Information and Processing Manual Rheinspan® AirMaxx - Triplaco nv

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Information 

and 

Processing Manual 

Rheinspan® AirMaxx 

(Version 2: April 2009) 

Nolte Holzwerkstoff GmbH & Co. KG 

Konrad-Nolte-Str. 40 

Postfach 1740 

D-76726 Germersheim 

� +49 (0) 7274/9470-211 

� +49 (0) 7274/9470-220

Contents 

Processing Manual Rheinspan® AirMaxx 

Contents __________________________________________________________________ 1 

1 History __________________________________________________________________ 3 

2 Technical properties _______________________________________________________ 4 

2.1 Basic technical data__________________________________________________________ 4 

2.2 Screw extraction strengths ____________________________________________________ 5 

2.3 Other fittings technologies ____________________________________________________ 6 

3 Processing _______________________________________________________________ 7 

3.1 Feeding of processing plants __________________________________________________ 7 

3.2 Surface finishing ____________________________________________________________ 8 

3.3 Cutting ____________________________________________________________________ 9 

3.4 Formatting________________________________________________________________ 10 

3.4.1 Test series "Formatting" conducted in partnership with HOMAG__________________________ 11 

3.5 Design notes _______________________________________________________________ 13 

4 Environment ____________________________________________________________ 13 

4.1 Formaldehyde emissions / PCP, lindane ________________________________________ 13 

4.2 Fire behaviour _____________________________________________________________ 14 

4.3 Storage ___________________________________________________________________ 14 

4.4 Ageing and disposal ________________________________________________________ 14 

5 Areas of application_______________________________________________________ 15 

5.1 Furniture manufacturing ____________________________________________________ 15 

5.2 Commercial construction ____________________________________________________ 15 

5.3 Advantages of Rheinspan® AirMaxx__________________________________________ 15 

5.3.1 Manufacturer __________________________________________________________________ 15 

5.3.2 Retail and trade occupations_______________________________________________________ 15 

5.3.3 Customer _____________________________________________________________________ 16 

5.3.4 Environment ___________________________________________________________________ 16 

6 Contacts ________________________________________________________________ 17 

7 Appendices______________________________________________________________ 18 

7.1 Fire protection certificates / Test reports BASF (abstract)_________________________ 18 

7.1.1 Test report 49mmAirMaxx________________________________________________________ 18 

7.1.2 Test report 16mm-AirMaxx _______________________________________________________ 19 

7.2 Formaldehyde Class E1 test certificate_________________________________________ 20 

7.3 "Material Connexion" certificate _____________________________________________ 21 

Nolte Holzwerkstoff GmbH & Co. KG 1

Index of illustrations: 


Fig. 1: Components of AirMaxx-----------------------------------------------------------------------------------------------3 

Fig. 2: Sample fittings: Excenter (top left), expansion anchor with half-round screw (top right), concealed hinge 

(bottom centre) ---------------------------------------------------------------------------------------------------------------6 

Fig. 3: Glue-in thread insert after extraction tests in normal chipboard and AirMaxx board----------------------7 

Fig. 4: Test design: Extraction of an extraction anchor------------------------------------------------------------------7 

Fig. 5: Sectional view of an AirMaxx board (above) and a normal chipboard (below) with thick edge----------9 

Fig. 6: AirMaxx board 18mm, cross-section with cut groove ---------------------------------------------------------10 

Fig. 7: AirMaxx board 18mm, coated with cut groove -----------------------------------------------------------------11 

Fig. 8: Thin and thick edge with AirMaxx--------------------------------------------------------------------------------12 

Fig. 9: Formatted AirMaxx boards at IMA------------------------------------------------------------------------------13 

Fig. 10: Direct weight comparison of a cabinet made from AirMaxx board (right) and standard chipboard 

(left)----------------------------------------------------------------------------------------------------------------------------16 

Index of tables: 

Table 1: Comparison of screw extraction strengths AirMaxx - Normal chipboard--------------------------------5 

Table 2: Comparison of screw extraction strengths Euro screw - Spax screw-------------------------------------5 

Table 3: Comparison of coatings with AirMaxx------------------------------------------------------------------------8 

Table 4: A variety of possible edgings----------------------------------------------------------------------------------10 

Table 5: Results of test runs at Homag---------------------------------------------------------------------------------12 


1 History 


In the beginning, the idea was to produce a wood material with a significantly lower 

weight than standard chipboard but with the same outstanding processing properties 

and similar strength. The first real revolution in the way chipboard is manufactured 

since 1930. 

