How is Storm Board made?
Our standard boards are made from 100% mixed waste plastic. This is usually classed as “unrecyclable” plastic and includes bottle tops, crisp packet, cosmetic packaging, food packaging, garden toys etc and means that there could be particles of wood and paper mixed in. Don’t worry, the plastic is cleaned and cooked at over 200 ̊C during processing.
Some of our specialist boards have a virgin plastic content. For example, if you want a white or a pink board, these colours are not available in recycled material, but would be available in a 70% recycled board. The same goes for a certified fire-retardant skin.
What to expect:
It may sound silly, but plastic is not wood and does not react like wood, so don’t expect a pallet of Storm Board to arrive looking and reacting just like wood. Wood is stiffer and planed to very tight tolerances. Storm Board is a moulded plastic product, and is produced larger than then end size, see the “oversize” table below.
Storm Board will have a smooth surface of recycled plastic, encapsulating a 100% waste plastic core. A pallet of Storm Board will often have a dip in the middle, which is a result of the cooling process. If you turn the boards over on a flat surface, this will come out. Storm Board edges will be higher than the centre. The voids that make up the cellular core will be irregular, some larger than others, this is what makes the boards light and stiff.
The colour will be speckled. If a light virgin colour is chosen, then the core will often show through.
Plastic or Wood Board?
When choosing Storm Board over plywood, consider the application and total final cost. Outdoors, for example as a hoarding, Storm Board does not need painting, does not need aluminium composite, will outlast plywood, is jet washable and can be reused on the next site. It does expand / contract more than plywood, and so a slightly different fixing profile should be used, like the top hat system. The key in transitioning from wood to plastic boards is to adapt the system used currently for wood slightly, so that it is ideal for plastic and sustainable re-use.
Single use plywood from forests or re-useable Storm Board from waste, your choice ...
Specifications Storm Board HI Grade
|Dimensions||min. 2440 x 1220 x 19 mm (oversize)|
|Weight||approx. 32 kg|
|Density||approx.. 589 kg/m3 (see appendix)|
|Stiffness||0.35 GPa at 23 oC (see appendix)|
|Colour||stock – speckled grey, natural or green black colour will have an “A” and “B” quality face specials such as “Splash” effect or White to order|
|Coefficient of expansion||HI: 3 - 4 mm/2.4m/10oC|
|Weather resistance||Weather proof and will not rot - ideal for outdoor use. Impact strength increases, the wetter it becomes.|
Other Custom Colour Options
Storm Board Grades
Storm Board HI (High Impact)
The HI board is the most utilitarian of our boards. It has a smooth PE/PP surface encapsulating the mixed plastic waste core. It’s really tough, easy to clean, with good chemical resistance. It is hard for paint/graffiti to stick to it, unless a key is made by sanding. It is formable, UV stable and can be plastic welded.
Agri Board – these are “B” quality/ “seconds” HI boards
- Construction site hoardings
- Sheds, shelters, storage lockers
- Campsites – washing areas, recycling areas, play areas
- Gardens – raised beds, compost bins, lawn edging, furniture
- Plinths, Art installations
- Animal – husbandry, hutches, kennels
- Farming – stall lining, calf hutches, stables, slurry pits
- Warehousing – shelving, bump corners, packing tables
Storm Board SF (Shop Fitting)
The SF board was developed to be similar to MDF for the shop fitting and furniture industry. It is very stiff, making it more brittle than the HI board, can be painted and laminated with much tighter tolerances. With the advent of self-adhesive “car wrap” material any surface look is achievable. The wraps such as Di-Noc and Coverstyl, do not require a laminating press, and can be applied to one side only. Some of these wraps have a fire rating too.
SF has a skin made from polystyrene (old coat hangers), which make it black, and if used outdoors needs a coating, as it is not UV stable.
- Counters, furniture carcass
- Cubicles, changing rooms
- Pillar cladding
- Shop window
- Office tables & desks
Storm Board sizes
|Oversize||This is the standard format direct from the moulding machine (at 20 oC ambient temperature): HI 2471 x 1235 mm - SF 2506 x 1258 mm|
|Cut-to-size||2440 x 1220 x 19 mm|
|Tolerance||+/- 5 mm|
|Oversize Benefits||The skin on the side adds to the board’s overall strength and protection during transport.|
Storm Board grades – AGRI is a “B” grade material
SB AGRI Grade has a wider tolerance range of +- 5mm
Storm Board core
The core is a non-perfect recycled waste material, which is not compounded or prepared. Voids in the core will occur (<4 cm Ø), which helps make the panel light and stiff.
Possible Agri Board
Voids causing dimples in surface Sunken edges & corners, making these boards “B” Grade
Using P2 Storm Board
|Coating||For the rendered look, non-slip and UV protection, we recommend CorkSol coating. www.corksoluk.com Wrap with Di-Noc or Coverstyl|
|Fire Retardancy||The standard boards are not fire rated, however fire-retardant coatings can be applied to the surface.For walls – CorkSol cork coating certified to Euroclass Bs2D0 or CorkSol stone coating certified to Euroclass Bs1D0.We can supply a board produced with a skin made from certified flame-retardant plastic. This material has been certified in accordance with UL94 at grade V0.|
|Cutting||You can cut Storm Board with a hand saw, jigsaw, router, bench saw, and skill saw. We suggest running saws at slower speeds to avoid melt and with blades recommended for plastic cutting.|
|Drilling||Storm Board drills well with wood drill-bits and can be countersunk.|
|Routing/CNC||Storm Board can be CNC routed; we suggest using tungsten carbide tooling. We have seen the best results at slow speed with 2 flute bits. CNC messages make Storm Board stand out.|
|Gluing||Wood glues don’t work. We suggest Novaseal Signfix Ultrabond adhesive (available from website) or alternatively 2-part polymer glues.|
|Fillers||Wood filler doesn’t work. We suggest Epoxy fillers.|
|Painting/Printing||Storm Board comes in black/dark grey speckled skin colour. We can colour the skin in manufacturing at an extra cost for large volume. As standard, HI has an anti-graffiti finish, so paint has difficulty finding purchase, but Vinyl graphics adhere well.It is also possible to UV print the boards, a great alternative to Aluminum composite materials on site hoardings.SF board is paintable and printable.|
|Edge Banding||Edge banding can be applied using standard glue fixing, or mechanically by routing into the core and using a T edge. Use adhesive wraps to wrap over the edge.The current trend is to show off the recycled core leaving it exposed or painted. The edge can also be plastic welded.|
|Screwing||Screws fix well in Storm Board as its elasticity means it stretches and grips the screw’s thread. And expansion gap must be allowed when being used outdoors.|
|Nailing||As Storm Board expands and contracts, we don’t recommend nails, as the only fixing method.|
|Welding||Storm Board HI can be plastic or vibration welded.|
|Forming||Storm Board HI can be heat formed.|
|Cleaning||Storm Board can be jet washed at low pressure, with min. 100 mm nozzle distance from board.|
Suitability for Use and Warranty
Nothing herein constitutes a warranty express or implied, including any warranty of merchantability or fitness for use, nor is protection from any law or patent to be inferred. The exclusive remedy for all claims is replacement of materials. Contact the sales office for a copy of the complete Storm Board Terms and Conditions of Sale.
Information provided is for guidance only, the customer is solely responsible for making sure Storm Board is fit for purpose. All information is based on tests carried out on panels made in the UK. Using recycled mixed waste material in manufacturing will always account for variation.