MDF manufacture

In Australia and New Zealand, the main species of tree used for MDF is plantation-grown radiata pine; but a variety of other products have also been used, including other woods, waste paper and fibres.
The trees are debarked after being cut. The bark can be sold for use in landscaping, or burned in on-site furnaces. The debarked logs are sent to the MDF plant, where they go through the chipping process. A typical disk chipper contains 4–16 blades. Any resulting chips that are too large may be re-chipped; undersized chips may be used as fuel. The chips are then washed and checked for defects.
The chips are then compacted using a screw feeder, are heated/steamed for 30–120 seconds to soften the wood, then joined with liquefied wax and fed into a defibrator. The defibrator maintains a high pressure and temperature while grinding the wood chips into a pulp.

From the defibrator, the pulp enters a blowline, where it is joined with resin, often urea-formaldehyde. The wax improves moisture resistance and the resin initially helps reduce clumping, but ultimately is the primary binding agent. The material dries quickly when it enters an expansion chamber and expands into a fine, fluffy and lightweight fibre that is stored until needed at the forming line.
Dry fibre gets sucked into the top of a pendistor, which evenly distributes fibre into a uniform mat below it, usually of 230–610 mm thickness. The mat is pre-compressed and either sent straight to a continuous hot press or cut into large sheets for a multi-opening hot press. The hot press activates the bonding resin and sets the strength and density profile.
After pressing, MDF is cooled in a star dryer or cooling carousel, trimmed and sanded. In certain applications, boards are also laminated for extra strength.
The Environmental Impact of MDF has greatly improved over the years.[citation needed] Today, many MDF boards are made from a variety of materials. These include other woods, scrap, recycled paper, bamboo, carbon fibres and polymers, forest thinnings and sawmill off-cuts.
As manufacturers are being pressured to come up with greener products, they have started testing and using non-toxic binders. New raw materials are being introduced. Straw and bamboo are becoming popular fibres because they are a fast-growing renewable resource.

 

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MDF Moulding

Medium-density fibreboard (MDF) is an engineered wood product made by breaking down hardwood or softwood residuals into wood fibres, often in a defibrator, combining it with wax and a resin binder, and forming panels by applying high temperature and pressure. MDF is generally denser than plywood. It is made up of separated fibres, but can be used as a building material similar in application to plywood. It is stronger and much denser than particle board.
The name derives from the distinction in densities of fibreboard. Large-scale production of MDF began in the 1980s, in both North America and Europe
Over time, the term MDF has become a generic name for any dry process fibre board. MDF is typically made up of 82% wood fibre, 9% urea-formaldehyde resin glue, 8% water and 1% paraffin wax. and the density is typically between 500 kg/m3 (31 lb/ft3) and 1,000 kg/m3 (62 lb/ft3). The range of density and classification as light, standard, or high density board is a misnomer and confusing. The density of the board, when evaluated in relation to the density of the fibre that goes into making the panel, is important. A thick MDF panel at a density of 700–720 kg/m3 may be considered as high density in the case of softwood fibre panels, whereas a panel of the same density made of hard wood fibres is not regarded as so. The evolution of the various types of MDF has been driven by differing need for specific applications.

 

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Crown Molding

Crown molding is typically applied along the seams where ceiling meets wall. Usually it is not placed flush against the wall nor against the ceiling. Instead, when viewed from the molding’s end (or as a cross-section), it, the ceiling, and the wall form a “hollow” triangle. This adds a difficulty to the installation process, namely the need for complex cuts to form corners where two walls meet.

There are two common ways to fashion inside corners. One is to use a compound miter saw to cut the ends of the corner pieces along two axes simultaneously. The other, called coping, is a two step process, first to cut a simple miter and then to use a coping saw to undercut the miters.

Many different companies now manufacture crown molding in materials such as plastic and foam. These typically are offered with corner blocks, and are popular with DIY home improvement enthusiasts.

The use of a coped joint for interior corners saves the trouble of having to determine and cut the exact inside degree measurement, since most corners are not exactly 90/45 degrees. Outside corners must be mitered, and care must be taken in measuring and cutting, since not all outside corners measure true. If the angle is not exactly 45/22.5 degrees, a corner measuring device or piece of scrap crown molding may be used to obtain the right measurement before the final cut is made.

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what is baseboard.

