Oak lumber is procured from saw mills located close to our flooring plants. The green lumber is dried to an average 8% moisture content in a controlled 2-step process. Following the drying process, the oak lumber boards are ripped into sticks. The sticks are inspected manually and with electronic sensors, and then cross-cut to eliminate some natural defects found in wood like open knots, bark and other imperfections. The cut sticks have a random length between 1 to 6 feet. The ends of the wood sticks are shaped, which allows each stick to form joints with other sticks at their ends.
Melamine glue is applied to the lateral sides of individual sticks and the sticks are assembled side-by-side on a conveyor to form a 4 foot wide layer of stick. Joints are formed at the ends of sticks. The assembled wood layer is transferred to a large radio-frequency press. The press applies side pressure on the assembled wood sticks and cures the wet glue in a few seconds by means of radio-frequency heating to make a rough panel. At the out-feed end of the press, the wood panel is rip-sawed into individual rough boards of approximately 10” to 13” in width. The boards are cut to the length as specified in the OEM drawings, typically between 20 to 53 feet. The rough boards are machined on all four sides to make finish boards as per the drawings.
There are numerous different flooring thicknesses, widths, lengths and edge profiles, which are customized for the various trailers, containers, and truck bodies.