Processing instructions

egger Laminates

EGGER Laminates are a versatile material that is usually fabricated in conjunction with wood based products or other carrier substrates to produce so-called composite elements. There are many diverse applications which, depending on the individual intended purpose, necessitate the selection of different laminate qualities as appropriate. Traditional areas of use and application include the kitchen and door industries, the office furniture sector, exhibition stand construction, shopfitting, interior design, shipbuilding and the automotive industry.

1. Description of the material

EGGER Laminates are decorative laminates based on curable resins. They are constructed by fusing multiple layers and consist of melamine resin impregnated decor paper and one or several phenolic resin impregnated core layers. These multiple layers are pressed together by means of high pressure and heat. The composition of the laminate, the qualities of resins and papers, the surface texture, the use of special overlays as well as the press parameters during production determine the quality of the laminate and ultimately the field or area of application for which it is suitable. For further detailed information please refer to the technical data sheets EGGER Laminates and select the appropriate laminate quality. Laminate composition, using EGGER Laminate MED as an example

Overlay

Impregnated decor paper

Impregnated sodium-craft-paper Parchment paper

2. storage
EGGER Laminates must be stored in enclosed, dry areas at approximately 18 C to 20 C and a relative humidity of approximately 55 % to 65 %. After removing the original packaging, the laminate sheets should be stacked horizontally on a flat base of equal or greater dimension, with their edges flush.
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The decorative face side of the uppermost sheet of laminate should be facing down and the laminates should be covered with a protective board of equal or greater dimension (see illustration 1). Where horizontal storage is not possible, the laminate sheets should be stored at an angle of 80, in an inclined rack providing support to the surface area and ends (see illustration 2).

Laminate sheet stack Protective board

Illustration 1

Correct! Illustration 2

Incorrect!

3. Fabrication
3.1 HanDLing
Prior to fabrication, check the EGGER laminate for any obvious damage after removing the packaging. Any person involved in transporting or handling laminates should wear personal safety equipment such as gloves, safety shoes and suitable work wear, etc. The decor sides should never be pushed against one another or dragged over one another. Abrasion between decorative faces should be avoided. Sheets of laminate should be lifted up or, if necessary, pulled over one another with two reverse sides facing. When laminate sheets are being transported or carried, the method of rolling them up with the decorative face inwards has proved useful. Avoid any rubbing movements.

3.2 cutting Process

The laminate can be cut to size using standard woodworking equipment, e.g. panel saws, bench circular saws, hand-held circular saws or jigsaws. Panel saws or bench circular saws are generally used. A good cutting result depends on a variety of factors, such as decorative face side up, saw blade projection, feed rate, tooth shape, tooth pitch, rotational and cutting speeds.

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Example: circular bench saw: Cutting speed: Rotational speed: Feed rate: approx. 40 to 60 m/sec. approx. 3,000 to 4,000 rpm. approx. 10 to 20 m/min (manual feed)

It is also necessary to firmly hold the laminate across its surface to avoid vibration or chatter which can cause the formation of hairline cracks that may develop into stress or notch cracks at a later stage. With the exception of panel saws, all cutting involves manual feed. Due to the high-quality melamine resins used for the surface of the EGGER laminate, the tool wear is considerably greater than with conventional wood-based materials. We recommend that you use carbide metal-tipped or even diamond-tipped saws cutters or router bits. Use the following tooth shapes depending on the standard of finish you require (coarse or fine cut):

Flat tooth

Alternate bevel tooth

Duplovit tooth Hollow tooth face

Duplovit tooth with bevel

Pointed duplovit tooth

Trapezoidal flat tooth

Use a cutting guide when working with a hand-held circular saw or jigsaw. Cutting must be from the underside of the board.

3.3 conDitioning
Before processing, both, the substrate and the EGGER Laminate should be conditioned under normal climatic conditions (approximately 20 C and a relative humidity of approximately 55 % to 65 %) so that both materials are at equilibrium of moisture content. Materials that are processed when they are too moist tend to shrink over time, which may lead to cracks and warpage.

