DesertBoard: Built in the UAE, for the world

In the UAE, DesertBoard stands as a trailblazer in sustainable construction, redefining the industry with its innovative Palm Strand Board (PSB). The recent completion of a full-scale mock-up home in Dubai Creek Harbour, constructed entirely from PSB boards, marks a pivotal achievement, showcasing the material’s structural integrity and design versatility for residential applications.

Rooted in the UAE’s rich heritage, where date palm trees have long symbolised resilience and resourcefulness, DesertBoard draws inspiration from traditional Barasti houses that utilised palm fronds for shelter in the harsh desert climate.

This legacy, combined with the forward-thinking vision of the UAE’s founding father, Sheikh Zayed bin Sultan Al Nahyan, culminated in the creation of the world’s first engineered palm-based wooden board in 2021.

By transforming annually regenerated palm fronds — once discarded as waste — into a high-strength, eco-friendly building material, DesertBoard has established itself as a pioneer in the bioeconomy, upcycling natural resources into a product that aligns with modern sustainability demands while honouring the region’s cultural heritage. “We’re taking what Mother Nature gives us annually and upcycling it into a product that decarbonises the built environment,” says Kamal Farah, a Director at DesertBoard, emphasising the company’s commitment to sustainability and cultural legacy.

DesertBoard’s mission is intricately aligned with the UAE’s ambitious sustainability and economic diversification goals. PSB is crafted from bio-ecological residual raw material — palm fronds pruned annually for tree health — eliminating the need for deforestation while also supporting the UAE’s Net Zero 2050 Strategy. The production process aligns with the UAE’s 2030 Green Agenda, particularly through the Green Diversification Programme, which promotes eco-friendly manufacturing, and the National Waste-To-Resources Programme, which transforms discarded materials into valuable resources.

By capturing palm fronds before they are buried or burned, DesertBoard prevents harmful methane and CO2 emissions. This process locks approximately 45,000 tonnes of CO2e into the built environment each year — underscoring the company’s contribution to the circular economy. This number is set to increase as the facility grows to full capacity.

“Our boards prevent methane and CO2 emissions, all while being a carbon-negative material,” Kamal notes, highlighting PSB’s role in advancing the UAE’s circular economy.

The inception of DesertBoard dates back to 1997, sparked by the vision of its Chairman, Hatem Farah, who witnessed the wasteful disposal of palm fronds and their potential in the building industry. Recognising the historical significance of palm fronds in constructing shelters, fences, and other structures, he sought to modernise their use by developing an engineered wooden board. This idea, initially conceived as a solution to an environmental problem, required nearly two decades of research and development to create specific processes and engineer the first wooden board.

Founded in 2011, the company produced its first board in 2021 at its state-of-the-art facility in Abu Dhabi. Purpose-built with a future-first mindset, the 55,000-square-metre factory features proprietary, custom-engineered technology, advanced dust-collection systems, and industry-leading German press machinery, setting a new benchmark for sustainable manufacturing in the region.

Kamal, a civil engineer with a Master’s from the University of Bristol and UK construction experience, joined DesertBoard three and a half years ago as Director. His leadership has driven refinements, including the shift to formaldehyde-free adhesives.

“It took years of dedicated R&D to perfect the process, but today, DesertBoard produces a sustainable board specifically engineered for safe indoor use.

Free from formaldehyde and other harmful additives, PSB meets rigorous safety standards, making it ideal for residential, commercial, and institutional interiors. It’s a healthier alternative to conventional wood-based boards, without compromising on strength or performance,” Kamal reflects, underscoring the perseverance behind PSB’s development.

The manufacturing of PSB sets DesertBoard apart from conventional wood-based panel production. Sourced exclusively from UAE palm fronds, PSB utilises a renewable resource that requires no tree felling, distinguishing it from deforestation-dependent materials like oriented strand board (OSB) or medium-density fibreboard (MDF).

Kamal explains how the process begins with collecting fronds during the annual pruning season, a necessary practice for palm tree health that generates significant raw material. “If left to decompose, these fronds release methane, a potent greenhouse gas, or CO2 when burned, contributing to environmental degradation and pest proliferation. DesertBoard’s factory transforms this raw material into 110,000 m³ of boards annually — a fraction of the 3 million m³ of boards imported regionally, but a critical step toward reducing reliance on foreign materials.”

