Technical Information dispelling traditions - Formica

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formica_technical.qxd:formica_technical.qxd 28/11/08 16:01 Page 37Formica ® Veneers 1 of 3Formica ® Veneers wood surfacing is a real wood veneer laminatedto a phenolic core, which combines the practicality of a highpressure laminate with the warmth of natural woodgrains.The Veneers range incorporates the beauty of a natural woodwith exotic designs, giving more consistent quality and easeof use than wood veneers, while demonstrating sensitivitytowards the environment.Formica ® Veneers may be fabricated in the same manneras conventional Formica laminates, but because of itscomposite form special care should be exercised beforeand during fabrication.Formica ® Veneers are available in three surface finishes:MelamineThe surface is protected with a melamine overlay, giving adurability similar to that of conventional decorative laminates.PolyurethaneClear durable polyurethane (Pu) finish, enhancing the colour andgrain of the veneer. It looks and feels like wood, and requiresno varnishing.WaxSimilar to Polyurethane finish, but with the surface touch ofnatural wood.Storage and handlingAlthough the phenolic core of Formica ® Veneers facilitates thehandling of large sheets, care must still be exercised when liftingand carrying the product. If handled carelessly, splitting along thegrain may occur.Always carry Formica ® Veneers sheets vertically, and never slidefabricated panels on the decorative face.Storage conditions should be the same as those recommendedfor conventional decorative laminates (18-25°C and 50-60%relative humidity).Sheets should be stored flat and horizontal, back to back with thetop sheet turned face down. A cover board should be placed overthe stack to prevent top board curl.Protect from sunlight and moisture, and never store directly on thefloor. As with all real wood products, a slight overall colour changemay occur over a period of time. Do not allow partial exposure tolight as this may cause uneven colour change.ConditioningBecause Formica ® Veneers are 50% real wood, they are moresusceptible to the effects of changes in humidity than conventionallaminates. In common with other wood products, they will expandin damp conditions and shrink in dry conditions. It is thereforevitally important that correct preconditioning is carried out.Prior to bonding the Veneers sheets, substrates and backingveneers should be stored together in conditions similar tothe anticipated end-environment for a period of 8-10 days.Separators should be used to ensure maximum air circulationaround the components.SubstratesThe recommended substrates for use with Formica ® Veneersare MDF, chipboard and plywood.Plasterboard, calcium silicate boards, blockboard and solid timberare not recommended. Do not bond Formica ® Veneers direct toplastered or rendered walls.The substrate must be of good quality, with a smooth surface.All the usual precautions to avoid telegraphing should beobserved, i.e. clean press area, freedom from dust and debris,uniform adhesive spread.AdhesivesFormica ® Veneers should be properly press bonded to thesubstrate using a rigid or semi-rigid adhesive such as UF or PVA.Contact adhesives, particular hand applied, are not recommended.Any adhesive smear should be removed with a damp cloth beforecuring takes place. Do not use any solvents on PU or Wax finishes.PressingCleanliness in the pressing operation is of paramount importance.Formica ® Veneers may be hot pressed, but the press temperatureshould not exceed 60°C. Cold or warm pressing will producebetter stress free panels.Pressures should be normal for the type of adhesive used, typically2-5 kg/cm2 for PVA, and 3-5 kg/cm2 for UF.PostformingPolyurethane finish Formica ® Veneers can be postformed in asimilar manner to conventional postforming laminates, using staticforming machines. However, the forming temperature is lower andthe window of formability is much narrower. The ideal formingtemperature is between 140°C and 150°C, and the minimumrecommended forming radius is 12 mm in the longitudinal direction(i.e. with the grain) and 25 mm in the transverse direction.The above temperatures and minimum radii are intended only asa guide and may vary slightly with the grain pattern and type ofpostforming equipment. It is, therefore, recommended thatfabricators conduct their own preliminary trials.The protective film may be left on during the postforming process,but should be removed immediately after forming.Whilst it is possible to postform Polyurethane Formica ® Veneerson continuous postforming machines, trials should be carriedout to ensure that the protective film does not foul the rollers.And if the protective film is removed, trials should be carriedout to ensure that the forming bars and rollers do not markor damage the surface.Melamine and Wax finish laminates are not postformable.Formica Limited, Coast Road, North Shields, Tyne & Wear NE29 8RE. Tel: 0191 259 3000. Fax: 0191 258 2719.Formica is a registered trade mark of Formica Corporation or its subsidiaries.Technical Services Department April 2004.36