In 2006 – in partnership with BASF Ludwigshafen – Nolte Holzwerkstoff GmbH & Co. 

KG took the first steps towards developing today's Rheinspan® AirMaxx board. 

Since mid-2007, production has been maturing into what is now a stable industrial 

manufacturing process with an annual production of up to100,000m³ being targeted 

in the longer term. 

This significant weight reduction amounting to approx. 30% compared to normal 

chipboard is achieved through the introduction of expanded polystyrene balls into the 

core layer of the board. These replace a portion of the wood chips. 

+ = 

Fig. 1: Components of AirMaxx 

Among other things, the weight savings achieved in this way open up new 

possibilities for our customers in terms of product packaging. These in turn help to 

minimise transportation and handling costs. 

The great advantage of our new technology: Our customers can still use their old 

technology. The processing machinery and properties for AirMaxx are exactly the 

same as those for standard chipboard – unlike honeycomb board – and it is almost 

as strong. 

In this manual, we would like to provide you with the data and information you need 

to help you achieve the best possible results when processing AirMaxx. 


2 Technical properties 

2.1 Basic technical data 


Nolte Holzwerkstoff GmbH & Co. KG 4 

Thickness class 

Testing norm Unit up to 20mm up to 40mm up to 60mm 

Chipboard AirMaxx Chipboard AirMaxx Chipboard AirMaxx 

Building material class DIN 4102-1 B2 

DIN EN 13501-1 D-s2,d0 

Formaldehyde emissions class EN 120 E1 

Raw density kg/m³ 620-650 450-500 620-650 400-450 620-650 400-450 

Raw density tolerance kg/m³ ± 30 

% ± 7 ± 7.5 ± 8 

Length & width tolerance EN 324-1 mm/m ± 5 

Thickness tolerance EN 324-1 mm ± 0.3 

Rectangularity EN 324-2 mm/m 2 

Edge straightness EN 324-2 mm/m 1.5 

Curvature mm/m < 2 

Moisture content 

EN 322 % 9 (± 4) 

Bending strength EN 310 N/mm² 13 7.8 8.5 6.3 7 5.0 

Internal bond EN 319 N/mm² 0.3 0.18 0.2 0.18 0.2 0.2 

Surface soundness EN 311 N/mm² 0.8 0.6 0.8 0.8 0.8 0.8


2.2 Screw extraction strengths 

(Tested using the internal testing procedures developed by Nolte Möbel, based on 

EN120 and the AMK data sheet) 

Test set-up: 

12mm 

Example: Comparison of normal chipboard with Rheinspan® AirMaxx , 38mm 

Euro screw 5.0x30, pre-drilled with 5mm drill 

Table 1: Comparison of screw extraction strengths AirMaxx - Normal chipboard 

Comparison: Euro screws – Spax screws 

Extraction 

Surface – AirMaxx 640 

Surface – chipboard 998 

Edge – AirMaxx 325 

Edge – chipboard 860 

During the tests it was demonstrated that the use of Euro screws in place of Spax 

screws of the same size achieved an improvement in screw extraction strength of 20 

– 30%. 

Example: 32mm chipboard, 

Euro screw 5.0x30, pre-drilled with 5mm drill 

Spax screw 4.0x30, pre-drilled with 4mm drill 

16mm screw-in depth 

Extraction 

N 

Surface – Euro screw 494 

Surface – Spax screw 410 

Edge – Euro screw 228 

Edge – Spax screw 160 

Table 2: Comparison of screw extraction strengths Euro screw - Spax screw 

Nolte Holzwerkstoff GmbH & Co. KG 5 

N 

20mm


If it is possible, from a design point of view, to double the screw-in depth of the Euro 

screw into the Rheinspan® AirMaxx board, tests show that it achieves screw 

extraction values approaching those for standard chipboard. 

