CHARACTERISTICS OF LAMINATED FLOORING

MATERIALS

Wong Lip Gen

Bachelor of Engineering with Honours

(Mechanical Engineering and Manufacturing Systems)

2009

UNIVERSITI MALAYSIA SARAWAK

BORANG PENYERAHAN TESIS

Judul: Characteristics of laminated flooring materials

SESI PENGAJIAN : 2008/2009

Saya WONG LIP GEN

mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti

Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak.

2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan

untuk tujuan pengajian sahaja.

3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan.

4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan

tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.

5. ** Sila tandakan (√) di mana kotak yang berkenaan

SULIT (Mengandungi maklumat yang berdarjah keselamatan atau

kepentingan Malaysia seperti yang termaktub di dalam AKTA

RAHSIA RASMI 1972).

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh

organisasi/badan di mana penyelidikan dijalankan).

TIDAK TERHAD

Disahkan oleh

_________________________ ___________________________

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap: No 191, Tmn Sejahtera, Pn. Marini binti Sawawi

Bakar Arang,

08000 Sungai Petani,

Kedah.

Tarikh: __________ Tarikh: __________

Catatan * Tesis ini dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana, dan Sarjana Muda.

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyertakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau

TERHAD.

√

R13a

APPROVAL SHEET

This Final Year Project report entitled “CHARACTERISTICS OF LAMINATED

FLOORING MATERIALS” was prepared by WONG LIP GEN as a partial

fulfillment of the requirement for the Bachelor of Engineering (Hons.) Mechanical

Engineering and Manufacturing System is here by read and approved by:

Madam Marini Sawawi Date

Project Supervisor

Faculty of Engineering

University Malaysia Sarawak

CHARACTERISTICS OF LAMINATED FLOORING

MATERIALS

WONG LIP GEN

This project is submitted in partial fulfillment of

the requirements for the degree of Bachelor of Engineering with Honours

(Mechanical Engineering and Manufacturing Systems)

Faculty of Engineering

UNIVERSITI MALAYSIA SARAWAK

2009

Dedicated to my beloved family and friends

ii

ACKNOWLEDGEMENTS

I would like to address my appreciation to University Malaysia Sarawak for providing

the university facilities to conduct the research. I also would like to express my gratitude

towards the substantial assistance and guidance offered by my supervisor, Mdm. Marini

in accomplishing this final year project. Again, I wish to dedicate my appreciation

towards Mdm. Marini effort contributed to the writing of the report by commenting on

an earlier draft of each chapter. Nevertheless, I would like to take this opportunity to

thanks Mdm. Mahsuri who had inspired and corrected my point of views. Other than

that, I want to emphasis my deepest thank to the various people who have provided

technical support in order for me to proceed with the experiments. In alphabetical order

they are: Mdm. Hasmiza Kontet, Mr. Masri Zaini and Mr. Sabariman Bakar.

iii

ABSTRACT

In this study, the surface and moisture characteristics of commercially

manufactured laminated floorings and engineered hardwood floorings were evaluated.

The influences of outdoor exposure on surface quality of the samples ranging from 1

week to 3 weeks were determined using Stylus technique. In additional, the influences of

the indoor moisture conditions on the surface roughness, absorption rate and swelling

thickness of the samples soaked from 2 hours to 15 days were investigated. Two

roughness parameters, average roughness Ra and maximum roughness Rmax, calculated

from the surface profiles of the samples employing a profilometer were used for the

analyses. The samples have higher Ra and Rmax values when the Stylus tip traversed

across the grain compared to along the grain. Statistically, a significant difference

existed between laminated and engineered hardwood floorings. As a result, the

engineered hardwood showed higher values for the outdoor and indoor tests compared to

laminated flooring in terms of Ra, Rmax, moisture absorption rate and swelling thickness.

The experimental result also proven the influence of moisture have higher tendency

iv

damaging the flooring samples compared to the influence of environment. Throughout

the experiment, engineered hardwood samples degraded the most. This is because they

are prone to moisture and weathering damages. The experimental results also showed

laminated flooring samples have better surface quality, higher moisture resistance and

are more durable.