In architecture, a baseboard (also called skirting board, skirting, mopboard, floor molding, or base molding) is a usually wooden board covering the lowest part of an interior wall. Its purpose is to cover the joint between the wall surface and the floor.
It covers the uneven edge of flooring next to the wall; protects the wall from kicks, abrasion, and furniture; and can serve as a decorative molding.
At its simplest, baseboard consists of a simple plank nailed, screwed or glued to the wall; however, particularly in older houses, it can be made up of a number of mouldings for decoration.
Plastic baseboard comes in various plastic compounds, the most common of which is UPVC. It is usually available in white or a flexible version in several colors and is usually glued to the wall. Vinyl baseboard is glued with adhesive and can be difficult to remove or to replace. It has a long lifespan, which can mean lower maintenance.
Wooden baseboard can be available in untreated, lacquered or prepainted versions. Prepainted baseboards can be made from a single piece or finger jointed wood, often softwoods, while hardwoods are either lacquered, or raw for staining and made from a single piece of wood.
Radiators are sometimes installed inside or in front of baseboards (baseboard radiators). These radiators rely on hot water as their heat source.Electric heating is also used in this manner.
A baseboard differs from a wainscot; a wainscot typically covers from the floor to around 1-1.5m high (waist or chest height), whereas a baseboard is typically under 0.2m high (ankle height).

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Decorative Moulding

Decorative Moulding
Decorative moulding in the form of crown moulding, base moulding, window and door casing, and chair rails can all serve practical purposes – but why stop there? Each of these fixtures not only protects the
home and hides blemishes, but they also provide alternative design aspects that shouldn’t be taken lightly. Choosing the best,
high-quality decorative moulds makes sense when dedicating the time and resources required building or re-touching a home.
Please contact us for specifics on how we can best utilize decorative
moulds in your home.

Chair Rails
The ultimate preventive fixture, the chair rail is a must-have for any room with walls in danger of being backed up into. Chair rail details can be created from simple moldings and are applied to any wall, about 36 inches from the base of the floor. A great way to divide your room Chair rails is beautiful, adding an extra design touch of their own. Commonly used in Front foyers of the home and in the dining room and study/library. Chair Rail is often accompanied with applied or recesses Panel Moulding.

Crown Moulding
One of the most recognized home trim pieces, crown and cove molding steal the show in any room. Crown and Cove moulding is placed at the top of the wall where the ceiling meets it.

Outside Corner, Quarter Round, Cove
Placed along the bottom of the baseboard, Quarter rounds are
designed to hide the seam between flooring and the baseboard.
Outside Corner is meant to cover Plywood joints at a 90 degree angle. Often used on staircases or recessed panels at 90 degree
angles. Coves are often used on furniture or as means of hiding the
gaps between recessed panel mould and a backerboard.

Jambs
The door jamb is vitally important to the overall security of the door; recognized as the vertical frame of the door, jambs are put in place to hold the door up. Surrounded by the casing, jamb extensions are also used to extend new window frames flush with the drywall.

Doors
Nothing says elegance in the manner supplied by our interior doors from the Masonite Collection. Including the Moulded Panel Series, the
Palazzo Series, and the Crown MDF Series, you’ll forget these doors are fashioned for entry and exit, as their superior design and look provide distinctive designs that increase the attractiveness of any room. French doors are another alternative to regular doors, made with a wide range
of Glass, wood or metal caming. French doors are often put in Offices or dining areas.

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Baseboard

Baseboard.

The baseboard is the casing’s best friend, as it is meant to match designs while tying the look of the whole room together. Acting also as reliable guard, the baseboard runs along the bottom of the wall, protecting against any nicks or lower abrasion.
Baseboard’s purpose is to cover the gaps between the wall and
Flooring, often accompanied by a Shoe moulding or Quarter Round.

Door Stops and Mullions
Used to hide the gap between the door frame and the door itself, the door stop is placed along the sides and top of the door Jamb, designed to keep the door flush with surrounding casing. Door stops are also used as shoe moulding for the baseboard, hiding any imperfections left by an uneven floor.

Window Sill
Without the window sill, a window is often considered unpolished or merely just a means to let light in. Window sills themselves are decorative in nature, running along the bottom of the window to provide a more refined look. Whether you wish to sit and gaze from a sill, or
maybe place a nice plant on the sill to receive natural light, the window sill serves as a great means to extend the window for such purpose.
Window sill is often accompanied with a small crown or apron

 

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Finger-Joint

Finger-Joint(FJ) Pine consists of small pieces of wood that are recycled and jointed together to create lengths for door casings and 16’ or 17’ lengths for crowns,base and chair rails. This allows for ease of installation and less installation joints,typical of solid woods.

