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Plywood production requires a good log, called a peeler, which is generally straighter and larger in diameter than one required for processing into dimensioned lumber by a [[sawmill]]. The log is peeled into sheets of veneer which are then cut to the desired dimensions, dried, patched, glued together and then baked in a press at 140 °C (280 °F) and 19 MPa (2800 psi) to form the plywood [[wood panel|panel]]. The panel can then be patched, resized, sanded or otherwise refinished, depending on the market for which it is intended.
Plywood production requires a good log, called a peeler, which is generally straighter and larger in diameter than one required for processing into dimensioned lumber by a [[sawmill]]. The log is peeled into sheets of veneer which are then cut to the desired dimensions, dried, patched, glued together and then baked in a press at 140 °C (280 °F) and 19 MPa (2800 psi) to form the plywood [[wood panel|panel]]. The panel can then be patched, resized, sanded or otherwise refinished, depending on the market for which it is intended.


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== History ==
[[Image:2005plywood.PNG|thumb|left|Plywood output in 2005]]
Plywood has been made for thousands of years; the earliest known occurrence of plywood was in [[ancient Egypt]] around 3500 BCE when wooden articles were made from sawn veneers glued together crosswise. This was originally done due to a shortage of fine wood. Thin sheets of high quality wood were glued over a substrate of lower quality wood for cosmetic effect, with incidental structural benefits. This manner of inventing plywood has occurred repeatedly throughout history. Most high quality English furniture makers working in the eighteenth and nineteenth centuries (and since) have used veneering as a technique. In addition to making the most out of the highest quality materials available, it reduces prices and improves stability of construction. The irregularities of grain which confer decorative interest often result in uncontrollable warping and cracking if any attempt is made to use the wood in thicknesses much greater than those characterizing cabinet-making veneers (typically 1-2mm).

Modern plywood in which the veneer are cut on a [[Lathe#Rotary lathes|rotary lathe]] from softwood logs is of relatively recent origin, invented by [[Immanuel Nobel]]. The first such lathes were set up in the [[United States]] in the mid [[19th century]]. Plywood has been one of the most ubiquitous building products for decades.

Compare to OSB ([[Oriented strand board]]) and MDF ([[Medium-density fiberboard]]).

One of the earliest applications of mass-produced modern plywood manufacturing in the United States was recorded in Portland, Oregon by the Portland Manufacturing Company. The owner, [[Thomas J. Autzen]] helped develop a bonding technology, which greatly shortened the drying and manufacturing process. His early engineering contribution played an important role in making plywood one of the most abundant and affordable building products ever produced.

In India, waterproof plywood is also known as "kitply". Though Kitply is a brand, it has become a generic designation, since the company that makes it pioneered the use of waterproof plywood in India.

The landscape historian John Stilgoe has theorized that the 4' x 8' dimensions of a standard sheet are due to the space required for moving a mule into a barn{{fact|date=January 2008}}.


== US plywood grades ==
== US plywood grades ==

Revision as of 00:29, 15 February 2008

Towers of Hanoi constructed from plywood. Notice the high quality wood veneer (light color) covering the lower quality inner wood (dark color).

Plywood is a type of engineered wood made from thin sheets of wood veneer, called plies or veneers. The layers are glued together, each with its grain at right angles to adjacent layers for greater strength.There are usually an odd number of plies, as the symmetry makes the board less prone to warping [1], and the grain on the outside surfaces runs in the same direction. The plies are bonded under heat and pressure with strong adhesives, usually phenol formaldehyde resin,[2] making plywood a type of composite material. Plywood is sometimes called the original engineered wood.[3]

A common reason for using plywood instead of plain wood is its resistance to cracking, shrinkage, twisting/warping, and its general high degree of strength. It has replaced many dimensional lumbers on construction applications for these reasons.

A wall lamp made partially from plywood

Types of plywood

Average-quality plywood with show veneer
High-quality concrete pouring plate in plywood

A vast number of varieties of plywood exist, with many conditions and uses. Softwood plywood is usually made either of Douglas fir or spruce, pine, and fir, and is typically used for construction and industrial purposes.[4] Decorative plywood is usually faced with hardwood, including red oak, birch, maple, lauan (Philippine mahogany) and a large number of other hardwoods.

