The Effect of the Laminate Flooring Manufacturing Process on Durability and Price
Durability and price are major considerations if you are contemplating installing laminate flooring in your home. Learning about how different laminates are manufactured will help you make an informed decision when you are ready to make your purchase. Direct pressure and high pressure are the two manufacturing methods.
Direct Pressure Method
In the direct pressure process, laminate flooring consists of four layers:
- Backing or stabilizing layer: the bottom material that adds strength and stability to the laminate board.
- Board or core layer: the central layer that supports the weight and stress of foot traffic; it is usually high-density fiberboard but may also be particle board or medium-density fiberboard.
- Decorative layer: a photo rendering of the design which imitates a natural material such as slate or hardwood.
- Wear layer: a resin-based coating usually comprised of multiple coats of aluminum oxide or melamine; it is designed to provide protection from wearing, staining and fading and to resist abrasion.
These four layers are fused together at a temperature of about 400 degrees Fahrenheit and at a pressure of over 600 lbs./sq. in. The decorative and stabilising layers are pressed together onto the core layer.
High Pressure Method
In the high pressure process, laminate flooring has five layers; the fifth layer is made of special high-strength paper. The decorative layer and overlay are pressed onto this layer first, and then this fused material is glued to the core layer. The backing and top wear layers are treated separately and then fused directly onto the core. The high pressure method creates a floor that is very strong and suitable for very heavy foot traffic.
Flooring thickness ranges from 6 to 14 mm depending on the process. The thicker the flooring, the higher the durability and the cost. In general, laminate flooring made by the high pressure method is higher priced than that made by the direct pressure method.
In the final manufacturing steps for both methods, surface textures are imprinted onto the laminate flooring sheets. The sheets are then cut into square tiles or planks. Using specialized machinery, the tongue and groove locking system is cut into the edges.
Watch how laminate flooring is manufactured in this video tour by Kronotex USA:
