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Fire Performance
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With which Reaction-to-Fire Euroclasses do Formica laminates comply?
Formica flame-retardant laminates are capable of achieving Euroclass B, which is the best performance for organic materials. Formica standard grade laminates comply with the requirements of Euroclass D.
Do Formica decorative laminates meet Class 1 or Class 0 of UK Building Regulations?
Formica flame-retardant laminates meet Class 1 and Class 0 when bonded to appropriate flame-retardant substrates using appropriate adhesives. Where Class 1 or Class 0 is required, it is important to specify FR grade laminates, such as VFP.
Do I need flame-retardant Formica laminates for a half-hour fire resistant door?
Fire resistance depends only on the fire properties of the core of the door. Providing that the core has the required fire resistance (eg half-hour / one hour) then any grade of Formica laminate can be used on the surface.
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HPL Manufacture
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How is Formica high pressure laminate made?
Formica high pressure laminate consists of layers of specially selected kraft and printed decorative papers impregnated with thermosetting synthetic resins. These are fused together under heat and high pressure in a controlled environment so that the component parts consolidate to form a single high density sheet of laminate.
What gives Formica high pressure laminates their special decorative qualities?
The decorative surface of Formica high pressure laminate is created by encapsulating a printed or plain colour décor paper within hard wearing melamine resin. Alternatively, real wood veneer or real metal surfaces are offered, as with Veneer Laminate and Metallic Laminate materials. Through our Digital Service your own individual design can be encapsulated in Formica high pressure laminate.
Are the manufacturing processes and finished products environmentally friendly?
Yes. Formica Corporation, like all the component companies of Formica Corporation, recognises the importance of safeguarding the Earth’s natural resources. We have a solid commitment to protecting the environment both in sourcing the materials for, and in manufacturing, our products.
Formica high pressure laminates consist of paper and thermosetting synthetic resins, with paper comprising more than 60% of the product. The pulp for manufacturing this paper uses timber from managed sustainable softwood forests and from recycled paper products.
Formica laminate waste can be burned in modern, officially approved industrial incinerators, or can be disposed of in official landfill sites. Thermo-recycling, which recovers 18 - 20 MJ/kg, is the best option for disposing of waste HPL.
Phenol formaldehyde resin is used in the core layers of Formica high pressure laminate, while melamine formaldehyde resin is used in the surface layers. These resins are irreversibly inter-reacted, with cross linked chemical bonds being formed; this results in a stable, non-reactive material whose characteristics are totally different from those of the constituent parts. The laminate formulation does not include asbestos, cadmium, polychlorinated biphenyls, chlorofluorocarbons (CFCs), bromine / chlorine compounds or heavy metals.
The decorative surfaces resist all common household solvents and detergents and, in normal use, do not release any gases or other substances. They are, therefore, approved for food contact.
Formica high pressure laminate is difficult to ignite and has properties which retard the spread of flame. Decorative laminates, like all organic materials, will emit CO and CO2, depending on burning conditions; they burn much like other wood-based products.
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Physical Properties
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Are Formica high pressure laminates heat resistant?
For short periods, they will withstand surface temperatures of up to 180°C (356°F) without deterioration of surface colour (although in some cases a slight loss of sheen may occur). Continuous localised heat should be avoided.
Cooking vessels in normal use can achieve much higher temperatures; for example, the base of a pan containing cooking fat can exceed 250°C, so do not place hot pans etc directly on to laminate-faced work surfaces.
Are Formica high pressure laminates suitable for food contact?
Yes. They are suitable for use in food contact applications and have been awarded the Certificate of Hygienic Merit by the Royal Institute of Public Health.
How do I clean Formica high pressure laminates?
In most cases, simply wipe surfaces with water and a mild detergent. Plane and lightly textured surfaces are more easily cleaned than deeply textured finishes.
How do Formica high pressure laminates react to chemicals?