It was concluded that the laminated and engineered hardwood floorings is only

limited for interior installation except for bathrooms. Laminated flooring is suitable to be

used for the damp places such as kitchen, dining rooms and vicinity nearby the

bathrooms which have higher tendencies exposed to the moisture. For engineered

hardwood, the applications only limited to interior parts with the lowest moisture

exposure such as living room, bedrooms, and staircase.

v

ABSTRAK

Dalam kajian ini, sifat kekasaran dan kelembapan lantai berlaminar dan lantai kayu

keras kejuruteraan telah disiasat. Faktor yang mempengaruhi kualiti permukaan sampel

semasa pendedahannya terhadap persekitaran selama satu sehingga tiga minggu telah

dikenal pasti dengan menggunakan teknik Stylus. Selain itu, pengaruh daripada

kelembapan keadaan dalaman keatas sifat kekasaran permukaan, kadar penyerapan, dan

penebalan setelah direndam dalam air selama 2 jam hingga 15 hari telah dikajikan.

Keduaan parameter iaitu purata kekasaran Ra dan kekasaran maximum Rmax, telah

dikirakan dari permukaan profil sampel dengan menggunakan profilometer bagi tujuan

menganalisis. Kesemua sampel telah mempamerkan nilai Ra dan Rmax yang lebih tinggi

sekiranya penghujung Stylus merentasi ira dengan melawan orientasinya dibangdingkan

mengikuti orientasi ira. Perbezaan statistik yang nyata wujud diantara lantai berlaminar

dengan kayu keras kejuruteraan. Sebagai akibatnya, sampel kayu keras kejuruteraan

mempamerkan nilai keseluruhan yang lebih tinggi yang merangkumi aspek Ra, Rmax,

kadar penyerapan mahupun dari segi penebalan saiz. Sepanjang tempoh eksperiment

vi

dijalankan, kualiti kayu keras kejuruteraan merosot dengan ketara. Penyerosotan kualiti

sampel tersebut berpunca daripada sifat semula jadinya yang lebih cenderung terhadap

kerosakkan yang diakibatkan oleh kelembapan dan penukaran cuaca yang tidak menentu.

Keputusan eksperimen juga menunjukkan bahawa lantai berlaminar mempunyai kualiti

permukaan yang lebih baik, sifat pertahanan kelembapan yang tinggi dan lebih tahan

lama.

Sebagai kesimpulan, lantai berlaminar dan lantai kayu keras kejuruteraan hanya

dihadkan untuk kegunaan dalaman sahaja kecuali bilik mandi. Lantai berlaminar sesuai

untuk kawasan yang berkecenderungan tinggi terdedah kepada kelembapan seperti dapur,

bilik makan, dan perkeliling bilik mandi. Lantai kayu keras kejuruteraan applikasinya

hanya terhad kepada kawasan yang kering sahaja seperti ruang tamu, bilik tidur dan

tangga.

vii

TABLE OF CONTENTS

PAGE

Thesis Title

Dedication

Acknowledgements ii

Abstract iii

Abstrak v

Table of Contents vii

List of Tables ix

List of Figures x

Nomenclature xiv

Chapter 1 INTRODUCTION

1.1 Background Study 1

1.2 Objectives 6

1.3 Problem Statement 7

Chapter 2 LITERATURE REVIEW

2.1 Introduction to Flooring Options 8

2.2 The Structure of the Laminated and Engineered

Hardwood Flooring

12

2.2.1 Layout of Laminated Flooring 12

2.2.2 Layout of Engineered Hardwood Flooring 14

2.3 Surface Texture Definitions 16

2.3.1 Surface Texture Parameters 17

2.3.2 Surface Roughness Measurement Test 17

viii

2.3.2.1 High Density Fiberboard (HDF) 19

2.3.2.2 Medium Density Fiberboard

(MDF)

