Reference projects

Buildings, vehicles, electronics and Co.: In many areas, more stringent fire-protection requirements apply. Sustainable biomaterials can fulfill these requirements with, among other things, the help of flame retardants. These are currently predominantly produced from petroleum-based, mineral and other finite raw materials. In collaboration with the Fraunhofer IAP, we are developing and testing flame retardants using a plant-based raw material that accrues in large quantities as a by-product in industry: corn steep liquor. The phytic acid contained therein is to be made usable as a flame-retardant active substance. Using a wood-plastic composite (WPC) as an example, we are able to demonstrate the application potential and flame-retardant properties. The aim is the development of an economical production process for the flame retardant on a technical scale. The project provides a contribution towards improving the competitiveness of bio-based flame retardants and increasing the utilization of biomaterials. As a result, we are supporting the development of a bio-based circular economy using locally available waste materials (bioeconomy).

Medium-density fiberboard (MDF) is widely used in furniture construction. It has a very homogeneous surface that can be coated particularly smoothly. Furthermore, it can be produced economically and sustainably from regionally available wood and recycled waste wood. As a result, it also plays a major role in the construction industry - for example as a substrate for floor coverings or wall panels. Through this research project, we are aiming to make MDF and similar fiberboards even more sustainable. In collaboration with industrial partners, we are developing a formaldehyde-free adhesive system with bio-based materials that are available on the market at low cost. The special highlight: The new adhesive system functions without conventional adhesives.

Cross-laminated timber has established itself within the construction industry as a versatile wood product. It is used in load-bearing and non-load-bearing components such as walls, ceilings and floors. In collaboration with researchers from the TU Braunschweig and industrial partners, we are developing cross-laminated timber with very good fire and environmental properties. We intend to achieve this through the development of bio-based flame retardants using residues from agriculture and wood processing. These are to be incorporated into adhesive systems and coatings for cross-laminated timber elements. The project results should enable an improved exploitation of the market potential of cross-laminated timber in timber construction for medium- and high-rise buildings.

Lightweight vehicles and construction materials are particularly energy efficient. With the goal of achieving the lowest possible weight combined with good thermal insulation, composite materials are often used that can only be recycled to a very limited extent, if at all. In addition, they are usually comprised of petrochemical or other finite raw materials. In collaboration with industrial partners, we are developing a resource- and climate-friendly solution: recyclable lightweight-construction materials on the basis of renewable raw materials with individual forming possibilities. The special feature: the integration of a functional layer should enable the production of heatable furniture and interior components with a lighting function. The application and market potential is very high throughout all sectors.

Heat, drought, storms, bark beetles: In the Harz National Park, climate change is leading to widespread forest damage. Reforestation will take decades. This has a significant impact on the timber and forestry industry, tourism and, consequently, the well-being of the regional population. In collaboration with research and regional partners, we are developing various scenarios for reforestation and are predicting their ecosystem services as well as their socio-economic effects above and beyond this. One approach involves replacing the dead spruce stands with more climate-resistant deciduous tree species. At the Fraunhofer WKI, we are investigating the achievable wood quality and yield as well as the suitability of the wood for the production of wood-based materials.

There are already more than 30,000 wind turbines in Germany. By 2030, there could be more than twice as many. A wind turbine is usable for around 20 to 30 years and must then be disposed of. The tower made from steel and concrete is already very easy to recycle, but the rotor blades have not been up until now. They consist of complex multi-material composites – firmly bonded by thermoset resins. One promising approach: With the aid of detachable resin systems, rotor blades could be constructed in such a way that the materials can be separated by type at the end of the service life. In collaboration with research and industry partners, we are developing industrially feasible production, separation and processing procedures for this purpose. The focus of the Fraunhofer WKI lies in the processing and reutilization of recovered glass fibers and balsa-wood components. As a result, we are helping to ensure that a high-quality reutilization of 100 percent of the wind-turbine materials is possible at the end of their service life.

Particle boards are a sustainable and inexpensive construction material for houses and furniture. They can be produced from regionally available wood residues and recycled waste wood. Through this research project, particle boards will become even more sustainable. In collaboration with industrial partners, we are developing particle boards that are produced using a new kind of adhesive which should not contain any health-critical formaldehyde and which consists entirely of biogenic raw materials. Furthermore, we are conducting tests to determine whether the particle boards can be produced using alternative types of wood, which will be increasingly available in the future as a result of forest restructuring.

After 20 to 30 years, wind turbines have reached the end of their service life and need to be dismantled. In future, up to 75,000 tons of waste from rotor blades will be produced every year, including large quantities of fibre-reinforced plastics. Up to now, they have been used to generate energy (incinerated) or shredded and recycled as cement aggregate. Together with research and industry partners, we are developing a resource-efficient solution: using pyrolysis, the fiber composite plastic from the rotor blades is broken down into its components to recover the fibers used. Both these »recyclate fibers« and the pyrolysis oils and pyrolysis gases produced at the same time can be used industrially. The focus of the Fraunhofer WKI is on the wet-chemical processing of the recyclate fibers for the renewed production of materials. In this way, we are helping to reduce the raw material requirements of the wind industry.

Building with timber provides an important contribution towards climate protection. When combined with concrete, the range of applications for wooden structures can be extended. A bonding technology co-developed by the Fraunhofer WKI enables the accelerated production of timber-concrete composite elements (TCC elements). In the current “SafeTeCC” research project, we are optimizing and standardizing the manufacturing process in order to make it suitable for use on construction sites and to ensure process reliability. Simultaneously, the component properties are to be optimized. The aim is to establish the utilization of TCC elements in multi-story building construction - as a competitive alternative to precast steel-reinforced concrete elements. In this way, we are helping to increase the proportion of renewable raw materials in the construction sector and, consequently, to achieve climate and sustainability goals.

Lightweight cars, trucks and trains made from renewable raw materials can contribute towards the protection of resources and the climate. As a joining technology for the production of lightweight components, adhesive bonding offers particular advantages and is therefore increasingly gaining in importance. In collaboration with research and industry partners, we are developing a bio-based, switchable PU adhesive for large surfaces. This should enable the production of panel-shaped laminated materials made from wood or wood and metal, which are not formed into 3D components until a later stage in the process chain. This opens up new possibilities for the flexible, economically efficient production of sustainable lightweight vehicles as well as for repair purposes and recycling. The special feature: Thanks to the re-detachable adhesive bond, it should be possible to separate the wood and metal according to type and with as little damage as possible.