Formica high pressure laminates have been widely and satisfactorily used for many years in medical and industrial laboratories. They easily resist the effects of staining by substances in everyday use, including tea, coffee, milk, citric acid, acetone, alcohol, fruit juices, detergents, bleaches and colouring agents.
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Standards
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Which Standards apply to Formica high pressure decorative laminates?
Formica high pressure laminates conform to EN 438 and ISO 4586. These Standards define the performance of the various grades of laminate in relation to their application. For example, the wear resistance specified for horizontal grade laminate is higher than that specified for vertical grade laminate.
Which is the higher quality specification: European Standard EN438 or International Standard ISO 4586?
For all practical purposes, EN438 and ISO 4586 can be considered equivalent in terms of performance and quality requirements.
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Specifying
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What are the key factors in determining a specification for Formica products?
The following criteria are essential:
• Product type
• Colour / Pattern / Reference Code
• Surface finish / texture
• Grade
• Sheet size
• Fire Performance
• Wet or dry area application
• Substrate and balancer
• Joint and edge treatment
• Fixing method
Are there any relevant standard specification clauses?
Yes. The following NBS clauses are relevant when specifying Formica products.
K13 Rigid Sheet Fine Linings / Panelling
Clauses: 130, 140
K32 Framed Panel Cubicle Partitions
Clauses: 10, 120
L20 Doors / Shutters / Hatches
Clauses: 20, 230
N10 General Fixtures / Furnishings / Equipment
Clauses: 350, 40
N13 Sanitary Appliances / Fittings
The NBS web site (www.nbsplus.co.uk) contains pro-formas for each of those clauses, ready to complete with your details. For an example of a completed clause see 'Specification Clauses' under 'Specifying’ in the ‘Technical’ section.)
Can I use my own design?
Yes. The production processes of the Formica Digital Service allow individual custom designs to be encapsulated in Formica HPL. Laminates created through the Digital Service can be used in a variety of applications, both horizontal and vertical.
Do you match RAL?
Our plain colours are cross-referenced to the NCS colour standard and, where relevant, to the Pantone Matching System, Pantone Textile System, RAL, RDS and BS systems. The Colour Matching tool in the Site Tools contains a facility by which you can enter any Formica Plain Colours or ColorCore reference and call up the matching references or, conversely, enter an NCS, Pantone, RAL, RDS or BS number to call up the matching Formica Plain Colour or ColorCore item reference code(s).
How should I decide panel sizes?
By considering the various sheet sizes at the design stage. Sheet size depends on the product specified. Additionally, a variety of patterns and plain colours is available in large sheet size (3660mm x 1830mm x 12mm or 3660mm x 1525mm) ideal for washroom cubicles, and in 2150mm x 950mm suitable for most interior door applications. You can use the Advanced Search tool in the Site Tools to identify Formica items available in particular sheet sizes, among many other possible search criteria.
Can corporate identities be created in Formica laminate?
Yes. Our Digital Service provides the opportunity to incorporate logos and graphic images within Formica high pressure laminate through specialised printing and laminating processes. Additionally, corporate identities can be engraved or routered into the surfaces of Formica ColorCore® laminate, Compact Grade laminate or Formica Solid Surfacing Material.
I have a laminate sample that appears slightly different from the way it looks in the brochure / the web site. Why is this?
The sample is what you rely on when you commit yourself to specifying.
The designs shown in our brochures are matched as closely as the printing process will allow, but printing can never exactly reproduce actual laminate.
Similarly, the images on this web site have been matched as closely as the technology allows, but their representation is subject to the ability of individual users’ computer video systems (graphics card and monitor settings) to reproduce accurately the true colours and patterns of each design.
Brochures and web images are very helpful for your initial research, but Formica Corporation always recommends that you examine actual laminate samples before specifying, fabricating or installing.
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Product Availability
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Are all Formica high pressure laminates available in all sheet sizes and surface finishes?
