LAMINATES - BUILDING MATERIAL

1. SUBMITTED BY:
SAMRIDHI GUPTA
JAGMIT SINGH
HARSIMRANJEET KAUR
SUBMITTED TO:
AR. AAKRITI DHIMAN

2. Lamination is the technique of manufacturing a material
in multiple layers, so that the composite material
achieves improved strength, stability, sound insulation,
appearance or other properties from the use of differing
materials. A laminate is a permanently assembled object
by heat, pressure, welding, or adhesives

3. There are different lamination processes, depending
on the type of materials to be laminated. The
materials used in laminates can be the same or
different, depending on the processes and the object
to be laminated. An example of the type of laminate
using different materials would be the application of
a layer of plastic film—the "laminate"—on either
side of a sheet of glass—the laminated subject.
MATERIALS

4. Vehicle windshields are commonly made by laminating
a tough plastic film between two layers of glass. This is
to prevent shards of glass detaching from the
windshield in case it breaks. Plywood is a common
example of a laminate using the same material in each
layer. Glued and laminated dimensioned timber is used
in the construction industry to make wooden beams,
Glulam, with sizes larger and stronger than can be
obtained from single pieces of wood. Another reason
to laminate wooden strips into beams is quality control,
as with this method each and every strip can be
inspected before it becomes part of a highly stressed
component

7. Decorative laminates are laminated products primarily
used as furniture surface materials or wall paneling. It
can be manufactured as either high- or low-pressure
laminate, with the two processes not much different
from each other except for the pressure applied in the
pressing process.
It is said that the first decorative High Pressure
Laminate was produced by Marc-Anton André, who is
the sixth generation of Johann Ludwig André, in 1959.

8. According to McGraw-Hill Dictionary of Architecture
& Construction, high-pressure laminates consists of
laminates "molded and cured at pressures not lower than
1,000 lb per sq in. (70 kg per sq cm) and more
commonly in the range of 1,200 to 2,000 lb per sq in.
(84 to 140 kg per sq cm).
HIGH PRESSURE LAMINATES

9. LOW PRESSURE LAMINATES
Low Pressure laminate is defined as "a plastic laminate
molded and cured at pressures in general of 400 pounds
per square inch (approximately 27 atmospheres or 2.8 x
106 pascals).

10. QUALITY STANDARDS
There are various industrial standards specifically applied
for high-pressure decorative laminates:
European Standard EN438
The European Standard EN438 is one of the standards
that most decorative laminates manufacturers selling to
worldwide market (such as Abet Laminati, Dekodur
Laminating Technologie, Violam, Formica, Maica,
Wilsonart, Greenlam) adhere to. The specific code is
EN438, entitled: Decorative high-pressure laminates
(HPL) sheets based on thermosetting resins,
specifications. It replaces the BS3794 standard.

11. The specific part of EN438 which applies to high-
pressure laminates is Part 3. The full title to this standard
is: High-pressure decorative laminates (HPL) Sheets
based on thermosetting resins (Usually called laminates)
Part 3: Classification and specifications for laminates less
than 2 mm thick intended for bonding to supporting
substrates. In total there are 9 parts to the EN438.

12. ANTIBACTERIAL
Antibacterial properties are important for decorative
laminates because these laminates are used as kitchen
tops and counter tops, cabinets and table tops that may
be in constant contact with food materials and younger
children. Antibacterial properties are there to ensure that
bacterial growth is minimal.

13. One of the standards for Anti-Bacterial is the ISO
22196:2007, which is based on the Japanese Industrial
Standards (JIS), code Z2801. This is one of the
standards most often referred to in the industry with
regards to tests on microbial activities (specifically
bacteria) and in the JIS Z2801, two bacteria species are
used as a standard, namely E. Coli and Staphylococcus
aureus. However, some companies may have the
initiative to test more than just these two bacteria and
may also replace Staphylococcus aureus with MRSA, the
methicillin-resistant version of the same bacteria.

14. Again, different countries may choose to specify
different types of microbes for testing especially if they
identified some bacteria groups which are more
intimidating in their countries due to specific reasons.