23

2.3.2.3 Hardwood 34

2.4 Moisture Absorption 39

2.4.1 Sorption Behaviour 40

2.4.2 Effect of Moisture Absorption 47

2.4.2.1 Tensile Properties 50

2.4.2.2 Flexural Properties 51

2.4.2.3 Modulus Properties 52

Chapter 3 METHODOLOGY

3.1 Introduction to Stylus Technique 53

3.2 Apparatus 54

3.3 Process and Procedure 58

3.4 Expected Problems 63

Chapter 4 RESULTS AND DISCUSSIONS

4.1 Introduction 64

4.2 Surface Roughness Test 65

4.2.1 Environmental Exposure Test 65

4.2.2 Moisture test 74

4.3 Moisture Absorption Rate 85

4.3.1 Swelling Thickness 87

Chapter 5 CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions 90

5.2 Recommendations 92

REFERENCES 99

APPENDIX A 112

APPENDIX B 126

ix

LIST OF TABLES

TABLE PAGE

2.1 Comparison between the commercially available

hard flooring materials

9

2.2 Comparison between the commercially available

resilience flooring materials

10

2.3 Janka hardness values of wood 15

2.4 Comparison of MDF and HDF physical properties 25

2.5 Property data for eight commercial MDF 25

2.6 Experimental design and properties of the samples 30

2.7 Characteristics of samples and experimental

schedule

32

2.8 Chemical constituents of the lignocellulosic fillers

(rice-husk flour, wood flour and rice-husk powder)

45

3.1 Table of cut-off values (recommended cut-off by

ISO 4288 – 1996)

54

4.1 The average of the roughness parameters based on

exposure duration to the environment

66

4.2 Average roughness parameters of the flooring

panels

74

4.3 Average density of the samples 85

4.4 Average moisture absorption rate based on the

soaking duration

85

4.5 Average swelling thickness for the flooring panels 88

x

LIST OF FIGURES

FIGURE PAGE

1.1 The lock and fold mechanism of the floating floors 3

1.2 Boards are placed on a cushioned underlayment and

ensure the boards were orientated in the right

position. After that lock and fold it

4

1.3 The floating floors were joined together without

glue or tapping

4

2.1 The structure of laminated flooring 12

2.2 The structure of engineered hardwood flooring 14

2.3 Surface roughness of the samples at: (A) dry

condition, (B) 2-h soaked, and (c) 24-h soaked

21

2.4 Average Ra values of the samples 22

2.5 Average Rz values of the samples 22

2.6 Average Rmax values of the samples 23

2.7 Average roughness value of parameters of samples

treated with 3% concentration of ZnB

27

2.8 Average roughness value of parameters of samples

treated with 5% concentration of ZnB

27

2.9 Surface roughness of Thai particleboard and MDF 29

2.10 Comparison between the MDF panels 31

2.11 Average roughness, Ra values for all samples 33

2.12 Average values of Ra, Rz and Rmax of keruing

samples

35

xi

2.13 Average values of Ra, Rz and Rmax of merbau

samples

36

2.14 Average values of Ra, Rz and Rmax of keranji

samples

36

2.15 Average values of Ra, Rz and Rmax of balau samples 37

2.16 Average values of Ra, Rz and Rmax of dark red

meranti samples

37

2.17 Water absorption curves at (a) room temperature

(23˚C) and (b) boiling temperature (100˚C) for

different specimens

44

2.18 Thickness swelling and moisture absorption of the

PP-RHF bio-composites and control panels

46

2.19 SEM micrograph failure showing (a) matrix

cracking, (b) fracture running along the interface

and (c) fiber–matrix debonding due to attack by

water molecules

48

2.20 SEM micrograph showing degradation of

composite (a) crack development (b) lost of resin

particles due to high accelerated ageing at 100 ˚C

48

2.21 SEM micrograph of composite fiber (a) showing

kinks or nodes (b) showing fiber misalignment and

entanglement

49

2.22 SEM micrograph of water immersed composite

showing effects of voids (a) voids, (b) voids acting

as reservoirs and (c) matrix cracking and

delamination after 37 days of immersion

50

2.23 Three-point bending test 51

3.1 The main measuring unit of Taylor Hobson

Surtronic 25

55

xii

3.2 Right Angle Pick-up, 5 µm (200 µin) Stylus tip

radius (code: 112/1505)

