Product Description
Thick Phenolic Core Laminate can be manufactured using any Pionite solid color or pattern, and is available with either brown or black phenolic core. Laminate edges can be polished for a finished appearance. To further enhance the edge appearance, Thick Phenolic Core Laminate can be manufactured with colored stripes within the core.

Optimal flatness is obtained by specifying the same color and finish on both sides of thick phenolic core laminates.

Thick Phenolic Core Laminate is available in thicknesses up to 1 inch (25 mm) and offers the same chemical resistance properties as standard Pionite® laminate. Thick Phenolic Core Laminate can be manufactured with enhanced chemical resistance, for details please see our ChemGuard Technical Bulletin. Thicker grades of Thick Phenolic Core Laminate can be very heavy. Because of this increased weight, manual handling may be difficult. Please consult the chart below for approximate sheet weight and thickness.

Typical Uses
Typical Uses Pionite Thick Phenolic Core Laminate is ideally suited for toilet and dressing room privacy partitions. Other uses for Thick Phenolic Core Laminate include tabletops, doors, workstations, wall panels, and desktops.

Fabrication Tips
When working with Thick Phenolic Core Laminate, the following techniques will produce a quality application.

1. To minimize the potential of warpage, laminate should be stored horizontally at an approximate temperature of 70 deg. F to 75 deg. F (21 deg. C to 24 deg. C) and 45% to 50% relative humidity. Good air and humidity circulation on all sides of the panel is important to maintain flatness. Exposure to extreme temperature and humidity can cause warpage.
   
   
2. Thick Phenolic Core Laminate can be sawed, drilled, routed and tapped. Tool bits should be carbide tipped and run at high speeds to minimize chipping. To minimize the development of surface scratches caused by router bits, lubricating the laminate edge with a wax stick is recommended prior to tooling.
   
   
3. Although stress cracks are unlikely, cutouts for electrical outlets, sinks, etc., should be oversized and inside corners should have a minimum radius of 1/8" (3 mm) and be filed smooth.
   
   
4. Self-tapping screws can be used in pre-drilled holes.
   
   
5. Metal brackets or clips can be used to join laminate panels. In some cases it may be necessary to use shims to level out the joint.
   
   
6. DO NOT SCREW INTO THE EDGES OF PIONITE THICK PHENOLIC CORE LAMINATE.
   
   
7. DO NOT USE SPLINES IN THE EDGE OF Pionite THICK PHENOLIC CORE LAMINATE.
   
   
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. Avoid drilling holes close to the edge. A minimum distance of 1- 1/2 times the hole diameter from the edge is recommended.
   
   
10. Revealed edges of Thick Phenolic Core Laminate may be finished by using coarse (80 grit) sandpaper to remove the saw striations followed by sanding with fine (180-220 grit) sandpaper. The edge can then be polished with a light oil or wax resulting in an attractive, glossy finish that accents the decorative surface of the Thick Phenolic Core Laminate.
    
    
11. Mitered edges should be avoided.
    
    
12. 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.
    
    
13. Contact adhesive can be used to bond the glueable surface of Thick Phenolic Core Laminates.
    
    
14. Epoxy adhesive is recommended for bonding Thick Phenolic Core components. Light sanding of the surface with 100 grit sandpaper will improve bond strength.
    
    
15. Fabricated assemblies should meet DLPA (Decorative Laminate Products Association) and ANSI A161.2-1979 specifications where applicable.

Technical Information
Typical Test Results for Pionite Thick Phenolic Core Laminates

NEMA LD3-1995 Test Method

                                              3
   Load per Lineal Inch of Span = (D)(E)(W)(T)
                                  _____________
                                             4
                                    O.1563(S)

   Where  D = Deflection (in.)
          E = Modulus of Elasiticity (750,000 psi)
          W = Width of panel (in.)
          T = Thickness (in.)
          S = Span (in.)

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 Thick Phenolic Core Laminate. Thick Phenolic Core Laminate can be manufactured to provide Class A fire test performance. For details, call Pionite Customer Service at 1-800-PIONITE (746-6483).