formica_technical.qxd:formica_technical.qxd 28/11/08 16:01 Page 38Formica ® Veneers 2 of 3MachiningFormica ® Veneers may be cut and machined using the sameequipment as for conventional Formica laminates. TCT saws andcutters are recommended, and these must be kept sharp and ingood order.When cutting double sided panels, precautions must be takento prevent splitting and breakout on the underside. The use ofa scribing saw is recommended, particularly on cross-grain cuts.Lowering the saw blade will also reduce underside chipping.The saw fence must be parallel with the saw to prevent facechipping caused by the back of the saw flicking up the surface.Overhanging laminate may be trimmed off with normal laminatetrimmers using sharp TCT cutters. Make sure that any guidewheels are rotating freely to prevent marking the surface.Do not use cutters with fixed pin guides.Formica ® Veneers may also be trimmed with a sharp block plane,and finished with a file or fine abrasive paper to remove the arris.Cut-outs and through fixingsAs Formica ® Veneers are more susceptible to the effects ofchanges in humidity than conventional laminates, it is especiallyimportant to follow the recommendations in the DesignConsiderations section in order to avoid stress cracking.Any cut outs (for access, switches, ventilation grilles, etc.)with side length of up to 250mm, must have the internal anglessmoothly radiused to a minimum of 6 mm. This radius should beincreased pro rata as the side length increases. In general, thelarger the radius that can be accommodated the lower the riskof stress cracking.Where radiused corners are not possible butt joints should be usedto achieve right-angles.Screw or bolt fixings, for appliances that are fixed to the faceof a panel, should have a clearance hole bored through theFormica ® Veneers.Holes for fixings that pass right through the panel and into thesubstructure should also be provided with adequate clearance.The minimum recommended clearance is 1.5 times the diameterof the fixing.Countersinking should be in the surface of the substrate,and not in the laminate.Nails should never be driven through a Formica ® Veneersfaced panel.Skirtings, cornices and other applied timber mouldings shouldeither be bonded or screwed in place. If screws are used,adequate clearance must be provided as described above.Edge lippingThe edges of panels surfaced with Veneers may be edged by anyof the conventional methods. The most sympathetic material isobviously real timber, but edging with Formica ® Veneers orColorCore can also be used to good effect.Excess adhesive should not be allowed to cure on the surface,as its removal may result in damage.Release agents may be used, but should be first checked on anoff-cut to ensure compatibility. Any residual release agent shouldbe removed carefully.Do no use any solvents on Polyurethane and Wax finishes.Solid timber edges should be sealed and finished accordingto the application.BalancingFor optimum flatness use the same laminate on both sides(Category A).Flatness meeting BS 4965 requirements (1 mm maximumdistortion over 600 mm length) can be achieved using theappropriate balancer (Category B).For small panels, or where flatness is less important,any conventional laminate backing board may be used(Category C).Pre-conditioning should be carried out as for normal laminates.FinishingFormica ® Veneers laminates are pre-finished and therefore requireno further surface treatment.ApplicationsFormica ® Veneers are produced in finishes to suit a variety ofapplications and requirements.Polyurethane and Wax finishesIntended for dry interior, light duty applications, e.g. horizontalsurfaces on domestic bedroom and sitting room furniture, verticalwall panels above two metres from floor level where only moderatedurability, stain and heat resistance are required.Melamine finishIntended for dry, interior, horizontal and vertical applications whereimproved durability and resistance to stains and heat are required.Care and MaintenanceFormica ® Veneers should be treated in the same manner as finewood furniture and may be cleaned with a damp cloth and milddetergent. Do not use polishes or waxes on any Formica ® Veneerssurface.Do not place hot objects directly on the surface of Polyurethaneor Wax finish Formica ® Veneers, and do not use any abrasive orsolvent cleaners.Melamine finish can be cleaned in the same way as conventionallaminates. It will withstand moderate heat, but very hot objects(hot pans, casserole dishes, etc.) should not be placed directlyon the surface.Formica Veneers productCategory A(Optimum flatness)Category B(Flatness withinBS4965 limit)Category C(For sealingpurposes only)37Melamine finishPolyurethane and WaxfinishesLaminate identical tothat of face laminateProduction backingboardUniversal backingboardFormica Limited, Coast Road, North Shields, Tyne & Wear NE29 8RE. Tel: 0191 259 3000. Fax: 0191 258 2719.Formica is a registered trade mark of Formica Corporation or its subsidiaries.Technical Services Department April 2004.Any conventionallaminate backingboard
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