How flooring became popular due to its low cost and beautiful appearance.
This best option for the floor, as it can be laid on any surface.
In order for the coating to be durable and safe for the health of those living in the house, you should carefully study what the laminate consists of.
Laminate is a multilayer material, the strength of which directly depends on the quality of the main layers included in its composition. Sawdust is used to produce this finishing floor covering.
In most cases, laminate consists of four main layers:
- Protective layer. The top layer, which is a laminating film. It protects the material from mechanical damage, heat and contamination. Consists of acrylic resin. Includes microparticles of minerals, such as corundum. Thanks to this, the material wears out more slowly. At the final stage of production top layer varnish to make the surface glossy.
- Decorative layer. This is thick paper impregnated with special resin compounds. The desired design or pattern is applied to it, imitating different breeds wood, stone or tile. There are many shades. Therefore, this flooring fits perfectly into any interior. When planning repairs and installing laminate flooring, you need to buy it in reserve and at one time. So that the shade of the batch is the same.
- Layer of wood fiber or particle board. This is the main part of the laminate, which makes up 90% of its composition. Produced by pressing under high pressure sawdust and glue. The result is a slab that gives the laminate elasticity and density and is responsible for noise and heat insulation. It is lightweight and easy to machine. The interlocking joints are cut into this layer, so it must be strong. The service life of the coating depends on this.
- Bottom protective layer. Protects products from fungal infections, moisture and mold. Gives the laminated board stability. The material is cardboard impregnated with paraffin resins or.
Advantages of laminate flooring
This material has a number of advantages:
- Durability and strength. Laminate flooring is resistant to mechanical stress, chemicals and heating.
- The minimum service life is 7 years. Although it can last for decades depending on the manufacturer and operating conditions.
- Decorative qualities. Laminate looks similar to parquet boards made from valuable wood. It looks beautiful on the floor, and the cost is much lower than wood products. For much less money you can create a beautiful home.
- Low cost. Due to its composition, laminate is cheaper than parquet. Its installation is simple and does not require additional costs.
- Easy installation. Mounted using locking connections. Therefore, there is no need to spend extra money on glue, nails or other materials. Even less experienced workers can do the job.
- Easy to maintain. Laminate flooring is easy and pleasant to care for. To keep it clean, simply wipe it with a cloth and soapy water.
Is laminate flooring harmful?
From the description of the composition of the laminate it follows that it consists of 90 percent wood sawdust and shavings. They are used to make a lot of other finishing materials and furniture. Therefore, there should be no questions regarding environmental performance and safety. But it's not that simple. Concerns arise from the adhesive and protective resins that bind the layers together.
The main layer of the laminated board consists of chipboard, or fibreboard, in the production of which they use safe and good quality glue. This layer meets all security parameters.
IN chemical composition The laminate, namely its top layer, contains melamine or acrylic resin, which contains formaldehyde. Because of this substance, there is an opinion that laminate flooring is harmful. This component is toxic and harmful, but acts as a connecting element between the layers.
On main question There is no clear answer as to whether laminate flooring is harmful during long-term use. It all depends on a combination of several factors:
- Concentration of formaldehyde resins. This substance is used to make almost all types and finishing materials. With high-quality production, its concentration is minimal. This characteristic is indicated in the laminate classification.
- Formaldehyde begins to be actively released into environment when heated. If you plan to install heated floors in your home, you should weigh the pros and cons of this material.
- If there is laminated furniture in the house or apartment, on the walls vinyl wallpaper, the floor is covered with laminate, there is a possibility of exceeding the safe level of formaldehyde.
- It is worth comprehensively assessing the composition of the materials that you plan to use to cover the surfaces of walls, floors and ceilings.
- If the product catches fire, a very toxic gas is released into the air, which can lead to poisoning. Therefore, you should immediately leave the place where there is smoke and call the fire brigade.
In terms of safety, laminate flooring is divided into several emission classes. This is the name given to the degree of formaldehyde release. Almost all well-known manufacturers produce products with emission classes E0, E1. The proportion of hazardous substances in the composition of such material is negligible and does not pose a health hazard. And vinyl material of emission class E2, E3 is generally not recommended for use in the bedroom and nursery.
From the above material it follows that safety depends on the binder layers, which make up only 10% of its composition. And the main raw materials from which it consists are natural shavings and sawdust.
