Feature Article
Building with soybeans
America is the number one producer of soybeans,
and the number one innovator of new technologies and products made from soybeans

Concept home built from soybeans

Soy-Based Building Materials Highlighted at Builders’ Show

     The building and construction industry is an area that United Soybean Board (USB) New Uses Committee (NUC) has targeted in the promotion of soy-based products such as insulation, wood adhesives and carpet backing. USB representatives recently attended the International Builders’ Show, the largest annual construction industry show, to educate industry leaders on the environmental, economic and safety benefits of integrating and installing soy-based products into new and existing construction.
    More than 104,000 attendees, including residential and commercial builders, remodelers, subcontractors, distributors and engineers, all met together in Las Vegas to share new ideas in the educational sessions and visit the trade show floor where more than 1,400 suppliers and organizations, such as USB, were available to provide information on their products. The USB exhibit, complete with updated panels showcasing the latest trends in soy-based product development, provided information on building materials, such as wood adhesives, carpet backing, insulation and roofing coatings, that utilize soy as a key ingredient.
    The most successful soy-based adhesive product to date is the commercialization of PRF/Soy 2000, a two-part adhesive system used to finger joint lumber. The process uses a phenol-resorcinol-formaldehyde resin on one side of the finger joint, and a soy-based adhesive on the other side. When pushed together, the two parts create an immediate bond that, after drying, has greater tensile strength than the wood itself.
    The carpet backing, a thin layer between the fibers and foam cushion that keeps the carpet fibers bound together, is made from SoyOyl™, a soy-based polyol manufactured by Urethane Soy Systems Company (USSC) of Princeton, Ill. SoyOyl replaces petroleum polyols typically used in carpet backing applications.     South Dakota Soybean Processors, a farmer-owned cooperative in Volga, S.D., supplies the soybean oil used to produce the alternative polyol. SoyOyl is also used to create the spray foam insulation, which can be used in both commercial and residential construction. The insulation provides the same insulation performance in a four-inch layer than fiberglass batting can provide in a six-inch layer. This can cut down on construction costs, allowing builders to use 2-by-4-inch studs instead of 2-by-6-inch studs.
    Niemann Laboratories, with a project funded by the soybean checkoff through USB, is developing a soy-based applied roofing coating, Natural Bitumen Jacket, that provides relief from intense sunlight. Natural Bitumen Jacket is a bright white, soybean oil-based product that is applied over bituminous substrates and has a rapid cure time. By reducing the amount of energy absorbed from intense sunlight, the use of air conditioning units to offset absorbed heat is also reduced. This has allowed Niemann Labs to gain “Energy Star” approval, a California government backed standard identifying highly efficient products and superior energy performance.
    “Participating in major industry events such as the International Builders’ Show gives us an opportunity to further educate key influencers on the benefits and properties of soy-based materials, and we have seen a definite upward trend in their knowledge level,” says Eric Niemann, USB NUC chairman and Builders’ Show attendee. “Exhibit visitors’ questions have grown from ‘I didn’t know you could do that with a soybean’ to ‘What’s the next application for the soy resin?’”
    Updates on the development and commercialization of soy-based products can be found at www.unitedsoybean.org.

 