3.4 BonDing
Depending on the intended application and specific product requirements involved, EGGER Laminate can be bonded to a range of different substrates using a variety of different types of adhesives or glues. It is suitable for bonding onto classic wood-based materials such as: Chipboard / MDF / HDF. Wood-based materials such as blockboard and veneer plywood require special attention and in-house press tests should be carried out prior to going into full scale production. It should be noted that blockboard and veneer plywood do not reach the same homogeneity as chipboard as they consist of veneers and / or solid wood. In fluctuating climatic conditions, the dimensional changes of constituents such as veneer and/or solid wood do not reach the same uniformity as can be guaranteed with wood chips. However, a flat and tension-free substrate is a prerequisite for an even surface, necessitating therefore that a substrate calibration as well as a wood moisture content test (internal application 8 %) be carried out. Materials that are processed when they are too moist tend to shrink over time, which may lead to cracks and warpage. When using Multiplex boards, preference should be given to veneer plywood made of softwoods (e.g. poplar, birch, okoume, abachi). Similarly, blockboards should consist of narrow strips with a softwood surface layer to prevent surface irregularities. However, the substrate must be tension-free and the surface must be flat/even. It is not recommended to bond laminate to solid wood substrates. The laminate and substrate must always be cleaned thoroughly before bonding. The materials must be free from dust, grease, oil or perspiration marks before the adhesive is applied. It is important that the composite element has a symmetrical structure and that the adhesive is applied evenly to both, the front and the reverse side in order to prevent warping of the composite board. In general, EGGER Laminate can be bonded in presses (flat bed, short-cycle and twin belt presses) with conventional urea resin glue and dispersion adhesives, using either hot or cold processes. The reference values shown in the table below are influenced by: The type and quality of substrate Adhesive / glue system Processing conditions It is therefore always recommended to carry out bonding trials under local conditions as well as to follow the instructions provided by adhesive supplier.
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adhesive type

spread of adhesive [g/m2]

open assembly time [min.]

Press pressure [bar]

Press temperature / Press time 20c 40c 60c

Dispersion adhesives: PVAc adhesives

90 150 on CPL or substrate 90 150 on CPL or substrate

1 30

approx. 3

8 60 min.

4 12 min.

45 160 sec.

Two-part PVAc adhesives

1 30

approx. 3

Observe manufacturers instructions

Depends upon composition

condensation resin adhesives: Urea resin, melamine/urea resin, Phenolic resin, resorcinol resin

90 150 on CPL or substrate 100 180 on CPL or substrate

2 20

approx. 3 5

15 180 min.

5 30 min.

1 12 min.

Depends upon type of hardener approx. 2 15 approx. 3 5 Press time depends on type of hardener

contact adhesives with and without hardeners: Polychloroprene adhesives reaction adhesives: Epoxide-, unsaturated polyester and polyurethane adhesives

je 150 200 on CPL and substrate

Finger test1

min. 5

At least 1 minute

150 200 on CPL or substrate

According to type used

Contact pressure stack flat

Depends upon type and hardener

Hot melt adhesives:

180 300 on CPL or substrate

Extremely short Pressure roller

Depends upon type

1)

The open assembly time is dependent upon the ambient temperature and the adhesive type; it is defined by a so-called finger test.

4. Postforming process
In addition to square edged, flat bonded laminated composite boards, EGGER Laminates are also used for postforming purposes. The distinguishing feature of postformed elements is the seamlessly bonded laminate on surface and profile area. With a range of different laminate qualities on offer, EGGER can provide the required solution for a variety of particular postforming applications. In view of the multitude of profiles and specifications as well as individual processing system requirements, it is absolutely essential that compatible quality parameters and laminate dimensions are defined prior to production. Profiles are primarily cut in the shape of convex radii and formed using static or stationary postforming machines or continuous postforming lines. Concave profiles can only be achieved with static forming equipment and require special preparation of the substrate. Experience of postforming and subsequent machining processes is also necessary.