15. A common anti-fungi standard is the ASTM G21-09.
Not all manufacturers will take the initiatives for product
R&D for anti-Fungi attributes. Manufacturers like Maica
Laminates send their products for laboratory tests for
certification following the ASTM G21-09 standard,[6]
while Formica (South America) partners with Microban
Protection,which is a company manufacturing additives,
including the anti-bacterial additives.
ANTI FUNGI

16. There are many different standards with regards to fire-
resistant and flame-retardant properties of high-
pressure decorative laminates. While different countries
may have different standards for the building industry to
adhere to, most countries may agree on some of the
more common standards being used in the industry.
Very often, just like other standards applicable to the
industry, the tests may be European Standards with their
equivalent in the US Standards.
Fire-resistant and flame-retardant

17. For example, many Commonwealth countries may be
comfortable with the British Standards 476 especially
Parts 6 and 7, while there will still be US Standard
equivalence in the ASTM.

18. The list of tests applicable to decorative laminates will
never be exhaustive. As the technology improves, there
will be many more tests to ensure the safety of the
products upon use by the end consumer, for example
perhaps the tests on transfer of surface substance to
food materials if prepared on the decorative laminates as
a kitchen surface. The core tests will then also branch
out based on the specific requirements and standards
adopted by different countries.
OTHERS

19. Two of the internationally acknowledged "Green"
certificates for decorative laminates are MAS Certified
Green and GREENGUARD. The MAS Certified Green
and GREENGUARD marks are to certify that the
products have low chemical emissions. Chemicals tested
include VOCs, formaldehyde and other harmful
particles. The tests are based on single occupancy room
with outdoor ventilation following the ANSI/ASHRAE
Standard 62.1-2007, Ventilation for Acceptable Indoor
Air Quality. GREENGUARD especially, has two
GREEN CERTIFICATES

20. There are also many other "Green" certifications, some
which are requirements by the authorities before the
product can be used as building materials. These include
the Singapore Green Label which is recognised by the
Global Ecolabelling Network (GEN) and all its
member countries.
main consideration, GREENGUARD and
GREENGUARD GOLD. The GREENGUARD n
GOLD was previously known as the GREENGUARD
Children and Schools Certified, signifying its relevance
of very low allowable chemical emissions levels to
ensure the safety of young children and school
environment.

22. Decorative high-pressure laminates are usually used for
furniture tops especially on flat surfaces, including
cabinets and tables. Decorative compact laminates are
sometimes constructed as toilet cubicle systems,
laboratory tables and kitchen tops. Some new usage
models include wall panels with conceptual designs and
custom prints.

25. The popularity of large format printing using inkjet
printers have given a cheaper alternative to decorative
laminates, minus the quality. For most uninformed
consumers, the large format printing are similar to
laminates, and seem to offer more variety of designs and
applications. For example, large format prints can be
printed on wall stickers, and then installed on walls.
Unlike decorative laminates, there are no special
adhesive to be used, and the price may sometimes seem
so much cheaper comparatively.
However, there are health considerations for large
format prints because of the solvent inks used,
especially with their relatively high concentrations of
VOCs

26. Here are a few unconventional decorating ideas you can
try at home with laminate sheets:
Choose a pattern that looks like stone for a “natural”
table runner. It looks great underneath potted plants and
other earthen displays.
Line the inside back of a bookcase to make an
interesting backdrop for books and collectibles.
Apply laminate to a sheet of particleboard to create a
custom headboard.
Resurface a coffee or side table for enhanced eye appeal.
Use as a photo backdrop for objects, pets or children.
Resurface the wooden base of a bar. For an industrial
chic look, try decorative metals.

27. Resurface a kid’s desk or art table For a place where
water spills and crayon smudges are inevitable, laminate
is the perfect, easy-to-maintain option.
Apply it to stair risers to add an unexpected pop of
color or pattern.
Frame various-sized pieces, treating them as art; mix and
match similar or varied patterns. Stone looks, such as
3474 Petrified Wood in the laminate line 180fx® by
Formica Group, or graphic patterns, such as the Geo
and Dogbone Collections and 6942 Charcoal
Boomerang (pictured below) show well.

28. Resurface a worn wood breakfast tray to give it a new
look. Try a woodgrain so that it still looks like wood
(such as 204 Butcherblock Maple), or go for a bolder
graphic or solid color laminate.

