PERFORMANCE CRITERIA FOR COMPOSITE CORE MATERIAL USED IN LAMINATE FLOORING

Daniel A. Hare Vice President, Technical Affairs Composite Panel Association Gaithersburg, MD 20879

ABSTRACT _____________________________________________________________________________________________ A wide variety of core material is being used in laminate flooring today. The type and quality of the core material used can influence the overall performance and quality of laminate flooring. Particleboard and Medium Density Fiberboard (MDF) are particularly well suited for this application. Both products offer extremely smooth surfaces and excellent dimensional stability as well as uniform density, thickness tolerance and physical/mechanical properties. Another attribute of these products is their machinability, an important criterion for manufacturing laminate flooring. The Composite Panel Association (CPA) sponsors two voluntary industry standards for particleboard and medium density fiberboard. American National Standards Institute (ANSI) Standards ANSI A208.1 1993 Particleboard and ANSI A208.2 1994 Medium Density Fiberboard (MDF) list the requirements and test methods for dimensional tolerance, physical and mechanical properties and formaldehyde emission limits. Both standards, developed with input from manufacturers, users and other general interest groups are updated regularly according to ANSI procedures. In addition to the ANSI Standards, CPA members have developed additional recommended performance criteria for composite core material used in laminate flooring.

INTRODUCTION The rapidly growing market for laminate flooring is providing an exciting new opportunity for particleboard (PB) and medium density fiberboard (MDF) manufacturers. If market projections for laminate flooring are anywhere close to correct, a significant amount of particleboard and medium density fiberboard could be utilized to service this rapidly expanding market. A wide variety of composite core material is or has been used in the manufacture of laminate flooring. Composite products that have been used as core material in laminate flooring include particleboard, medium density fiberboard, hardboard and a wide variety of other products. Some of these products have performed very well. Others have not. In some cases, one type of composite core material may work well with one type of laminate flooring but perform marginally with another type. Through experience and extensive product testing, laminate flooring manufacturers have determined that core material can have a significant impact on the final performance of laminate flooring. A failure in the core layer will result in product failure and a dissatisfied customer. Laminate flooring failures reflect negatively on both the laminate flooring and composite panel industries. Since consumers have no reason to consider the technical aspects of a product failure, they often react emotionally, and the negative perceptions generated by their response can become a marketing managers nightmare. The laminate flooring market has become very competitive. It has been demonstrated that even minimal price differences influence purchasing decisions of consumers. Laminate flooring manufacturers, in their search to gain market share, must exercise caution when balancing quality against profit. Product problems may not manifest themselves for several years after the product has been installed. When do-it-yourselfers will be installing the product in residential applications, it is even more important for laminate flooring manufacturers to use a high quality core material that has been certified by an independent, third party organization to be in conformance with industry standards. Laminate flooring manufacturers can produce the best product in the world, but if it is not installed properly, a failure may occur. It is imperative that do-it-yourselfers, as well as professional installers, carefully follow manufacturers installation instructions and use only adhesives that have been approved by the laminate flooring manufacturer.