In order for the finishing floor covering in the form of a laminate to last a long time and be safe, several parameters should be taken into account when choosing it. For example, strength class. For long-term use of the floor, it is better to choose a commercial type of laminate with indicators of 34 units or more.
It is preferable to buy products famous brands with existing certificates.
When purchasing, you should pay attention to the type of locking connection and the presence of wax impregnation. The tightness of the panels to each other depends on these characteristics. When choosing a texture, try to choose a material that does not repeat the pattern frequently.
The video shows the types of laminate:
Laminate production technology has a number of key points, compliance with norms and rules allows you to achieve results in short time. Laminate is produced in the form of thin sheets, their thickness is 7–11 mm, with dimensions of 1.0–1.4 m by 0.2 m. The products must be assembled by sequential connection using tenons and grooves provided along the edges.
Other types of flooring materials are also popular: parquet, carpet, linoleum, tiles. But laminated coating remains a leader due to its practicality and durability.
This is explained obvious advantages laminate over other coatings:
- Its cost is significantly lower than that of parquet, carpet or tiles.
- The coating is superior to linoleum in moisture resistance, wear resistance and abrasion resistance.
- A huge selection of textures and colors attracts not only the end consumer, but also design specialists.
Classification
Laminate classes are divided into commercial 31–34 and household 21–23. Laminated coatings home use They last no more than five years, so wear-resistant and impact-resistant material for commercial purposes is increasingly being used in everyday life. They all differ in performance properties and price.
The classification of coatings is approved by the European Union Directive, samples are tested according to the following indicators:
- strength;
- abrasion resistance;
- soundproofing properties;
- moisture resistance.
The higher the class, the better the listed properties of the laminate. Laminate coating of class 32 is guaranteed to last 15–20 years, and class 31 – 10–15 years. In addition to classes, there is such a marking as AC. It indicates the wear resistance of the coating and varies from 3 to 6.
Features of Class 31
A similar product is chosen for apartment flooring. It is better to lay it in rooms where they will be used lightly.
Characteristic indicators:
- laminate thickness from 6 to 8 mm;
- surface smoothness;
- the need for an underlying layer during installation.
The installation of such material is suitable for installing a base in a bedroom or office, where household members spend a minimum of time.
Class 32 Secrets
This type of laminate is the most preferable option for apartment floors. The coating in a residential area will last about 15 years, and for an office the service life is three times less. Product Features:
- thickness is 7–12 mm;
- you must use a background for this class;
- resistance to cleaning agents;
- embossed, anti-slip coating;
- shockproof;
- There is a layer of wax to protect the joints from liquids.
The following classes are even more different high quality. It is important to understand for what purposes coverage is required: this will allow you not to overpay for unnecessary properties.
Technical characteristics of class 33
For heavy loads, it is worth choosing a similar laminate: its service life is 20 years, but there are other advantages: 
- Durability, resistance to abrasion, temperature, sun, moisture.
- Good sound insulation allows you to avoid the need for a substrate.
- Suitable for indoors special purpose, equipped with many electrical appliances due to their antistatic properties.
- High quality locks for assembly.
The product is suitable for office premises, apartments large families, pet owners.
Advantages of class 34
Durable and durable appearance, used for public places, especially beneficial in sports halls. This class sometimes comes with a lifetime warranty and is 10-12mm thick.
Advantages of class 43
This is new on the market building materials, showed itself perfectly in rooms with increased exploitation. Only a few manufacturers make laminate flooring. Instead of fiberboard, polyvinyl chloride (PVC) is used to make this laminate. Advantages and features:
- actively used for kitchens, balconies, bathrooms and saunas;
- high flexibility and strength;
- Manufacturers guarantee 25 years of coating service life.
The use of an underlay prior to installation of this coating is not required.
Despite long term services or high class product, you should use it carefully and wring out the cloth well before cleaning. If, when laying the laminate, it is impossible to install the panel due to an obstacle, then the craftsmen cut off the lock or part of it to secure the panel with special glue.
Manufacturing Equipment
To produce laminate, several units of equipment are required; the main machines and mechanisms of the master include the following units:
- multifunctional sawing machine;
- special hot press;
- milling apparatus;
- mechanical packer.
In addition to the main list, there are additional units of equipment: a loader, a drying chamber. The minimum set of technical equipment will cost 1.5 million rubles.
