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Laminate Floor Construction

The inner core is generally made from high-density fiberboard and also forms the tongues and grooves for locking planks together. The core is also the base that all the upper layers and the backing material are fused too. Some manufacturers treat the inner core with melamine resins or water-resistant sealers to help protect the inner core from moisture.

The laminated planks are usually fused together in either a one or two step process. In the two-step process several layers are first glued together and then these layers are combined with the remaining materials and than glued and fused into a plank. This method is called High Pressure Laminate (HPL). The other method is where all materials are fused together in one step and this is called Direct Pressure Laminate (DPL).

The two main glueless locking systems either involve a tongue and groove that is reinforced from underneath by an aluminum, mechanical locking system or a tongue-and-groove glueless locking system built right into the middle core that allows the planks to snap or clic together during installation.

Some other laminate floors have a tongue that was pre-glued at the factory with a specially formulated, water-resistant glue. Once the tongue is moistened with a wet sponge it activates the glue and locks the planks together. Laminate floors are also offered that require specially formulated glue to be applied to the tongue and groove at the time of the installation to secure the planks to one another.

For more realism several laminate manufacturers are now offering a micro-beveled edging on certain styles. Others have added texturing to their surface layer to give their floors more realism and enhance the overall appearance of the laminate planks.

• Backing - is usually a melamine plastic layer used to give additional structural stability and added moisture protection to the planks.
• Core - generally made from high-density fiber board (HDF), particle board, or plastic, the core adds impact resistance, and forms the tongue and groove locking system. Melamine plastic resins are also impregnated in the core by some of the manufacturers to improve the moisture resistance of the core.
• Melamine - is a plastic-type resin used throughout the construction process to add durability, and stability to the laminated planks.
• Print Film - which is also called the decorative layer gives the floor the appearance of a real hardwood or tile. Some manufacturers, have been able to replicate the old wood floors found only in some old historical buildings.
• Wearlayer - is a tough clear melamine layer with aluminum oxide particles. Using heat and pressure the wearlayer becomes an incredibly hard and durable finish. The resin-filled wearlayer is so dense it becomes extremely difficult to stain, scratch, or burn.
• Underlayment - is a clear thin plastic sheet that is installed over the substrate before the laminate floor is floated. The plastic sheet helps the laminate floor to float freely above the substrate.