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Particleboard and medium density fiberboard are engineered wood products that are ideally suited for use in laminate flooring. They provide the end user with a dimensionally stable, flat panel product that is uniform in density and thickness, has a smooth surface and is free of knots and other defects normally found in solid wood products. Both products are manufactured from residual material, allowing maximum utilization of forest resources. Particleboard and medium density fiberboard have excellent machinability, an important characteristic in todays modern high speed production lines. In the manufacture of particleboard and medium density fiberboard, wood particles or fibers are refined under controlled conditions to a desired geometry, blended with some type of synthetic resin, formed into a mat and pressed into a uniform panel under heat and pressure. The manufacturer can adjust process parameters to engineer a product for a specific application. Among the many applications of particleboard and medium density fiberboard are furniture, cabinets, laminate flooring, underlayment, manufactured home decking, doorcore, paneling, moulding and millwork, stair treads and shelving. In 1997 over 5.64 billion square feet (3/4 basis) of particleboard and 1.72 billion square feet (3/4 basis) of medium density fiberboard were produced in the United States and Canada. Anticipating an increase in the demand for particleboard, medium density fiberboard and other composite wood products, North American production capacity for particleboard and medium density fiberboard is scheduled to increase significantly by the year 2000. Some of this additional capacity is targeted for the laminate flooring industry. COMPOSITE PANEL ASSOCIATION The Composite Panel Association (CPA) represents the North American producers of particleboard, medium density fiberboard and other compatible products. CPA was formed in March 1997 when the members of the National Particleboard Association (NPA) and the Canadian Particleboard Association (Can PB) voted to become one organization. The benefit of this union, according to members, is an increased effectiveness in addressing the various issues and opportunities facing our industry. At present CPA has 32 member companies that manufacture particleboard, medium density fiberboard or agricultural fiber based composite panel products. CPA members represent over 85 percent of the North American production capacity for particleboard and medium density fiberboard. CPA is an American National Standards Institute (ANSI) accredited standards developer and currently sponsors two (2) ANSI standards: ANSI A208.1 1993 Particleboard ANSI A208.2 1994 Medium Density Fiberboard (MDF) Both standards were developed using the ANSI canvas method. Under this method, manufacturers, users and general interest groups have an opportunity to provide input. ANSI requires that standards be maintained at least every five years. Developers have the option of renewing, revising, or withdrawing a standard. The ANSI standard for particleboard, A208.1 1993, is currently undergoing revision. The ANSI standard for medium density fiberboard, A208.2 1994, is scheduled to be renewed/revised next year. ANSI standards A208.1 and 208.2 list the minimum physical / mechanical property requirements for various grades of particleboard and medium density fiberboard. An individual companys own internal specifications may be more stringent than the ANSI standards. Properties covered in the above ANSI standards include dimensional tolerances (width and length, thickness, squareness, and straightness), physical / mechanical properties (moisture content, density tolerance, concentrated load, modulus of rupture and elasticity, internal bond, hardness, linear expansion, edge and face screw holding capacity, thickness swell) and formaldehyde emissions. Both ANSI standards reference the test methods used to measure the physical / mechanical properties. Most test methods were developed and approved by the American Society for Testing and Materials (ASTM). PERFORMANCE REQUIREMENTS FOR COMPOSITE CORE MATERIAL USED IN LAMINATE FLOORING Performance criteria for composite core material used in laminate flooring depend on the type of laminate flooring being manufactured. Laminate flooring manufactured with a high pressure laminate (HPL) on the surface requires composite core material with specific physical / mechanical properties. Laminate flooring manufactured with a low

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pressure laminate (LPL) on the surface may require composite core material with slightly different performance requirements. CPA member companies have been working closely with laminate flooring manufacturers during the last several years to identify pertinent performance criteria for composite core material used in laminate flooring. Although some laminate flooring manufacturers have established their own internal specifications for their products, CPA members, in an effort to assist the laminate flooring industry, have developed some minimum performance criteria for composite core material used in laminate flooring. While the ANSI standards for particleboard and medium density fiberboard identify several important performance criteria for composite core material used in laminate flooring, other physical / mechanical properties not included in the above ANSI standards may also be important to some laminate flooring manufacturers. Among them are impact resistance, surface strength, moisture resistance and machinability. Listed below and in Table I are some of the performance criteria that CPA members have determined are important for laminate flooring. In some cases, the minimum performance value or appropriate test method has not been determined. In developing these recommended performance criteria, CPA members agreed that initially it would be best not to establish separate performance criteria for particleboard and medium density fiberboard used in HPL and LPL type laminate flooring. As more information is developed, a more detailed approach may be warranted. Dimensional Tolerances Width, Length, Thickness Composite core material must meet the required dimensional tolerances established by laminate flooring manufacturers. In many cases, these tolerances are more stringent than those in the ANSI standards. Thickness tolerance, both within panel and between panel, is especially critical with the high speed equipment used to machine the tongue and groove. Density (also referred to specific gravity) Density is the weight per unit volume of a panel. Since there is a strong relationship between density and most physical / mechanical properties, it is perhaps the single most important performance criterion. Units of measure are pounds per cubic foot or grams per cubic centimeter. The recommended test method for measuring density is ASTM D 1037 - 96 Section 119 120. CPA members recommend that composite panel material used in laminate flooring have a minimum density of 50 pounds per cubic foot. Laminate flooring manufacturers are constantly looking for lower density products since their use can result in significant weight saving. Lower density products may also be used, providing other performance criteria are met. Vertical Density Profile (surface / core density) Vertical density profile (or ratio of surface to core density) is a measure of the density through the thickness of a panel. Most composite panels exhibit a density profile in which the face or surface layers have a slightly higher density than the core layer. In some cases, the profile is fairly flat, while in others there can be a 10 to 15 percent difference between the surface and core density of a panel without any difference in overall panel density. Particleboard and MDF manufacturers have some control over the vertical density profile during the manufacturing process. For laminate flooring, the composite core must have a high enough face density to give the required hardness and impact resistance and a high enough core density to give the desired machinability and edge quality. Vertical density profile can be measured easily with electronic instruments. Laminate flooring manufactured with HPL on the surface may require composite core material with a different vertical density profile than that required for laminate flooring manufactured with LPL on the surface. The HPL laminate will contribute significantly to the overall surface performance of the laminate flooring. Laminate flooring manufactured with LPL would probably require the use of composite core material with a higher surface density in order to meet the required surface performance criteria. Since each laminate flooring product is slightly different, CPA members have been unable to develop any recommended values for surface or core density.