Production technology and its features
In Europe, in the 80s of the 20th century, they began to produce laminated flooring. Laminate is a simplified, generally accepted version of the name. Now the bulk of this material is produced in Europe. Launching a laminate production line is complicated by the characteristics of the raw materials.
There are 4 layers in the structure of the laminate, they make the product durable and wear-resistant. Improvements performance characteristics achieved by increasing the layers, but the main 4 remain unchanged:
- The overlay or top layer serves to protect against the mechanical effects of operation, chemical influences, and sunlight.
- The decorative layer is a special paper or foil to imitate different structures of wood, tiles and other materials.
- The middle layer of the laminate consists of fiberboard and has good strength properties.
- The bottom layer is made of resin-impregnated or waxed paper; it protects the material from impact, abrasion and penetration of liquids.
The bottom layer is sometimes made of plastic, the total thickness of two upper layers ranges from 0.2 mm to 0.9 mm. The thickness of the bottom layer ranges from 0.1 to 0.8 mm.
There are five stages in laminate production technology:
- Production of high-density fiberboards.
- Saturation, impregnation of the surface of a product is a process called impregnation.
- Finishing the workpiece.
- Sawing
- Milling.
- Packing.
The laminated board is formed from HDF board (high-density fiberboard). There are several methods for producing laminate:
- HPL – using high pressure.
- CPL – conveyor production.
- DPL – direct pressing.
- CML or RML – continuous pressing of several layers.
- PDL – pattern printing technology.
- ELESGO is a method of drying the surface of an electron beam.
Differences in laminate production methods
With HPL technologies, materials are glued together using a cold, warm or hot method, this process is called lamination. Bonding at high temperatures allows for high quality, which is why hot lamination is often used.
Before gluing, the surface is cleaned of dust, after which glue and hardener are evenly applied. The two parts are passed through a press, gluing at a temperature of about two hundred degrees Celsius. After gluing the overlay with the decorative layer, they begin to connect this part with the base and bottom layer using glue.
The production of laminate using CPL technology is the connection of the base with the top layer through pressing. The layers are passed through rollers at high temperature. Craftsmen glue together several top layers and then press them onto an HDF board.
DPL is characterized by the absence of bonding. They take layers that have undergone the impregnation process and press them at a temperature of two hundred degrees. The resin contained in the products melts, gluing them together. After drying, a monolithic plane of the top layer of the laminate is formed.
With CML or RML methods, kraft paper is used to increase strength; this additive leads to a significant increase in the cost of the laminate.
Feature of PDL technology decorative pattern, but place the image on a fiberboard. There is no need for additional layers of decor. Further production is carried out according to DPL technology.
The top layer, consisting of paper with an image of two layers of overlay, is dried electron beam. ELESGO technology involves the use of acrylate resins for preliminary impregnation of the overlay. After hardening, a durable elastic film is obtained. The layers are joined with glue under pressure and at high temperature.
Is such production profitable?
Setting up laminate production is an expensive undertaking; total costs will exceed $800 thousand. In addition to the main production, it is necessary to engage in forestry and woodchip production. Such a complex enterprise is much more reliable, but the total costs will stop many businessmen.
Video: Laminate production
Much has already been said and said about laminate. However, one can continuously list all his various advantages that brought him such popularity. It's time to tell a little about the history of the appearance of laminate on the finishing materials market.
Laminated panels first appeared on the market in the 70s of the last century. The basis of production was the Swedish manufacturing company Perstorp, so Europe can confidently be called the birthplace of laminate. The first trial, or, as it is now fashionable to say, pilot batch, sold out at incredible speed. Demand began to grow, and quite quickly. Then the manufacturers decided to put the production of laminated panels on stream, and since 1977, laminate production began in industrial scale. As they say, appetite comes with eating.
Due to their advantages, laminated panels by the 90s of the XX century became the most popular and very popular material among the entire range of floor coverings, gradually replacing linoleum, which was so widespread until recently.
Now, we can say with confidence that laminate occupies a leading position in the flooring market, displacing such a long-lived product as linoleum.
Over time, the quality changed, more durable and wear-resistant options were created. A division of laminate into classes and types has appeared - one thing has remained unchanged - the structure of the laminate. Let's try to understand in more detail what the laminate is made of.
