Make sure your build is safe for your health

Designing and building out a van is something many vanlifers like doing themselves, BUT did you know many construction materials have toxins in them and living in your newly built van can make you sick?

Selecting non-toxic materials is often an overlooked step when doing a van build. It's easy to fall into the trap of using conventional home construction materials, thinking they're just as fit for van life. However, materials like raw wood, while common in homes, might not be the best choice for your van. Let's dig in to ensure you have a van as healthy as it is cozy.

Have you ever experienced that new car smell? It’s actually a pretty popular smell that many people like. However, that new car smell can be a hazardous concoction of chemicals that mix together to create this strong smell in the air. The new car smell doesn’t last forever with the air moving through your car from the window and from you using your air conditioning. Similar to that new car smell, new construction also has its own new smell, and, in some cases, it can be far more aggravating to your respiratory system.

We spend lots of time in our vans, cooking, hanging out when it rains, and even sleeping with our faces right on top of something that could be making us sick. Wood materials, including those used in flooring, furniture, and cabinets may contain certain toxic chemicals that find their way into the environment through the chemical off-gassing process when used in your van space.

Off-gassing refers to the release of volatile organic compounds (VOCs) from various materials, including raw lumber. These VOCs can pose potential health risks, especially in confined spaces like van interiors. Then add heat from the weather and the levels increase even further.

When you're exposed to these toxins, it can affect you in several ways. You might start to feel respiratory irritation; this is where VOCs, or volatile organic compounds, irritate your airways and you might end up coughing, feeling congested, or having difficulty breathing. They can also cause headaches, nausea, and dizziness. And in more severe situations, if you're exposed to these compounds for a long time, it could lead to serious health problems, including issues with your respiratory system, liver and kidney damage, and it has even been linked to some types of cancer.

When it comes to wood, there are many different types of wood that are used as building materials and each of these woods will have certain chemical compounds that are introduced during the manufacturing process.

Pressure-treated wood is a type of wood that has been embedded with a chemical preservative that protects the wood from insects, humidity, and moisture. That sounds great. We need to have our vans protected from these things, but do you know what they do to pressure treat that wood? There are several different ways, but the most common involves the wood being placed in a holding tank that removes the air and replaces it with a preservative. High pressure is used to force a solution of water and preservative chemicals deep into the wood. Because the wood is literally flooded with the chemical solution, it usually arrives at the store still wet, and the drying process can take several weeks to completely dry out.

Even untreated or raw lumber contains VOCs including formaldehyde, acetaldehyde, and benzene.

There are several dangerous chemicals to be aware of, each with its own set of risks.

1.      Chromated Copper Arsenate, or CCA, is a commonly used preservative in treated wood to prevent it from rotting. This is especially true for lumber used outdoors, thanks to its humidity and water resistance. But there's a catch - this chemical preservative incorporates arsenic, chromium, and copper into the wood, making it a significant health hazard. The National Center for Healthy Home reports that because arsenic is a known carcinogen, exposure to CCA can lead not only to nerve damage but also to symptoms like dizziness and numbness.

2.      Polyurethane, a versatile plastic that, when it dries from its liquid state, creates a super tough varnish resistant to water, solvents, and wear. However, it also harbors chemicals that are respiratory toxins. This means they can trigger or exacerbate breathing problems, including asthma and potentially other serious health issues.

3.      Formaldehyde - a name you might recognize because it's used in embalming. But it's also widely used in building materials and household products. Known to be a carcinogen, formaldehyde is notably present in pressed wood products bonded with urea-formaldehyde resins. This means that common items made from particleboard, hardwood plywood paneling, and medium-density fiberboard could be emitting formaldehyde. The Agency for Toxic Substances and Disease Registry highlights that exposure to this chemical can irritate the eyes, nose, throat, and skin and can worsen asthma and other respiratory conditions.

VOCs are a significant issue. These organic chemicals easily evaporate at room temperature and become gases. Besides building materials like raw and treated lumber, VOCs are found in everyday products, including paint and adhesives. The EPA even says prolonged exposure can cause cancer.

In the confined space of your van, this means the smells coming from the chemicals and VOCs off-gassing can quickly become overwhelming, especially when you are living and sleeping on the material in a closed, and sometimes unventilated space.