Internal Bond Internal bond is a measure of the internal fiber to fiber bond strength and may be an indication of machinability and integrity of the tongue and groove. Internal bond is determined by ASTM D 1037 - 96 Section 28 33. Units of measure are pounds per square inch or Newtons per square millimeter. CPA members recommend that composite core material have a minimum internal bond of 130 psi. Modulus of Rupture (MOR) and Elasticity (MOE) - also referred to as static bending or flexure MOR is a measure of how much load a product can carry before breaking. MOE is a measure of how much a product will sag or deflect under load. For laminate flooring, MOR and MOE are important when handling the product during manufacturing and installation. The recommended test method for measuring MOR and MOE is ASTM D 1037 - 96 Section 11 20. Units of measure are pounds per square inch or Newtons per square millimeter. CPA members recommend that composite core material have a minimum MOR and MOE of 2400 psi and 350,000 psi respectively. Thickness Swell As will solid wood, composite wood products will swell when exposed to water and / or moisture. Particleboard and medium density fiberboard manufacturers add wax or other types of sizing agents during the manufacturing process to impart some temporary moisture resistance to the product. The degree of swelling will depend on the duration and type of contact (physical contact with water or exposure to high humidity). Short term swell values are generally highest along the edges of the panel where moisture can easily penetrate. Depending on the conditions and amount of swell, thickness swelling may be irreversible. The recommended test method for measuring thickness swell is ASTM D 1037 - 96 Section 100 106, a test in which specimens are submerged in water for 24 hours. Values are reported in percent swell. CPA members recommend that composite core material have a thickness swell of less than 15 percent. Edge and residual thickness swell (after drying) may be important performance criteria for composite core material used in laminate flooring. CPA members do not have enough data at the present time to establish a recommended performance value. Impact Resistance Impact resistance is a measure of a substrates ability to resist surface damage due to impact from falling objects or pointed heavy objects, such as shoe heels or furniture legs, striking the surface. Impact resistance is influenced by surface density. The level of impact resistance required will depend to a large degree on the type of laminate used. Since thin laminates have very little, if any, impact resistance composite core material for use in laminate flooring made with LPL on the surface must have higher impact resistance than material used in products with HPL on the surface. The recommended test methods for measuring impact resistance are ASTM D 1037 96 Sections 91 95 or ASTM D 2394. CPA members do not have enough data at this time to establish minimum impact resistance values. Hardness Hardness is a measure of the force required for an object to penetrate the surface of a panel. Hardness is influenced by surface density and is especially important when thin laminates are used. As with impact resistance, required hardness of the composite core material will vary with the type of laminate flooring product. Recommended test method for measuring hardness is ASTM D 1037 96 Section 68 73. Units of measure are pounds or Newtons. CPA members recommend that composite core material have a minimum hardness of 1000 pounds. Surface Strength Surface strength is a measure of the strength of a panels surface. It may influence the strength of the bond between the laminate and substrate and may affect the materials potential for delamination. The recommended test method