Initially, the laminate consisted of three layers; in fact, the name laminate itself means multilayer. The top, protective layer, which by its nature consists of resins - melamine or acrylic. Its task is to protect the body of the board from mechanical impact or abrasion. The next layer is decorative, which makes the laminate look like parquet or parquet boards, or maybe marble or natural stone, there are quite a lot of options. Next comes the base layer, or body. It is made of chipboard or fibreboard, which actually gives the laminated panels the proper elasticity and density.
In the manufacture of laminate, fiberboard or chipboard sheets are used, onto which the remaining layers are then applied
Somewhat later, another layer appeared, which performs a moisture-proof function and is made of various kinds materials - it can be plastic or cardboard, impregnated special compounds paraffin based.
Thanks to the appearance of a moisture-proof layer, a moisture-proof laminate has appeared that can be installed in rooms with high humidity
A properly selected laminated coating can for many years impeccable service. Of course, in any construction supermarket, a sales consultant will tell you about all the advantages and disadvantages of a particular model. But, still, it would not be bad to independently understand the quality of the material and know what factors need to be paid to special attention. Therefore, it is worth taking a closer look at the structure of laminated panels.
At the moment, it is believed that a large number layers a laminate has, the better it is
So, in order - the top layer. This is a transparent coating that is a combination of melamine and acrylic resins. Some manufacturers make it multilayer, and due to the presence of melanin, we can talk about the environmental friendliness of the material. In addition, special additives can be used, for example, mineral microparticles, which after additional processing are added to protective composition and significantly increase the resistance of the top layer to abrasion or mechanical damage, such as scratches. The protective layer also resists the effects of direct sun rays and chemical compositions.
The decorative layer is purely aesthetic. You can choose a laminated coating that will be ideal for any design.
The main component is chipboard or fibreboard. It is responsible for the strength and resistance of the slab to various types of loads; it is largely responsible for and influences the cost of the material.
The last, stabilizing layer of paraffin-impregnated cardboard, has the main task of giving the load-bearing board additional strength and protecting it from moisture and the appearance of negative phenomena such as fungus and mold.
Having appeared on the market about 25 years ago, laminate managed to push into second place the most popular flooring option - parquet. It has become a more economical and aesthetically attractive alternative, not inferior to parquet in reliability, strength and durability.
Is this possible? Yes, quite. The composition of the laminate and its structure make it wear-resistant and impact-resistant. Isn't that what you're looking for in a new flooring solution?
Laminated board consists of several layers that differ in quality and structure. As a rule, there are 4 of them, in the case of an additional substrate - 5. So, such a cake includes a special protective top layer, the structure of which includes melamine and acrylic resins. The next component is the paper layer, which performs decorative function. Next comes the base and stabilizing layer.
Let's look at the entire design in more detail.
Laminate composition: layered structure and its functions
The lowest layer of any lamella is called stabilizing. The whole essence and functions of such an important component can be understood by the name itself. His main tasks:
- Preventing moisture from entering the base of the laminated tiles;
- adaptation to temperature changes;
- adaptation to sudden changes;
- ensuring a stable floor condition.
What about the base of a standard slat? He is responsible for several important functions, among which:
- Guaranteed stability of the entire panel;
- impact resistance;
- stability of geometric parameters;
- moisture resistance;
- ability to withstand floor pressure and long-term loads.
With a humidity of 5-7% and a density of 80-960 kg/m? The panel structure includes:
- Paraffin-wax emulsion – less than 1%;
- water – from 5 to 7%;
- melamine-urea resin (mastic binder) – 11%;
- wood chips (chopped wood fiber) with a predominance of pine or spruce wood - 82%.
Above the base is the next necessary layer - paper impregnated with a special melamine resin. It is characterized by the presence of a certain image that imitates stone, valuable tree species, etc. The purpose of such a layer is to protect the lamella, making it resistant to ultraviolet rays and other external irritants.
By the way, such paper can imitate all kinds of surfaces, including minerals, ceramics, wood textures, graphite, old wood, sand different colors, parquet and stones. This means that depending on design solution which you would like to bring to life, you can choose ideal option for your home. In addition, from year to year manufacturers add completely different color scheme and textures.
The most common type is the so-called “deck version” of installing parquet boards. This design distinguishes several types of lamellas at once, these are one-, two- and even three-strip.
