LAMINATE FLOORING

All you need to know about laminate construction.

Learning how laminate is manufactured is easy and simple. We’ve outlined

the basics below and ask that you read through them to better understand how this

unique product is created.

Knowing how laminate is constructed provides you with knowledge of laminate right from its beginning. That’s important information because these are the

materials you’ll be living with and walking on for years to come should you choose

this flooring product.

Knowing laminate construction also helps you better understand and evaluate its performance aspects.

So read on, and we’ll do our best to help you know how laminate is made,

the various steps involved, and the reasons why certain processes are performed.

In the section “Introduction to Laminate,” we told you laminate is a manufactured product that is a true look-a-like of hardwood flooring, natural

stone and many other types of flooring.

Now, you may be wondering, how can laminate flooring resemble these other

products so closely?

The answer lies in the process of how laminate is made.

It’s a combination of the precision of today’s manufacturing

techniques and the expertise of the men and women behind the materials, machines and methods that create laminate.

All work in harmony to produce a beautiful, functional flooring that closely

simulates other beautiful, functional floorings.

To know laminate, think baking and a four-layer cake.

Today’s laminate floors are available in a multitude of designs, patterns, and textures, yet they all consist of four main components that are bonded

together.

The bottom layer, or backing, is a melamine plastic layer that lends dimensional stability to the planks and also helps guard against moisture from the sub-floor. (Moisture infiltrating any flooring is the enemy.)

The next layer is a core board, generally made from high-density fiberboard or

particle board which may also contain melamine plastic resins that help improve the

moisture resistance of the core.

Then a decorative layer or print film is adhered on top of the core board giving the floor its hardwood or tile look.

This decorative layer is a printed high-resolution photo-reproduction of wood

grain, natural stone or ceramic tile pattern. (Now you know how the look-a-like is

born.)

And the frosting? On the top of our “cake” is a durable wear layer, providing protection and stain resistance.

Now many wear layers also contain aluminum oxide, as well as melamine resin, and that creates exceptional durability. The kind that will stand up to the most

active household – even yours.

All four layers of our “cake” are then combined in a high-pressure

process.

Now we’ll take you through the manufacturing process of laminate one step at a time.

Step 1: stacking with electronic precision.

The process begins with the assembly of the 4 layers of raw materials in large

sheets.

This typically takes place on a production line, where modern technology enables each layer to be stacked on top of another with incredible accuracy and

precision.

How precise you may ask? Most manufacturers use sophisticated electronic

calibrating equipment and digital camera systems to keep the sheets in perfect alignment.

The backing layer is first on the line, with the core board placed directly on

top of that.

Next, the printed decorative layer is stacked on top of the core board. The final layer to be stacked on is the wear layer.

Step 2: now the pressure is on.

Once the 4 layers have been stacked, they are ready for pressing.

The presses used to create laminate flooring have hydraulic rams that apply

tremendous pressure to the stacks.

The stacks of layers are pressed at high temperatures reaching 400 degrees

Fahrenheit, with up to 600 pounds per square inch of pressure for 20 to 30 seconds.

Manufacturers carefully monitor the time and temperature when pressing the layers to successfully cure and bond the stacks into a single sheet of finished

decorative laminate.

If the laminate that is being manufactured is designed to have a textured

surface, the press has specialized plates that imprint the textured pattern onto the

sheets, creating more natural looking planks or tiles.

Step 3: a time out to cool off.

After the sheets are pressed they are left to cool to ensure that they fully cure and to prevent any surface imperfections.

Then the sheets are stacked and stored for a time so that they can continue to

acclimate, thereby enhancing the stability of the boards.

Step 4: planks, profiling and precision.

Once the boards are fully acclimated, they are milled, or cut into planks.

The freshly cut planks then move on to be profiled. Multiple profiling saws

create the tongue and groove edges on the sides of the planks that enable the floor to lock together with ease.

The blades on the profiling saws use electronic and laser systems that produce

incredibly accurate edges for a perfect fit. Further assurance of the precision of your

floor.

The finished planks then go through a quality inspection and are checked for

color, texture, finish, size and correct interlocking capabilities.

Once approved, the planks are then stacked, packaged and loaded onto trucks for distribution.

