Phenolic Film Faced Plywood

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To obtain a finished piece of plywood, several sheets of veneer must be glued together. The fibers in each layer of veneer are perpendicular to each other, which gives strength to the finished product. The finished sheets are resistant to any kind of deformation. This property makes plywood an ideal material for formwork systems in concrete construction.

In the production of birch plywood, an odd number of veneer sheets are glued together into a piece of plywood 3 to 40 mm thick. The sheets are glued together using an adhesive that is also produced here, in a special mixer. It consists of chalk, water, resin, and wood or rye flour. Strict adherence to the production guidelines of the adhesive is crucial in order prevent the layers of plywood from ungluing. Modern mills have equipment that automatically adjusts the proportions of the adhesive’s ingredients in line with the formulation of the solution.

In the next step – rolling – the veneer sheets are pressed between two rollers, and smeared with the adhesive. The adhesive is evenly distributed across both sides of the sheets, after which the sheets are sent for pressing.

“Dry veneer alternates with veneer that is coated with adhesive. The number of sheets depends on the thickness of the plywood. At the end of the assembly process of one sheet of plywood, the machine feeds two dry veneer sheets (the last sheet for the previous “sandwich“ and the first sheet for the next), which will later enable one sheet of plywood to be separated from another. After this, the prepared stack is sent for pre-pressing,“ says Elena Vershinina, quality control manager at the Perm Plywood Mill, which belongs to the SVEZA group.

Cold pre-pressing of glued veneer sheets is done just before the hot-pressing in order to obtain quality bundles that are easy to transport and load into a hot press. The cold pre-pressing takes about 5-10 minutes at a pressure of 1-1.5 MPa.

After that, the glued sheets are loaded onto a hot press rack for final adhesion at a temperature of 120-130°C, at a pressure of 1.2-1.8 MPa.

After pressing, the glued sheets are trimmed on all four sides into the size requested by the customer: for example, 1250×2500 mm or 1220×2440 mm, with a precision up to 3 mm. In the production of film faced plywood, the machine performs a preliminary trim to 1290×2550 mm, so that after applying the film, the sheet can be trimmed again, taking off the remaining millimeters.

After that, the plywood is sanded on a machine to give it a smooth surface and an even thickness. After that, the plywood is fed through sanding belts with different grain sizes. After that, the plywood is once again classified according to its appearance: the operator assesses the quality of the sheets.
In the final stage, a film is applied to both sides of the plywood sheets. Then the plywood is loaded onto a multi opening press, which can simultaneously hold 15-18 sheets. Pressing, where the film bonds with the surface of the sheet, takes 4.5-10 minutes at a temperature of 130-136оC. The pressing time depends on the density of the film, the thickness of the plywood, and the type of finish (smooth or wire mesh). The film gives the plywood additional protection from water and mechanical damage, and from corrosive environments. In this way, the ordinary “white“ plywood becomes coated or film faced plywood.

In addition to the glossy film, a wire mesh coating can be applied to film faced plywood, which has an anti-slip effect. This kind of plywood is in demand in the transport Typeering industry: it is used in the floors of trailers and light commercial vehicles. It is also used for flooring in scaffolding on construction sites.

Next, the film faced plywood is sent to the cutting line, where it is cut to the designated size.

After that, the finished product is sorted according to its appearance and geometric parameters, and packaged. After the sorting is finished, the bundles of plywood are delivered to the paint-spraying booth. Here, a special latex paint with an acrylic base is applied to the ends of the sheets. This coating protects the plywood from moisture and expansion.

The better the ends are painted, the more water-resistant the sheets will be, and thus the plywood will be able to withstand more concrete pouring cycles. This is especially important for slab formwork, where the plywood is exposed to high mechanical loads and corrosive environments, i.e. concrete mix.