From virgin wood to composites: The evolution of outdoor materials

Join us on this fascinating journey through the history of the transformation of materials used in outdoor spaces.  Understand how the spaces where we relax and entertain have been reshaped over time and the factors that triggered these changes.

Our ancient ancestors traveled constantly and lived in caves or in shelters built with perishable materials.   Over time, as modern civiliza
tions developed, people settled in valleys seeking permanent homes by riverbanks to live in communities and cultivate fertile soil.  They needed to build durable shelters and they turned to wood, the only material at the time that was functional, strong, and readily available in abundance.   They also relied on wood for heating and cooking.   Wood was used primarily for shelters  not to mention its use for transportation aids and tools and its extensive use in other outdoor applications such as the construction of bridges.   It became a fundamental material in human civilization for thousands of years.

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stone - history of materials

Ancient Egyptians used local woods and even imported other types from the Middle East to fulfill their need for luxurious handcrafted furniture.

Wood for furniture was also widespread in ancient Greece where it was also used as a construction material for public and private buildings, primarily for roofs, doors, and timber gates.

Ancient Greek temples were distinct structures, constructed from timber, clay, and stone.

Iron was also one of the materials used for outdoor purposes in ancient times.   Early humans initially utilized meteoritic iron, a rare and valuable resource, before they learned to extract it from ore around 1200 BCE.   This marked the beginning of the Iron Age.  This technological advancement enabled the creation of stronger and more durable tools, weapons, and construction materials.   In ancient civilizations, such as those in Mesopotamia and Egypt, iron was primarily used for tools and weaponry.  As societies progressed, its potential for outdoor construction became more and more evident.  The Romans were among the first to harness iron’s strength for structural purposes, using it in the construction of bridges, gates, and even in some construction elements, providing increased durability and security.

meteoric iron

During the medieval period, iron became more and more useful.  Blacksmiths created iron gates, railings, and hardware for castles and fortifications.  These items not only provided security, but also featured decorative elements, showcasing the material’s versatility.   At the same time, wood remained a crucial construction material, widely used in the gates of castles, bridges, and weapons.  Additionally, wooden beams were commonly used for the roofs of communal buildings and temples.   Wood also played a significant role in developing European architectural styles, particularly in constructing wooden houses and timbered structures.

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The use of wood was widespread and extensive in many areas.   It had numerous benefits, including durability, versatility, and beauty.  However, its lifespan was generally shorter compared to stone and iron.

During the Renaissance, there were innovations aimed at extending the lifespan of wooden structures, leading to advancements in woodworking techniques and wood preservation methods.  For instance, one method involved slightly burning the ends of wooden posts before embedding them in the ground to avoid quick rot and decay.

During the age of Exploration and Colonial Expansion, shipbuilding let to a massive increase in the demand for hardwood.   Oak and teak, renowned for their durability, became the preferred materials for fulfilling the growing commercial and exploration expansions of European nations.  The British Royal Navy, in particular, used vast quantities of oak, resulting to extensive deforestation in England and its colonies.  Colonial expansion in the Americas introduced Europeans to new types of wood that proved extremely valuable.   Cedar, redwood, and mahogany were prized for their resistance to decay and insects, making them ideal for outdoor use.

The Industrial Revolution in the 18th and 19th centuries marked a significant turning point in the use of iron which proved to be more durable, especially for outdoor applications.  The development of cast iron and wrought iron allowed for mass production and more intricate designs.  Cast iron became popular for park benches, street lamps, and fences, while wrought iron was prized for its malleability, enabling the creation of ornate railings, wrought iron fences and wrought iron and wood gates.

The same period marked significant advancements in woodworking, thanks to sawmills, planers, and the overall mechanization of woodworking.   This allowed for more precise and large-scale production of wooden products.   Furthermore, there was a shift towards more scientific methods of wood treatment and preservation with the introduction of chemical preservatives, such as creosote and chromated copper arsenate (CCA).   These preservatives extended the lifespan of wood, especially for outdoor applications, for wooden fences and wooden gates.

