requires comprehensive literature search prior to proposing Malaysian approach>

Basis for further technical improvement if Basis for further technical improvement if necessary.necessary.

SPECIFIC OBJECTIVESSPECIFIC OBJECTIVES

Objective 2: Objective 2: To develop suitable techniques for production of To develop suitable techniques for production of

value-added timber products from existing value-added timber products from existing plantations and its technology transferplantations and its technology transfer

Benefits Development of techniques taking into Development of techniques taking into

consideration the constraints of the juvenile consideration the constraints of the juvenile stocks in hand. stocks in hand.

Carry out necessary economic studies before Carry out necessary economic studies before dissemination of information to relevant parties;dissemination of information to relevant parties;

Not a pure “academic” or “scientific” exercise. Commercial product development is one of the targets

Expected Outputs

3.1 Objective 1: To produce technical data using harmonised procedures developed

Output 1.1: Harmonised procedures for evaluation of basic properties of plantation species Output 1.2: Trained counterparts in new testing techniquesOutput 1.3: Scientific data on anatomical, physical and

mechanical properties of test timber speciesOutput 1.4: Technical data on sawing, machining, veneering,

drying and bonding properties; Output 1.5: Technical information on bio-deterioration and

preservative treatment, and chemical properties of wood, tannins and sugars in bark of test timber species

Expected Outputs

3.2 Objective 2: To develop suitable techniques for production of value-added timber products from existing plantations and technology transfer

Output 2.1: An assessment report on the suitability of plantation species for doors and windows,

Output 2.2: An assessment report on the suitability of plantation species for advanced particleboards;

Output 2.3: Technical evaluation on the production of sliced and peeled veneers.

Output 2.4: Website (containing project related materials including data, reports, manuals and personnel involved), training workshop/ project ending seminar.

““Approach” used:Approach” used:

““Objectivity” – serving the purposeObjectivity” – serving the purpose ““Universality”Universality” ““Practicality”Practicality”

Species selected:Species selected:

Acacia mangium – Peninsular MalaysiaAcacia mangium – Peninsular Malaysia Engkabang (Engkabang (Shorea macrophyllaShorea macrophylla) - Sarawak) - Sarawak Teak (Teak (Tectona grandisTectona grandis) - Sabah) - Sabah

To date:

Activity 1.1.1: Evaluation of methods for preparation of sample logs <Method of getting representative logs for a selected plantation>(Adapted from relevant ISO procedure)(Dr. Tan, Mr. Andrew Nyorik & Mr. James Josue):

i) Select a test area (> 150 trees) representative of the plantation plot of interest!

ii) Record tree diameters at DBHiii) Arrange diameters of tree in ascending ordersiv) Dividing logs into > 6 groupsiv) No. of logs per group neededvi) Further division of logs for different testsvii) Each test with its detail methods of samples preparation

To date:Activity 1.1.2: Assessment of methods for determination of

physical and mechanical properties (Dr. Omar, Mr. Alik, Mr. Zamrie)

a) Physical and mechanical properties:

• 2 schemes for testing small clear specimens of timber to obtain fundamental strength properties are accepted internationally

• Test specimen (i) 2 in (50 mm)<ASTM> & (ii) 20 mm square cross section <BS/ ISO>.

20 mm square cross section is employed (BS 373: 1957). Green (> FSP) and Dry (~19%) test specimens

gdg d

dd

d

gg

gg

g

d

d d

d gg

Sample cutting layout

Billet allocated

bending

Compression //g

Shear

Tension (optional)

Dry; 30x30mm)Green;

30x30mm)

Compression I g

Hardness

Impact loading

To date:b) Anatomical study (Mr. Lim S. C., Mr. Yang & Mr. James Josue):

The method of evaluation selected made reference to international practices such as:

• IAWA (1989) for microscopic features;

• PROSEA Vol. 5(1), (2), (3);

• Decamps (1973) for macroscopic and microscopic features; and

• Anonymous (2004) for methods of study.

For the microscopic study, all the 163 features as listed by International Association of Wood Anatomists (IAWA) were included in the form of a table to ensure that no important features of the timber are left out.

To date:Activity 1.1.3: Evaluation of testing methodologies for

assessment of processing properties (Mr. Wong T. C. (TRTTC) & Dr. Murata, FFPRI, Tsukuba)

c) Sawing properties

Using Japanese and Malaysian approaches.

Items included:-

• Basic sawing configuration - Saw and Saw-tooth, and other set-up, for 2 cutting patterns (“Live” sawing and cant sawing)

Sawing yield - Volume and Value Recovery in relation to taperness of logs, types of cutting, quality of logs etc.; and

Power/ energy consumption.

