Laminating and Solid Surfacing

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Warping Particleboard

10/4/16       
dmranney Member

I'm normally a cabinet maker/woodworker, but a good client asked me to whip up some simple formica table tops.

I picked up the particle board ("industrial" grade) Sunday morning and roughed out the tops - 30" x 54" and 30" x 27". I left them in two stacks in my shop and when I came back Monday night the ones on top of the stacks were pretty noticeably warped. The rest of the tops were still dead flat - just the topmost ones had warped in a convex manner -towards the air I suppose. I took the warped ones and set them up so air can get at both faces now. We'll see if they stabilize and flatten out again in a day or two. Relative humidity in the shop is currently around 68%.

I'm wondering if you all think:
-This is normal
-They'll flatten out once air can get at all sides
-I need to seal the faces with something before working further with the tops (maybe shellac?)
-I need to use a balancing sheet when I eventually laminate the formica, rather than sealing the other face with shellac or poly
-I should use a different substrate
-I should stick to work I know how to do

Thanks for any input.


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View higher quality, full size image (640 X 480)


View higher quality, full size image (640 X 480)

10/4/16       #2: Warping Particleboard ...
Snaglpuss

If the stack was like the one in the photo with the straight edge,
the top of the top sheet was drying faster than it's bottom causing it to shrink and pull up.
If it crowned overnight then the sheet would have been gaining moisture on the top side causing it to expand more than the bottom making the hump.
We see stuff like this all the time esp. in the winter on plywood- the top sheet(s) are usually curling up in short order due to the heat and dry conditions in the shop.

10/4/16       #3: Warping Particleboard ...
David R Sochar Member

That is a high shop humidity, so I would expect to see the center rise as the exposed surface gained moisture, like Mr Puss mentioned.

Turn the top sheet over and wait a day, and it will go the other way. Long term is to get the humidity closer to 40%. Short term is to put a piece of cardboard or 1/4" ply over the top of the stacks overnight.

However, if you have these sit for a few days or weeks(gaining moisture), and then you bring in some nice fresh laminate and stick it on with contact, you may see the core shrink a bit in service, when they get into a drier environment.

It is best to have both materials acclimatize in the shop, in the same area in the shop for a week or so before putting them together. Other good practice would dictate a balanced construction with a backer, and maybe better glue.


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