plywood

A structural material made of layers of wood glued together, usually with the grains of adjoining layers at right angles to each other.

[PLY¹ + WOOD¹.]

Background

Plywood is made of three or more thin layers of wood bonded together with an adhesive. Each layer of wood, or ply, is usually oriented with its grain running at right angles to the adjacent layer in order to reduce the shrinkage and improve the strength of the finished piece. Most plywood is pressed into large, flat sheets used in building construction. Other plywood pieces may be formed into simple or compound curves for use in furniture, boats, and aircraft.

The use of thin layers of wood as a means of construction dates to approximately 1500 B.C. when Egyptian craftsmen bonded thin pieces of dark ebony wood to the exterior of a cedar casket found in the tomb of King Tut-Ankh-Amon. This technique was later used by the Greeks and Romans to produce fine furniture and other decorative objects. In the 1600s, the art of decorating furniture with thin pieces of wood became known as veneering, and the pieces themselves became known as veneers.

Until the late 1700s, the pieces of veneer were cut entirely by hand. In 1797, Englishman Sir Samuel Bentham applied for patents covering several machines to produce veneers. In his patent applications, he described the concept of laminating several layers of veneer with glue to form a thicker piece—the first description of what we now call plywood.

Despite this development, it took almost another hundred years before laminated veneers found any commercial uses outside of the furniture industry. In about 1890, laminated woods were first used to build doors. As the demand grew, several companies began producing sheets of multiple-ply laminated wood, not only for doors, but also for use in railroad cars, busses, and airplanes. Despite this increased usage, the concept of using "pasted woods," as some craftsmen sarcastically called them, generated a negative image for the product. To counter this image, the laminated wood manufacturers met and finally settled on the term "plywood" to describe the new material.

In 1928, the first standard-sized 4 ft by 8 ft (1.2 m by 2.4 m) plywood sheets were introduced in the United States for use as a general building material. In the following decades, improved adhesives and new methods of production allowed plywood to be used for a wide variety of applications. Today, plywood has replaced cut lumber for many construction purposes, and plywood manufacturing has become a multi-billion dollar, worldwide industry.

Raw Materials

The outer layers of plywood are known respectively as the face and the back. The face is the surface that is to be used or seen, while the back remains unused or hidden. The center layer is known as the core. In plywoods with five or more plies, the inter-mediate layers are known as the crossbands.

Plywood may be made from hardwoods, softwoods, or a combination of the two. Some common hardwoods include ash, maple, mahogany, oak, and teak. The most common softwood used to make plywood in the United States is Douglas fir, although several varieties of pine, cedar, spruce, and redwood are also used.

Composite plywood has a core made of particleboard or solid lumber pieces joined edge to edge. It is finished with a plywood veneer face and back. Composite plywood is used where very thick sheets are needed.

The type of adhesive used to bond the layers of wood together depends on the specific application for the finished plywood. Softwood plywood sheets designed for installation on the exterior of a structure usually use a phenol-formaldehyde resin as an adhesive because of its excellent strength and resistance to moisture. Softwood plywood sheets designed for installation on the interior of a structure may use a blood protein or a soybean protein adhesive, although most softwood interior sheets are now made with the same phenol-formaldehyde resin used for exterior sheets. Hardwood plywood used for interior applications and in the construction of furniture usually is made with a urea-formaldehyde resin.

Some applications require plywood sheets that have a thin layer of plastic, metal, or resin-impregnated paper or fabric bonded to either the face or back (or both) to give the outer surface additional resistance to moisture and abrasion or to improve its paint-holding properties. Such plywood is called overlaid plywood and is commonly used in the construction, transportation, and agricultural industries.

Other plywood sheets may be coated with a liquid stain to give the surfaces a finished appearance, or may be treated with various chemicals to improve the plywood's flame resistance or resistance to decay.

Plywood Classification and Grading

There are two broad classes of plywood, each with its own grading system.

One class is known as construction and industrial. Plywoods in this class are used primarily for their strength and are rated by their exposure capability and the grade of veneer used on the face and back. Exposure capability may be interior or exterior, depending on the type of glue. Veneer grades may be N, A, B, C, or D. N grade has very few surface defects, while D grade may have numerous knots and splits. For example, plywood used for subflooring in a house is rated "Interior C-D". This means it has a C face with a D back, and the glue is suitable for use in protected locations. The inner plies of all construction and industrial plywood are made from grade C or D veneer, no matter what the rating.