No. All Formica high pressure laminates are designed and manufactured with the most appropriate combinations of surface finish, grade and sheet size. You can find the availability pattern for any individual laminate item on its own page in this web site; alternatively, you can consult the composite availability tables, organised by range, under 'Product Availability' in the ‘Specifying’ part of the ‘Technical’ section.
Can special designs be created?
Yes. The production processes of the Digital Service allow individual custom designs to be encapsulated in Formica HPL. Laminates created through the Digital Service can be used in a variety of applications, both horizontal and vertical.
What quality standard should I quote for laminate-faced boards and panels?
BS 4965: 1999.
What is Compact Grade?
Formica Compact Grade high pressure laminate is a high performance, versatile, homogeneous material, much thicker than conventional laminate and generally with a decorative surface on both sides.
Compact Grade (also known as solid grade) is an impressively strong and damage-resistant material with excellent dimensional stability and mechanical strength. It is frequently used to manufacture lockers, cubicles and wall panels in high traffic or wet areas in public buildings. Its inherent properties also make it an ideal choice for laboratory work surfaces.
Is Metallic Laminate available in postforming grade?
Yes. Some items in the Metallics Range are available in postforming grade. Please check the composite availability table for Metallics under 'Product Availability' in the ‘Specifying’ part of the ‘Technical’ section.
What do the letters ‘HGP’ mean?
HGP is taken from the classification system contained in EN 438 and denotes a particular grade of high pressure laminate – in this case Horizontal, General Purpose, Postforming. This grade is suitable for the vast majority of horizontal and vertical applications.
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Fabrication
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How can bowing of composite panels be avoided?
Panels and boards faced with laminate nearly always require the reverse side to be faced with a similar material to counter-balance the effects of dimensional changes that may occur. Pre-conditioning of the substrate materials, surfacing laminates and backing laminates before they are bonded minimises the effects of differential movement caused by the materials’ reaction to changes in relative humidity. In addition, always use face and backing laminates cut from the same direction of the laminate sheet and never at right angles to each other.
What are the most suitable substrates for bonding Formica laminates?
Plywood, chipboard and medium density fibreboard (MDF) are good substrate materials for fabrication. Being cellulose-based, their dimensional movement characteristics are similar to those of decorative laminates.
Certain industrial applications call for specialised substrates such as mineral boards, metal sheets, honeycomb cores and plastic foams; these require special bonding and fabrication techniques.
What is ‘postforming’?
The term ‘postforming’ describes the process of bending decorative laminates into simple cylindrical concave or convex curves. This procedure is applied to specially developed grades of Formica laminate which retain all the properties of standard grade laminates.
On internal and external angles, curved surfaces – with their absence of visible seams – are often more aesthetically pleasing than sharp edges; they also eliminate joints in which dirt and water can accumulate.
How do I machine Metallic Laminate?
With the exception of F2178 (Brushed Stainless Steel), Metallic laminates can be machined and fabricated using the same standard tools, equipment and techniques as for any Formica high pressure laminate. Extra care is needed for a good quality finished appearance.
Can Metallic Laminate be postformed?
Yes. Some items in the Metallics Range are postformable, identified by the letters ‘PF’ printed on the protective coating. These laminates can be formed in the temperature range 120°C - 130°C using normal static or continuous postforming machines. The recommended minimum forming radius is 12mm, though tighter bends can be achieved depending on equipment and technique.
What substrates and adhesives are recommended for Metallic Laminate?
The nature of Metallic surface finishes (especially polished finish) demands that substrates have a high quality surface, free from undulations and imperfections.
Most adhesives can be used, except for those based on urea (UF and MUF types).
To avoid surface distortion, spread adhesives evenly and free from inclusions. With polished finishes, best results are achieved using adhesives with low shrinkage (such as PVA) to minimise telegraphing. Because some surface rippling is inevitable, it is not possible to achieve a perfect mirror finish. Good fabrication technique can minimise this optical distortion.
