Finishes.Veneer-wrapped profile products are available pre-finished with stain and/or topcoat for color consistency and can be treated with an environmentally friendly ultraviolet (UV) cure. Painted and top coat stain with environmentally friendly UV cures can be spray-applied resulting in full coverage of part profiles, such as window and door parts, as well as custom moulding components. With applied stain colors and UV curing, volatile organic compound (VOC) and hazardous air pollution (HAP) emissions are virtually eliminated, the cure is nearly instantaneous, and the end result provides resistance to scratches and chemicals. Typically, factory-applied stains and UV coating is more cost-effective than jobsite finishing and results in a better quality product without generating emissions at the worksite.

Limitations. The main limitation of profile wrapping concerns the size of the piece that is being wrapped. The process is linear in nature, meaning that the lengths of wrapped veneer are limited by what can be moved around inside the factory and the amount of space available at the out-feed of the profile wrapper. That being said, the vast majority of the products produced in this manner are up to 16 feet long, with 18-foot lengths available upon request. Width is limited by the capacity of the wrapper, which in most cases is a maximum width of 9.6 inches. There is also a minimum outside radius to profiles of .059. If requirements exceed those dimensions, it may be possible to achieve the desired result via process engineering, wrapping components for subsequent assembly or hand wrapping.

Veneer

Components can be wrapped in more than 100 different natural wood veneer species, as well as a range of synthetic film materials. Widely available are foils and interior or exterior films that are typically vinyl or impregnated cellulosic material that can be imprinted with almost any "look," including wood prints as well as solid colors and patterns that can be used cost effectively to complement solid wood finishes.

The most common wrapping option, say manufacturers, is real wood veneer, which allows for consistent color and grain with minimal knots and mineral streaks. Veneer is available pre-sanded, eliminating the need for grain filling. Veneers also offer the advantage of using an exotic species that may be unavailable or cost prohibitive in solid lumber.

Manufacturers may offer flitch- and grade-matching for assuring visual appeal and consistency in the final product. A flitch is a set of individual veneer leaves sliced from a single log, and each flitch has its own distinct grain, color, width and other qualities. Sliced veneers from each flitch are bundled in the exact order in which they are cut, to more easily attain proper matching.

Reconstituted Veneers. Manufactured wood veneers made to resemble certain wood species, are another option. Reconstituted veneers are made from light colored veneers that are dyed, glued and assembled in a mould, where they are pressed and cured, and then sliced from the edge of the block to produce veneers of the same thickness and consistency. While reconstituted veneers will not have the character of natural veneers, they tend to be more economical in many species and have the uniformity and defect-free appearance suitable for applications requiring consistent pattern and color and minimum waste.

Wood Look-alikes. Innovation in veneer-wrapping technology has enabled wood look-alikes that are profiled to customer specifications and wrapped with an ultra-thin, durable vinyl printed to appear indistinguishable from real wood. The products, which work well in high-use interior applications such as hotel rooms and conference centers, are easy to maintain by surface wiping. They are available in a variety of wood looks, such as walnuts, maples, cherries, oaks and birch, and can be wrapped over nearly any type of substrate.

Flat laminates were used to meet hurricane criteria on the pro shop door at an upscale Florida resort. Photo courtesy of Contact Industries

 

Flat Laminates. In flat lamination, a "veneer" or laminate is bonded to a flat surface. The principal difference between a veneer and a laminate is the thickness of the veneer used in the product. In order for a veneer to wrap over a profile, it needs to be thin enough to be pliable to cover profiles of various shapes without cracking. A thin veneer to be profile wrapped is considered to be .013 to .021 inches. A thick veneer to be flat laminated is considered to be .031 to .125 inches in thickness, in other words, too thick to allow for much flexibility and therefore better suited to covering surfaces that are essentially flat. Flat laminates have a maximum width of 17 inches, and a maximum length of 18 feet.

A profile veneer product has the veneer applied in a lineal, ever moving horizontal production process, whereas a flat laminated veneered product is a "batch" process of product through either a cold press or a radio frequency oven. Whether flat-laminated or veneered, the cores are made the same way. However, whereas veneers are frequently edge-glued and finger jointed to achieve longer lengths, the thicker laminates are not.

A flat laminated component is sometimes specified to achieve greater durability as it can withstand greater wear and achieve certain performance standards (such as modulus of elasticity (MOE) or modulus of rupture (MOR)) that may be unattainable by a thin veneered component. For example, flat laminates were used for the golf pro shop doors at an exclusive Florida golf resort, where aesthetics and strict adherence to Miami Dade Wind Load performance testing were key. The core material was specially designed solid lumber that was face glued to have sufficient durability in order to meet the criteria of the Miami Dade Hurricane Code. Specifically, a Douglas Fir LVL substrate with a measured modulus of elasticity and modulus of rupture was used to meet the hurricane code ratings. The project involved some 864 linear feet of stiles and 278 linear feet of rails fabricated from ¼-inch finger-jointed pine face and a ¾-inch finger-jointed pine band wrapped with ¼-inch face veneer of lustrous wood known as Khaya, or African mahogany, and ¼-inch Khaya edge band. Prior to installation, the components were tested to withstand the 58-70 psf load capacity standards set forth by the Hurricane Testing Laboratory.

Similarly, an LVL substrate with pine veneer was used in a combination of wrapped and laminated parts at London's Falcon Wharf , a complex of 124 apartments with 17 floors of glass-enclosed balconies. Door stiles and window components were designed to perform under adverse climate conditions, notably significant changes in temperature and humidity which would cause normal solid wood components to twist and check extensively. Doors and windows separate a glass-enclosed deck which at times acts similar to a greenhouse for plants. During construction, temperatures often soared to 130 °F, and the components functioned smoothly.

At London's Falcon Wharf, door stiles and window components for enclosed decks were Douglas fir LVL with pine veneer to ensure dimensional stability under extreme conditions. Photo courtesy of Contact Industries