 

The advantage to FJ pine mouldings are the definition of detail, much sharper than MDF, the workability, nailing ease and personal preference for wood.
FJ pine can have some imperfections. Due to FJ production including many different species of pine from around the globe, this product can have raised grain, thus lacking the smoothness of other species. Close inspection prior to installation and painting is key.
All FJ & primed FJ mouldings have trimbacks. Trimbacks occur during manufacturing. The moulding comes through the molder at the correct length ordered, but a defect is spotted. Rather than throw the whole piece of moulding away, the defect is cut out, leaving varied lengths. Trimbacks (lengths other than those ordered) should not exceed 10% of the footage ordered.

 

Casing

While casings are essential to any room, their use is intended for both functional and decorative purposes. Designed to conceal the gap between drywall and frame, casings are considered to be the “star” trim accessory of any room, as they are generally the first thing people notice upon entering. Please refer to the images below or contact us
with any questions regarding casings for your home.

 

 BackBands

More of a functional element than anything, the backband provides thickness at the edge of a casing, adding elevation and an intensified look when a thick baseboard or wall panel is used.

 

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door Jambs

Door Jambs have a range of functional and attractive features to suit the individual style of your home or building.
• Tapered (backed-off) for easy installation of wall linings
• They are manufactured to a standard length of 5.2m or as a set complete with stops
• Arrissed (radiused) edges to help maintain their quality appearance longer
• Slightly undershot Jambs enable the architrave to be fitted tightly to the jamb
and plasterboard
• Manufactured from finger-jointed clear radiata pine, a plantation grown renewable resource
• Strong nail and screw holding capacity
Door Jambs are simple to install and are especially designed for dry wall framing
such as LASERframe® and a wide range of plasterboard and the angled side ensures
the board is fitted flush against both the jamb and the architrave, giving a gap-free finish

 

Classic Mouldings

Simplistic style

Classic Mouldings create continuity with the past whilst echoing the simplicity and style
of the post-war era. These profiles are almost retro, recapturing the look of the older family home with its unpretentious informality

Colonial Mouldings

Bringing back the past

There is an extensive range of colonial profiles for renovations or restoration of Californian bungalows and classic turn-of-the-century villas. The authentic shapes are warm and elegant with all the charm of yesteryear.

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Window reveals

What’s the Advantage of wood moulding:     
High quality surface treatment
anti scratch and striking
no crack no deformation
Ready for painting
Products can be Water resistant

Products can be painted to any colors you want. Hundreds of design are available, customer private design are available, it will make your room look natural and perfect.
 
What’s the Production process?  
1).make the raw materials in different shapes
2).coated with a thin layer gesso
3).dry and sand
4).coated gesso second time
5).dry and sand again, then spray water base primer on mouldings

Window reveals           
Functional and attractive features to suit your individual style
Window reveals features to suit the individual style of your home or renovation.
• Finger-jointed on the edge (not the face)
• Attractive appearance due to straight line join
• Natural warmth of radiata pine
• Outside edge is arrissed (radiused) to help maintain their quality appearance longer
• Strong nail and screw holding capacity

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Moulding Use

At their simplest, moldings hide and help weather seal natural joints produced in the framing process of building a structure. As decorative elements they are a means of applying light- and dark-shaded stripes to a structural object without having to change the material or apply pigments. Depending on their function they may be primarily a means of hiding or weather-sealing a joint, purely decorative, or some combination of the three.

As decorative elements the contrast of dark and light areas gives definition to the object. Imagine the vertical surface of a wall lit by sunlight at an angle of about 45 degrees above the wall. Adding a small overhanging horizontal molding to the surface of the wall will introduce a dark horizontal shadow below the molding, called a fillet molding. Adding a vertical fillet to a horizontal surface will create a light vertical shadow. Graded shadows are possible by using moldings in different shapes: the concave cavetto molding produces a horizontal shadow that is darker at the top and lighter at the bottom; an ovolo (convex) molding makes a shadow that is lighter at the top and darker at the bottom. Other varieties of concave molding are the scotia and congé and other convex moldings the echinus, the torus and the astragal.

Placing an ovolo directly above a cavetto forms a smooth s-shaped curve with vertical ends that is called an ogee or cyma reversa molding. Its shadow appears as a band light at the top and bottom but dark in the interior. Similarly, a cavetto above an ovolo forms an s with horizontal ends, called a cyma or cyma recta. Its shadow shows two dark bands with a light interior.

Together the basic elements and their variants form a decorative vocabulary that can be assembled and rearranged in endless combinations. This vocabulary is at the core of both classical architecture and Gothic architecture.

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