Film Faced Plywood: Benefits & Uses

Film faced plywood is a high-grade plywood with a special coating of phenolic or melamine film. This coating enhances the plywood’s durability, water resistance, and wear resistance, making it particularly suitable for demanding construction tasks, such as concrete formwork and outdoor uses.

Unlike standard plywood, film faced plywood has an exterior film that protects the wooden surface from moisture, abrasion, and chemicals, making it ideal for use in tough environments. Its surface finish is smooth and uniform, allowing it to be reused multiple times in various applications.

How Is Film Faced Plywood Made?

Film-faced plywood is a durable and high-strength type of plywood that is coated with a film of phenolic or melamine resin. It is commonly used in construction, furniture, and vehicle manufacturing due to its water-resistant and smooth surface. The manufacturing process is meticulous and involves several crucial steps, which we will explore in detail below.

1. Veneer Selection

The process begins with selecting high-quality hardwood or softwood veneers. The choice of wood depends on the required strength, durability, and resistance to environmental factors. Hardwoods like birch are often preferred for their superior strength, whereas softwoods like pine are chosen for cost-effectiveness.

2. Veneer Layering and Adhesion

Once selected, the veneers are layered together using high-strength adhesives. The layers, known as plies, are arranged in a cross-grain pattern, meaning each layer is rotated 90 degrees from the one below it. This arrangement enhances the structural integrity of the plywood, preventing warping and increasing load-bearing capacity.

3. Film Application

A key differentiating factor of film-faced plywood is the application of a protective film layer. This film is a high-density paper impregnated with phenolic or melamine resin.

Purpose of the Film

• Provides a smooth, waterproof, and chemical-resistant surface.
• Enhances durability against wear and tear.
• Prevents concrete from sticking when used in formwork applications.

The film is carefully placed on both sides of the plywood before pressing to ensure a uniform finish.

4. Hot Pressing Process

The plywood stack is then placed into a hydraulic press where high pressure and heat (typically around 120-150°C) are applied. This step is critical for:

• Ensuring the adhesive between veneers cures completely.
• Properly bonding the film to the plywood surface.
• Achieving a uniform thickness and density.

The duration of the pressing process depends on the type of adhesive used and the thickness of the plywood.

5. Cutting and Edge Sealing

After the pressing process, the large sheets of plywood are cut into standard sizes, such as 4×8 feet or custom dimensions based on application needs.

• Edge Sealing: The cut edges are coated with waterproof paint, usually acrylic or polyurethane-based, to prevent moisture penetration and enhance longevity.

Key Materials Used In Film Faced Plywood

Material	Function
Hardwood or Softwood	Main structural component
Phenolic/Melamine Film	Protective, waterproof, and smooth coating
Phenolic Adhesive	High-strength bonding between veneer layers

Key Features Of Film Faced Plywood

Film faced plywood has several distinguishing features that make it stand out from other types of plywood:

1. Water Resistance

Due to its film coating, film-faced plywood is highly resistant to water and moisture, making it perfect for outdoor and wet applications.

2. Durability

It is far more durable than standard plywood due to the phenolic resin layer that protects it from wear and tear.

3. Smooth Finish

The smooth, polished surface allows it to be used in applications that require a flawless finish, such as concrete formwork.

3. Reusability

One of the most important aspects of film-faced plywood is its reusability. It can be used multiple times before showing signs of wear, which makes it cost-effective.

4. Resistance to Chemicals

The phenolic resin film makes this plywood resistant to chemicals, adding to its versatility in industrial environments.

Types Of Film Faced Plywood

Film faced plywood comes in various types, which vary based on the core material, film type, and plywood grade. The following are the most common types:

1. Popular Core Film Faced Plywood

Made from poplar wood, this type is light in weight, affordable, and suitable for indoor and outdoor uses that require moderate durability.

2. Birch Core Film Faced Plywood

Known for its high strength and rigidity, birch core plywood is ideal for heavy-duty applications, such as concrete formwork.

3. Bamboo Film-Faced Plywood

Bamboo film-faced plywood is eco-friendly and offers superior strength and durability, making it perfect for heavy-use environments.

4. Hardwood Core Film Faced Plywood

This type is made from hardwood veneers and is incredibly strong, durable, and water-resistant.

5. Anti-slip Film Faced Plywood

Designed with a textured surface to provide extra grip, this plywood is often used in flooring applications, especially in outdoor and industrial environments.

Benefits Of Using Film Faced Plywood

Using film faced plywood in construction and industrial applications offers several key advantages:

1. Durability and Longevity

Thanks to the phenolic resin coating, film faced plywood can endure harsh weather conditions, heavy loads, and frequent use without deteriorating. It can be used multiple times in concrete formwork and other demanding tasks.

2. Waterproof and Moisture-Resistant

The phenolic film applied to the plywood surface creates a waterproof barrier, which prevents moisture from penetrating the wood layers. This makes film faced plywood ideal for outdoor applications like marine construction and bridge building.

3. High Load-Bearing Capacity

Because of its layered construction, film faced plywood has a high load-bearing capacity, which is essential in applications like scaffolding and concrete shuttering.

4. Smooth Surface Finish

The smooth surface of film faced plywood reduces the need for additional finishing in projects like concrete formwork, where a flawless surface is required.

5. Cost-Effective

The fact that it can be reused multiple times makes film faced plywood a cost-effective option for contractors and builders. Instead of replacing materials after every use, film-faced plywood can last for several cycles, saving on costs.

6. Chemical Resistance

Its ability to resist chemicals adds to its versatility in construction and industrial applications where chemical exposure is common.

Applications Of Film Faced Plywood

Film faced plywood is used in a variety of industries due to its unique properties. Below are some of the most common applications:

1. Concrete Formwork

One of the primary uses of film faced plywood is in concrete formwork. Its smooth surface and strength make it ideal for creating molds for concrete structures, as it can withstand the pressure of wet concrete and create a flawless finish.

2. Flooring

The anti-slip variety of film faced plywood is commonly used in industrial flooring, such as in warehouses and factories, where durability and safety are key concerns.

3. Marine Applications

Thanks to its waterproof properties, film faced plywood is frequently used in marine construction, including docks, ships, and boats.

4. Furniture Making

In some cases, film faced plywood is used in making furniture, especially where a durable, smooth surface is required, such as tabletops or cabinetry.

5. Scaffolding

Its high strength and reusability make it a popular choice for scaffolding and support structures on construction sites.

6. Vehicle Manufacturing

In the transportation industry, particularly in truck and trailer floors, film faced plywood is valued for its strength, water resistance, and durability.

Conclusion

Film faced plywood is a highly versatile and durable material used in construction, industrial, and marine applications. Its water resistance, reusability, and smooth surface finish make it an excellent choice for concrete formwork, scaffolding, and other demanding tasks. 

Understanding the different types and features of film faced plywood can help you select the best product for your specific needs, ensuring long-lasting performance and cost-effectiveness.

Frequently Asked Questions? (FAQs)