The use of formaldehyde-free glue ensures PSB meets stringent indoor air quality standards, earning certifications such as the Al Sa’afat (Dubai Municipality) certificate of product conformity. This sustainability-driven approach not only prevents emissions but also creates a carbon-negative product, as evidenced by its environmental product declaration (EPD) certified by IMQ, which confirms PSB as a carbon sink even when accounting for transportation and manufacturing impacts.

“We’re not cutting down trees; we’re using what’s naturally available and turning it into a value-add product,” Kamal explains, emphasising the sustainability of sourcing locally and preventing emissions.

Talking about PSB’s versatility, Kamal explains that its uses extend across a wide range of applications — from construction to interior design, landscaping, events, exhibitions, and beyond. In the UAE, major developers like Aldar, Emaar, and Select Group have used PSB for fire-resistant doors in their developments, while projects like the Tarabot in the UAE and Al Musalla installations in Saudi Arabia — which won prestigious architectural awards — highlight its aesthetic and structural potential. The boards have been exported to India, Saudi Arabia, the UK, and Japan, and used in fire-rated doors, furniture, flooring, acoustic panels, and even prefabricated structures.

PSB’s high density and screw-holding capacity make it ideal for durable furniture, outperforming chipboard and MDF, which are prone to swelling and degradation. Its lightweight nature suits prefabricated construction, enabling faster building processes in congested urban areas or remote locations like the World Islands, where heavy materials like concrete are impractical.

PSB has been explored for non-construction uses as well, such as pallets and crates, supporting industries seeking to decarbonise their supply chains. The boards further proved their durability and adaptability during the 2024 Dubai flooding, with the Edge Morph installation in Dubai Design District standing firm. The boards’ durability, along with their fire-rated, moisture-resistant, and termite-resistant capabilities, ensure long-term performance in harsh climates. “From I-Beams to fire-rated doors, PSB is a platform for endless possibilities,” Kamal says.

The Gulf region presents both immense opportunities and unique challenges for PSB. The push for sustainability, exemplified by Saudi Arabia’s ROSHN housing project and the UAE’s Masdar City, creates a fertile market for eco-friendly materials. PSB’s structural properties and prefabrication potential align with the region’s need for rapid, scalable construction to meet housing demands. However, the dominance of concrete and steel in Gulf construction, coupled with limited awareness of wood-based building, poses challenges.

DesertBoard aims to catalyse a wood-construction industry, leveraging PSB as a platform for innovation in structural elements like I-beams and cross-laminated panels. Globally, the European Union’s deforestation regulations and Japan’s strict formaldehyde emission standards position PSB as a compliant, potentially high-demand alternative.

DesertBoard is revolutionising sustainable architecture by embracing circular economy principles and reducing reliance on imported materials. The company has earned global recognition, including four wins at the IF Design Award in Hamburg, the KEZAD Appreciation Award in Abu Dhabi, and the Innovation Champion of the Year at Dubai’s Future of Architecture Summit.

DesertBoard is poised to expand its impact through innovative product development and global outreach. Within the next few years, the company plans to explore structural applications, such as manufacturing I-beams and prefabricated slats, which could establish new building codes for wood-based construction in the UAE. These advancements would enable PSB to compete with traditional materials in high-rise and large-scale projects, further decarbonising the built environment.

DesertBoard envisions PSB as a model for countries with date palm cultivation, such as Saudi Arabia, Egypt, and Morocco, where similar biocircular economies could thrive. By promoting carbon accounting and Scope 3 emission reductions, DesertBoard aligns with emerging mandates in the GCC and Europe, where regulatory institutions increasingly demand lower carbon footprints. The material’s adaptability for DIY projects, transport, and furniture positions it as a versatile solution for a decarbonising world.

At its core, PSB embodies the principles of a biocircular economy. By upcycling palm fronds, DesertBoard prevents environmental harm while creating a value-added product. The boards’ carbon-negative profile, biodiversity-positive impact (no trees are cut), and formaldehyde-free composition make them a cornerstone of sustainable architecture. Unlike chipboard or MDF, which can degrade quickly in humid conditions, PSB offers superior strength and longevity, reducing waste and replacement costs. Its local production minimises transportation emissions, supporting the UAE’s economic and environmental goals.

“As global architecture further embraces mass timber and sustainable materials, PSB is well-positioned to lead, offering a scalable, replicable model for regions with abundant date palm resources. DesertBoard’s commitment to continuous R&D ensures that PSB will evolve, meeting the demands of a sustainability-driven construction industry. It’s the future of building,” Kamal concludes, encapsulating its transformative potential.