Improvement of the density and processability of eco-friendly decking products from natural fiber composites using locally available resources

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Vision Extrusions Group LTD is a Canadian company which is globally recognized as a leader in the construction industry by producing a wide range of products including windows, doors, decks, and fences via polymer profile extrusion as substitutes for wood. Recently, a new facility for the production of composite decking profiles based on recycled polyethylene and rice husk was opened. Rice husk provides several advantages such as low water absorption, low mould issues, and relatively high flexural modulus. However, problems such as high equipment wear (fast abrasion related to the high particle hardness) and high density of the final products are associated with this material. Furthermore, rice husk is not locally available in large quantities in Canada thus increasing raw material costs, limiting availability and being not sustainable. For these reasons, the company is highly interested to develop new products by substitution of rice husk with locally available natural fibers. So the main objective of this research proposal is to study the feasibility of producing the composites with mixtures of natural fibers. The main parameters to study are the type of natural fibers (hemp, flax, and maple wood flour), their sizes and their concentration, as well as optimize the processing conditions. The formulations will be mechanically characterized (flexural modulus and strength, impact strength), with water uptake, dimensional stability, and density. The optimum will be obtained through design of experiments and multivariate data analysis to get the best composites in terms of properties, costs and weight.