4.1 suBstrate seLection anD PreParation

The correct choice of substrate, plus factors such as board temperature, wood moisture, surface characteristics, substrate composition, profile design, glue system and application rate, etc., determine the quality of the finished postforming elements. EGGER EUROSPAN raw chipboard has proved to be highly suitable for such applications in view of the smooth, even surface and homogeneous board structure. When using chipboard, great importance should be placed on a dense and high-strength middle layer, otherwise bonding failure can occur or a telegraphing- through effect of the middle layer may be experienced. The correct substrate must be selected as early as at the profiling stage; depending on the depth of the profile, it may be necessary to use MDF. Plywood panels and veneer boards require special attention. It is most important that the wood moisture of the boards is low (max. 8 %) and that the different materials have been properly conditioned (see sections 3.3 and 3.4). Due to the glue layers and the alternating fibre direction of the veneer layers, the profile cutting process is more difficult than it is with chipboard or MDF and results in an uneven wear of the cutting tools. The profile should be cut following the direction of the fibres on the face veneer.
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4.2 ProFiLe cutting

The tools generally used for profiling substrates are cutters with indexable carbide inserts or diamond-tipped cutters for volume production. A good cutting result depends on various factors including feed rate, rotational speed, number of cutters as well as the quality of the substrate. The quality of the profile cut (blade marks, raised chips etc.) can be improved by using diamond sanding disks or sanding stations. It is advisable to check the selection and specification of tools with an appropriate tool manufacturer. Profiles must be cut with precision, i.e. stepped or incomplete cuts should be avoided, as they will lead to postforming problems. Tight radii in particular demand extreme precision. When the profile cutting process has been completed, any dust and loose chips must be removed with a brush, by compressed air or suction.

4.3 gLuing
Certain restrictions apply to the postforming process and must be considered in addition to section 3.4 which provides recommendations and information on types of adhesive suitable for surface bonding. Irrespective of the postforming process applied, the laminate is generally bonded in two processing stages: Step 1: Bonding of laminate to surfaces of profiled substrate (front and back). Step 2: Bonding in the profiled area (rounded edge) occurs at a later stage as part of the postforming process. As a general rule, the amount of glue applied to bond the flat surfaces should be appropriate in quantity without allowing glue to ooze out into the profile or rounded area, especially when using condensation resin glues (urea resin). The profile area is bonded using special PVAc glues with rapid initial adhesion and a short open assembly time. This is necessary in order to counteract the memory effect of the laminate. Always follow the instructions provided by the adhesive supplier.

4.4 static PostForming Process

In view of the variety of static postforming methods, we shall explain only the commercial process using contact heat. This allows the production of convex postformed elements in small and medium batches. Prior to the actual postforming (forming) procedure, the following preparatory processing steps must be performed: Step 1: Bonding of laminate to surfaces of profiled substrate (front and back). Step 2: Flush-trimming of the backing laminate and /or profiling of substrate reverse as necessary. Step 3: Application of special PVAc adhesive to laminate overhang and profiled area of substrate. In step 1 care must be taken to ensure that there is a sufficiently long laminate overhang on the front to accommodate the substrate thickness and profile design. This is known as the laminate projection (see illustration 3). The actual postforming process, i.e. forming the laminate and bonding it to the substrate, is carried out using a flat, heated, pressurized and movable metal forming bar (see illustrations 4 6). The contact heat provided by the heated metal forming bar heats up the laminate to the required postforming temperature. The required temperature for EGGER Laminates is in the region of approximately 150 C to 170 C, however, the temperature is affected by the following factors: Laminate thickness and decor Type and amount of glue in the postforming area Forming speed

Illustration 3

Illustration 4

Illustration 5

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Illustration 6

Illustration 7

It is therefore extremely important to control the laminate temperature precisely in the postforming area (temperature sensor). Once the postforming temperature has been reached, the metal forming bar, maintaining a constant even pressure, automatically follows the profile outline of the postformed element, thereby bonding the laminate to the substrate. The speed at which the sequence of the postforming processing stages occurs can be controlled, allowing an optimum temperature adjustment for the postforming process. Exceeding the temperature may result in delamination (blister formation); on the other hand, if the temperature is too low, cracks (fractures) are likely to form. Essentially, the forming speed depends on the amount of energy, the laminate thickness, but also on the profiling of the substrate. To prevent the laminate from drying out and heat from being lost, the laminate must be warmed through and postformed as quickly as possible. EGGER Laminate should preferably be formed parallel to its production direction which can be identified by the direction of the sanding lines on the reverse.

