Structural Flakeboards and Composites 3027 



ECONOMICS OF MANUFACTURE 



On the basis of the market analysis and the test results, Hoover et al. (1979) 

 conducted an economic feasibility study. They concluded that this roof decking, 

 which is capable of spanning 5 or 6 feet, could be competitive with steel roof 

 decking. In 1980, the team presented another economic feasibility study of an 

 operation to manufacture the product; this study is summarized in section 28-29. 



24-18 THIN FLAKEBOARDS 



With appropriate control of manufacturing procedures, it may be possible to 

 platen-press medium-density thin panels with fiber faces and flake cores to 

 compete with high-density fiberboards used to face doors. 



Lyon and Short (1977) found that door skins having cores of 3-inch-long, 

 0.015-inch-thick sweetgum flakes produced on a shaping lathe, and faces of 

 southern pine disk-refined fibers, have promise. In their study they platen- 

 pressed panels 0. 155 inch thick in 2 minutes at 300°F. Content of phenolic-resin 

 solids, applied as a liquid, was 1 1 percent. Among their conclusions were the 

 following: 



• An increase in percentage of flakes in such panels increases MOR, 

 MOE, dimensional stability, and impact strength, but decreases IB 

 strength. 



• On laboratory-scale panels, fiber/flake layered panels within the densi- 

 ty range of 45 to 60 Ib/cu ft have superior MOR and MOE compared to 

 commercial medium-density thin particleboard; IB strength of such 

 layered panels is lower than that for commercial medium-density pan- 

 els, but is acceptable. 



• At 50 Ib/cu ft, laboratory-fabricated 50/50 fiber/flake panels are equiv- 

 alent to commercial high-density boards with respect to MOR and 

 MOE. To achieve equal IB, layered panels of 80/20 fiber/flake furnish 

 are required. 



• Laboratory panels made with fiber faces and up to 60 percent flakes in 

 the core have uniform smooth surfaces similar to those of commercial 

 medium-density panels, but are not as uniform or smooth as commer- 

 cial high-density boards. 



Lyon and Short found that these door skins were most stable if made from 100 

 percent flakes (LE from 50 to 90 percent RH = 0.021 percent); if fabricated 

 with 60/40 fiber/flake layering, LE increased significantly (to 0.058 percent). 

 Section 28-23 summarizes Briggs' discussion of the economic feasibility of 

 platen pressing oriented flakeboard cores for decorative- hardwood plywood. 

 Section 28-24 summarizes Springate and Roubicek's analysis of manufacturing 

 thin fiberboard or particleboard from southern hardwoods to compete with lauan 

 plywood. 