Replacing expensive foreign oil
with American soybeans

    Americans spend upwards of $14 billion each year on diesel fuel -- some 30 billion gallons -- and that price tag rises every year as the cost of importing crude oil and refining it into diesel goes up.
    Making this much diesel every year uses up more than 800 million barrels of petroleum, which is about 27 percent of all the crude oil imported into the U.S.
    The largest diesel-consuming states are Texas and California, consuming 2.4 and 2.3 billion gallons respectively; about 8.2 percent and 7.9 percent of the U.S. total onsumption.
    In the U.S., more soybean oil is used than any other industrial vegetable oils, such as linseed oil, tung oil, etc. Industrial use of soybean oil accounts for only 3 percent of total soybean oil use, or about 300 million pounds per year. The emerging soy diesel market is creating new uses and demand for soybean oil.
    Before 1992, soy diesel or bio-diesel was little known in the U.S. But in Europe and some other countries, bio-diesel had been in commercial use for years. Now, it has made its presence as a viable addition to the alternative and clean fuels market in the U.S. As the worldwide bio-diesel production is rapidly increasing, the U.S. government and other public and private sectors started the research, development, and commercialization of soy diesel.
     As a renewable transportation fuel that can blend with petroleum diesel at less than 1 percent to 100 percent ratios, soy-diesel will play a major role in increased domestic utilization of soybeans.
     It represents a potential market of 60 million gallons or 420 million pounds of soybean oil annually. Initial users of soy-diesel include government fleet and mass transit buses, but this is expected to expand to mining equipment, marine vessels, and other environmentally sensitive operations. The biggest limiting factor to soy diesel’s market penetration is the price, since soy oil commands about $1.07 per gallon more than diesel.
    A solution to this disadvantage is to choose a blend ratio (currently 20 percent soy-diesel to 80 percent petroleum) based on cost analysis for best emissions reduction.
     Several issues ago we introduced the concept of modern, beautiful and energy-efficient concrete homes (Jan. 8, 2004; Insulated Concrete Form Construction). Today we introduce the soybean home.
     No, this is not a creation of Hollywood science fiction writers. American Soybean producers are showcasing the newest in soy-based products at the Farm Science Review in Columbus, Ohio. Thanks to funding from the soybean checkoff and the Ohio Soybean Council (OSC), the House That Soy Built was a success at making industrial uses for soy come to life.
     “The House That Soy Built has been a great vehicle to show consumers and technical researchers just how easy it is to use soy-based products in everyday applications,” says Susie Turner, Executive Director of the OSC. “For instance, plastics made from soybean derivatives can be found in seat cushioning, sink basins and carpet backing – applications that are used daily by industry and consumers. ”The structure of the house is made using finger-jointed lumber and oriented strand board, which uses a soy-based adhesive. Polyurethane spray foam insulation based on soy polyols, a urethane raw material, is also used. It also comes complete with a soy-based kitchen, living room and bathroom. The newest addition to the House was a new use area featuring everything from soy oil based lubricants and soy biodiesel to soy-based hand scrub soap.
     “Soy-based products are proving again and again to be a cost effective, green alternatives to traditional petrochemical-based products,” says Eric Niemann, Chairman of the United Soybean Board New Uses Committee. “Soybean checkoff funds continue to provide the necessary resources to research new innovative uses for soy based derivates for the manufacture of plastics, chemicals, lubricants, adhesives, and solvents.”
     In a real-world application of soy technology, The Ohio State University (OSU) unveiled the first soy biodiesel-fueled Campus Area Bus Service (CABS) transit coach. Increased usage of soy biodiesel has long been an initiative of both the OSC and the soybean checkoff, and this unveiling signifies the beginning of a yearlong pilot program to incorporate soy biodiesel into university transportation services. “By working with high-profile organizations such as Ohio State to utilize soy biodiesel in their fleet, we continue to foster acceptance of the alternative fuel,” says Steve Miller, chairman of the OSC and a soybean farmer from Crawford County. “The more soy biodiesel is used across the state, and through the nation, the more opportunities we create for Ohio’s soybean farmers.”
     Transportation and Parking Services estimates that CABS buses will use 42,000 gallons of B20 during the pilot project. When the program begins in September, Ohio State will be the largest university using soy biodiesel. Through the efforts of the OSC, the House That Soy Built and the Farm Science Review will continue to be regular venues to illustrate to consumers just how easily they can incorporate soy-based products into everyday life.
     For more information, visit the Ohio Soybean Council at http://www.soyohio.org/

The structure of the house is made using finger-jointed lumber and oriented strand board, which uses a soy-based adhesive. Polyurethane spray foam insulation based on soy polyols, a urethane raw material, is also used. It also comes complete with a soy-based kitchen, living room and bathroom.


Soy foam insulation is competitively priced and outperforms fiberglass

     The face of construction is changing. With the continuous rise in lumber prices and new advancements in rollforming technology, steel framing is on the verge of becoming the standard for building construction.When framing with steel studs expanding foam insulation is the only solution for thermal performance. Unlike other forms of insulation, foam’s expanding capabilities completely fill each stud channel. Foam seals from all air infiltration and strengthens the wall cavity.
     The technology for thermal efficient spray foam insulation has existed for over ten years, but has never been economically competitive with fiberglass or cellulose.

 

     For more information on BioBond,. visit http://www.biobond.com/

 


Photos of foam installed in metal struts from Biobond.