The other class of plywood is known as hardwood and decorative. Plywoods in this class are used primarily for their appearance and are graded in descending order of resistance to moisture as Technical (Exterior), Type I (Exterior), Type II (Interior), and Type III (Interior). Their face veneers are virtually free of defects.

Sizes

Plywood sheets range in thickness from. 06 in (1.6 mm) to 3.0 in (76 mm). The most common thicknesses are in the 0.25 in (6.4 mm) to 0.75 in (19.0 mm) range. Although the core, the crossbands, and the face and back of a sheet of plywood may be made of different thickness veneers, the thickness of each must balance around the center. For example, the face and back must be of equal thickness. Likewise the top and bottom crossbands must be equal.

The most common size for plywood sheets used in building construction is 4 ft (1.2 m) wide by 8 ft (2.4 m) long. Other common widths are 3 ft (0.9 m) and 5 ft (1.5 m). Lengths vary from 8 ft (2.4 m) to 12 ft (3.6 m) in 1 ft (0.3 m) increments. Special applications like boat building may require larger sheets.

The Manufacturing
Process

The trees used to make plywood are generally smaller in diameter than those used to make lumber. In most cases, they have been planted and grown in areas owned by the plywood company. These areas are carefully managed to maximize tree growth and minimize damage from insects or fire.

Here is a typical sequence of operations for processing trees into standard 4 ft by 8 ft (1.2 m by 2.4 m) plywood sheets:

Felling the trees

• Selected trees in an area are marked as being ready to be cut down, or felled. The felling may be done with gasoline-powered chain saws or with large hydraulic shears mounted on the front of wheeled vehicles called fellers. The limbs are removed from the fallen trees with chain saws.
• The trimmed tree trunks, or logs, are dragged to a loading area by wheeled vehicles called skidders. The logs are cut to length and are loaded on trucks for the trip to the plywood mill, where they are stacked in long piles known as log decks.

Preparing the logs

• As logs are needed, they are picked up from the log decks by rubber-tired loaders and placed on a chain conveyor that brings them to the debarking machine. This machine removes the bark, either with sharp-toothed grinding wheels or with jets of high-pressure water, while the log is slowly rotated about its long axis.
• The debarked logs are carried into the mill on a chain conveyor where a huge circular saw cuts them into sections about 8 ft-4 in (2.5 m) to 8 ft-6 in (2.6 m) long, suitable for making standard 8 ft (2.4 m) long sheets. These log sections are known as peeler blocks.

Making the veneer

• Before the veneer can be cut, the peeler blocks must be heated and soaked to soften the wood. The blocks may be steamed or immersed in hot water. This process takes 12-40 hours depending on the type of wood, the diameter of the block, and other factors.
• The heated peeler blocks are then transported to the peeler lathe, where they are automatically aligned and fed into the lathe one at a time. As the lathe rotates the block rapidly about its long axis, a full-length knife blade peels a continuous sheet of veneer from the surface of the spinning block at a rate of 300-800 ft/min (90-240 m/min). When the diameter of the block is reduced to about 3-4 in (230-305 mm), the remaining piece of wood, known as the peeler core, is ejected from the lathe and a new peeler block is fed into place.
• The long sheet of veneer emerging from / the peeler lathe may be processed immediately, or it may be stored in long, multiple-level trays or wound onto rolls. In any case, the next process involves cutting the veneer into usable widths, usually about 4 ft-6 in (1.4 m), for making standard 4 ft (1.2 m) wide plywood sheets. At the same time, optical scanners look for sections with unacceptable defects, and these are clipped out, leaving less than standard width pieces of veneer.
• The sections of veneer are then sorted and stacked according to grade. This may be done manually, or it may be done automatically using optical scanners.
• The sorted sections are fed into a dryer to reduce their moisture content and allow them to shrink before they are glued together. Most plywood mills use a mechanical dryer in which the pieces move continuously through a heated chamber. In some dryers, jets of high-velocity, heated air are blown across the surface of the pieces to speed the drying process.
• As the sections of veneer emerge from the dryer, they are stacked according to grade. Underwidth sections have additional veneer spliced on with tape or glue to make pieces suitable for use in the interior layers where appearance and strength are less important.
• Those sections of veneer that will be installed crossways—the core in three-ply sheets, or the crossbands in five-ply sheets—are cut into lengths of about 4 ft-3 in (1.3 m).

