Post-formed laminate benchtop (0.7mm laminate on 25mm, 33mm, 39mm substrate)
Resin-Impregnated Paper
ATLAS CODE
COM-LAM-RES-002
Category composite
Material Family Laminate
Regulatory Status Group 3 (standard); Group 2 (fire-retardant grades)
Density
HPL surface >= 1,350 kg/m? (laminate); substrate varies by board type kg/m³
Carbon (A1-A5)
Fossil: 6.23-9.40 kg CO2-e/m²; Biogenic: -14.73 to -20.5 kg CO2-e/m² kgCO₂e
Fire Class
Group 3 (standard); Group 2 (fire-retardant grades)
Lifespan
Residential: 10-15 years; Commercial: 8-12 years; Tropical: 8-10 years yrs
Description
Post-formed laminate benchtops use a thin high-pressure laminate (HPL) surface bonded to an engineered wood substrate, then heat-formed around the edge profile. HPL is produced from resin-impregnated papers pressed under heat and pressure; compact laminate data report density ?1,350 kg/m? and mechanical properties such as flexural strength ?80 MPa and modulus ?9,000 MPa for the laminate itself. Overall benchtop performance depends on substrate type, thickness and edge detailing.
Primary Sectors
[Residential][Hospitality][Commercial][Healthcare]
Typical Uses
- Residential kitchen benchtops and splashbacks
- Commercial kitchen work surfaces (AS 4674 compliant)
- Office and reception desk surfaces
- Laboratory benchtops (chemical-resistant grades)
- Retail display and point-of-sale counters
- Healthcare facility work surfaces
- Educational facility desktops and benches
- Hospitality bar tops and servery counters
- Bathroom vanity tops (moisture-resistant substrates)
- Laundry benchtops and utility surfaces
Recycled Content 10-30% pre-consumer; <5% post-consumer
Renewable Content 45-55% (wood fibre component)
Recyclability Technically recyclable but limited facilities; energy recovery preferred
Embodied Carbon Fossil: 6.23-9.40 kg CO2-e/m²; Biogenic: -14.73 to -20.5 kg CO2-e/m² kgCO₂e
Embodied Energy 227-243 MJ/m² (renewable: 124-133 MJ/m²; non-renewable: 103-110 MJ/m²) MJ/kg
EPD Available Yes
Advantages
Cost-effective at $200-600/m² installed vs $800-2000/m² for stone400+ décor options with consistent colour matchingSeamless post-formed edges eliminate moisture ingress pointsLightweight enabling DIY installation potentialRepairable for minor scratches and chips10-15 year warranty from major manufacturersImmediate availability ex-stock for standard coloursChemical resistance pH 2-12 for household substancesThermal resistance to 180°C for kitchen applicationsAS 4386:2018 and NCC compliance certified
Cautions
Visible seams in installations exceeding 3.6m lengthsPermanent heat damage above 180°C thresholdCannot be resurfaced or refinished like solid surfacesEdge moisture vulnerability if sealing failsLimited to 300mm unsupported cantileversSubstrate swelling irreversible if water penetratesNot suitable for outdoor applicationsGroup 3 fire rating restricts high-rise useCannot achieve seamless integrated sinks8-12 year lifespan in tropical climates
TECHNICAL DATA: PERFORMANCE PROPERTIES COM-LAM-RES-002
Density (Dry) HPL surface >= 1,350 kg/m? (laminate); substrate varies by board type kg/m³
Specific Gravity >= 1.35 (laminate)
Porosity HPL surface: <2% (effectively non-porous); Substrate: 35-45% (sealed) %
Water Absorption Surface: ≤0.1% (24hr immersion); Substrate: ≤8% thickness swell (24hr) %
Hardness Grade 3 scratch resistance; ≥350 Taber cycles (CS-10 wheels, 1kg load)
Surface Roughness Ra 0.2-10 μm depending on texture (matt: 5-10 μm, gloss: 0.2-0.5 μm) μm
UV Resistance Grade 4 colour fastness (AS/NZS 2924.2); ΔE<3 after 500hr xenon arc
Chemical Resistance pH 2-12 extended contact; resistant to household chemicals per AS/NZS 2924.2
pH Tolerance pH 2-12 (24hr contact); pH 1-13 (spot contact <10min)
Compressive Strength HPL: 160-180 MPa; Particleboard: 10-12 MPa; MDF: 15-18 MPa MPa
Tensile Strength >= 60 MPa (laminate, EN ISO 527) MPa
Flexural Strength >= 80 MPa (laminate, EN ISO 178) MPa
Shear Strength Interlaminar: 1.5-2.0 MPa; Substrate internal bond: 0.40-0.60 MPa MPa
Elastic Modulus >= 9,000 MPa (laminate, EN ISO 178) GPa
Yield Strength Not applicable (brittle failure mode) MPa
Impact Resistance 800mm drop height (500g steel ball); 1.8-2.0 Nm (AS/NZS 2924.2) J/m
Bearing Capacity 2.0 kPa UDL (domestic); 4.0 kPa UDL (commercial); 1.8-2.7 kN concentrated kN/m²
Poisson's Ratio 0.25-0.35
Creep Resistance Deflection <L/300 under sustained load at 23°C, 50% RH
Abrasion Resistance ≥350 revolutions initial point; ≥150 revolutions wear-through (Taber)
Thermal Conductivity HPL: 0.25-0.30 W/m·K; Substrate: 0.10-0.15 W/m·K W/mK
Thermal Resistance R-value: 0.21 m²·K/W (25mm); 0.28 m²·K/W (33mm); 0.37 m²·K/W (39mm) m²K/W
Specific Heat Capacity 1,300-1,500 J/kg·K J/kgK
Thermal Expansion 3.0 × 10⁻⁵ m/m/°C (longitudinal); 4.5 × 10⁻⁵ m/m/°C (transverse) μm/m·K
Melting Point Chars without melting (thermosetting polymer) °C
