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Edge banding with (3") brushed aluminum problem.4/30
We are having some waves show up in 3" brushed aluminum edge banding on 5 ft long curved retail shop countertops. The curved front edge is built up using 4 CNC cut pieces (1" wide) of 5/8" MDF stacked under a 5/8" MDF melamine countertop. We use white wood glue and hydraulic press for 12 hours. After clean up we apply brushed aluminum laminate using hand troweled contact cement. We are drying the adhesive fully and hand rolling firmly. One month later some countertops bow up to 1/2" in middle, and the edge banding gets wavy. MC = 8 to 12%. What is cause/solution of bowing and the waves? Design/material issue? See good and bad edges in picture.
The mdf has shrunk, same thing happend to me with brass. A countertop 5 meters long shrunk 7-8 mm
I would guess that the hand trowled contact is the cause. Anything that i have ever seen that was laminated with brushed on or "hand trowled" adhesive has failed. Only use a high quality spray like Wilsonart or similar for the very best results.
Maybe the shrinking is the problem tho...donno.
metal moves thermally wood moves by absorbing and releasing moisture. We spray our metals now . There are a wide variety of spray metals on the market.They are getting much easier to apply.
Odd Babic and Chris,
After further review it appears as though it my be an application error the middle piece pictured looks as though it got off track during application and was pulled back in line. I have done this before with the same results. The product you are using is on a phenolic backer it should be just fine.
You might consider a different way of indexing the laminate in the laminating process. Consider putting the top on blocks that make it parallel to a work bench (that is flat) at about 3/8". Then laminate the facing with the edge of the laminate against the bench top. This way you will keep the laminate parallel to the top and alleviate the problem that Chris is talking about. If your top is not square to the face though you will end up with hollow spots which are best just back filled with bondo but don't try to roll them flat.
Could be that the laminate wasn't laid straight and is buckling to that as it expands. Also, building up in layers like that, you have no way to determine that all layers expand and contract at the same rate. This could cause the buckling if one sheet used for the build up was less stable than the rest. Laminate has alot more side to side deflection when it comes to expansion and contraction than aluminum does. Aluminum is much more linear.