1. Bamboo raw material
Inspect culm quality and select prime lengths for Teragren products.
Cut to 30 to 35 feet in the field, culms are inspected at the factory for age, cracking, pests and general health. The premium part of each length is selected for Teragren products and then cut into slats. The remaining culm lengths are sent to nearby factories for use in other non-Teragren products.
2. Moisture control
Check kiln-dried slats to confirm moisture content of approximately 6 to 9 percent.
After the slats have been treated in a natural borate solution to kill pests and mildew, they rest in the kiln drying room for four to five days. This stabilizes the bamboo to prevent the likelihood of cupping, delamination, and expansion and contraction of end products.
3. Slat grading and sorting
Inspect slats for grain, quality, color consistency, thickness and length, and bundle by function in the end product (e.g., top "wear" layer or substrate).
After the slats are first planed, they are inspected and graded for use in flat grain or vertical grain layers of our products. Those with the most consistent grain and color are reserved for use in the visible top or "wear" layer. Others form the strong cores or substrates of various Teragren products.
4. Moisture control
Kiln dry bundles of slats and confirm moisture content of approximately 6 to 9 percent before lamination.
Bamboo is a natural material that, like other hardwoods, absorbs and loses moisture from the air around it. By fastidiously acclimating the slats at various points in the manufacturing process, we ensure the optimal conditions for each phase of manufacturing which also ensures a more durable end product.
5. Lamination
- Double-check each slat layer for consistent color and thickness before proceeding with adhesive lamination on the hydraulic press
- Check adhesive coverage on slats
- Inspect top layer to ensure that best slats are presented as wear surface
- Check hydraulic press plates for cleanliness, duration, temperature and pressure
- Inspect blanks—the laminated layers of slats—for potential delamination
6. Blank grading and sorting
Inspect, grade and sort planks for defects, voids, delamination or inconsistent coloration.
7. Moisture control
After being stored in a humidity-controlled warehouse for two weeks, blanks are checked for moisture content of approximately 6 to 9 percent.
8. Milling
- Test run and sample plank inspection
- Plank inspection every 10 minutes to ensure consistent milling tolerances from production run to production run
9. Sealing and sanding
- Inspect tongue-and-groove polyurethane seal
- Sand product one time and inspect for sanding quality
Sealing the tongue-and-groove edge of Teragren products is an extra step that helps prevent moisture absorption after installation and ensure long product life.
10. Finish line
- Sand planks again before finishing
- Inspect the 7-coat German aluminum oxide/polyurethane finish coatings
11. Packaging
- Inspect each carton for correct type and quantity of completed planks
- Final color inspection of planks
- Check for correct SKU marked on carton
In addition, Teragren conducts random spot checks throughout production.
