Plywood is an important wood-based construction material yet prone to water uptake, as such potentially decreasing mechanical properties and increasing decay risk. It is therefore, essential to understand the moisture behavior and structural changes of plywood in service. In this research, several plywood specimens were exposed to outdoor weathering conditions for approximately 1 year. During this period, the average moisture variation of and moisture distribution in different veneer layers of a set of plywood specimens and detailed field weather information were recorded continuously. The internal structure of the specimens was also monitored by periodically scanning using X-ray CT. Measurements indicate that moisture distribution in plywood is not homogeneous in outdoor conditions. The second layer can, in some plywood types, accumulate a significant amount of rain, and long rainy periods and cloudy weather can keep the moisture content of the inner layers of plywood significantly high. Moisture accumulation and moisture dynamics, in combination with wood species, are the main factors causing structural changes, mainly occurring as cracks, of the plywood veneers in service. The glue line between the veneers, however, is not ruptured after 1 year of outdoor exposure. Plywood with layers having a slow water sorption and fast water desorption could effectively avoid internal moisture accumulation and cracks in service. Based on the knowledge of the interrelationship of weather data, internal moisture behavior and structural changes in service, fit-for-purpose design of plywood could be improved and service life prediction is at hand.
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