Mark
I've looked into alternatives, but haven't found anything particularly promising yet. I've recently tried to source FSC certified OSB, but the few mills there are, can't/won't make the sizes we need. I also looked into soy foam and other core materials but it looks like you have to add some nasty stuff (nastier than styrene or borate) to prevent them from being first class critter food for more than a few years.
Open call to everyone: If there is a potential "greener" panel material that we can use, please tell me. If it really works or anyone wants to be a beta-site, I'll make you the deal of the week.
Paul Malko
Foard Panel
paul@foardpanel.com