(i) Testing Methods of Various Wood Properties of Fast Growing Tropical Timbers, Technical Report of the Product Development Committee No. 18, FFPRI, Japan

(ii) Procedure of Sawing Yield Test, Sawmilling and Machining Laboratory, Forestry and Forest Products Research Institute, Japan

(iii) ASTM D 1666-87(2004) Standard Test Methods for Conducting Machining Tests of Wood and Wood-base Materials

Major references

To date:Activity 1.1.3: Evaluation of testing methodologies for assessment of processing properties (Dr. Salmiah, Mr. Lai and Mr. Kandau)

(d) Durability studies :

• A few tests including lab. and grave yard tests could be conducted to determine the natural durability of wood.

o Field stake test (FFPRI, ASTM D1758)o Fungus cellar Test (FFPRI, and a number of

reports)o Accelerated Laboratory Decay Test (FFPRI &

ASTM D2017-2005)

Differences in the methods between different standard bodies are not significant

2 Tests identified2 Tests identified

i)i) Accelerated Laboratory Decay Test (Base reference Accelerated Laboratory Decay Test (Base reference used - ASTM used - ASTM D2017-2005)

Quick results could be obtained;Quick results could be obtained;

Test results may be reproduced irrespective of geographical Test results may be reproduced irrespective of geographical locality, but the same loss of weight may have different locality, but the same loss of weight may have different interpretation on durability depending on climatic interpretation on durability depending on climatic differences;differences;

Testing timber against specific wood rotting fungi Testing timber against specific wood rotting fungi (more (more relevant to the country of “origin” of the standard)relevant to the country of “origin” of the standard);;

Calculated mass loss of the timber specimens as an Calculated mass loss of the timber specimens as an indicator to durabilityindicator to durability

2 Tests identified2 Tests identified

i) Accelerated Laboratory Decay Fungal Test (e.g. i) Accelerated Laboratory Decay Fungal Test (e.g. ASTM D2017-2005)(Cont.!)ASTM D2017-2005)(Cont.!)

Fungi identifiedFungi identified-- -- Lantinus sayor-caju (Main)Lantinus sayor-caju (Main)

-- -- Gloeophyllum trabium – Brown rot (Comparison)Gloeophyllum trabium – Brown rot (Comparison) -- -- Trametu versicolor – White rot (Comparison)Trametu versicolor – White rot (Comparison)

Medium : 2 % Malt extract agarMedium : 2 % Malt extract agar

Dimension: 25 x 25 x 5 mm (l);Dimension: 25 x 25 x 5 mm (l);

Exposure: 12 weeks.Exposure: 12 weeks.

2 Tests identified2 Tests identified

ii) ii) Treatability test Treatability test

Based on calculation method stipulated in Malaysian Based on calculation method stipulated in Malaysian Standards – MS 360;Standards – MS 360;

Loading is calculated by treating heartwood samples of 20 x Loading is calculated by treating heartwood samples of 20 x 20 x 450 mm by full cell process in water borne chemical to 20 x 450 mm by full cell process in water borne chemical to REFUSAL!REFUSAL!

Treatability classes:Treatability classes: < 80 lit/ m3; VERY DIFFICULT< 80 lit/ m3; VERY DIFFICULT

80 – 160 lit/ m3; DIFFICULT80 – 160 lit/ m3; DIFFICULT 160 – 240 lit/ m3; MODERATE160 – 240 lit/ m3; MODERATE > 320 LIT/ M3; VERY EASY.> 320 LIT/ M3; VERY EASY.

To date:Activity 1.1.3: Evaluation of testing methodologies for assessment of processing properties (Mr. Nigel Lim)

c) Peeling & slicing.

o Totally new method;

o The test parameters/ variables for the study have been identified based on ease of application and utilization potential.

o The study parameters identified are: log rounding/ trimming loss,

continuous form veneer peeler core/residual slab, drying and veneer properties such as surface roughness and peeler checks.