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In the 20th century, the introduction of steel, an alloy of iron, revolutionized outdoor construction.   Steel’s superior strength and resistance to corrosion made it ideal for skyscrapers, bridges, and outdoor sculptures.  The development of weathering steel, which forms a stable rust-like appearance after exposure to the elements, added both aesthetic appeal and durability to outdoor structures.  Today, iron and its alloys remain essential in outdoor construction, from infrastructure projects like bridges and railings to decorative and functional elements in gardens and public spaces.

The 20th century, on the other hand, brought about a growing awareness of the negative impact on the environment caused by the use of timber and the mining and processing of iron.   Concerns were raised over the health risks associated with traditional chemical preservatives.   Deforestation, increased pollution, and global warming all emphasize the importance of saving trees, not to mention the effects of soil erosion and wildlife.

Consequently, there was a significant shift towards more sustainable and eco-friendly wood treatments.  This led to the creation of engineered wood products, including plywood, oriented strand board (OSB), laminated veneer lumber (LVL), and wood composites.  These products have improved strength and durability, making them well-suited for various outdoor applications.

From ancient times to the modern era, the use of wood is a proof of human ingenuity and adaptability.    Over the years, not only wood but also iron have been treated and innovated to meet the demands of each era.   As we strive for a more sustainable future, the continued exploration of eco-friendly products will give substitutes for these materials and will help protect our planet’s well-being.

Aluminium is another material extensively used for outdoor applications that should not be overlooked.   Aluminium has a relatively short history of human use, although historians suggest that ancient cultures may have unknowingly been using potassium aluminium sulfate in medicine, textile colouring and combined it with clay for pottery.   It was also used as a mordant and a fire-resistant coating for wooden structures.   It wasn’t until the early 19th century that the metal was isolated from the Earth’s crust.   Initially, it was scarce and available at a very high price, even more expensive than gold due to its difficult refinement process.   By the middle of the century special processes were invented that made aluminium abundant, affordable and widely accessible.   It became commercially viable with a large-scale of use in the aerospace and automotive industry due to its corrosion resistance and light-weight properties.

Aluminium played a crucial role during World War I and World War II.   Its strategic importance soared due to its critical role in engineering and aircraft production.   By the middle of the 20th century, aluminium overtook copper as the most widely produced non-ferrous metal.   During the post-war era, aluminium production capabilities expanded dramatically.   Aluminium usage became crucial in the industrialization booming and saw a rapid growth in the construction industry as well.   Its resistance to corrosion made it an ideal replacement for wood and iron for outdoor use, leading to its adoption in building facades, window frames, and roofing.

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The metal’s strength and durability in outdoor environments, solidified its reputation as a reliable construction material.   Its wide-spread use was further extended during the mid-20th century with innovations such as combining aluminium with other metals like magnesium and silicon for enhanced strength and durability in outdoor applications.  These alloy materials became popular in the construction of bridges, railings, and even entire structures.   Aluminium was also used for recreational equipment and consumer goods, valued for its lightweight and rust resistance in boat and bicycle manufacturing, as well as for lawn furniture.   From being rare and unusual, aluminium became commonplace, especially in the outdoor applications, decorating modern buildings with aluminium curtain walls, aluminium fences, aluminium gates, cladding and exterior panels.   However, by the end of the 20th century, environmental concerns grew as bauxite mining led to deforestation, soil and water pollution and disruption of ecosystem processes.   Aluminium production from bauxite ore requires high-energy-intensive consumption with gas emissions and severe consequences for global warming   On the other hand, recycling aluminium requires only about 5% of the energy needed to produce new aluminium from bauxite.   Therefore, aluminium can be considered as an environmentally friendly choice, depending on efficient recycling processes to produce new aluminium from raw materials, coupled with efforts to improve production and mining processes to minimize environmental consequences.

The urgency to address environmental challenges has led experts to develop new durable, recyclable and eco-friendly materials to mitigate the “greenhouse effect”.

