01: Faux-wood plastic laminate panels

• Plastic laminate is a thermoset plastic

• It is strong, hard, and durable

• Resistant to fire, stains, and scratches

• Glossy (for vertical surfaces)

• Satin or textured (for horizontal or vertical surfaces)

• Melamine layer (top, hard surface)

• Laminated, meaning fusing (under pressure and heat) layers of paper that have been impregnated with phenolic resins and melamine

• Two types:

  • High pressure laminates: molded and cured with 1,200 to 2,000 pounds per square inch of pressure, resulting in 1/16 inch thick material used for horizontal surfaces such as countertops​

  • Low pressure laminates: molded and cured at maximum of 400 pounds per square inch of pressure, resulting in 1/32 inch thickness and used for vertical and low-wear applications such as wall panels and doors

02: Plastic laminate countertop with stainless steel edge

Production & Installation

• In the early 1900s, Westinghouse scientists Herbert A. Faber and Daniel J. O'Conor developed Formica, the brand name for the first marketed plastic laminate

• Multiple layers of material impregnated with phenolic resins and/or melamine

• Most layers are made of brown kraft paper saturated with phenolic resins, topped with a visible resin-impregnated image sheet and coated with a top layer of melamine

• Thermoset

• Texture is added in the pressing process

• Adhered to a substrate with adhesive

• Flooring: constructed in a sheet and cut into individual planks

Maintenance​

• Can be vacuumed and cleaned with a light spray and rag

• Must use a  household cleaner--nothing abrasive

• Gentle solvents such as nail polish remover can remove ink and stains

• Stains can also be removed with a baking soda paste

• Plastic laminate cannot be partially replaced if one area is damaged

03: Plastic laminate countertop

• Durable and does not discolor easily

• Can withstand high temperatures and fire-resistant

• Can emit toxic fumes during manufacturing process due to phenolic resin

• Plastic laminate can emit gases after installation, so it must be given time to dissipate before the space is occupied

• Adhesives may give off toxic or irritating fumes

• Cannot be recycled much because it is thermoset

• Melamine particles are dangerous if ingested, but they should not be present after the manufacturing process