Forming the plywood sheets

• When the appropriate sections of veneer are assembled for a particular run of plywood, the process of laying up and gluing the pieces together begins. This may be done manually or semi-automatically with machines. In the simplest case of three-ply sheets, the back veneer is laid flat and is run through a glue spreader, which applies a layer of glue to the upper surface. The short sections of core veneer are then laid crossways on top of the glued back, and the whole sheet is run through the glue spreader a second time. Finally, the face veneer is laid on top of the glued core, and the sheet is stacked with other sheets waiting to go into the press.
• The glued sheets are loaded into a multiple-opening hot press. presses can handle 20-40 sheets at a time, with each sheet loaded in a separate slot. When all the sheets are loaded, the press squeezes them together under a pressure of about 110-200 psi (7.6-13.8 bar), while at the same time heating them to a temperature of about 230-315° F (109.9-157.2° C). The pressure assures good contact between the layers of veneer, and the heat causes the glue to cure properly for maximum strength. After a period of 2-7 minutes, the press is opened and the sheets are unloaded.
• The rough sheets then pass through a set of saws, which trim them to their final width and length. Higher grade sheets pass through a set of 4 ft (1.2 m) wide belt sanders, which sand both the face and back. Intermediate grade sheets are manually spot sanded to clean up rough areas. Some sheets are run through a set of circular saw blades, which cut shallow grooves in the face to give the plywood a textured appearance. After a final inspection, any remaining defects are repaired.
• The finished sheets are stamped with a grade-trademark that gives the buyer information about the exposure rating, grade, mill number, and other factors. Sheets of the same grade-trademark are strapped together in stacks and moved to the warehouse to await shipment.

Quality Control

Just as with lumber, there is no such thing as a perfect piece of plywood. All pieces of plywood have a certain amount of defects. The number and location of these defects determines the plywood grade. Standards for construction and industrial plywoods are defined by Product Standard PS1 prepared by the National Bureau of Standards and the American Plywood Association. Standards for hardwood and decorative plywoods are defined by ANSIIHPMA HP prepared by the American National Standards Institute and the Hardwood Plywood Manufacturers' Association. These standards not only establish the grading systems for plywood, but also specify construction, performance, and application criteria.

The Future

Even though plywood makes fairly efficient use of trees—essentially taking them apart and putting them back together in a stronger, more usable configuration—there is still considerable waste inherent in the manufacturing process. In most cases, only about 50-75% of the usable volume of wood in a tree is converted into plywood. To improve this figure, several new products are under development.

One new product is called oriented strand board, which is made by shredding the entire log into strands, rather than peeling a veneer from the log and discarding the core. The strands are mixed with an adhesive and compressed into layers with the grain running in one direction. These compressed layers are then oriented at right angles to each other, like plywood, and are bonded together. Oriented strand board is as strong as plywood and costs slightly less.

Where to Learn More

Books

Bramwell, Martyn, editor. The International Book of Wood. Simon and Schuster, 1976.

Duncan, S. Blackwell. The Complete Plywood Handbook. Tab Books, 1981.

Forest Products Laboratory. Wood Handbook: Wood as an Engineering Material. United States Department of Agriculture, 1987.

Hornbostel, Caleb. Construction Materials, 2nd Edition. John Wiley and Sons, Inc., 1991.

Periodicals

Gould, A.R. "Hardwood Plywood." Workbench (October/November 1994): 62-63.

Okrend, L. "Plywood for Construction." Workbench (June/July 1994): 44-45.

Russell, L.S. "Picking Structural Panels." Architectural Record (October 1992).