Through innovations and mechanical advancements, wood-plastic composites (WPCs) were developed.   These are hybrid materials made from wood fibers and plastic, and they first emerged in response to the increasing demand for durable, low-maintenance and sustainable building materials.   The concept of combining wood with plastic dates back to the 1960s when researchers began experimenting with blending these two materials to create a composite that leveraged the strengths of both, an innovative material that was initially called “plastic wood”.   The breakthrough for WPCs came in the 1980s when advancements in polymer technology and manufacturing processes made it possible to produce this durable and versatile material on a commercial scale.  The first generation of WPC products was primarily used in automotive interiors and other industrial applications, and these early composites were using a mix of recycled plastics and wood flour, addressing both the environmental concerns of plastic waste and the need for new wood-based materials.

wpc πάτωμα

In the late 1980s, early 1990s,  commercialization of wood-plastic composites (WPC) gained momentum and their potential for outdoor use became more noticeable.   While traditional wood was aesthetically pleasing and strong, it required significant maintenance and was susceptible to problems like rot, insect damage, and weathering.   On the other hand, WPCs offered a promising alternative by combining the natural look and feel of wood with the durability and low maintenance of plastic.  In the mid 20’s WPCs were introduced to the residential market.  Initially, decking products quickly became most popular than other profiles, as homeowners looked for long-lasting and eco-friendly alternatives to traditional wood flooring.   The use of recycled plastic and reclaimed wood made WPCs an appealing choice for environmentally conscious consumers.

wpc περίφραξη

In the early 21st century, there were significant technological advancements in WPC technology.  Improved manufacturing processes resulted in composites with better performance characteristics, such as enhanced resistance to UV radiation, moisture, and temperature fluctuations.  Co-extrusion technology, which involves covering the WPC core with a protective outer wood-like layer, emerged as a key innovation.  This process further improved the durability and aesthetic appeal of WPC products and panels, making them even more suitable for outdoor applications like composite decking, castellation cladding, composite exterior cladding, ceiling cladding, fences with WPC fence panels, and railing with a more natural wood effect.

As the technology behind Wood-Plastic Composite (WPC) matured, it led to an expansion of its applications beyond just wall panels, decking boards, and fence slats.  WPCs are now being used in a diverse array of outdoor structures, including but not limited to outdoor furniture, pergolas, park benches, and playground equipment.   This broadened use is attributed to the material’s exceptional versatility, ability to withstand weathering, and low maintenance requirements, making it an ideal choice for various outdoor applications.   The continued growth of the WPC market is associated with a combination of factors, including consumer preference for sustainable materials and regulatory pressures aiming at reducing the impact of building products on the environment.   Furthermore, in regions with harsh climates, WPCs have gained significant popularity due to their superior performance when compared to traditional wood products, which often deteriorate over time.

Another major driver that grew the demand for composite WPC adoption has been its environmental benefits.   WPCs are typically made from a blend of recycled plastics and reclaimed wood fibers, which helps divert waste from landfills and reduces the demand for virgin wood.  This mirrors the broader trend towards sustainability in the construction and home improvement industries.  Manufacturers have also focused on improving the lifecycle impact of WPC products.  Advances in recycling technologies have made it possible to produce WPCs that are themselves recyclable, closing the loop and further enhancing the material’s eco-friendly credentials.

Looking ahead, the future of WPC material in outdoor use looks promising.  Ongoing research and development efforts are focused on enhancing the performance characteristics of WPC wood plastic composite.   This includes increasing their strength further, improving their resistance even more and developing new formulations that use even more sustainable raw materials.  Innovations in manufacturing techniques, such as 3D printing, hold the potential to create highly customized WPC products, tailored to specific applications and aesthetic preferences and more profile designs for wood like WPC wall panels, fence panels and decking boards.   As the construction industry continues to prioritize sustainability and durability, WPCs are likely to play an increasingly important role in shaping the built environment.

In conclusion the history of wood-plastic composites for outdoor use is a testament to the material’s versatility and innovation.  From their origins in the late 20th century to their widespread adoption of today, WPCs have transformed the landscape of outdoor construction.  The production of WPC makes use of wood waste and recycled plastics, addressing the demand for virgin wood and plastic and emphasizing sustainability.   By combining the best attributes of wood and plastic, WPCs provide a sustainable, durable, and low-maintenance alternative to traditional materials, contributing to a greener and more resilient future.

When looking back at the history of materials, it is clear that there has been a significant emphasis on the planet’s sustainability in all aspects, including but not limited to the manufacturing of materials sector.  New, environmentally friendly materials are replacing many of the materials used in the past.  One such valuable material is WPC, prized for its ecological production composition, long life and, low maintenance needs.

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