Choosing the right materials for a millwork counter in a commercial cafeteria is crucial to ensure durability and longevity, especially in a high traffic and potentially high moisture environment. Both DFP (Douglas fir plywood) and MDF (medium-density fiberboard) have their pros and cons, so let's break down the considerations for each:
DFP (Douglas Fir Plywood):
Pros:
Water-resistant properties, especially when sealed and finished properly.
More structurally stable than MDF due to its layered construction.
Generally more impact-resistant than MDF.
Better screw-holding capabilities.
Familiarity in working with plywood for construction.
Cons:
Can warp if exposed to significant moisture or not sealed properly.
Heavier than MDF, which could affect ease of installation.
Variability in quality, depending on the grade and manufacturer.
MDF (Medium-Density Fiberboard):
Pros:
Less likely to warp compared to solid wood or plywood due to its uniform composition.
Smoother surface, which can be advantageous when applying laminate.
Easier to shape and cut intricate designs if necessary.
Generally more affordable than higher-grade plywood.
Cons:
Prone to swelling and disintegration when exposed to moisture, especially if the laminate is compromised.
Not as impact-resistant as plywood.
Heavier than particleboard but lighter than plywood.
Given your concerns about moisture and the potential for swelling with MDF, it's understandable to hesitate in using it for a high-traffic, potentially moisture-prone environment like a cafeteria. While MDF is less likely to warp compared to solid wood, its susceptibility to moisture-related issues could be a significant drawback in your situation.
Based on your description, exterior-grade Douglas fir plywood with a hardwood trim and plastic laminate finish seems like a prudent choice. It combines the water-resistant properties of plywood with the added durability of hardwood trim. Proper sealing and finishing techniques will be crucial to prevent warping and moisture-related problems. Regular maintenance and quick action in case of any laminate damage will also help prolong the life of the counter.