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 : 2000

INTERNATIONAL TROPICAL TIMBER ORGANISATION (ITTO)  PROJECT APPROVAL (2004);  IMPLEMENTATION (Sept 06 – Sept 09) Paper presented at the IUFRO ALL DIV by: Y. E. TAN (FRIM) N. LIM (TRTTC) J. JOSUE (FRC) K. S. GAN (FRIM) MS ISO 9001 : 2000

1. Depleting Raw Materials supply  Depletion in quality timber (from natural & second growth forest) & rubberwood  Recycling of wood wastes, agricultural by-products  Maximise utilisation of lesser utilised wood species, plantation & other lignocellulosic resources. 2. Cost of production increased (Cost of resin, wood resources & labor increased)  Minimise wastage  Improvement in machines efficiency  Enhancement in process optimisation MOTIVATION: Issues in Forest Products sector

3. Stricter competition due to globalisation  Improvement in product quality & technical content  CE marking  JAS/ JIS accreditation scheme  Standards harmonization of products quality 4. Environmental issue  Sustainable forest management policy  Minimise air/ water pollution  Moving towards environmental-friendly process Issues in Forest Product Sector MS ISO 9001 : 2000

Sharp downward trend!

Total value : RM 23.4 billion (USD 6.9 bil.) Source: MTIB (Plywood) (Furniture)

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

Hence, there is a room for plantation forests in Malaysia, of which the current level of area of plantation is low by any standards. to supplement current shortage of wood supply; to supplement current shortage of wood supply; as raw materials for booming furniture industry in the country; as raw materials for booming furniture industry in the country; Other socio-ecological reasons. Other socio-ecological reasons.

DEVELOPMENT 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 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 establishing effects of site, clones, silvicultural treatment, etc;  Not just using rate of growth as the main criterion;  Proposed approach to be adopted by all ITTO countries if possible  Proposed approach to be adopted by all ITTO countries if possible  Basis for further technical improvement if necessary.

SPECIFIC OBJECTIVES Objective 2: To develop suitable techniques for production of value-added timber products from existing plantations and its technology transfer To develop suitable techniques for production of value-added timber products from existing plantations and its technology transfer Benefits  Development of techniques taking into consideration the constraints of the juvenile stocks in hand.  Carry out necessary economic studies before dissemination of information to relevant parties;  Not a pure “academic” or “scientific” exercise. Commercial product development is one of the targets

Expected Outputs 3.1Objective 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 techniques Output 1.3: Scientific data on anatomical, physical and mechanical properties of test timber species Output 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: “Objectivity” – serving the purpose “Objectivity” – serving the purpose “Universality” “Universality” “Practicality” “Practicality” Species selected: Acacia mangium – Peninsular Malaysia Acacia mangium – Peninsular Malaysia Engkabang (Shorea macrophylla) - Sarawak Engkabang (Shorea macrophylla) - Sarawak Teak (Tectona grandis) - Sabah Teak (Tectona grandis) - Sabah

To date: Activity 1.1.1: Evaluation of methods for preparation of sample logs (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 DBH iii)Arrange diameters of tree in ascending orders iv)Dividing logs into > 6 groups iv) No. of logs per group needed vi) Further division of logs for different tests vii) 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) & (ii) 20 mm square cross section.  20 mm square cross section is employed (BS 373: 1957).  Green (> FSP) and Dry (~19%) test specimens

gd g d d d d g g g g g d d d d g g 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 (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. oField stake test (FFPRI, ASTM D1758) oFungus cellar Test (FFPRI, and a number of reports) oAccelerated Laboratory Decay Test (FFPRI & ASTM D )  Differences in the methods between different standard bodies are not significant

2 Tests identified i) Accelerated Laboratory Decay Test (Base reference used - ASTM used - ASTM D ) Quick results could be obtained; Quick results could be obtained; Test results may be reproduced irrespective of geographical locality, but the same loss of weight may have different interpretation on durability depending on climatic differences; Test results may be reproduced irrespective of geographical locality, but the same loss of weight may have different interpretation on durability depending on climatic differences; Testing timber against specific wood rotting fungi (more relevant to the country of “ origin ” of the standard); Testing timber against specific wood rotting fungi (more relevant to the country of “ origin ” of the standard); Calculated mass loss of the timber specimens as an indicator to durability Calculated mass loss of the timber specimens as an indicator to durability