2.3 Other fittings technologies 

In our experience, Rheinspan® AirMaxx can be used with the standard fittings 

used with normal chipboard as, unlike honeycomb board, it has a solid core layer that 

provides purchase for the fittings. 

Tests have shown that "excenter fittings" are preferable to "defix fittings" in order to 

prevent fractures in the core layer. 

The use of expansion anchors is recommended, e.g. when mounting concealed 

hinges, in order to increase purchase in the board. 

Fig. 2: Sample fittings: Excenter (top left), expansion anchor with half-round screw (top right), concealed 

hinge (bottom centre) 

Internal tests assessed the use of different types of connecting screws and thread 

inserts commonly used in the furniture industry and compared the results for AirMaxx 

to those for normal chipboard. 

These tests have shown that the extraction strengths for normal chipboard are on 

average approx. 30% better than for AirMaxx. Nonetheless, the fittings grip the board 



well. Glue-in thread inserts achieved very good results and are therefore particularly 

recommended. 

Fig. 4: Test design: Extraction of an extraction anchor 

Fig. 3: Glue-in thread insert after extraction 

tests in normal chipboard and AirMaxx board 

Accompanying long-term tests were conducted by Hettich. These included load cycle 

tests using AirMaxx. 

Both test series produced positive results. The tested doors were still fully functional 

after the load cycle test. No screws had come loose or twisted. 

3 Processing 

3.1 Feeding of processing plants 

AirMaxx is suitable for use with push-feeding systems in processing plants. 

However, for thick boards it is important to ensure that the transfer finger is 

sufficiently thick – otherwise there is a danger of fractures in the coating layer. 

For suction of the raw boards, it is necessary to adjust parameters such as air flow, 

pumping speed, number of suction cups and cross-section for the AirMaxx board. 

This is important as otherwise there is a danger of the cups sucking through the 

board due to its more porous surface. This does not apply to coated boards, which 

can be suctioned without difficulties. 

Generally, a vacuum blower is more suitable than a vacuum suction cup or ejectors. 



We are successfully using a directly operated vacuum blower for high suction volume 

manufactured by Schmalz, who also supported us in conducting a number of tests. It 

has the following technical specifications: 

� Pumping speed: 310 m³/h 

� Vacuum: -420 mbar 

� Nominal output: 4,0 KW 

The minimum air throughput per suction cup of 10-12m³/h is another useful 

orientation value. 

There is no general rule of thumb for the feeding of processing plants using vacuum 

suction, as equipment and conditions vary and must therefore also be evaluated 

separately. 

3.2 Surface finishing 

Finish film with hot-melt 

adhesive 

Finish film with 2component 

urea resin 

Finish film with PVAC glue 

Coating 

HPL/CPL 

Painting – Spraying paint 

Painting – Direct painting 

Veneer 

Melamine/KT 

Very stable finish; for processing with standard equipment 

under the normal temperature and pressure conditions 

Very stable finish, process with somewhat increased 

quantity of urea and higher pressure 

Process with somewhat increased quantity of glue and 

higher pressure 

Very stable finish: for processing with standard equipment; 

Edge: prior sealing of the core layer with UV putty or a blind 

edge is absolutely essential. More hot-melt adhesive or 

putty is required due to the coarser composition of the core 

layer. 

Easy to process: Regrinding is required to improve the 

stability of the edge 

Increased quantity of paint required due to more porous 

coating layer, increased quantity of primer and base colour 

required 

Increased quantity of paint required due to more porous 

coating layer, increased quantity of primer and base colour 

required 

Somewhat increased quantity of PVAC glue required, easy 

to process 

Easy to process; Important: For pressure-regulated 

controls, reduce the processing pressure 

Table 3: Comparison of coatings with AirMaxx 


3.3 Cutting 


Rheinspan® AirMaxx can be cut to size and milled on all standard wood working 

machines using the tools commonly used for chipboard. There is no additional fouling 

of cutting tools. 

Both hard metal and diamond-equipped tools can be used. No excessive adhesions 

are visible on the blade even after longer periods of operation. 

To avoid fractures in the coating layer, AirMaxx should always be sawn using a 

scoring saw, fractures in the core layer are avoided by using a protective saw where 

the saw blade exits. 