4.5 continuous PostForming Process

A continuous postforming operation is more efficient than the static postforming process described above. However, as it does require volume production and is not suitable for one-off requirements, continuous processes are exclusively operated on an industrial scale. This method is only suitable for forming convex shapes and again, the laminate should be formed parallel to its production direction. Whilst it is possible in principle to form in a transverse direction, there are considerable limitations in terms of postformability (tightest radius), component dimension and the postforming process itself is considerably longer and more difficult. Depending on the conceptual design of the plant, the necessary production steps are carried out in sections and / or online. Prior to the actual postforming process taking place, it is a prerequisite for either plant concept that the profile has been cut on the substrate (see 4.2) and that the laminate has been bonded to the substrate (see 4.3); both have certain advantages and disadvantages. The following explanations and illustrations describe the postforming process, using the example of EGGER profile series Model 200, also known as L-profiles. PRODUCTION STEP 1: Postforming element after profile cutting, with laminate bonded to flat surfaces on front and back, also referred to as a pressed part (see illustration 8).

Illustration 8 PRODUCTION STEP 2: In the first section of the postforming line, the pressed part passes through additional cutting and trimming units and receives its final profile shape. On so-called L-profiles, this merely entails flush-cutting the laminate on the reverse to the substrate and trimming back the laminate on the front to the required overhang (see illustration 9). Illustration 9 PRODUCTION STEP 3: In the second section, the special PVAc glue is applied evenly to the substrate and the laminate overhang by means of glue rollers and/or spray nozzles. To ensure a good bond in the subsequent forming stages, it is extremely important that the glue is applied evenly to both surfaces (see illustration 10). Illustration 10
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PRODUCTION STEP 4: In the third section, the applied special PVAc glue is vented by means of hot air blowers, i.e. the water contained in the glue evaporates, and activates it for the subsequent forming process. At the same time the laminate is heated by infrared heaters in preparation of the forming process. This is sometimes referred to as softening (see illustration 11).

Illustration 11

PRODUCTION STEP 5: In the fourth section, the forming process itself takes place. The forming or bending tool guides the laminate in the direction of the profile. In the subsequent pressure zone, profile and compression rollers mould the laminate into its final shape, i.e. the profile and compression rollers generate the laminating pressure required to bond the laminate to the substrate within a short space of time (see illustrations 12 15).

Illustration 12

Illustration 13

Illustration 14

Illustration 15 PRODUCTION STEP 6: In the fifth section, the postformed elements receive the final finishing treatment. In the case of L-profiles, this entails cutting the face side laminate overhang on the reverse flush to the element as well as buffing the bevelled routed edge if necessary. In addition, if required, a lacquer and / or hot melt seal can be applied to the underside of U-profiles, such as the EGGER profile series Model 300.

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5. general processing instructions

5.1 cut-outs
Cut-outs are not usually made until after the laminate has been bonded to a carrier substrate, i.e. they are sawn out on so-called laminated composite panels. Before processing, ensure that the laminated composite panel is supported securely so that the sawing, routing or drilling work is not likely to cause any damage. In particular, narrow board areas surrounding apertures can break or crack if the board is inappropriately handled during processing. The board cut-outs should also be secured so that they cannot break or fall out in an uncontrolled way and thereby cause injury to individuals or damage property. Cut-out edges should always be radiused (minimum radius 5 mm) as sharp edges have an adverse effect on the material and can lead to crack formation. This applies particularly to the hob area (worktops) where the frequent exposure to heat causes the laminate to dry out, thereby increasing shrinkage tension. When installing halogen lights (built-in spot lights), it is important to ensure that the temperature load does not exceed 70 C. Please specifically observe the instructions and installation templates supplied by the respective manufacturer! The cut-outs should preferably be made using a portable hand router or CNC milling machine. When using jigsaws, the cut-out corners should be pre-drilled with an appropriate radius (see illustrations 16 17) and the cut-out sawn out from radius to radius. You should cut from the underside of the board to prevent the laminate coating from ripping off. The edges should be finished by means of sandpaper, filing or manual top milling to eliminate cracks due to chipping. The same finishing work should be done when using a circular hole cutter for halogen spot lights.

Correct! Illustration 16

Incorrect!

Correct! Illustration 17

Incorrect!