   Biobond introduces a soy based polyurethane insulation that equals the thermal and acoustic performance of existing spray foams – at an affordable price.
     Soy foam insulation blocks the entry of outside air, decreasing the need for HVAC equipment, and reducing utility bills.
     Soy foam also blocks air and sound pollutants creating a cleaner, more comfortable indoor environment.
     Unlike other spray foams, soy foam insulation applications are water blown, contain no formaldehyde and emit no VOCs, ozone or CFCs into the atmosphere.
     Biobond soy based foam has a semi-open celled structure which creates its own vacuum, but is semi permeable to water allowing to detect roof leaks.
     By replacing petroleum-oil with soy-oil, soy foam insulation is environmentally friendly, and supports American agriculture.

Case Study: Using BioBond soy based foam insulation

Steel Framed Office

Overview:

Jobsite is Western Colorado's premiere jobshop provider for all type of sheet metal manufacturing and supplier of the largest rollforming equipment product line. A 80,000 square foot plant was built to house Jobsite's large manufacturing equipment.

Project:

The problem encountered was the 10,000 square foot office was built with steel studs and sided with steel panels which conduct large amounts of thermal transfer. Also the office was built adjacent to the noisy jobshop area.

Solution:

For thermal transfer Biobond sprayed foam on all exterior walls of the office area. An R-18 was achieved by spraying 5.5 inches of foam in-between each 2x6 steel stud. Biobond soundproof the wall that separated the shop and the office by filling the wall with 5.5 inches of 0.5 pound density foam. For added sound performance, each wall inside the office was also sprayed with 3.5 inches of foam.

Result:


Jobsite found that the temperature was consistent throughout the entire office and their heating and cooling bills were significantly less that expected. Numerous clients have commented that they were not aware of the loud jobshop operations in the manufacturing area. Employees were happier because of their quieter more comfortable working environment.

 

Adhesives made from soy can cut the cost
of producing plywood and oriented strand board

Heartland Resource Technologies has been able to develop a low-cost soy
adhesive called Soyad that has the potential to replace traditional petroleum resins.

     North America is not only the leading manufacturer, but also the leading consumer of engineered wood products such as plywood and oriented strand board (OSB). These products require large amounts of adhesives during the manufacturing process. In fact, sales of phenolic resins, a traditional petroleum-based adhesive, exceeded 2.8 billion dollars and are projected to grow over 20 percent in the next seven years.
     Growing environmental concerns and government mandates have placed the engineered wood products industry in need of a reliable, plentiful and environmentally safe adhesive alternative. The issue concerns the volatile organic compounds (VOCs) released in the manufacturing, setting and the end use application of the petroleum-based resins.
     That is just one reason why the Iowa Soybean Promotion Board and the soybean checkoff are funding research into soy-based adhesives for the engineered wood industry. As a result of this funding, Heartland Resource Technologies (HRT) has been able to develop a low-cost soy adhesive called Soyad that has the potential to replace traditional resins. “We got involved in this market because we knew it was one that has great potential, and so far, we have had very encouraging results,” said Karen Anderson-Schank, Marketing Manager for the ISPB. The main ingredient of Soyad is denatured soy flour. It is partially hydrolyzed in a caustic environment. This enables the hydrophilic sites to be exposed, affording the resin better adhesion ability, mainly through hydrogen bonding, and better cross-linking as both the amines and hydroxyl groups are now readily accessible. The system becomes cured and non-reversible once the flour is cross-linked into the resin network.
     This means that the Soyad system has the advantage of being easily tailored to react under many different conditions, and the shelf life of the system is twice that of petroleum-based adhesives. Since soybeans are a widely grown and annually renewable crop, soy prices fluctuate much less and remain much lower than those of crude oil.
     “We were skeptical, at first, as to whether or not we could make a soy-based or protein-based product that was water resistant,” says Frank Trocino, HRT’s chairman, “But what we ended up with is a product that performs equal to and sometimes better than the phenol-formaldehyde adhesives.” Soyad’s far-reaching potential encompasses virtually all panel-board products using phenol formaldehyde as well as the molded wood industry with products such as toilet seats and picture frames. The product, along with others from HRT, is currently at a marketing and implementation stage. Adhesive and engineered wood manufacturers are showing a high level of interest due to the savings in production and the excellent performance of the product.
     For more informaiton, see Heartlands website at http://www.heartlandresource.com/

 

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