Laminate Flooring: Construction Process
Laminate flooring is a tongue and groove interlocking flooring pattern. It comes in both planks and squares. Nowadays, most laminate floors use some kind of glueless locking mechanism, also known as ‘clic’ floors.
There are two major glueless locking mechanisms. One consists of a tongue and groove that is supported from the bottom by an aluminum, mechanical locking mechanism. Other is a tongue and groove locking mechanism fixed into the middle core. Some laminate flooring manufacturers also provide micro-beveled edges.
Laminate flooring can be laid almost anywhere, including dry concrete floors, or wooden sub-floors. The low clearance space height helps in restoration of old houses where thickness of floor could be an issue. Laminate flooring always floats over the sub-floor and is never glued to the substrate.
The core material basically comprises of HDF-high density fiberboard. It is saturated with melamine to make it exceptionally hard. Melamine is a plastic-based resin used for added strength and resilience to the planks.
There are usually 2 kinds of laminate flooring construction:
Direct Pressure Construction
The process consists of simultaneously bonding together all the layers of flooring directly to the core. All the layers are also soaked with melamine resins under heat and pressure.
High Pressure Construction
This process is performed in two steps. The Kraft paper layer is glued to the print film and then this unified layer is bonded to the core. All the glueing and bonding work is done under pressure.
Both these kinds of laminate flooring offer an exceptionally hard surface that is resistant to scratching, discoloration or wearing. The only difference is in the method of construction, i.e. the way the layers are attached to the core.
Laminate flooring construction consists of the following layers:
- Backing: A melamine plastic layer used to provide extra structural strength
- Core: It is manufactured from high-density fiber or plastic panel. It imparts impact resistance and is the basis of tongue and groove locking mechanism.
- Print Film: This is the exterior surface, also known as the decorative layer. It resembles the appearance of hardwood.
- Wearlayer: It is a layer of melamine layer with a certain amount of aluminum oxide. It is saturated with resin under pressure. It is highly resistant to stains or scratches.
- Underlayment: It is a thin plastic layer laid over the sub-floor. It enables the laminate flooring to float freely over the sub-floor.
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