5.2 seaLing eDges, cut-outs anD DriLLeD HoLes

In general terms, laminated composite elements, like worktops, front elements etc., are effectively protected from moisture penetration by the laminate surface. Moisture and damp can still reach the substrate, however, via unprotected edges such as cut-outs, corner joints, mitres, long back edges, drill holes, screw holes and fixtures. For horizontal applications in particular (worktops), it is essential to carry out sealing work in the final installation. EGGER melamine edging or EGGER Edging ABS are the best products for sealing visible exposed edges. The best products for sealing concealed cut edges have been found to be sealing profiles and self-curing sealants such as silicon rubber, polyurethane and acrylic. When using sealants, you must also use a primer; either a film-forming one or a cleaning primer depending on the material. You must follow the manufacturers instructions carefully when using these materials.
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It is absolutely essential that you clean the areas you are sealing and to allow the manufacturers specified venting time when using primer. Apply the sealant leaving no gaps or holes and then smooth over with water and detergent. Mask off areas near joints to prevent soiling of the surface. Any pipes or leads that are to be brought up through the worktop should be centred with a minimum distance of 2 to 3 mm on either side and carefully sealed (see illustration 18).

Illustration 18 Cut edges can also be sealed using a two-part lacquer or two-part adhesive. Manufacturers supply sealing rings, profiles or collars with attachments such as mixer taps, sinks and hobs. Always follow the manufacturers instructions when fitting these items.

5.3 ancHoring
When attaching the fixing rails provided with complete wall seal profile systems, ensure that the laminate is predrilled in the screw fastening area. The holes must be at least 1 mm larger than the screw diameter to prevent tension building up in the material (see illustration 19). We also recommend protecting the inside of the screw hole with sealant before fixing the screw.

Illustration 19

6. Quality characteristics / technical data

EGGER Laminates fulfil the high EGGER quality standard as well as current applicable Standards and regulations. EGGER Laminates are tested for all relevant quality requirements in accordance with EN 438-2:2005. These requirements are met by all laminate qualities that are available to suit individual applications. For details on areas of use and fields of application, as well as technical data and available formats, please refer to the individual data sheets provided for the respective EGGER laminate qualities.

7. maintenance and cleaning recommendations

Thanks to their resistant, hygienic and dense surface EGGER Laminates do not need special care. As a general rule, dirt and spilled substances such as tea, coffee, wine etc. should be cleaned immediately as the cleaning effort increases if they are left to dry. When necessary, cleaning should be done with non-aggressive agents.

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Cleaning agents must in particular not contain any abrasive components, as they may adversely affect the gloss level or scratch the surface. Due to everything from light and fresh to severe and stubborn stains being possible in daily use, which are caused by the most varied substances, correct cleaning is an important matter. The following instructions should be observed in daily use: Placing burning cigarettes on the laminate surface leads to surface damage. Always use an ashtray. Laminate surfaces should not be used as a cutting surface as this can also leave cutting marks on highly resistant laminate surfaces. Always use a chopping board. Placing hot cooking utensils such as saucepans and frying pans directly from the hob or oven onto the laminate surface should be avoided, as, depending on the heat exposure, a change in the gloss appearance or damage to the surface can arise. Always use heat resistant mats. Spilled liquids should always be cleaned up immediately, especially in the areas around cut-outs and joints as prolonged exposure to some substances may cause a change in the gloss appearance of the laminate surface.

These recommendations apply especially to matt and gloss laminate surfaces. These have a distinctive look and feel, but have a greater tendency to show wear and tear. More detailed information can be found in our leaflets: EGGER Laminate Structure ST9 Perfect Matt EGGER Products Structure STHG High Gloss EGGER Laminate Cleaning and Maintenance instructions EGGER Laminate with Protective Foil EGGER Laminate W1001 EGGER Laminate in Pearlescent Print Decors EGGER Laminate in Role Format

Subject to technical modifications and amendments.

These processing instructions have been prepared to the best of our knowledge and with all due care. The information contained within this document is based on practical experience as well as in-house tests and reflects our current state of knowledge. It is intended for information only and does not constitute a guarantee in terms of product properties or their suitability for specific applications. We are unable to accept any responsibility neither for printing errors, errors in relation to Standards nor for any mistakes or omissions that may have otherwise occurred. It should also be noted that changes may be implemented as a result of the ongoing development process of EGGER Laminates or as a result of changes to Standards and / or in legislation. The contents may therefore not serve as an instruction manual nor does it constitute a legally binding basis. Unless otherwise stated, our General Terms and Conditions apply. 10/10

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