Now that we have dealt with the decor, we move on to the next layer - the top part or overlay. This is a high-strength transparent film, the thickness of which does not exceed 0.9 mm. The overlay contains synthetic resins. This is what it's all about main secret lamination.
The highest quality products, in addition to synthetic resins, also include microparticles of solid minerals. Most often this is corundum, which helps to increase strength and repel dust particles.
What is the purpose of the lamination layer? It is created for:
- Obstacles to abrasion;
- protection from and impacts;
- resistance to moisture;
- resistance to pollution;
- facilitating the cleaning process;
- resistance to ultraviolet radiation;
- resistance to abrasive cleaning agents.
! It is the top layer, its structure and functional characteristics that 90% determine the price, as well as the quality of the material that you are going to buy.
For many, special synthetic and melamine resins do not seem the best option for home. Yes, indeed, prohibited resins, as well as certain formaldehydes, do not promise anything positive. But, in fact, the likelihood of any harm is negligible.
We all know that in the production process of any product, specialists are guided by the so-called GOSTs and standards that do not allow products of dubious composition and origin to enter the building materials market. In addition, if these are slats from European manufacturers, they are always designated in E1 format, which means that the material is absolutely environmentally friendly and safe.
Today you can buy laminate flooring without worry, install it in your home or office, and use it for many years. Basic care, beautiful appearance, durability and reliability make it an indispensable coating. Have you already chosen your option?
Laminate appeared on the flooring market more than 20 years ago and made a revolution, seriously displacing linoleum, which was the leader in sales volumes at that time. This success is based on easy installation, attractive price and incredible resemblance to natural wood. When starting to make a choice, it is important to know what the laminate is made from, what technology is used and what quality the product is offered. This information will help you not make a mistake in making a decision, since buyers on the market are offered floor coverings with different technical characteristics domestic and commercial use. Despite the differences in design, they are united by the same type of laminate structure, which guarantees a long service life.
Laminate production began in Western Europe in the mid-80s of the twentieth century. Products from Germany, Belgium, and Sweden are still in stable demand on the world market. Russian and Chinese companies keep up with industry leaders, producing the most popular collections at an affordable price.
Installation of laminate boards
Manufacturers do not hide what the laminate is made of, because this demonstrates to the buyer its reliability and practicality. It's no secret that some of potential clients They think that they are being offered fiberboard with a decorative film. This is wrong. The composition of the laminate does not include loose fibreboard, but a rigid plate pressed under high pressure. Its production technology is more complex, which allows for improved strength characteristics and moisture resistance.
The structure of the laminate consists of four layers:
- Protective – the topmost layer, the function of which is to protect the board from scratches, the abrasive effects of dust, static loads and abrasion. If you look at the structure of the laminate in cross-section, this layer is a thin, durable film of acrylic or melamine resins. The thicker the film, the longer it will last. finishing layer. In household collections, the thickness of the protective layer does not exceed 0.2 mm, in semi-commercial collections it is 0.2-0.4 mm, in commercial collections it is more than 0.4 mm;
- Decorative - in the structure of the laminate, this is the thinnest layer, made of durable paper with a pattern applied to its surface. Decorative coating reliably imitates natural wood, popular varieties ornamental stone, leather or artificially aged metal;
- Main (carrying) – responsible for basic characteristics laminate panels such as overall thickness, strength, thermal insulation coefficient. It is a compressed slab of high rigidity, with a thickness of 6 to 12 mm. A lock of complex configuration is cut into it, making installation simple and effective. The thickness of this layer is determined by the manufacturer depending on the scope of use;
- Stabilizing – provides the panel with geometric stability and protects against negative impacts. It is made of paraffin-impregnated paper or melamine film; some manufacturers use a thin protective coating of plastic. The layer prevents the penetration of moisture, the effects of fungus, mold and steam. In some collections it is supplemented with a substrate that provides better acoustic properties to the coating.
Having figured out what laminate flooring is made from, you can understand that its structure is distinguished by functionality and practicality. Each layer performs a specific role, therefore it consists of different materials that can easily cope with a specific task.