[Article by: Chris Cavette]

A wood product in which thin sheets of wood are glued together, grains of adjacent sheets being at right angles to each other in the principal plane. Because of this cross-grained orientation, mechanical properties are less directional than those of natural lumber and more dimensionally stable. Tree farms are now cultivated specifically to yield logs suitable for processing into sheets for plywood.

The American Plywood Association identifies several grades of product. Plywood is designated group 1 when made from northern-grown Douglas-fir, western larch, and such southern pines as loblolly and longleaf, or other woods noted for their strength. Plywoods in groups 2, 3, and 4 are made from woods of successively lower strengths. Consequently, group 1 plywood offers the greatest stiffness, group 4 the least.

Plywood with waterproof glue is designated exterior type; it is also used interiorly where moisture is present. Plywood with nonmoisture-resistant glue is designated interior type; it can withstand an occasional soaking but neither repeated soakings nor continuous high humidity.

Veneer grades A through D extend from a smooth surface to a surface with occasional knotholes and limited splits. If the outer face of the plywood is cut from only heartwood or sapwood, free from open defects, the plywood is assigned veneer grade N, indicating that it will take a natural finish. See also Stem; Veneer.

Most commonly used plywoods are ¼-in. (0.6-cm) sanded interior paneling or ½-in. (1.3-cm) exterior grade plywood sheeting. Other standard thicknesses extend to 1 in. (2.5 cm) for interior types and to 1⅛ in. (2.8 cm) for exterior types. The most common panel size is 4 × 8 ft (1.2 × 2.4 m); larger sizes are manufactured for such special purposes as boat hulls.

Finished plywood may be unsanded, sanded, or overlayed with several types of coatings for decorative and specialty uses. Plywood in appropriate grades is used in many different applications, such as furniture, wall facings, shelving, containers, crates, fences, forms, subflooring, and roof decking. See also Wood products.

For more information on plywood, visit Britannica.com.

Plywood boards are made of thin layers, or veneers, of wood which are glued together, the grain of each being set at right angles to that of the next in order to give greater strength. Light in weight and capable of being bent into elegant, curvilinear forms it has been in use in furniture making since the 18th century, notable exponents including Thonet in the 19th century, Alvar Aalto and Marcel Breuer before the Second World War and, in the wake of considerable technological innovations in the early 1940s, Charles Eames, Eero Saarinen, Robin Day, and Arne Jacobsen in the post-war years.

Structural wood made of three or more layers of veneer (usually an odd number), joined with glue; usually laid with the grain of adjoining plies at right angles.

A panel composed of layers of inner plys, or other core material joined with an adhesive to a face veneer of hardwood and a back veneer, usually also composed of hardwood.

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Softwood plywood made from spruce

Plywood is a type of engineered wood made from thin sheets of wood, called plies or wood veneers. The layers are glued together, each with its grain at right angles for greater strength. There are usually an odd number of plies, as the symmetry makes the board less prone to warping ^[1] The adhesives used in plywood have become a point of concern. Both urea formaldehyde and phenol formaldehyde are carcinogenic in very high concentrations. As a result, many manufacturers are turning to low formaldehyde emitting glue systems, denoted by an "E" rating ("E0" possessing the lowest formaldehyde emissions). Plywood produced to "E0" have effectively zero formaldehyde emissions^[2].

A common reason for using plywood instead of plain wood is its resistance to cracking, shrinkage, twisting/warping, and its general high degree of strength. In addition, plywood can be manufactured in sheets far wider than the trees from which it was made. It has replaced many dimensional lumbers on construction applications for these reasons.

Birch plywood

Contents 1 Types 2 Production 3 US plywood grades 4 Applications 4.1 Softwood plywood applications 4.2 Birch plywood applications 4.3 Tropical Plywood Applications 5 See also 6 References 7 External links

Types

Average-quality plywood with show veneer

High-quality concrete pouring plate in plywood

A vast number of varieties of plywood exist for different applications. Softwood plywood is usually made either of Douglas fir or spruce, pine, and fir (collectively known as Spruce-pine-fir), and is typically used for construction and industrial purposes.^[3]

Hardwood plywood is used for some demanding end use. Birch plywood is characterised by its excellent strength, stiffness and resistance to creep. It has a high planar shear strength and impact resistance, which make it especially suitable for heavy-duty floor and wall structures. Oriented plywood construction has a high wheel carrying capacity. Birch plywood has excellent surface hardness, damage and wear resistance. ^[4]

Decorative plywood is usually faced with hardwood, including red oak, birch, maple, lauan (Philippine mahogany) and a large number of other hardwoods.