Likewise, the use of a protective cutter is also recommended. New, sharp tools 

should also be used to prevent fracturing of the edges. 

Special information concerning suitable cutting tools and tooth geometries is 

available on request from the company HOLZMA. 

Any sawdust and waste created are easily removed via existing extraction systems – 

in contrast to PVC, no separate extraction system is required. 

For further information on disposal and incineration, please refer to Section 4.2 Fire 

behaviour and 4.4 Ageing and disposal. 

Fig. 5: Sectional view of an AirMaxx board (above) and a normal chipboard (below) with thick edge 


3.4 Formatting 


Edge processing is possible without major difficulties on standard formatting lines. 

However, fine adjustments must be made to power units, fittings, tools and feeders. 

Thin edge/Flat edge (up to 

0.7mm) with hot-melt 

adhesive 

Thin edge/Flat edge (up to 

0.7mm) with PVAC glue 

Thick edge (up to 2.5mm) 

with hot-melt adhesive 

Soft edge as thin edge with 

hot-melt adhesive 

Soft edge as veneer edge 

with hot-melt adhesive 

Veneer edge with PVAC 

glue 

Veneer edge with hot-melt 

adhesive 

HPL/CPL edge 

The use of a weak filled adhesive is recommended, 

application of somewhat greater quantity with normal 

temperature and pressure conditions 

Unstable finish, less advisable (can be used as a blind 

edge) 

Very stable finish, highly recommended for thicknesses 

from 22mm; application of the thick edge prevents possible 

fractures in the core layer; somewhat greater quantity of 

hot-melt adhesive required� outstanding binding of the 

edge 

Less advisable; particularly with soft profiles, which engage 

very strongly with the core layer (S-profiles); barrel profiles 

are generally a better option; use of hot-melt adhesive is 

comparable with use for flat edge 

Slightly greater quantity of glue required, after grinding the 

edge quality is comparable with that of chipboard 





Processing is easy with slightly greater quantity of glue 

required, achieves a good edge quality due to the strength 

of the material 

Table 4: A variety of possible edgings 

Edges can also be finished on all standard equipment. 

A grooving cutter with bevel is recommended for cutting grooves. An adequate 

distance to the edge must be ensured to prevent the edge cracking. Double-sided 

grooves can also be produced. 

Fig. 6: AirMaxx board 18mm, cross-section with cut groove 



Fig. 7: AirMaxx board 18mm, coated with cut groove 

3.4.1 Test series "Formatting" conducted in partnership with HOMAG 

A close partnership was also maintained with Homag in relation to the formatting 

tests conducted at Nolte Möbel. The results of these tests are presented in the 

following section: 

AirMaxx board was subjected to a number of test series both on throughfeed and 

stationary machines. The results of these tests were presented to us by HOMAG. 

The complete test report is available on request. 

Throughfeed machine (using example of Optimat KAL310) 

Feed rate: 20m/min 

Temperature: 145°C 

Adhesive: Unfilled hot-melt adhesive 

Stationary machine (using example of Optimat BAZ322) 

Vacuum pump: 140m³/h 

Work table 

Tools with cutters drawing to the centre of the board (prevents fractures in the 

coating layer) 


Results in brief: 

Coated with melamin and / or 

lining film 

uncoated 

Thin edge/ 

Flat edge 


Throughfeed machine Stationary machine 

Increased quantity of glue 

required. 

Very good edge adhesion. 

For material thickness greater 

than 40 mm, the core layer 

pushes through somewhat. 

Thick edge recommended. 

Thick edge Increased quantity of glue 

required. 


Highly recommended for 

material thicknesses greater 

Thin edge/ 

Flat edge 

than 40 mm. 


required. 


For material thicknesses 

greater than 40 mm, the edge 

finish becomes a little 

unstable. 

Thick edge recommended. 

Thick edge Increased quantity of glue 

required. 

Excellent edge adhesion. 

Edge adhesion is also very 

good with thick materials 

Table 5: Results of test runs at Homag 


required. 

The core layer fractures a 

little in the corner areas. 

The corners are not 

adequately compressed by 

the edge. 


required. 

