Product Identification

Three standard grades of Pionite laminate are suitable for most applications.

• General Purpose Type G48 is most often used in horizontal applications where high-impact resistance and a durable, decorative surface is required.
• Postforming Type F39 is designed for manufacturing countertops and other horizontal surfaces where the laminate may be heated and rolled over the substrate edge to eliminate seams.
• Type F28 is designed for applications where impact resistance is less critical. Type F28 can also be postformed.

Product Composition

High-pressure laminate is manufactured in a flat press by combining decorative papers saturated in melamine resin with phenolic-impregnated kraft layers at pressures exceeding the NEMA standard of 750 psi (5.17 MPa) and temperatures approaching 300 deg. F (150 deg. C). The panels are trimmed to size and the backs are sanded to facilitate bonding. The thickness of the laminate is determined by the number of kraft layers used. The laminating process combines the durability of melamine resins with the aesthetics of decorative papers creating a surfacing material that has been the standard for well over forty years.

Typical Uses
Pionite standard laminate is designed for either horizontal, vertical, or postforming applications. This laminate is seen on countertops, tables, vanities, interior doors, cabinets, contract furniture, and retail store fixtures.

When working with Pionite, these techniques will produce a quality application.

1. Proper conditioning of the laminate, substrate, and backing sheet minimizes possible warping, shrinking, or expansion of assembled panels. Ideally, all components should be conditioned at 70 deg. F to 75 deg. F (21 deg. C to 25 deg.C) and 45 to 50 percent relative humidity for 48 hours prior to assembly.
   
   
2. Always bond laminate to a suitable substrate such as medium to high density fiberboard, particleboard, or metals. It should not be glued directly to plaster walls, gypsum wallboard, or concrete.
   
   
3. Recommended adhesives include solvent or water-based contact cement, white glue (PVA), epoxy, and hot melt glue. Consult your adhesive supplier for specific application requirements.
   
   
4. The use of backing sheets is recommended to minimize warpage. The thickness of the backing sheet should be relatively equal to the thickness of the decorative laminate on the face of the assembly.
   
   
5. All saw blades and router bits used for cutting should be carbide tipped. Feed rate should be slow and tool speed should be high. To minimize the development of surface scratches caused by router bits, lubricating the laminate edge with a wax stick is recommended prior to tooling.
   
   
6. All edges of laminate should be filed smooth with file direction towards substrate to help prevent stress cracks and to minimize chipping.
   
   
7. Inside corners of cutouts for electrical outlets, sinks, etc., should have a minimum radius of 1/8" (3 mm) and be filed smooth. This reduces the likelihood of stress cracks.
   
   
8. When nails or screws must be used, it is advisable to first drill an oversized hole through the laminate. This reduces the likelihood of stress cracks.
   
   
9. See Pionite Postforming Technical Bulletin for postforming application tips.
   
   
10. All laminate is intended for interior use only, and should not be exposed to extreme humidity, continuous sunlight, or temperatures above 275 deg. F (135 deg. C) for extended periods of time.

Technical Information
Physical Properties

Fire Test Data

High pressure decorative laminate is frequently used in installations governed by local fire codes. Burning characteristics of laminate are greatly influenced by the adhesive and substrate utilized. Listed below are typical flame spread index and smoke developed values for Pionite standard grade laminate. When specifying Class I or A rated laminate, refer to Pionite Fire Rated Technical Bulletin.