Plywood for indoor use generally uses the less expensive urea-formaldehyde glue which has limited water resistance, while outdoor and marine grade plywood are designed to withstand rot, and use a water resistant phenol-formaldehyde glue to prevent delamination and to retain strength in high humidity.

The most common varieties of softwood plywood come in three, five or seven plies with a metric dimension of 1.2 m × 2.4 m or the slightly larger imperial dimension of 4 feet × 8 feet. Plies vary in thickness from 1/10" through 1/6" depending on the panel thickness. Roofing can use the thinner 3/8-inch plywood. Floorboards are at least 5/8-inch depending on the distance between floor joists. Plywood for flooring applications is often tongue and grooved. Two of the edges will have "grooves" notched into them to fit with the adjacent "tongue" that protrudes from the next board.

High-strength plywood, known as aircraft plywood, is made from mahogany and/or birch, and uses adhesives with increased resistance to heat and humidity. It was used for several World War II fighter aircraft, including the British-built Mosquito bomber.

Plywood production

Plywood production requires a good log, called a peeler, which is generally straighter and larger in diameter than one required for processing into dimensioned lumber by a sawmill. The log is peeled into sheets of veneer which are then cut to the desired dimensions, dried, patched, glued together and then baked in a press at 140 °C (280 °F) and 19 MPa (2800 psi) to form the plywood panel. The panel can then be patched, resized, sanded or otherwise refinished, depending on the market for which it is intended.

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US plywood grades

Plywood grades are determined by a veneer quality on the face and back of each panel. The first letter designates quality of face veneer (best side), while the second letter denotes the surface quality of the back of the panel.[5] The letter "X" indicates the panel was manufactured with scrap wood as the center plies, not "exterior" as is commonly thought. The A-D rating is only good for construction plywood, not for hardwood plywoods such as oak or maple.

"A": Highest grade quality available. Can be defect free or contain small knots, providing they are replaced with wooden plugs (the fillers having a "boat" or a "football" shape) or repaired with synthetic patch. This grade may contain occasional surface splits that are repaired with synthetic filler. The surface is always sanded and provides for smooth paintable face quality.

"B": Second highest quality veneer grade. Normally a by-product of downgraded "A" quality veneer. Solid surface, but may contain small diameter knots and narrow surface splits. Normally repaired with wooden plugs or synthetic filler. The surface is normally sanded smooth.

"C": Considered to be a lower end face quality, but a reasonable choice for general construction purposes. May contain tight knots up to 1½ inches diameter, some open knot holes, some face splits, and discoloration. Some manufactures may repair the defects with synthetic filler. Panels are typically not sanded.

"D": Considered to be the lowest quality veneer and often used for the back surface for construction grade panels. Allows for several knots, large and small, as well as open knots up to 2½ inches diameter. Open knots, splits, and discoloration are acceptable. "D" grade veneers are neither repaired nor sanded. This grade is not recommended for permanent exposure to weather elements.

Plywood applications

Plywood is used in any application that needs high quality wooden sheet material. High quality in this context means resistance to cracking, breaking, shrinkage, twisting and warping. Plywood is also used as an engineering material for stressed-skin applications.Also, Plywood has been used in this fashion for marine and aviation application since the WWII era. Most notable is the British De Havilland Mosquito bomber, (which was primarily made out of wood.) Plywood is currently used in stressed-skin applications quite successfully.[citation needed]. The American designers Charles and Ray Eames and Phil Bolger are world-famous for their plywood-based furniture.

See also

Further reading

  1. ^ http://www.westsystem.com/webpages/epoxyworks/18/plywood.html
  2. ^ Handbook of Finnish Plywood, Finnish Forest Industries Federation, 2002, ISBN 952-9506-63-5 [1]
  3. ^ "Milestones in the History of Plywood", APA - The Engineered Wood Association. Accessed October 22, 2007. "Plywood is often called the original engineered wood product because it was one of the first to be made by bonding together cut or refashioned pieces of wood to form a larger and integral composite unit stronger and stiffer than the sum of its parts."
  4. ^ O'Halloran, p.221.
  5. ^ http://www.timber.org.au/NTEP/menu.asp?id=104#Veneer_quality