The process for creating flooring
Flooring is a floor material made from solid wood.
For Japanese people, who remove their shoes at home, the floor is the area closest to the body and with the most opportunities for physical contact. Using solid wood flooring for that area you most come in contact with makes your daily life and your living space all the more pleasant.
In addition to the physical sensation of solid wood flooring, its appearance and sense of quality are among its greatest charms. In the same way that cuisine looks more appealing when served on fine dishware, furniture looks more luxurious when resting atop a high-quality floor. When you flip through stylish interior design or architectural magazines, you see that most of the houses use solid wood flooring.
That is how much solid wood flooring improves the appearance and sense of quality in a home.
Scratches and dents are some of the demerits of solid wood flooring, but changing your view point will help you see these instead as forms of “flavor” and “affection.” Another charm of solid wood is being able to enjoy the color as it changes over the years.
1. Lumbering and sawing
Logs are systematically cut, while taking into consideration tree growth rates. The logs are sawed into planks by calculating the “drying allowance (the amount the wood shrinks as it dries)” and the “chipping allowance (the amount of surface shaved to turn it into laminated wood)” that is necessary to match the final thickness of the laminated wood.
2. Drying and conditioning
The Planks created are sun-dried (air drying) for several weeks and then artificially dried in a drying room. Through the processes of artificial drying, the moisture in the wood (moisture content) is reduced to less than 10%. During the drying stage, the planks shrink, twist, bend, warp and crack. This shows the nature and individuality of each tree as they differ based on their growing conditions. If the planks are not dried, it could cause cracks, bending or mold. Following the artificial drying procedure, the planks are removed from the drying room and exposed to the outside air for several days, which returns the moisture content to approximately 12%. (Conditioning)
3. Wood conversion and material selection
Flawed portions are cut out of the planks and the planks are then sorted by grade.
4. Joint processing
Three to five planks, the edges of which have been milled, are joined lengthwise to prevent the joint section from slipping. The surface joints are in a straight line, so nothing feels out of place.
5. Tongue-and-groove joints processing
Tongue-and-groove joints are installed lengthwise along the plank. These joints make it easier for the planks to attach together during installation and they improve appearance by hiding nails.
In addition, solid wood is a living thing, so the width of the planks will expand and shrink depending on the humidity in the environment in which they are used. However, this processing prevents gaps showing the underfloor even if the widths of the planks have shrunk.
Next, tongue-and-groove joints are also installed on the ends of the planks (end-matching).
End-matching facilitates and accelerates on-site installation. The planks firmly fit together, which helps prevent warping and twisting. In addition, it allows for a more beautiful finish as it hides the unevenness of the joints.
6. Surface sanding processing
Simply put, sanding processing means the state of having applied sandpaper. It may be difficult to see, but the product is covered in fuzz, so the surface is meticulously smoothed using a machine called a wood sander.
The surfaces of coated products are coated. The coating is applied and then the surface is polished. This process is repeated to beatify the coated product.
8. Packaging and shipping
The finished products are subjected to a close external inspection one by one. They are then beautifully packaged and shipped. The pieces of flooring in contact with the surface of the box are inserted face down to ensure that their surfaces are not damaged by the cutter blade when removing flooring from the packaging.