Recommendation: Saw 

edges straight or approach 

the corners from outside 

(counter direction). 

Uncoated boards should be 

processed on a nesting 

machine. Vacuum rating 


Similar tests were conducted at the company IMA; these results confirm those 

achieved in the tests at Homag. This test report is also available on request if 

necessary. 

3.5 Design notes 

Fig. 9: Formatted AirMaxx boards at IMA 

Like chipboard, AirMaxx already has a basic deflection due to its own weight. This 

can be countered using suitable design solutions. 

To achieve especially good bending strength, substructures or concealed edge band 

should be used. 

Static load tests (deflection caused by a load of 63kg over 28 days) conducted by CS 

Schmal showed that AirMaxx has good deflection properties: for a board length of 

1200mm, the test board showed a deflection of 3mm. 

4 Environment 

4.1 Formaldehyde emissions / PCP, lindane 

AirMaxx board is manufactured just like normal chipboard with E1 glue systems. 

AirMaxx is therefore below the threshold value of 8mg/100g set for E1 boards and 

calculated using the perforator method (according to DIN120). 

The formaldehyde analyses have shown that formaldehyde emissions from AirMaxx 

are even lower than those from chipboard (on average between 4.0 and 5.0 

mg/100g). 

In the longer term, a reduction of formaldehyde emissions to E1/2 quality is planned. 



Emissions of PCP/lindane are also below the threshold levels. A study of VOC 

emissions is in the planning phase. 

4.2 Fire behaviour 

The fumes produced by the burning of Styropor® (Kaurit Light®) are comparable 

with the fumes from burning wood materials, there are no known special 

environmental hazards. From temperatures of approx. 1000°C, given a sufficient 

supply of air, Styropor® burns completely leaving no residue. 

The burning of AirMaxx board does not therefore result in increased hazards for the 

environment or ground water. AirMaxx has been officially classified according to DIN 

4102 in the fire protection classification B2 / normally flammable materials (see 

document appendix). 

A retention reservoir for water used in fire fighting is not required for facilities 

manufacturing or storing Styropor. 

4.3 Storage 

Generally there are no differences between the requirements for storing standard 

chipboard and those for storing Rheinspan® AirMaxx. 

However, it seems to be advantageous to increase the amount of dunnage in order 

to reduce the bending of the large format board to the minimum level possible. 

Furthermore, it is also important to lay the dunnage parallel. 

4.4 Ageing and disposal 

The ageing stability of Styropor® has been proven through many years of 

observation and investigation. Material fatigue caused by long-term stress is not 

expected. 

As wood constitutes the majority of waste from AirMaxx boards, the product is 

subject to the German Waste Wood Ordinance (Altholzverordnung) and has been 

classified as Waste Wood Category A II (like other wood materials). Recycling of 

material is permitted under the terms of the German Waste Wood Ordinance. 

Thermal utilisation in a thermal plant complying with the Federal Immission Control 

Act (4. BImSCH) is also permissible. Authorities have thus eliminated any possible 

concerns regarding restrictions on disposal. 

An ecological efficiency analysis has been produced by BASF and is available on 

request. 


5 Areas of application 


Rheinspan® AirMaxx is particularly suitable for use in the following areas and 

applications: 

5.1 Furniture manufacturing 

o Flanks and side elements up to 60mm 

o Lightweight furniture concepts 

o Kitchen worktops 

o Lightweight office furniture 

o Lightweight concepts for sliding doors 

5.2 Commercial construction 

o Partition walls 

o Shop and exhibition stand construction 

o Doors 

o Interior fittings for pre-fabricated houses 

o Caravan and ship construction 

o Container construction 

5.3 Advantages of Rheinspan® AirMaxx 

5.3.1 Manufacturer 

o Lower logistics costs 

o Easier handling in the factory 

o Protect employee health 

o No new or additional investment required 

o Substitution of more expensive lightweight products such as honeycomb 

board, hempboard or plywood 

o Saves packaging materials 

o Reduces the need for costly and specialised fittings technologies 

5.3.2 Retail and trade occupations 

o Unique selling proposition "lightweight construction" 

o Lower logistics costs 

o Compliance with weight limits per packaging unit (legal requirements) 