What substrates and adhesives are recommended for Veneer Laminate?
Good quality MDF, chipboard and plywood with a smooth surface are recommended. Veneer Laminate should be properly press bonded to the substrate using a rigid or semi-rigid adhesive such as UF or PVA. Contact adhesives, particularly hand-applied, are not recommended. Remove any adhesive smear with a damp cloth before curing takes place. Do not use any solvents on Veneer Laminate.
How do I fabricate Formica Solid Surfacing Material?
Specialised technical requirements apply to working with Formica Solid Surfacing in order to make the most of this versatile, high quality product. Formica appoints specially-trained companies to carry out fabrication of this material. For information on approved fabricators, please contact our Sales Department:
Tel: 0191 259 3000
Fax: 0191 258 2719
Email: sales@formica.co.uk
Any there any special techniques for fabricating Formica ColorCore®?
Yes. Formica ColorCore is more brittle than standard laminates and needs particular care in handling, cutting and finishing. Please refer to full details given in 'ColorCore Laminate' under 'Special Products' in the ‘Technical’ section.
How is Compact Grade cut and fixed?
Formica Compact Grade can be cut, shaped and routered using conventional carbide tipped tools and, in thicknesses of 12mm and over, it can be drilled and tapped for screw / bolt fixing.
What are the options for edging laminate-faced panels?
Panels faced with Formica laminate can be edged in a variety of ways:
• Postforming
• By self-edging using the same laminate as the face material
• With timber
• With Formica ColorCore
• With Formica Solid Surfacing
• With PVC
How do I avoid cracks from cut-outs?
By radiusing the internal corners, (minimum 5mm); by using rigid or semi-rigid adhesives; and by properly pre-conditioning the laminates and substrates. For full advice, please refer to 'Dimensional Movement' under 'Installation / Design Issues' in the ‘Technical’ section.
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Installation
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Do you have a recommended fixing system?
Yes. Formica Lifeseal® System Plus is a simple-to-use steel framing system designed to create fixed or demountable wall linings and partitions.
By what other methods can panels and boards be fixed?
Timber battens and face fixing are two further options. For full advice, please refer to 'Fixing Boards' under 'Installation / Cladding' in the ‘Technical’ section.
Can Formica laminates be fixed directly to existing wall surfaces?
No. Most existing wall surfaces, such as plasterboard or cement-rendered surfaces, or Gypsum board, (both plain and paper faced), are unsuitable for direct bonding because of surface irregularities, low internal bond strength and incompatible dimensional movement. In addition, the performance of hand applied contact adhesives is limited.
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Application
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What colours are the most durable for high wear horizontal use?
Light colours with small pattern effects, such as Dust or Grafix items, are ideal.
Are Formica products suitable for wet area applications?
Compact Grade laminate is ideal for areas of high humidity and for areas where frequent wetting is probable, as it is a homogeneous material and, in thicknesses of 6mm and above, requires no substrate.
Formica Solid Surfacing is also ideal for use in wet environments in horizontal and vertical applications.
Can Formica high pressure laminates be used in marine applications?
Yes. Formica HGP grade laminate, bonded to a non-combustible substrate, meets the requirements for flame spread, heat release, smoke generation and toxicity specified in IMO Resolutions A653 (16) and MSC (67). This grade of Formica laminate has been granted Marine and Coastguard Agency (MCA) Type Approval.
What options exist for signage?
The Formica Digital Service provides a straightforward, cost-effective means of creating and incorporating signage into any scheme. Specialised printing and manufacturing processes ensure perfect results. The finished high pressure laminates are low maintenance and will continue to look excellent for years.
What surface finishes are best for horizontal applications?
Formica high-pressure laminates come in a variety of different surface finishes. Some are available over a number of ranges; others are integral to particular designs and patterns.
