Around 2019 I became aware of HDPE (High-density Polyethylene) Recycled Lumber and Composite Lumber. A slow-burn fascination with this emerging material and industry has evolved into a personal research project of sorts, in which I question the logic, motives and aesthetic evolution of HDPE materials and products. These products are sold under a variety of names, such as Polywood, Plastic Lumber, HDPE Lumber, Trex, Composite Lumber etc. Manufactured as an alternative/replacement for conventional construction lumber, Plastic lumber is primarily used for outdoor applications such as decking, landscape barriers, stairs etc. and is also used to manufacture outdoor furniture, signage and a variety of other products for outdoor use.

Recycled plastic lumber is either manufactured to the same dimensions as commonly available wood products (construction lumber) such as 2 X 4’s, or molded into monolithic custom shapes such as bench supports, tire chocks or parking blocks. I find it interesting and ironic that a thermo-moldable material that can take almost any shape, is currently produced to mimic the exact shapes and profiles of existing wood products, which are produced in an entirely different way (logging and milling trees). The soft plastic can even be used with the same cutting and milling tools as wood, which is very convenient for businesses and individuals that are fabricating outdoor products from construction lumber.

Following these manufacturing developments, the objects produced have a certain look and feel. This holds especially true for furniture. Since plastic has different properties than wood (more flexible, less structural etc.) there are certain designs that translate more smoothly from wood to plastic. This usually translates to a ‘chunky’ aesthetic, or means that certain typologies are copied more than others. For example, the most common furniture objects produced are Adirondack Chairs, or classic-looking picnic tables. This is because the dimensions, joinery details and production techniques are closely aligned, requiring less thinking or development for the companies and fabricators using the material.

There is no doubt in my mind that these materials will be seen more and more, as consumers are sold to believe that recycled products are important materials for countering human’s impacts on our planet. There are obvious ethical and ecological reasons to choose Plastic lumber over conventional wood construction. Quoting Plastic Lumberyard.com: “It is entirely waterproof, making it perfect for decks, docks, and walkways that are in wetlands or at the shore. The color of the lumber is included throughout the entire board during the manufacturing process, so painting and staining will never be needed”. According to the American Chemistry Council and America’s Plastics Makers,  “…a plastic lumber deck in the backyard can entertain generations of families.”

The history of furniture follows a certain path, namely from simple to complex. Early furniture typologies such as tables, seating and storage were first executed with a minimum of processing due to the difficulty of making tools. Rocks were seats and tables. As human technology advanced, so did our methods for working with readily available compounds. Wood, metal, stone, ceramics and fibers.

HPDE lumber furniture and objects share much with DIY furniture and objects: simple construction, uncomplicated joinery, metal fasteners available from hardware stores, lack of refinement etc.

In an attempt to create furniture objects from recycled lumber with a new or different aesthetic, I began experimenting. At the time I was working for artists that had purchased a bicycle rack made from HPDE Lumber. They often used strange commercially available goods in art installations and videos. The rack sat around for years, unused, so I further recycled it, disassembling and further milling the material using various woodworking techniques. Instead of using the material as a standard contractor would, I employed more time-consuming techniques borrowed from the craft of fine furniture-making. I used chisels and gouges to shape the material into legs and a seat. I cut joints such as mortises and tenons, and laminated boards into planks by melting instead of gluing. I made a rustic-inspired stool with the same traditional techniques used for stake furniture.

I find the result to be in the uncanny valley. Although its form is easily recognizable, the material is not. It is an awkward and fertile combination.