CoreSpan® Co-Extruded WPC Aluminium

CoreSpan® Co-Extruded WPC Aluminium

CoreSpan® Co-Extruded WPC Aluminium


CoreSpan® was developed as a solution to the typical problems associated with conventional Wood Plastic Composites (WPC’s), and also those associated with natural wood.

CoreSpan® has advantages such as:
• The material doesn’t degrade when exposed to ultraviolet rays
• Is heat resistant up to 120º C
• Dimensional stability is similar to aluminium
• Greater flexural strength
• > 3% moisture retention after 30 days submerged in water
• Has 3 times the screw-holding strength to that of natural wood.
• Provides the look and feel of natural wood

CoreSpan® Technology
Conventional Wood Plastic
One of the biggest obstacles in manufacturing Wood Plastic Composites is the removal of moisture from the wood fibres used in the manufacturing process. Wood and petroleum-based thermoplastics will not adhere to one other naturally, and especially if the wood contains any moisture. “Conventional Wood Plastic” products do not address this issue. Typically, in these processes, wood flour is dried to 0.5%-3% moisture content. The wood is then added to an extruder along with the plastic. The two compounds are mixed in the extruder and pushed out through a die. Since the two products are not physically attracted to each other, and above all because of the moisture content, the products only co-exist and never completely bond to each other. Furthermore, wood acid can be created from this moisture, which can cause further problems in an extruder. The resulting product’s strength, water absorption ability, and many other physical characteristics may be adversely affected. This is why we take great care to control which wood fibres are used and treated in our manufacturing site, and why we never use conventional wood flour.
We reduce the moisture content of the wood fibres used to 0%. Our approach to manufacturing Wood Plastic Composites is very different to the one generally applied in the marketplace. We recognised at an early stage the problems that can occur if any moisture is present in the wood flour, and this is why we developed a process that eliminates 100% of the moisture content found in the wood fibres used to make CoreSpan®.


We patented a process based on a system similar to a PVC compounding system in which wood fibres are added to a high intensity mixer. The fibres are dried in the high intensity mixer through a friction process incorporating a special mixer blade design. Once the moisture has been driven out of the wood, a thermoplastic is added along with a special reinforcing agent. The plastic is then literally beat into the pores or tracheids of the wood, this being only possible due to the fact that the wood does not contain any moisture. This is the significant part of the process, as the plastic is fully integrated or embedded in the tracheids of the wood to create a single, matrix-like material. This is why CoreSpan® is physically stronger and more stable in terms of its dimensions than any other wood-fibre composite product. Furthermore, since the wood actually surrounds the plastic, the finished product looks and feels like natural wood.


This natural wood-like look and feel is also made possible because of the high wood content of the compound. Wood fibres are mixed with thermoplastics at an 8:1 volume ratio of wood to plastic

(55% wood / 45% polypropylene by weight). Since the majority of the compound is wood, the product naturally takes on the characteristics of a real hardwood.
CoreSpan® is made from a mix of waste wood discarded from construction sites or industrial plants that has been crushed into fiber, and discarded plastics that have been recycled and crushed into flakes. This mix is then heat-treated so it can be melted and moulded. The main raw material is therefore a new, environmentally friendly, 100% recycled material. The moulding method used is extrusion moulding. Since CoreSpan® is not subject to corrosion or termite damage, it is better suited than natural wood to outdoor applications, and is widely used for decks, pergolas, fences, and other outdoor landscaping features, as well as general construction materials.