I recently read a Facebook post from a woman in Florida who was told to build out her van using pressure treated lumber to combat condensation. After living in her van, she started to get very painful headaches. Even sleeping with the doors open she would get the headaches, but when she wasn’t in her van for a few days she wouldn’t have the headaches. Now, she faces selling her van or tearing everything out and starting all over.  

What can you do?

There are several safer options you can consider.

1.      Look for wood products that are either low in volatile organic compounds (VOCs) or completely free of formaldehyde. For instance, many brands offer formaldehyde-free plywood, which uses soy-based adhesives instead of traditional urea-formaldehyde resins. PureBond is one of the brands known for this. Then there are solid hardwoods like maple, birch, and walnut, which naturally emit fewer VOCs compared to softwoods, making them a healthier choice for your van.

2.      When it comes to engineered wood, some products are made with low-VOC or formaldehyde-free binders. You'll want to look for fiberboard and particleboard that meet the strict standards for formaldehyde emissions, such as those outlined in CARB Phase 2 by the California Air Resources Board. Another interesting alternative is recycled plastic lumber, which emits minimal VOCs, although it might not suit everyone's aesthetic preferences for all applications.

3.      Besides opting for low-VOC wood products, you might also consider entirely different materials, particularly if you're going to spend a lot of time in a high-humidity area. Bamboo is a great option in this case; it's not only sustainable and rapidly renewable but also has a natural aesthetic appeal. It comes in various thicknesses and can be used for multiple applications, from walls to cabinetry and flooring. Recycled plastic panels provide an eco-friendly alternative, made from recycled plastic waste, and are known for being lightweight, moisture-resistant, and easy to maintain. Aluminum composite panels, consisting of thin aluminum sheets bonded to a plastic core, offer durability, water resistance, and are available in various colors and finishes. Lastly, insulated wall panels, which have insulation sandwiched between two layers of thin sheet metal, can save you a lot of build time because they're easy to install and provide excellent insulation.

These alternatives not only reduce your exposure to potentially harmful chemicals but also contribute to a healthier living environment and support sustainability.

If you choose to go the wood route, sealing the lumber can help reduce off-gassing and create a safer environment inside your van.

Sealing the wood does a couple of important things. First, it forms a barrier on the wood surface which helps to trap and reduce the emission of VOCs. Second, it makes the wood less absorbent, reducing its capacity to soak up and then release moisture and other contaminants that could lead to mold growth.

For sealing the wood and cutting down on VOCs, you have a few good options.

1.      Shellac-based sealants are a natural choice that emits low levels of VOCs and provide an effective barrier.

2.      Water-based polyurethane is another great option, and it's better to use these over the oil-based types because they have a lower VOC content.

3.      Polyacrylic sealants are also worthwhile; they're durable, effective, and like the others, emit lower VOCs.

When applying these sealants, remember that proper ventilation is key—not just for your comfort, but for your health too. During the construction and especially while applying the sealant and waiting for it to cure, make sure the area is well-ventilated. Open doors and windows and use fans to keep the air moving. Keep this airflow going even after the sealant has been applied, particularly through the curing process which can differ depending on the product. Generally, water-based sealants will cure faster, typically within 24 to 48 hours if the ventilation is good.

Also, be sure to give everything plenty of time to dry thoroughly before you consider the space ready to live in. This helps ensure all the vapors have dissipated, making the van a safe place to spend time in.

By sticking to these pieces of advice, you can make a big difference in reducing the risks associated with volatile organic compounds, ensuring your van's sealant cures the right way and ultimately creating a healthier space to live in.

Remember, even after your van build is complete, keeping up with proper ventilation and airflow is crucial to stop condensation from building up. One effective way to keep the air moving is by installing roof vents or roof fans. For example, the MaxxAir is a great choice that many vanlifers go for. And if you're working with something smaller, like a minivan, don't worry—options exist for you too, such as the low-profile Le Mans Low Profile roof fan that I have personally chosen for my van. It's all about finding the right solutions to keep that fresh air circulating.

I'm not an expert on this topic, but I do think it's important to share this information, so you don't find yourself in a similar predicament as the woman from Florida. It really makes you think, how can you truly enjoy van life if your living space is compromising your health? This is why it's crucial to do your research and place a high priority on ensuring that your van provides a healthy living environment.