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for measuring surface strength is ASTM D 5651 95. Units of measure are Newtons (N) or pound-/force. CPA members do not have enough data at the present time to establish minimum surface strength values. Linear Expansion Linear expansion is the change in linear dimensions resulting from changes in relative humidity and moisture content. The recommended test method for measuring linear expansion is ASTM D 1037 96 Section 107 110. Values are reported in percent expansion. Since the laminate and backer sheet strongly influence the dimensional properties of laminate flooring, CPA members have not established any recommended performance values for linear expansion. The linear expansion characteristics of the finished flooring product must be evaluated in order to develop appropriate installation instructions for wall spacing. Moisture Resistance The term moisture resistance, or MR, is a term with various meanings and has been the subject of much debate within the composite panel industry. Many equate moisture resistance with thickness swell, while others equate it with bond durability. Some use both thickness swell and bond durability to define moisture resistance. Many of the test methods used to measure moisture resistance (ASTM D 1037, EN 321, EN 1087 1, Japanese Industry Standard JIS A 45908, etc.) actually measure thickness swell or strength retention after some type of cyclic test. CPA members recommend that MR grade products or products with enhanced bond durability and minimum thickness swell be used for applications where exposure to high moisture and / or relative humidity (kitchens, baths, entryways, etc.) is possible. While laminate flooring manufacturers have developed detailed installation instructions for their products and recommend specific adhesives to use when installing laminate flooring, it is possible that a completely watertight seal will not be formed along the joint between the strips of laminate flooring. Any microscopic void in the glueline between strips of flooring will result in a pathway for moisture to penetrate into the core layer. This is especially a concern with do-it-yourselfers installing the product. CPA members are working with affiliated associations in Europe and other parts of the world to develop a uniform definition for moisture resistance. Machinability The term machinability is another nebulous term that has been the subject of much debate within the composite panel industry. The tongue and groove is a critical element of laminate flooring and influences the overall performance of the finished product. Laminate flooring manufacturers require a core material that can be accurately machined to very tight tolerances. Core density and internal bond may provide some indication of machinability. At present there are no universally accepted test methods for measuring the machinability of composite wood products. Test methods are, however, available in which the wear on the cutting edge or cutter head amperage is measured. However, researchers have yet to establish any correlation between those measures and machinability of laminate flooring. In an effort to minimize tool wear, particleboard and medium density manufacturers carefully screen incoming raw material for grit content. Formaldehyde Emissions Formaldehyde emissions from laminate flooring may be of interest to some consumers. Many factors determine the level of formaldehyde emissions from laminate flooring. Among them are the type of surface laminate and backer sheet used, the type of adhesive used to bond the surface laminate and backer sheet to the core and the type of composite core material used. Recommended test method for measuring formaldehyde emissions from laminate flooring is ASTM E 1333 96. CPA members recommend that particleboard and medium density fiberboard used as core material for laminate flooring should meet the respective ANSI criteria for formaldehyde emissions. THIRD PARTY CERTIFICATION Core material is a critical element of laminate flooring and can have a significant impact on the performance of the final product. Manufacturers should use only material that has been certified by an independent, third party agency

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to meet performance criteria established by ANSI, the manufacturer or other appropriate organization. The use of an independent third party certification agency will provide the laminate flooring manufacturer with assurance that the core material is consistent and meets the required performance criteria. CPA has a Grademark certification program for physical / mechanical properties and formaldehyde emissions. Other organizations have similar programs. SUMMARY

Particleboard and medium density fiberboard are particularly well suited for use in laminate flooring. Both products offer uniform thickness, density and physical / mechanical properties. The laminate flooring market has become very competitive. Laminate flooring manufacturers, in their search to gain market share, must not cut corners or use materials of questionable quality in order to save a few cents. CPA members recommend that laminate flooring manufacturers use a high quality core material that has been certified by a third party organization to be in conformance with ANSI or other recognized industry standards. Do-it-yourselfers, as well as professional installers, should follow manufacturers' installation instructions and only use adhesives approved by the laminate flooring manufacturer. So that customers will obtain the best product available, it is important that composite panel manufacturers continue to work closely with laminate flooring manufacturers to develop pertinent performance criteria for composite core material used in laminate flooring.

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Table 1. Recommended Performance Criteria For Composite Core Material Used In Laminate Flooring Property Dimensional Tolerances Width, Length, Thickness Density (Overall) Recommended Value Conform with those established by customer 50 lb. / ft3 TBD 130 psi MOR 2400 psi MOE 350,000 psi 15 percent TBD Test Method ASTM D 1037 96

ASTM D 1037 96 Section 119 120 Various ASTM D 1037 96 Section 100 106 ASTM D 1037 96 Section 11 - 20 ASTM D 1037 96 Section 100 106 ASTM D 1037 96 Section 91 95 ASTM D 2394 ASTM D 1037 96 Section 68 73 ASTM D 5651 95 ASTM D 1037 96 Section 107 110 ASTM D 1037 96 EN 321 EN 1087 1 JIS A 45908 TBD ASTM E 1333 96

Density (Face / Core) Internal Bond

Modulus of Rupture (MOR) / Modulus of Elasticity (MOE) Thickness Swell

Impact Resistance

Hardness

1000 pounds TBD TBD

Surface Strength Linear Expansion

Moisture Resistance

TBD

Machinability Formaldehyde Emissions

TBD ANSI Criteria