Engineered Wood Flooring with a Densified Surface Layer for Heavy-duty Use

High-density wood is required in wood flooring, especially in engineered wood flooring (EWF) designed for heavy-duty applications. However, high-density wood resources are limited and their cost is high. A densification treatment makes it possible for lowor moderate-density woods to replace harder species by modifying them into highperformance and high-value products, such as engineered wood flooring for heavy-duty applications. The general objective of this study was to develop a prototype of engineered wood flooring using sugar maple hygro-thermally densified surface layers. The results showed that thin sugar maple lumber densified at 200 °C under the combined effects of steam, heat, and pressure with a heat-resistant fabric had great potential for the manufacturing of engineered wood flooring for heavy-duty use. As a result of treatment, it acquired high density, improved mechanical properties, and it had a relatively high dimensional stability and an attractive color. Tests in conditioning rooms showed that the EWF with a densified sugar maple (Acer saccharum March.) surface layer presented the lowest amplitude distortion between the dry and humid conditions compared with the standard EWF (0.15 mm vs. 0.17mm and 0.25mm).