o Increased sales through lighter packaging units 

o Substitution of more expensive lightweight products 

o Environmental aspects 


5.3.3 Customer 


o Noticeable reduction in weight 

o Easy handling 

o Example: Construction of flat-pack furniture 

� Moving large area sliding doors 

� For applications where furniture has to be moved frequently 

o No disadvantages in daily use, stronger than honeycomb board 

5.3.4 Environment 

o Weight reductions along the entire value added chain save fuel and reduce 

the volume of freight 

o Residue-free disposal and incineration 

Fig. 10: Direct weight comparison of a cabinet made from AirMaxx board (right) and standard chipboard 

(left) 


6 Contacts 


The following companies are on-hand to answer your technical and practical 

questions: 

General questions concerning Rheinspan® AirMaxx: 

Nolte Holzwerkstoff GmbH & Co. KG 

Konrad-Nolte-Str. 40 

Postfach 1740 

D-76726 Germersheim 

� +49 (0)7274/9470-211 

� +49 (0)7274/9470-220 

Questions concerning the raw material Styropor® Kaurit light®: 

BASF AG 

D-67065 Ludwigshafen 

Questions on the feeding of processing plants, formatting etc: 

Holzma 

Holzmastr. 3 

D-75365 Calw-Holzbronn 

Homag Holzbearbeitungs AG 

Homagstr. 3-5 

D-72296 Schopfloch 

Schmalz Vakuum-Technologie 

Aacher Str. 29 

D-72293 Glatten 


7 Appendices 


7.1 Fire protection certificates / Test reports BASF (abstract) 

7.1.1 Test report 49mmAirMaxx 

Test report no.: 7760 / 26008 

1. Material description: 

(Manufacturer information) 

Wood material board AirMaxx 49mm 

Colour: 

Area of Application: 

2. Summary of results and classification: 

Order received: 22.09.2008 

Sample received: 22.09.2008 

Date of test: 25.09.2008 

According to DIN 4102 Part 1: B2 non-burning dripping 

Comments: 

Application of flame (also) performed on sample turned at 90°. 

Note: The fire testing centre operated by BASF SE is not a testing centre recognised by the 

Federal State Building Codes or the Construction Products Directive. This report cannot 

therefore be used as a general technical approval of applicability and may not be used for the 

proof of the fire behaviour of the product according to the German Construction Products Directive. 

Our statements regarding fire protection relate exclusively to the samples tested and are 

based on the test results achieved under the test conditions described. The extent to 

which conclusions can be drawn regarding non-tested materials and their use under 

different conditions is at the judgement of the customer and at his own risk. 

BASF Fire Protection Engineering (Brandschutztechnik) Ludwigshafen, 25.09.2008 

Dr. Henn Spielmann 

Test centre manager Tester 


7.1.2 Test report 16mm-AirMaxx 

Test report no.: 7760 / 26009 

1. Material description: 

(Manufacturer information) 

Wood material board AirMaxx 16mm 

Colour: 

Area of Application: 

2. Summary of results and classification: 


Order received: 22.09.2008 

Sample received: 22.09.2008 

Date of test: 25.09.2008 

According to DIN 4102 Part 1: B2 non-burning dripping 

Comments: 

Application of flame (also) performed on sample turned at 90°. 

Note: The fire testing centre operated by BASF SE is not a testing centre recognised by the 

Federal State Building Codes or the Construction Products Directive. This report cannot 

therefore be used as a general technical approval of applicability and may not be used for the proof 

of the fire behaviour of the product according to the German Construction Products Directive. 

Our statements regarding fire protection relate exclusively to the samples tested and are 

based on the test results achieved under the test conditions described. The extent to 

which conclusions can be drawn regarding non-tested materials and their use under 

different conditions is at the judgement of the customer and at his own risk. 

BASF Fire Protection Engineering (Brandschutztechnik) Ludwigshafen, 25.09.2008 

Dr. Henn Spielmann 

Test centre manager Tester 


7.2 Formaldehyde Class E1 test certificate 



7.3 "Material Connexion" certificate

Information and Processing Manual Rheinspan® AirMaxx - Triplaco nv

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