5 Reasons Your Panel Might be Warping
You chose the right materials, yet, after laying up your panels, you see that some of your panels have warped. Can you still get a warped panel, even with the right materials? Unfortunately yes. Here are some common reasons for warping and what you can do to prevent it.
1. Moisture imbalance in the core
Your panel may be structurally balanced, but if the core material has an uneven internal moisture content, warping can occur as it dries unevenly after production. It’s important to acclimate your core material to the production environment prior to laying them up. Let them sit for 24 – 48 hours to equalize moisture content across the board.
2. Extreme temperature changes post-production
Just because you’ve acclimated your panel material prior to laying them up doesn’t mean you’re off the hook once the panel is complete. Anytime a panel is exposed to high humidity or excessive dryness, you risk warping. Store completed panels in a climate-controlled environment.
3. Manufacturing inconsistencies
If heat or pressure isn’t evenly applied during lamination, internal stresses can build up, especially if one side gets slightly more heat or adhesive than the other. Be sure you are regularly calibrating your press settings and monitor temperature. Also, ensure the glue is spread consistently across both faces. A well-balanced glue line helps maintain panel flatness.
4. Unbalanced surface Tensions
Just because you’re using a backer that has the same thickness as the decorative face, it doesn’t mean they’re balanced. Differences in surface tension between the face and the backer can cause one side to pull harder than the other. Be sure to select a backer with similar physical properties as the face material. You can find PolyBak’s technical data here.
5. Tension from fasteners or hardware
Improper screw placement, overdriving fasteners, or attaching hardware before the panel has fully acclimated can introduce uneven tension leading to warp. Again, let the panel acclimate fully to the installation environment. Pre-drill where needed, and avoid over-torquing screws. Use mounting methods that allow for slight movement if the panel expands or contracts slightly over time.
Warping is often a result of environmental and process imbalances, not just selecting the wrong material. Addressing moisture, heat, and other factors can dramatically reduce warpage in your panels.
If you’ve gone over each of these steps and are still experiencing warping, give our team a call at 616-243-2700. Our balancing backer experts are here to help!