2 Tests identified i) Accelerated Laboratory Decay Fungal Test (e.g. ASTM D )(Cont.!) ASTM D )(Cont.!) Fungi identified Fungi identified -- 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 agar Medium : 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 identified ii) Treatability test Based on calculation method stipulated in Malaysian Standards – MS 360; Based on calculation method stipulated in Malaysian Standards – MS 360; Loading is calculated by treating heartwood samples of 20 x 20 x 450 mm by full cell process in water borne chemical to REFUSAL! Loading is calculated by treating heartwood samples of 20 x 20 x 450 mm by full cell process in water borne chemical to REFUSAL! Treatability classes: Treatability classes:  < 80 lit/ m3; VERY DIFFICULT  80 – 160 lit/ m3; DIFFICULT  80 – 160 lit/ m3; DIFFICULT  160 – 240 lit/ m3; MODERATE  160 – 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. oTotally new method; oThe test parameters/ variables for the study have been identified based on ease of application and utilization potential. oThe 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 oFocussing on non-structural applications; oMajor references were ASTM, AS/ NZ and ISO. o3 Service Classes and 2 types of test (Bonding & Finger jointing) were chosen

Testing Procedures for Non Structural Laminated Timber Products AS Service Class Type of Adhesive Block Shear Test End uses Class 1 EMC<12% PVAcShear Strength Wood Failure (%) Interior framing, staircase Class 2 EMC<18% PVAc Phenol- resorcinol formaldehyde Kitchens, vanities etc, Painted outdoor furniture Class 3 EMC>18% Phenol- Resorcinol formaldehyde Sauna benches, unpainted outdoor furniture, landscaping application

Performance Requirements for Glue-Lines - Block shear test Wood density, kg/m 3 Performance criteria Average wood failure % Minimum wood failure % Less than 600Not less than 70%Not less than 50% Greater than 600Not less than 50%Not less than 30% Relationship between Wood Failure % and Shear Strength of Glue Line PropertyAverage valuesIndividual values Shear strength, MPa 68>114 to 66>10 Min. wood failure % AS

Block Shear Test Shear strength (kgf/cm 2 or MPa) = Maximum load at failure Glued area No of specimen : 30 or more

Testing Procedures for in Non-Structural Timber Products ISO 17087, ASTM & AS Testing Procedures for Finger Joints in Non-Structural Timber Products ISO 17087, ASTM & AS Performance /Service condition Type of Adhesive Adhesive bond durability test Strength TestWood Failure (%) Finger Joints failure modes End uses Dry Use (EMC<16%) PVAc  Cured (dry)  Three cycle soak  Elevated temperature (104 o C)  Temperature humidity (65 o C 16% EMC) BendingTension (?) Interior furniture, moulding, joinery, interior cabinets, windows Wet use (EMC>16%) Phenol- resorcinol formaldehyde  Cured (dry)  Boiling  Elevated temperature (104 o C)  Vacuum- pressure Outdoor furniture, fascia, trellis

Strength Test Procedures (ISO & ASTM ) BendingTension Modulus of Rupture (MPa), R= PLs bd 2 Tensile Strength (MPa), Ts= pbd No of specimen : 30 or more

Activity 1.1.3: Evaluation of testing methodologies for assessment of processing properties e) Drying properties (Dr. Gan) No “ISO” method available. No “ISO” method available. Four techniques were identified: Four techniques were identified:  Air drying  Drying rate – establish rate of drying, K value;  Quick drying assessment - establishing initial drying  Quick drying assessment - establishing initial drying parameters; and parameters; and  Drying schedule development  Drying schedule development The methods will be based on the Japanese methods The methods will be based on the Japanese methods

Conclusion Based on the principles of “Objectivity”, “Universality” and “Practicality” and with the intention of eventually used by the tropical countries:  A set of harmonised techniques for the determination of various basic properties of plantation timber determination have been proposed;  Actual testing of methods proposed will be conducted in Year II of project implementation while refinement will be made concurrently.  To make it more “universally” accepted, inputs from all parties/ countries are welcome.  A terminal seminar is expected to be held in 2009 in Malaysia.

MS ISO 9001 : 2000

Wood inhabiting fungi at base of A. mangium trees

Testing Procedures for Non Structural Laminated Timber Products AS Service Class Type of Adhesive Block Shear Test End uses Class 1 EMC<12% PVAcShear Strength Wood Failure (%) Interior framing, staircase Class 2 EMC<18% PVAc Phenol- resorcinol formaldehyde Kitchens, vanities etc, Painted outdoor furniture Class 3 EMC>18% Phenol- Resorcinol formaldehyde Sauna benches, unpainted outdoor furniture, landscaping application

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