Plywood for indoor use generally uses the less expensive urea-formaldehyde glue which has limited water resistance, while outdoor and marine grade plywood are designed to withstand rot, and use a water resistant phenol-formaldehyde glue to prevent delamination and to retain strength in high humidity.

The most common varieties of softwood plywood come in three, five or seven plies with a metric dimension of 1.2 m × 2.4 m or the slightly larger imperial dimension of 4 feet × 8 feet. Plies vary in thickness from 1/10" through 1/6" depending on the panel thickness. Roofing can use the thinner 5/8-inch plywood. Subfloors are at least 3/4-inch depending on the distance between floor joists. Plywood for flooring applications is often tongue and grooved. The mating edge will have a "groove" notched into it to fit with the adjacent "tongue" that protrudes from the next board. This keeps the boards from slipping past each other providing a solid feeling floor when the joints do not lie over joists. Tongue & groove flooring plywood is typically 1" in thickness.

High-strength plywood, known as aircraft plywood, is made from mahogany and/or birch, and uses adhesives with increased resistance to heat and humidity. It was used for several World War II fighter aircraft, including the British-built Mosquito bomber which was nicknamed the wooden wonder.

Certain plywoods do not have alternating plies. These are designed for a specific purpose. One such plywood is known as "Bendy Board". This is very flexible and is designed for making curved parts.In the UK this is known as "Hatters Ply" as it was used to make gents stovepipe hats in Victorian times. However these may not be termed as plywood in some countries because the basic description of plywood is layers of veneered wood laid on top of each other with the grain perpendicular on each layer.

Marine plywood is specially treated to resist rotting in a high-moisture environment. Marine plywood is frequently used in the construction of docks and boats. It is much more expensive than standard plywood; costs for a typical 4 foot by 8 foot 1/2 inch thick board is roughly $75 to $100 US or around $2.5 per square foot, which is about three times as expensive as standard plywood.

Marine plywood can be graded as being compliant with BS 1088, which is a British Standard for marine plywood. There are few international standards for grading marine plywood and most of the standards are voluntary. Some marine plywood has a Lloyd's of London stamp that certifies it to be BS 1088 compliant. Some plywood is also labeled based on the wood used to manufacture it. Examples of this are Okoume or Meranti

Other types of plywoods are fire retardant, moisture resistant, sign grade, pressure treated, and of course the hardwood and softwood plywoods. Each of these products are designed to fill a need in industry.

In addition to the glues being brought to the forefront, the wood resources themselves are becoming the focus of manufacturers, due in part to energy conservation, as well as concern for our natural resources. There are several certifications available to manufacturers who participate in these programs. FSC certified, Leeds Certified, FSI certified, and Greenguard certified. Many of these programs offer tax benefits to both the manufacturer, as well as the end user.^[5]

Production

Plywood production requires a good log, called a peeler, which is generally straighter and larger in diameter than one required for processing into dimensioned lumber by a sawmill. The log is peeled into sheets of veneer which are then cut to the desired dimensions, dried, patched, glued together and then baked in a press at 140 °C (280 °F) and 19 MPa (2800 psi) to form the plywood panel. The panel can then be patched, resized, sanded or otherwise refinished, depending on the market for which it is intended.

US plywood grades

Plywood grades are determined by a veneer quality on the face and back of each panel. The first letter designates quality of face veneer (best side), while the second letter denotes the surface quality of the back of the panel.^[6] The letter "X" indicates the panel was manufactured with scrap wood as the center plies, not "exterior" as is commonly thought. The A-D rating is only good for construction (softwood) plywood, not for hardwood plywoods such as oak or maple.

"A": Highest grade quality available. Can be defect free or contain small knots, providing they are replaced with wooden plugs (the fillers having a "boat" or an "American football" shape) or repaired with synthetic patch. This grade may contain occasional surface splits that are repaired with synthetic filler. The surface is always sanded and provides for smooth paintable face quality.