All laminate materials are safe for human health. This statement is typical for products famous manufacturers. What laminate flooring from a number of suppliers from Southeast Asia is made of remains a mystery to buyers. When choosing a laminate, preference should be given to products from well-known brands. It is distinguished by high quality top protective layer and reliable locks. No less important are the characteristics of the base layer, consisting of a pressed plate. Only leading manufacturers use technologies that meet strict standards.
Production
High-tech laminate production is historically located in European countries: Belgium, Germany, Sweden, France. Several large factories have also been built in Russia for the production of popular flooring. Reliable suppliers from China are emerging.
Setting up laminate production is not easy - it requires a serious raw material base, important factor which is the proximity of suppliers of polymer resins. It is not enough to know what laminate is made from. Professional staff required modern equipment, quality control laboratories, design bureau and well-functioning logistics.
Equipment for laminate production is selected depending on the technology being implemented. The specifics of the process play an important role in the cost of products, the quality of the final result, and the additional range of the enterprise. Thus, companies that produce high-pressure laminate also use their equipment to produce durable countertops for the furniture industry.
Is harmful laminate and the substances included in its composition? Having understood what laminate is made from, we can say that it is completely safe for human health. It is based on a plate high density which is produced under high pressure. This allows you to use less formaldehyde, the emission of which is the main disadvantage of chipboard and other particleboard materials. The top layer of resin polymerizes and does not release harmful substances. Melamine-impregnated paper used in laminate production is also not dangerous.
How do leading factories produce laminate? To glue all four layers into a single whole, a powerful press is used and the components are heated to a temperature of 200 degrees Celsius. It doesn't have any effect negative impact on environmental characteristics, and process does not allow the product to be classified as harmful.
Production technology
For three decades, laminate production technology has not stood still, but has not changed dramatically. All also uses a powerful press, polymer resins and high temperatures. But there are still differences. Let's look at the main modern technologies laminate production:
- DPL - Direct Pressure Laminate (direct pressing), the oldest and most perfect technology, which is used to produce up to 90% of products today. The decorative and stabilizing layers are impregnated with melamine; they are bonded to the main layer by pressing under pressure of up to 3000 kg/m2 in 40-60 seconds;
- HPL - High Pressure Laminate - high pressure laminate is produced using this technology. A special feature of the method is the separate formation under high pressure of the outer layer, consisting not only of protective coating And decorative paper with a pattern, but also several sheets of craft paper. A strong lamella is formed, which is glued to the main and stabilizing layers. The technology is expensive, but allows you to create a product with high strength characteristics. The disadvantage is that panels can only be produced with a smooth surface;
- CPL - Continuous Pressure Laminate (continuous pressure laminate), practically no different from the classic DPL technology, but under decorative layer several sheets of kraft paper are placed, which makes the coating more resistant to mechanical stress. The technology is used in the production of semi-commercial and commercial collections;
- DPR – Direct Print technology is the most modern today; unlike classic direct pressure laminate, decorative paper is not used. The design is applied directly to the base plate, heated to optimal temperature. High-tech plotters are used, which makes the production line independent of the volume of decorative paper and allows you to print exclusive small batches with any design.
When releasing products, manufacturers introduce additional technologies to make the surface textured. This helps to reproduce more accurately natural materials, repeating not only the color and pattern, but also the texture. Laminate with V-shaped chamfers along the entire perimeter of the panel or on its long sides is in high demand. Their presence allows you to reproduce the texture of the floor, characteristic of vintage interiors castles or pastoral style.
Conclusion
Laminate is a high-quality floor covering with a long service life. Correctly selected collections do not lose their appearance for 10-15 years. Commercial laminate flooring at home will last 20-25 years. The world's leading manufacturers produce products with a lifetime warranty, and they cost less than parquet or parquet boards.
Practicality is not the only advantage; another advantage is the low price. Manufacturers' range includes collections, the cost of which competes with the price of high-quality household linoleum. At the same time decorative qualities Laminate flooring is much higher and more environmentally friendly than PVC products.
Ease of installation is another advantage of laminate. The presence of durable click-click connections makes installation easy and accessible home handyman. If you have specialized tools at hand, you can install up to 80 sq.m. alone. half a day. It is important that the base is smooth and durable, but this requirement for the surface is made today by all manufacturers of linoleum and parquet.
Modern equipment and materials, as well as detailed production technology, make the flooring practical and unpretentious. Attractive price and wide range allow you to select a collection for budget renovation as well as to create an exclusive interior.