Now that you know how laminate flooring is made you can understand why it’s a beautiful, durable and cost-efficient flooring answer for many homes, and homeowners, across the county.

Knowledge about laminate styles.

Laminate offers you a large family of styles and our goal is to help you understand the big picture on installation types when it comes to this unique family of flooring products. This information will let you shop smarter and compare with confidence.

For many of us, when it comes to picking a style of any product, we usually “know it when we see it.” Perhaps that describes you, too.

Well, if laminate interests you, it’s virtually guaranteed you’ll find a style that’s right for your home.

This section explainslaminate types of installation, and offers you all the information you need to make smart choices.

Is it real or laminate?

If laminates looked fake the last time you checked, it’s time to check again !

Today’s laminates are looking better and better, and often need close examination to be identified.

Laminates have truly come a long way. Why?

Because of the growing popularity of laminates, manufacturers are creating an increasing array of traditional, rustic, and exotic wood grain designs.

In fact, presses have improved to the point where the texture imprinted on top of the design looks more real than ever, even with distressed wood or natural stone designs.

Want to know what’s new under the laminate sun?

As with sheet vinyl floors, some of the new laminates really have the look of natural materials, particularly the textured products that give the floor dimension. The most common, basic laminate designs have a wood grain appearance.

Some of the most popular laminates have rustic or historic wood grain patterns.

If you’re curious about what are the best sellers, it’s the natural stone look-a-likes, particularly slate and tumbled tile varieties.

Quality is focused on the photography.

The quality of the laminate partially has to do with the photography and the number of photographs per style, which is known as "screens" .

Here’s an example for you. When manufacturers emulate a natural stone tile, they try to recreate the variation in color, pattern and texture that is a result of cutting a natural product.

The more screens a product has, the more variation it can offer. And the more “authentic” the laminate looks.

Understand this about color.

Like any floor, select the laminate color to compliment the size of your room and the activities taking place in it.

Remember that lighter colors will make a smaller room appear larger, while darker colors will absorb the light and create a more intimate setting.

Choose a color that either coordinates or contrasts with your cabinets and other furniture. Avoid matching everything to the same color and style.

Let your creativity guide you ! And remember, contrasts can make your room more interesting.

Laminate flooring types – yours will be installed in one of these 4 forms. Glueless laminate flooring.

No mess, glueless installation makes these floors quick and easy-to-install.

They come in a variety of ceramic and wood designs and colorations, as well as some manufacturers offer a real, hardwood veneer instead of a printed layer. It looks amazingly hardwood-like.

These floors come in both planks and squares. A thin, plastic underlayment is needed to seal out moisture from below. (Remember, moisture is the enemy of your flooring.)

In fact, most laminate floors require a plastic underlay sheet (4 mil poly) be installed directly underneath the laminate planks or tiles.

This helps the floor float freely over the subfloor. Another option is to add a vapor barrier or noise reduction underlay before installing the laminate flooring.

Laminate flooring with attached underlay.

These floors come with several different types of tongue and grooved locking systems and an attached underlayment to reduce noise levels. That’s good to know.

Glued laminate flooring.

These are the original laminate floors that do require a special formulated glue to be applied to the tongue and grooved areas for each plank.

Once the glue is dried the planks are almost impossible to pull apart. These floors are offered in both planks and squares.

Pre-glued laminate flooring.No mess, because the glue is already applied to the tongue and grooves which makes these floors quick and easy-to-install.

A thin, plastic underlayment is needed to seal out moisture and prevent the glue from sticking to the substrate.

Moldings are the finishing touch.

Laminate moldings also affect the overall style and give your room a beautiful finished look.

Moldings are important because they cover the space that is allowed for the flooring to expand and move naturally on top of the subfloor, and they help with the transition to an adjacent floor.

Most manufacturers offer coordinating moldings for all styles and colors for any laminate flooring you choose.

However, be aware that moldings for laminates are slightly larger than their wood or ceramic tile counterparts.

Here, to familiarize you with various standard moldings, are some styles and definitions.

The Step Down Stairnoseis a coordinating piece providing the proper transition for all the steps in your home.

A Reducer Stripis the transitional piece the installers use to connect the laminate with another type of floor covering such as vinyl, thin ceramic tile, or low-pile carpeting.