30. Raw Materials
Decorative plastic laminate sheeting is made of resins
that react with aldehydes during the thermosetting
process. The resins are laminated onto layers of kraft
paper topped with a decorative sheet. Kraft paper is the
same brown paper used in grocery bags. The first plastic
laminates were made with phenolic resin, a polymer of
formaldehyde and phenol. Phenolic resins produce only
dark colors. In the 1930s, a urea-based resin called
melamine was developed that produced a clear surface.
In the modern manufacturing process, the top two layers
of paper are impregnated with melamine resin, and the
lower layers use phenolic.

33. Impregnating the paper
1 The process begins by soaking strips of paper in resin.
Decorative plastic laminates can be made in different
grades or thicknesses, depending on its intended use.
There may be from 7-18 layers of paper combined into
the final sheet. The bottom layers are kraft paper. The
paper comes in ribbons of different widths, commonly
of three, four, or five feet. The kraft paper is run
through a "bath tub" or vat containing phenolic resins.
The paper for the top layer of the sheet is translucent.
This is run through a vat of melamine resin.

34. The layer just beneath the top is the decorative layer.
This is a sheet of paper printed with the color or design
that will show through the clear top layer for the desired
surface pattern. This sheet is also run through a
melamine vat.

35. Drying
2 The resin-impregnated sheets are then put into a
drying chamber. Next, they are cut and stacked in layers.
The clear layer and the decorative layer are on top of the
kraft paper.
Thermosetting
3 The layers of paper are then loaded onto a flat-bed
hydraulic press for final curing. The press compresses
the sandwich of resin-soaked paper at 1,400 psi, while
heating it to a high temperature. The heat catalyzes a
reaction in the resins.

36. The phenol (or melamine) and formaldehyde molecules
Decorative Plastic Laminate attach to each other in an
alternating chain fashion, releasing water molecules in
the process. The resins flow together and then set.
Thermosetting converts the paper sheets into one single,
rigid laminated sheet. This sheet is dry and insoluble,
and it cannot be shaped or molded, even at high
temperatures.

37. Finishing
4 The dry sheet is cut into the desired size and shape. It
may also be bonded to a building material such as
plywood, flakeboard, fiberboard, or metal.

38. The plastic laminate manufacturing process produces
several by products, some of which are considered
hazardous. Toxic emissions emanate from phenolic
resins during the laminating process, and acrylic resins
and hardeners used in applying plastic laminates to
surfaces are also considered hazardous. Decorative
plastic laminate itself is not considered a "recyclable"
plastic. However, at least one major manufacturer has
taken steps to reduce harmful waste and emissions.
BY PRODUCTS/WASTE

39. By switching from solvent based to water-based
phenolic resins, the amount of toxins released during
lamination can be reduced. Recent changes in the
composition of melamine have also virtually eliminated
alcohol emissions from this type of resin as well.
Control devices such as so-called packed column
scrubbers also reduce particulate emissions into the air.

40. Paper and laminate residue generated during the
manufacturing process are burned in power boilers. This
reduces the amount of waste sent to landfills. Metal-
based pigments used in decorative papers also create a
waste problem, as these can be hazardous. The leading
manufacturer of plastic laminate has for this reason
reduced the use of such pigments, and plans to totally
eliminate the use of metal-based pigments in the future.
Although used laminate is not recyclable, some
companies have collated old laminates into new sample
sets suitable for distribution.

41. Sunmica and other brands of Laminates in India usually
have a thickness that ranges from 0.6 mm to 1.5 mm.
The thicker self-supporting Compact laminates on the
other hand have a thickness ranging from 3 mm to 30
mm
THICKNESS

42. The most standard size of laminate sheets produced by
most of the laminate companies in India is 8'x 4'(8 feet
by 4 feet). Some laminate manufacturers also make some
laminate sheets in special sizes such as 3 feet x 7 feet, or
5 feet by 12 feet, but the standard and common size is
8'x 4'.

43. The prices of the laminates are specified by the plywood
and laminate retailers in India in terms of cost (in Rs.)
per sheet of laminate. On the contrary plywood rates are
usually specified in terms of cost (Rs.) per square foot.
PRICES