Laminate Guide — Grades, Thickness and Where Each One Goes
Laminate is sold by decor and specified by grade, and the two have nothing to do with each other. The same oak pattern is available in a sheet that belongs on a wardrobe door and in one that belongs on a laboratory bench — and swapping them is how surfaces fail.
How laminate is built
Sheets of kraft paper are soaked in phenolic resin and stacked. A printed decor paper goes on top — that is the layer carrying the wood grain or the colour — and above it a translucent melamine-impregnated overlay that becomes the wear surface. The stack goes into a heated press, and the resins cure into a single solid sheet.
The number of kraft layers and the pressure applied are what separate the grades. A decorative laminate uses few layers at a few hundred psi. High pressure laminate uses more, at over 1,400 psi, producing a sheet that is thicker, stiffer and far harder to dent. Compact laminate keeps adding kraft layers until the sheet is self-supporting — from 2 mm up to 25 mm — at which point it needs no substrate at all.
That last point is the most useful thing to understand about laminate. Decorative and high pressure grades are surfacing materials: they are only as waterproof as the board they are bonded to, and the board is usually MDF or chipboard, which swells the moment water reaches an exposed edge. Compact has no board in it, so it is waterproof through its whole thickness. That is why washroom cubicles are compact and kitchen carcasses are not.
Grades and what they are for
| Grade | Thickness | Pressure | Use |
|---|---|---|---|
| Decorative | 0.6 - 1.0 mm | Low | Furniture, shutters, panelling |
| Post-forming | 0.5 - 0.8 mm | Low | Rolled worktop edges |
| High pressure (HPL) | 1.0 - 1.5 mm | Over 1400 psi | Worktops, counters, desks |
| Compact | 2 - 25 mm | Very high | Cubicles, lockers, benches |
| Chemical resistant | 12 - 20 mm | Very high | Laboratory surfaces |
| Fire retardant | Various | Varies | Wall lining, escape routes |
| Exterior compact | 6 - 12 mm | Very high | Facade and balcony cladding |
Fitting rules that prevent failures
- Laminate both faces of a board — a board laminated on one side only will bow towards the laminated face. A cheap balancing sheet on the hidden side solves it entirely.
- Acclimatise before bonding — stack sheets flat in the workshop for 48 hours. Bonding a sheet that is still moving locks the movement in and shows up later as bubbling.
- Band and seal every exposed edge — a raw board edge lets moisture into the substrate and the substrate swells. Around sink cut-outs, seal as well as band.
- Use slotted fixings on compact — compact expands and contracts across its width with humidity. Fixing it rigidly at both ends causes bowing months later.
- Round internal corners on cut-outs — a sharp internal corner is a stress concentration and will crack. Drill the corner before cutting the straight runs.
- Expect faster tool wear — laminate is abrasive. Use carbide tooling and accept it will not last as long as it does on timber.
Decorative laminates · High pressure laminates · Industrial and compact laminates
Frequently asked questions
Which laminate should I use for a kitchen worktop?
High pressure laminate at 1.0 to 1.5 mm, or post-forming grade if you want a rolled front edge with no visible joint. Decorative grade is not pressed hard enough for a horizontal surface that takes impact and heat.
What is the difference between HPL and compact laminate?
HPL is a surfacing sheet bonded to a board; compact is thick enough to be the panel itself, with no board involved. That makes compact waterproof through its full thickness, which is why washroom cubicles and laboratory benches use it.
What sheet size does laminate come in?
8x4 feet — 2440x1220 mm — is the international standard. 10x4 ft sheets are produced for worktop runs where a joint would be visible, and compact is available in larger panels to order.
Can laminate be used in a bathroom?
Decorative laminate on an MDF substrate should not be, because water reaching an edge swells the board. Compact grade is fully waterproof through its thickness and is the standard material for bathroom cubicles and vanity panels.
Why does laminated furniture sometimes bow?
Almost always because it was laminated on one face only. The two faces of the board then absorb moisture at different rates and the board curves. Laminating both sides, even with a cheap balancing sheet on the hidden face, prevents it.
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