An End Moldingor Carpet Reduceris used as a transition from laminate floors to different flooring surfaces when the reducer does not allow enough height, such as on high-pile carpet or thick ceramic tile.

T-Moldingis commonly used in doorways to join two laminate floors in adjoining rooms. It's also recommended when making transitions from a laminate floor to another floor that is approximately the same height.

Finally, a Quarter Roundmay be installed wherever the laminate floor meets the wall or baseboard.

We recommend that you work closely with us to become familiar with the moldings and transition pieces.

Ask to see samples if possible, so there are no surprises come installation time.

With a lot of knowledge, hopefully from the above, and a little imagination (that’s your department), you will find a laminate flooring that is just right for you and your home.

For definitions of other terms not listed here, please go to these sections: How It’s Made, Styles, Before You Buy and Installation.

Acclimation The adaptation of the laminate floor to its installation environment.

Backing In laminate flooring, the bottom layer, or backing, is a melamine plastic layer that lends dimensional stability to the planks and also helps guard against moisture from the sub-floor.

Decorative Layer In laminate flooring, a decorative layer or print film is adhered on top of the core board giving the floor its hardwood or tile look. This decorative layer is a printed, high-resolution photo-reproduction of wood grain, natural stone or ceramic tile pattern.

End Molding/Carpet Reducer Used as a transition from laminate floors to different flooring surfaces when the reducer does not allow enough height, such as on high-pile carpet or thick ceramic tile.

Floating Floor System Laminate floors are installed using a “floating floor system” in which a padded underlayment sits between the subfloor and the laminate planks. The planks sit directly on the underlayment and are not anchored to the sublfoor on the bottom but rather are anchored on the edges.

Glued Laminate Flooring These are the original laminate floors that do require a special formulated glue to be applied to the tongue and grooved areas for each plank. Once the glue is dried the planks are almost impossible to pull apart. These floors are offered in both planks and squares.

Glueless Laminate Flooring A no mess installation method where the planks or squares simply interlock together.

Laminate Is a manufactured product that simulates the look of hardwood, ceramic tile, natural stone and many other types of flooring.

Melamine Resin Used to help improve the moisture resistance and durability of the core board of laminate flooring.

Moldings Trim pieces that cover the space that is allowed for the flooring to expand and move naturally on top of the subfloor. They also help with the transition to an adjacent floor. Moldings for laminate floors are slightly larger than their wood or ceramic tile counterparts.

Overlapping Stair Nosing Similar to a flush stair nosing except the nosing overlaps the exposed edge of your floor. The overlapping stair nosing is secured to the sub floor and not to the laminate floor so the floor is free to move

Peaking Seams that have raised where the laminate planks or tiles join.

Plank A laminate floor panel that is typically 5 or 6 inches longer than wide.

Pre-Glued Laminate Flooring A no mess method of installation because the glue is already applied to the tongue and grooves. A thin, plastic underlayment is needed to seal out moisture and prevent the glue from sticking to the substrate.

Quarter Round Trim Installed wherever the laminate floor meets the wall or baseboard.

Reducer Strip The transitional piece installers use to connect the laminate with another type of floor covering such as vinyl, thin ceramic tile, or low-pile carpeting.

Screens The quality of the laminate partially has to do with the photography and the number of photographs per style, which is known as "screens". The more screens a product has, the more variation it can offer. And the more “authentic” the laminate looks.

Seams The junction where the panels connect together.

Square Nosing / Universal Edge Used where the laminate flooring butts up to carpeting, or various vertical surfaces where the edge will be exposed, such as along a fireplace.

Step Down Stair Nose A coordinating molding piece providing the proper transition for all the steps in a home.

Tile A laminate panel in a geometric shape – square.

T-Molding Commonly used in doorways to join two laminate floors in adjoining rooms. It's also recommended when making transitions from a laminate floor to another floor that is approximately the same height.

Underlayment A material used between the laminate flooring and the subfloor that acts as a sound and moisture barrier and also allows the floor to expand and contract with changes in the temperature.

Wear Layer The durable, top layer of laminate flooring. It provides protection and stain resistance. Many wear layers also contain aluminum oxide, as well as melamine resin, and that creates exceptional durability.