55

3.3 The Sketch depicting how a probe stylus travels

over a surface

56

3.4 Flow chart for surface roughness and moisture

absorption tests

58

3.5 The Stylus profilometer is set at dump mode by

connecting to a PC

60

3.6 The direction of traverse of the stylus tip is from

left to the right

61

4.1 Graph (a) and (b), the average roughness versus

exposure duration

67

4.2 Graph (a) and (b), the maximum roughness versus

exposure duration

71

4.3 Graph (a) and (b), the average roughness versus

soaking duration

75

4.4 (a) Water stains were spotted along the edges of LF

II panel (top) after oven for 8 hours and the LF II

panel (bottom) was fully dried after 24 hours. (b)

White ash panel after oven for 8 hours without

water stain along the edges.

78

4.5 Graph (a) and (b), the maximum roughness versus

soaking duration

80

4.6 Cupping and crowning observed on the flooring

materials

84

4.7 The graph of the moisture absorption rate versus

soaking

86

4.8 Graph of swelling thickness versus soaking 88

5.1 The backing layer and surface failure on the walnut

panel after soaked for 15 days

95

xiii

5.2 Surfaces of the laminated flooring panels, (a) and

backing layers, (b) after soaked for 15 days

96

5.3 The pick-up mounting 97

xiv

NOMENCLATURE

HDF - High Density Fiberboard

MDF - Medium Density Fiberboard

PVC - Polyvinyl Chloride

VOCs - Volatile Organic Compounds

Al2O3 - Aluminum Oxide

UV - Ultra-violet

Hj - Janka hardness (Pa)

S - Surface area of the ball (mm2)

F - Force (N)

R - Radius of the ball (mm)

h - Depth of impression (mm) or thickness of the

specimens (mm)

Ra - Arithmetic mean of the absolute departures of the

roughness profile from the mean line (µm)

Rmax/Rt - Maximum roughness aka. maximum peak to valley

profile height (µm)

CoF - Coefficient of friction

TP - Test Person

ANOVA - Analysis of variance

ZnB - Zinc Borates

PB - Particleboard

UF - Urea-formaldehyde

PF - Phenol-formaldehyde

SEM - Scanning Electron Microscope

ΔM (t) - Moisture uptakes (%)

xv

mo - Mass of the specimen before aging (kg)

mt - Mass of the specimen during aging (kg)

Wa - Air-dried weight of the material (N)

Wo - Oven-dried weight of the material (N)

mi - Initial weight of the moisture in the material (kg)

ms - Weight moisture in the materials when the material is

fully saturated

D - Mass diffusivity in the composite

t - Time (s)

j - Summation index

Mm - Maximum weight gain

d - Sample thickness in (mm)

t70 - Time taken to reach 70% saturation (s)

k - Initial slope of a plot of M (t) versus √ t

HFRUPE - Hemp fiber reinforced unsaturated polyester

DI - De-ionized

UPE - Unsaturated polyester

CSM - Chopped Strand Mat

ASTM - American Society of Testing and Materials

RHF - Rice-husk flour

WF - Wood flour

RHP - Rice-husk powder

MAPP - Maleated polypropylene

PP - Polypropylene

ρ - Density (kg/m3)

LF I - Laminated flooring panel with the thickness of 0.8 cm

LF II - Laminated flooring panel with the thickness of 1.2 cm

WAL - Walnut panel

ASH - White Ash

1

CHAPTER 1

INTRODUCTION

This chapter will briefly discuss the flooring options available in the market.

