Increasing the strength and fire resistance of lightweight wood-based materials through basalt inlays and mineral binders.

The aim of the project is to produce reduced-density, single-layer and triple-layer particleboard as well as oriented-strand board (OSB) for the construction and packaging sectors. The reduction in density will be achieved through integrating basalt fibre inlays with the board material.
Basalt has much higher strengths in comparison to wood-based materials, which is why the integration of basalt grids into the respective material is intended to increase strength while reducing density. This makes it possible to produce wood-based panel materials that still comply with the prescribed standards (DIN, DIN EN).
The reduction in density improves material utilisation during production; this applies to wood particles and binder, as well as other additives. The finished product is therefore also easier to handle and install. Additionally, costs related to logistics can also be reduced. Thus, the optimization of these wood-based materials considers both economically and ecologically sustainable aspects.
Basalt fibre inlays currently have no use in the wood or wood-based materials industry. With the production of innovative products, the project therefore reveals a new market for the use of basalt. The use of basalt fibre can therefore be preferred over other materials such as glass fibre, and carbon or chemical polymers because it is additive-free and requires lower temperatures during the production process.

When using wood-based materials in the construction sector, not only issues of density and strength, but also those of flame retardancy play an important role. To increase the flame retardancy, a novel binder liquid based on mineral and conventional organic binders is to be developed. It should be ensured that the binder to be developed is not flammable in itself. It will act as a fire retardant on the wood component due to the wetting of the wood particle surfaces during production. In addition, the binder splits off water at high temperatures due to thermal reactions and can thus prevent ignition. Furthermore, the use of silica sols in combination with the novel binder liquid is to be tested.