Structural Panels. Forestry 240 Wood Science. Plywood. Plywood Manufacturing. Rotary Lathe. Chargers. Chapter 14 - Structural Panels

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1 Forestry 240 Wood Science Chapter 14 - Structural Panels Structural Panels Structural Panels have revolutionized the nature of light woodframe construction. Larger panel area (32 ft 2 ) facilitates faster construction. High racking strength Uniform size and economical. Used for: Subflooring Roof and wall sheathing Corner bracing Concrete forming Structural panels combine the natural strength properties of wood with modern engineering, where natural defects are uniformly distributed. There are two main structural panel types, plywood and oriented strandboard (OSB). Peeled veneer layers are glued together so that the grain direction of some veneers run perpendicular to and others parallel to the long axis of the panel. Plywood Plywood Manufacturing Bolts are debarked and conditioned with steam or hot water to soften them up. Chargers Chargers then load the bolts onto the lathe for optimum veneer recovery. Rotary Lathe The lathe produces a continuous ribbon of green veneer that is subsequently clipped to recover usable veneer widths. The core is ejected and used for studs, landscape timbers, or pulp chips. 1

2 Clipping The clipper removes defects and cuts the veneer to lengths. Veneer Cutting Drying Veneers are then dried to around 2-6% moisture content to reduce shrinkage and for optimum resin adhesion. Sorting and Grading Veneers are graded and sorted into faces, backs, and cores. Assembling and Gluing Veneers are then glued, and successive panels are laid at right angles to each other. Pre-Pressing Pre-Pressing compresses the layers to ensure good glue transfer. 2

3 Hot Pressing An elevator loads the press. Pressing polymerizes the resin and solidifies bonds in the panel. Trimming The completed panels are then trimmed OSB OSB has replaced plywood as the structural panel of choice. Raw material costs are lower, can use lower grade logs. Higher yields, veneer yield is between 60 and 70%, where strand yields are 85-90%. OSB has the same or slightly higher mechanical strength properties as plywood, with greater density. It can be produced in a variety of lengths and sizes. OSB Manufacture OSB manufacture is similar to plywood with some key differences. OSB Manufacture Logs are flaked along the grain. Drying Flakes are dried to around 3% MC at very high temperatures, often in excess of combustion temperatures. Residence time is short and flakes keep moving to avoid fires. 3

4 Blending Resin and waxes are blended with the flakes. Forming Line Flakes are laid down on the forming line. The line speed is synchronized with the press. The mat is sawn to length. Pressing Hot pressing activates the resins and solidifies the panel. Exiting the Press Trimming Radial saws trim the panel to length and width. Packaging and Shipping 4

5 Thermosetting Synthetic Resins Phenol-formaldehyde (PF) Less expensive, available in powder form Diphenylmethane diisocyanate (MDI) Brighter finish Can tolerate higher MC; it draws moisture out of wood as it cures. Faster cure times, faster press cycles. May run PF on surface and MDI in core Panel Selection Structural panels are inspected by the American Plywood Association (APA). Plywood grades are identified by the face veneer grades, A, B, C, D. Sanding is also included in the designation CDx. Product Limitations Problems with swelling have been reduced by using water proof adhesives Storing and installing products according to APA standards and building codes prevents service problems Volatile off-gassing in service is not an issue because there is no residual free phenol or formaldehyde in the panels when they leave the factory, and MDI adhesives are completely polymerized into stable nonvolatile plastics. 5

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