Ignition Temperature 276-298°C piloted ignition °C
Sound Transmission Class (STC) STC 27-30 dB (25mm); STC 32-35 dB (33mm); STC 35-38 dB (39mm)
Noise Reduction Coeff. (NRC) NRC 0.05-0.10 (minimal absorption)
Optical
Light Transmittance 0% (opaque) %
Light Reflectance (LRV) LRV 5-85% depending on colour (white: 85%, black: 5%) %
Solar Reflectance (SRI) Not applicable (indoor use only)
High-pressure laminate technology emerged in 1913 with Bakelite phenolic resins, revolutionising surface materials. Formica Corporation commercialised decorative laminates in 1927, originally as electrical insulation. Post-forming technology developed in the 1950s enabled seamless curved edges, eliminating traditional square-edge vulnerabilities. Australian production commenced 1959 with Laminex establishing Melbourne facilities, followed by Formica (1962) and later Polytec. Continuous pressing technology arrived 1970s, improving consistency and efficiency. Environmental focus since 2000s drove E0 formaldehyde standards, water-based adhesives, and FSC certification. Recent innovations include anti-fingerprint nanotechnology surfaces, integrated LED lighting channels, and carbon-negative substrate development. Digital printing technology (2010s) expanded design possibilities beyond traditional rotogravure methods. Current R&D focuses on bio-based resins reducing petroleum dependency and circular economy initiatives for end-of-life recovery.
SAFETY, ECOLOGY & INSTALLATION COM-LAM-RES-002
Flame Spread Index 6-9 (AS 5637.1)
Smoke Developed Index 2-4 (AS 5637.1)
Combustibility Class Group 3 (standard); Group 2 (fire-retardant grades)
Ignition Temperature 276-298°C piloted ignition °C
Fire Resistance Rating Not fire-rated; substrate dependent performance hours
Heat Release Rate 300-600 kW/m² peak (cone calorimeter) kW/m²
Toxicity of Combustion CO, CO2, NOx emissions; hydrogen cyanide trace amounts
Embodied Carbon (A1-A3) Fossil: 6.23-9.40 kg CO2-e/m²; Biogenic: -14.73 to -20.5 kg CO2-e/m² kgCO₂e/kg
Embodied Energy 227-243 MJ/m² (renewable: 124-133 MJ/m²; non-renewable: 103-110 MJ/m²) MJ/kg
Water Footprint 15-25 L/m² manufacturing water consumption L/kg
EPD Available Yes
LEED Points MR credits: 1-2 points; EQ credits: 1 point (low-emission)
Circular Economy Score Level B - Responsible Products Framework (GBCA) /100
VOC Emissions E0: ≤0.050 mg/m³; E1: ≤0.124 mg/m³ formaldehyde (AS/NZS 4266.16) g/L
Skill Level Intermediate to advanced; licensed cabinetmaker for warranty
Crew Size 2 persons minimum for sheets >2m; 3 for post-forming operations
Installation Time 2-4 hours per linear metre (standard); 4-6 hours (complex cuts) hr/m²
Curing Time Contact adhesive: 15-30 minutes tack time; 24 hours full cure hours
Setting Time Immediate load bearing; 72 hours before full use min
Temperature Range Installation: 18-30°C; Service: -30 to +180°C °C
Humidity Range Installation: 35-65% RH; Service: 20-85% RH %
Required Tools
Circular saw with TCT blade (fine tooth)Router with bearing-guided bitsJ-roller for adhesive applicationHeat gun for post-forming repairsSpirit level (2m minimum)Scribing tools and compassContact adhesive spray gun or brushesEdge banding machine (commercial)Dust extraction system (mandatory)
Certifications Required
Trade qualification (Certificate III in Cabinet Making)White Card (construction induction)Asbestos awareness (renovation work)Manual handling certification
Weather Limitations
Temperature 18-30°C during installationRelative humidity 35-65%No installation during rain (moisture sensitive)Substrate conditioning 48 hours on-site
COMMERCIAL, LOGISTICS & REGULATORY COM-LAM-RES-002
Material Cost $100-400/m² (material only)
Installation Cost $50-250/m² labour; $200-600/m² total installed
Annual Maintenance $20-50/year (cleaning products and minor repairs)
Lifecycle Cost (50yr) $40-60/m²/year over 10-15 year lifespan
Market Availability Excellent - stocked nationally by Laminex, Polytec, Formica, Wilsonart
Lead Time Standard colours: ex-stock to 3 days; Custom: 2-3 weeks weeks
Design Life Residential: 10-15 years; Commercial: 8-12 years; Tropical: 8-10 years years
Warranty Period 7-10 years manufacturer warranty; 1-2 years installation warranty years
Maintenance Interval Daily cleaning; quarterly sealing inspection; annual professional check months
Service Temp Range -30°C to +180°C continuous; 200°C intermittent (<10min) °C
Freeze/Thaw Resistance 100 cycles without degradation (indoor use only)
Dimensional Stability ≤0.55% longitudinal; ≤1.05% transverse at 70°C (AS/NZS 2924.2)
DISCLAIMER: This specification document is generated from the CLAD Materials Atlas Database. Information is for general guidance only and does not constitute professional engineering advice. Values are typical and may vary by batch, manufacturer, and production run. Verify suitability for specific project applications independently.