"B": Second highest quality veneer grade. Normally a by-product of downgraded "A" quality veneer. Solid surface, but may contain small diameter knots and narrow surface splits. Normally repaired with wooden plugs or synthetic filler. The surface is normally sanded smooth.

"C": Considered to be a lower end face quality, but a reasonable choice for general construction purposes. May contain tight knots up to 1½ inches diameter, some open knot holes, some face splits, and discoloration. Some manufactures may repair the defects with synthetic filler. Panels are typically not sanded.

"D": Considered to be the lowest quality veneer and often used for the back surface for construction grade panels. Allows for several knots, large and small, as well as open knots up to 2½ inches diameter. Open knots, splits, and discoloration are acceptable. "D" grade veneers are neither repaired nor sanded. This grade is not recommended for permanent exposure to weather elements.

Applications

Plywood is used in many applications that need high-quality, high-strength sheet material. Quality in this context means resistance to cracking, breaking, shrinkage, twisting and warping.

Exterior glued plywood is suitable for outdoor use, but because moisture affects on the strength of wood, optimal performance is achieved in end uses where woods moisture content remains relatively low. On the other hand subzero conditions don't affect on plywood's dimensional or strength properties which opens some special application possibilities.

Plywood is also used as an engineering material for stressed-skin applications. It has been used for marine and aviation applications since WWII. Most notable is the British De Havilland Mosquito bomber, which was primarily made out of wood. Plywood is currently successfully used in stressed-skin applications.^{[citation needed]}. The American designers Charles and Ray Eames and Phil Bolger are famous for their plywood-based furniture.

Softwood plywood applications

Typical end uses of spruce plywood are:

• Floors, walls and roofs in house constructions,
• Wind bracing panels,
• Vehicle internal body work,
• Packages and boxes,
• Hoarding,
• Fencing

There are coating solutions available that mask the prominent grain structure of spruce plywood. For these coated plywood there are some end uses where reasonable strength is needed but lightness of spruce material is a benefit e.g.:

• Concrete shuttering panels
• Ready to paint surface for constructions

Birch plywood applications

Coated special birch plywood is typically used as a ready to install component e.g.:

• Panels in concrete formwork systems
• Floors, walls and roofs in transport vehicles
• Container floors,
• Floors subjected to heavy wear in various buildings and factories,
• Scaffolding materials

Birch plywood is used as a structural material in special applications e.g.:

• Wind turbine blades
• Isolation boxes for liquefied natural gas (LNG) carriers

Smooth surface and accurate thickness combined with the durability of the material makes birch plywood a favourable material for many special end uses e.g.:

• Die cutting boards
• Supporting structure of parquet
• Playground equipment
• Furniture
• Sign and fences for demanding outdoor advertising
• Musical instruments
• Sport equipments

Tropical Plywood Applications

• • Common Plywood
  • Concrete Panel
  • Floor Base
  • Structure Panel
  • Container Flooring
  • Lamin Board
  • Laminated Veneer Lumber (LVL)

Tropical Plywood are widely available from the South East Asian region mainly by Malaysia and Indonesia. Tropical Plywood boasts its premium quality, and strength. Depending on machineries, tropical plywood can be made with high accuracy in thickness, and is a highly preferable choice in America, Japan, Middle East, Korea, and other regions around the world.

See also

Wikimedia Commons has media related to: Plywood

Look up plywood in Wiktionary, the free dictionary.

• Engineered wood
• Fiberboard
• Glued laminated timber
• Hardboard
• Masonite
• Marine plywood
• Medium-density fiberboard
• Oriented strand board
• Particle board
• Pressed wood

References

1. ^ Epoxyworks magazinemagazine, Vol. 18: Plywood
2. ^ Engineered Wood Products Association of Australasia
3. ^ O'Halloran, p.221.
4. ^ Handbook of Finnish plywood, Finnish Forest Industries Federation, 2002, ISBN 952-9506-63-5 [1]
5. ^ Pro Woodworking Tips.com
6. ^ Education - Plywood

External links

• Material Uses Pro Woodworking Tips.com

This entry is from Wikipedia, the leading user-contributed encyclopedia. It may not have been reviewed by professional editors (see full disclaimer)

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