Among all the flooring options available, the main focus will be the laminated

flooring materials. Other than that, the engineered flooring materials will be used as

comparison. After that, the objectives and problem statement of this study were

drawn out.

1.1 Background Study

Before our early ancestors built shelters, they very likely softened their

primitive caves with sweet grasses, warm animal’s skins, and clean sand. All those

materials provided practical aids to comfort and cleanliness, as well as aesthetic and

tactile pleasure. Our ancestor wisdom has been evolving into today sophisticated

modern flooring technology. The flooring materials are categories into two types

“hard” and “soft”. The hard flooring materials include tile, stone, hardwood, and

laminated flooring. Meanwhile the soft flooring materials are such as cork, linoleum,

vinyl, carpet, and rubber. Normally hard flooring materials reflect more sound than

soft materials since the hard surface is an ideal sound reflector [1].

2

Laminated flooring has been widely used in Europe for over 20 years and

recently it is getting popular in North America [2]. In Malaysia, laminated flooring is

considering as a relatively new flooring option but it has gained a tremendous

response among Malaysian. The term “laminate” is defines as overlay (a flat surface)

with a layer of protective material or manufacture by placing layer on layer [3].

Generally the layout of the laminated flooring made up of four layers. The layers are

such as overlay, decorative paper, high density fiberboard (HDF), and backing [4, 5,

6, 7]. The engineered hardwood flooring is considered as the competitor to the

laminated flooring. The term “engineered” in the engineered hardwood flooring

referring to products that have several layers of wood laminated together to form one

board [8,9,10,11,12]. The layers of the engineered hardwood flooring are such as

finish layers, wear layer, rubberwood core, and bottom ply [9, 11]. The similarity

between laminated and engineered hardwood flooring are both also wood-based

materials which made up of several layers. With the innovation of nowadays flooring

technology both floors are available as floating floors. The floating floors are those

floors that are not mechanically fastened to the subfloor. They are suspended on top

of the floor while resting on a cushioned underlayment [13]. Therefore, floating

floors are easily to install or dismantle as compared to granite, marble, and tile which

are fixed to the ground. Originally only one method called “glue together” for the

installation of the floating floors where a bead of glue is squeezed into the grooves of

each plank or on top of the tongue. After the glue applied, the floating floors will be

tapped into place with hammer and tapping block [13]. The further improvement had

changed the installation method of the floating floors from glue together into lock

and fold method. This lock and fold method is more simple and no glue or tapping

3

required, Figure 1.1, 1.2, and 1.3 illustrated how the floating floors were joined

together.

Figure 1.1: The lock and fold mechanism of the floating floors.

Figure 1.2: Boards are placed on a cushioned underlayment and ensure the boards

were orientated in the right position. After that lock and fold it.

4

Figure 1.3: The floating floors were joined together without glue or tapping.

5

There are many types of flooring materials available in today market but most

of the consumer facing difficulty to distinguish their qualities because the data

regarding the surface and moisture characteristics are insufficient. In general, the

degree of surface roughness is defines as function of both raw material

characteristics such as species, particle size, fiber distribution, and manufacturing

variables including press parameters, resin content, face layer densification, and

sanding process of the panels [45]. Whereas the moisture absorption is related with

the swelling thickness of the material after soaked in water. The swelling thickness is

directly proportional with the rate of moisture absorption whereby the percentage of

moisture absorption can be calculated through the weight gained. Other than that, the

microstructure of the flooring materials is directly affected by the moisture

absorption. The moisture effect will weaken the mechanical properties of the wood-

based flooring materials besides altering the microstructure of the materials.

Currently, the information for commercially produced laminated flooring is

very limited. Therefore, the purpose of this study is to establish a database for the

laminated flooring regarding their surface and moisture characteristics in order to

clarify the queries from the consumer. In addition, the surface and moisture

characteristics of engineered hardwood flooring will be included as a comparison

with the laminated flooring. There are series of experiments will be conducted to

determine the surface roughness and moisture absorption characteristics of the both

flooring materials. After that comparison between both materials will be included in

the database.