To date:

Activity 1.1.3: Evaluation of testing methodologies for assessment of processing properties

d) Bonding & finger-jointing

o Focussing on non-structural applications;

o Major references were ASTM, AS/ NZ and ISO.

o 3 Service Classes and 2 types of test (Bonding & Finger jointing) were chosen

Testing Procedures for Non Structural Laminated Timber ProductsTesting Procedures for Non Structural Laminated Timber ProductsAS 5067-2003AS 5067-2003

ServiceClass

Type of Adhesive

BlockShear Test

End uses

Class 1EMC<12%

PVAc ShearStrength

WoodFailure(%)

Interiorframing,staircase

Class 2EMC<18%

PVAcPhenol-resorcinolformaldehyde

Kitchens,vanities etc,Painted outdoorfurniture

Class 3EMC>18%

Phenol-Resorcinolformaldehyde

Sauna benches,unpainted outdoorfurniture, landscapingapplication

Performance Requirements for Glue-Lines - Block shear testWood density, kg/m3

Performance criteria

Average wood failure %

Minimum wood failure %

Less than 600 Not less than 70% Not less than 50%

Greater than 600 Not less than 50% Not less than 30%

Relationship between Wood Failure % and Shear Strength of Glue Line

Property Average values Individual values

Shear strength, MPa

6 8 >11 4 to 6 6 >10

Min. wood failure %

90 70 45 95 75 20

AS 5067 - 2003

Block Shear Test

Shear strength (kgf/cmShear strength (kgf/cm22 or MPa) = or MPa) = Maximum load at failureMaximum load at failure

Glued areaGlued area

No of specimen : 30 No of specimen : 30 or moreor more

Testing Procedures Testing Procedures for for Finger Joints in Non-Structural Timber Products in Non-Structural Timber Products

ISO 17087, ASTM 5572-95 & AS 5069-2006ISO 17087, ASTM 5572-95 & AS 5069-2006

Performance/Service condition

Type of Adhesive

Adhesive bond durability test

Strength Test Wood Failure(%)

Finger Joints failure modes

End uses

Dry Use (EMC<16%)

PVAc Cured (dry) Three cycle soak Elevated temperature (104oC) Temperature humidity (65oC 16% EMC)

Bending Tension (?)

Interior furniture,moulding, joinery, interior cabinets, windows

Wet use (EMC>16%)

Phenol-resorcinol formaldehyde

Cured (dry) Boiling Elevated temperature (104oC) Vacuum- pressure

Outdoor furniture, fascia, trellis

Strength Test Procedures (ISO 17087 & ASTM 5572-95)

Bending Tension

Modulus of Rupture (MPa), R=Modulus of Rupture (MPa), R=PLsPLs

bdbd22 Tensile Strength (MPa), Ts=Tensile Strength (MPa), Ts=pp

bdbd

No of specimen : 30 or moreNo of specimen : 30 or more

Activity 1.1.3: Evaluation of testing methodologies for

assessment of processing properties

e) Drying properties (Dr. Gan)e) Drying properties (Dr. Gan)

No “ISO” method available.No “ISO” method available. Four techniques were identified: Four techniques were identified:

Air dryingAir drying Drying rate – Drying rate – establish rate of drying, K value;establish rate of drying, K value;

Quick drying assessment - Quick drying assessment - establishing initial drying establishing initial drying parameters; andparameters; and Drying schedule developmentDrying schedule development

The methods will be based on the Japanese methodsThe methods will be based on the Japanese methods

ConclusionConclusionBased on the principles of “Objectivity”, “Universality” and Based on the principles of “Objectivity”, “Universality” and “Practicality” and with the intention of eventually used by the “Practicality” and with the intention of eventually used by the tropical countries: tropical countries:

A set of harmonised techniques for the determination of various A set of harmonised techniques for the determination of various basic properties of plantation timber determination have been basic properties of plantation timber determination have been proposed; proposed;

Actual testing of methods proposed will be conducted in Year II Actual testing of methods proposed will be conducted in Year II of project implementation while refinement will be made of project implementation while refinement will be made concurrently. concurrently.

To make it more “universally” accepted, inputs from all parties/ To make it more “universally” accepted, inputs from all parties/ countries are welcome. countries are welcome.

A terminal seminar is expected to be held in 2009 in Malaysia. A terminal seminar is expected to be held in 2009 in Malaysia.

MS ISO 9001 : 2000MS ISO 9001 : 2000

Wood inhabiting fungi at base Wood inhabiting fungi at base of of A. mangiumA. mangium trees trees

Testing Procedures for Non Structural Laminated Timber ProductsAS 5067-2003

ServiceClass

Type of Adhesive

BlockShear Test

End uses

Class 1EMC<12%

PVAc ShearStrength

WoodFailure(%)

Interiorframing, staircase

Class 2EMC<18%

PVAcPhenol-resorcinolformaldehyde

Kitchens,vanities etc,Painted outdoorfurniture

Class 3EMC>18%

Phenol-Resorcinolformaldehyde

Sauna benches,unpainted outdoorfurniture, landscapingapplication

THANK YOU VERY MUCHTHANK YOU VERY MUCH