The choice of surface finish is important functionally as well as aesthetically. For example, textured surfaces and light colours normally have better scuff and scratch resistance than do plane surfaces and dark colours. Glossy laminates and dark plain colours are therefore not recommended for heavy duty working surfaces. Plane and lightly textured surfaces are more easily cleaned than deeply textured finishes.
Do different areas require special substrates?
Yes. The choice of substrate is critical to the overall performance. Analysis of the suitability of various substrates is tabulated in 'Substrates' under 'Fabrication / Pressing' in the ‘Technical’ section.
Is Metallic Laminate suitable for use externally?
No. Metallic Laminate is ideally suited to interior, light duty, vertical applications.
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Special Products
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What is the Formica Digital Service?
Our Digital Service gives designers the freedom to create truly customised interiors. Using advanced techniques and materials, we can create laminates with images tailored to individual needs. Applications such as furniture, doors, wall panels and signage can all be enhanced through the incorporation of custom-designed high pressure laminates.
What is Veneer Laminate?
Veneer Laminate is made by combining a reconstituted real wood surface with a phenolic core. This material offers the natural appeal and quality of real wood with the ease of handling and application of laminate.
Veneer Laminate provides the added benefit of colour consistency between sheets of the same design. As with all real wood products, there may be some colour change over a period of time due to the natural ageing process.
The Veneers Range provides a variety of natural and exotic designs; classic natural veneers; decorative Birdseyes; artistic Linea and Frisee designs; and patterns based on African wildlife.
What is Metallic Laminate?
Metallic Laminate is made using a core of high-pressure laminate with a real metal surface, combining the timeless look of solid plate metal with the ease of use of laminate.
Intended for light duty applications, Metallic Laminate is ideal for use on vertical surfaces, adding dramatic impact to any interior design.
Within the Metallics Range, styles of classic simplicity are complemented by striking modern industrial effects and by designs that echo the working of metal in traditional crafts. Finishes vary from a mirror-like polish to embossed and burnished metals.
What is Compact Laminate?
Formica Compact Grade high pressure laminate is a high performance, versatile, homogeneous material, much thicker than conventional laminate and generally with a decorative surface on both sides.
Compact Grade (also known as solid grade) is an impressively strong and damage-resistant material with excellent dimensional stability and mechanical strength. It is frequently used to manufacture lockers, cubicles and wall panels in high traffic or wet areas in public buildings. Its inherent properties also make it an ideal choice for laboratory work surfaces.
What is special about Formica ColorCore®?
Formica ColorCore is a high performance surfacing laminate with integral solid colour throughout the thickness of the material. ColorCore has been developed to maintain its appearance in high surface wear conditions and has proved ideal for applications such as doors, counter tops and check-out desks.
The product can be fabricated creatively to produce graphic and layered effects using techniques such as routering, carving and sandblasting. Edges become a real feature as the through colour effect minimises the appearance of joint lines. Formica ColorCore is available in fourteen vibrant solid colours.
What is Formica Solid Surfacing?
Formica Solid Surfacing is a homogeneous product made from cast resin with mineral fillers. Highly versatile and durable, the product is available in a range of sheets and pre-moulded shapes. It can be cut, machined and inlaid to create the most beautiful and lasting decorative designs and forms, perfectly suited to the most demanding and prestigious surroundings.
Non-porous, microbiologically inert, and resistant to staining, chemicals, heat and impact, Formica Solid Surfacing is non-toxic and approved safe for use in contact with food. The product has been awarded the Certificate of Hygienic Merit by the Royal Institute of Public Health.
Where can I use Formica Solid Surfacing?
Formica Solid Surfacing can be used in any situation where durability, aesthetics, hygiene and ease of maintenance are important. Some of the many applications include:
• Laboratory work surfaces
• Servery counters
• Check-in desks
• Reception desks
• Washroom vanity units
• Free-standing furniture
• Shower enclosures
• Kitchen work surfaces
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