When working on concrete construction projects, selecting the proper formwork material is crucial for both quality and cost-efficiency. Among the various options available, melamine-faced and phenolic-faced plywood stand out as popular choices. While they may appear similar at first glance, their performance characteristics differ significantly.
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This comprehensive guide examines both materials in detail, helping you make an informed decision based on your project's specific requirements. We'll compare their durability, water resistance, cost-effectiveness, and ideal applications through a balanced mix of detailed explanations and clear bullet-point comparisons.
Melamine- Film Faced plywood features a surface coating made from melamine-formaldehyde resin. This creates a hard, durable finish that offers several advantages:
However, its limitations become apparent in demanding conditions. The resin's molecular structure, while rigid, lacks the flexibility needed for prolonged exposure to moisture. When used in outdoor formwork or high-humidity environments, melamine-faced plywood may begin to delaminate after just 3-5 uses.
Phenolic- Film faced plywood utilizes a phenol-formaldehyde resin coating that delivers superior performance:
The cross-linked polymer structure of phenolic resin creates a moisture barrier that withstands even the harshest job site conditions. This makes it particularly valuable for large-scale commercial projects and construction in tropical climates.
Water exposure is one of the biggest challenges for concrete formwork plywood. The choice between melamine and phenolic coatings significantly impacts how well the material holds up under wet conditions.
These test results explain why large-scale projects in rainy climates or with repeated concrete pours typically prefer phenolic-faced plywood. Its ability to withstand moisture without degrading ensures consistent performance and reduces replacement costs.
When evaluating plywood for formwork, durability directly affects project economics. While initial costs matter, the number of reuses often determines the true value. The number of times plywood can be reused directly impacts project costs.
Factor
Melamine - Film Faced Plywood
Phenolic - Film Faced Plywood
Average Reuses
5–10 pours
20–50+ pours
Surface Wear
Scratches easily
Retains smoothness
Long-Term Cost
Higher (frequent replacement)
Lower (long lifespan)
Practical example: For a project requiring 100 formwork uses:
This stark difference in material consumption makes phenolic- Film faced plywood the smarter choice for large or repetitive projects, despite its higher upfront price. The reduced handling and waste disposal further enhance its economic advantages.
The percentage of melamine or phenolic resin directly determines quality and lifespan. Here's what professionals need to know:
Resin Type Content % Key Characteristics Boil Test Performance Recommended Use Case Melamine 30-40% Basic water resistance, soft surface Fails after 1-2 hours Temporary indoor formwork 50-60% Moderate durability, cost-effective Lasts 3-4 hours Short-term projects (<5 pours) 70%+ Brittle surface, prone to cracking Up to 6 hours Not recommended Phenolic 50-70% Good waterproofing (blended resin) 24-48 hours Medium-term projects 80-90% Excellent durability, flexible 72+ hours Commercial construction 100% Marine-grade performance 100+ hours Bridges, marine projectsCritical Findings:
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Pro Tip: Always specify resin percentages in purchase contracts - many "phenolic" products contain only 50-60% actual phenolic resin.
Reputable manufacturers adhere to strict quality benchmarks. When sourcing plywood, verify compliance with:
Always request certified test reports and inspect samples before large purchases. Be wary of suppliers offering "phenolic-like" products that may contain melamine blends, as these compromise performance.
For contractors prioritizing long-term performance and cost efficiency, phenolic - Film faced plywood consistently delivers superior results. Its exceptional durability and water resistance justify the higher initial investment, particularly for large-scale or repetitive projects.
Melamine- Film faced plywood serves well for temporary applications where budget constraints exist, but requires more frequent replacement. By carefully matching material properties to project requirements, construction teams can optimize both performance and profitability.
“Plywood is made all over the globe, but not all is made in state of the art modern factories and quality can vary wildly”, says Timber Manager, Bob Tee.
“The “ideal plywood” would have no core gaps or overlaps , equal thickness of veneer, be very durable, thick face veneer, be aesthetically pleasing, super flat, strong, stable and cheap!
Sadly it doesn’t exist and would we able to afford it if it was, probably not.
So, the questions we need to ask are what do we need the plywood to achieve (i.e. does it have to be flat, strong, stable and structural)? Or does it have to have a beautiful veneer for say clear lacquering but the strength is not so important?
At Elliotts , we feel it’s critical for us to understand the end use of plywood so we can make sure that we are offering the right product and at the right costs.”
What is softwood plywood?
One of the most common types of plywood, softwood is a strong but lightweight utility plywood that is extremely versatile.
What is softwood plywood used for?
Softwood is used for a wide range of construction applications, including:
If softwood ply is being used for external applications, make sure all faces, and edges are sealed before use. This will prevent moisture ingress.
Softwood plywood at Elliotts
At Elliotts, we supply Elliotts Pine from Brazil, this softwood plywood is available in xmm boards, in 12mm and 18mm thicknesses.
Softwood plywood is available to buy from your local Elliotts branch
What is hardwood plywood?
Hardwood plywood is sometimes mistakenly perceived as the “best” quality, which in some cases it is. But in some cases, another product will perform better. Although, it’s worth saying that hardwood plywood will give a good substrate for painting, lacquering or staining.
What is hardwood plywood used for?
Harwood ply is widely used for applications such as:
Hardwood plywood at Elliotts
We supply x mm hardwood plywood in 3.6mm, 5.5mm, 9mm, 12mm, 15mm, 18mm and 25mm thicknesses (EN314/2 Class 2, but can supply EN314/2 Class 3 to order):
Shop our online range of hardwood plywood
If you are looking for more details, kindly visit whole core film faced plywood.