TECNICAL MANUAL COUNTERTOP APPLICATION

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1 TECNICAL MANUAL COUNTERTOP APPLICATION

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4 TECHNICAL MANUAL COUNTERTOP APPLICATION INDEX INTRODUCTION Product Specification Product Features Packaging Details Handling Transport and Storage INSPECTION Pattern and Joint Laying Measuring and Inspection FABRICATION Fabricate with Saw Blade Machine Machining Principles Machining Parameter For bridge Milling Unit Fabricate with Water jet Machine Machining principles Machining Parameter For Water jet Machine Fabricate with CNC Machine

5 FABRICATION Fabricate with Handheld Cut-out recommendation Desining principles Grinding and Polishing recommendation Joint to Profile 45 recommendation INSTALLATION Preparing to the structure Installation over concrete kitchen cabinet Installation over plywood kitchen cabinet Quality control Cleaning and Maintenance Disclaimer 55

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7 INTRODUCTION

8 INTRODUCTION x x GRANDE COLLECTION The GRANDE Collection by COTTO is an extra-large porcelain slab produced in new format of cm. with 12 mm. thickness. Its superior size extends possibilities and flexibility in architectural application from floor and wall covering to countertops and external cladding. It is produced by state-of-the-art technology from production in Italy. It offers superior properties such as high physical strength, high resistance to heat, frost, acid, and scratch, with low maintenance requirement. SIZE AND THICKNESS 320 cm 160 cm Top view (Lenght and Width) 12 cm Front view (Thickness) COLOR SURFACES and APPEARANCES BASALTINA BIANCO ARGENTO GRAFITE WOOD WHITE GREY BLACK 3

9 INTRODUCTION CEMENT BONE ASH EBONY Remark: photos are for illustrative purpose only,and may not represent final look of products. 4

10 INTRODUCTION SPECIFICATION Specs Test method ISO standard reference ISO Value CEMENT Test Result WOOD STONE BASALTINA length and width : admitted deviation, in%, of the average size of each tile from the production dimensions ISO CONFORMING + 0, 15% + 2 mm , 15% + 2 mm , 15% + 2 mm - - Thickness : average thickness tolerance, in % versus production dimension ISO CONFORMING + 5% + 0,5 mm % + 0,5 mm % + 0,5 mm - - Straightness of edges ISO CONFORMING + 0, 1% mm , 1% mm , 1% mm - - Orthogonality in % ISO CONFORMING + 0, 2% + 2 mm , 2% + 2 mm , 2% + 2 mm - - Flatness (curving in the middle, corner and warping) ISO CONFORMING + 0, 35% + 2 mm , 35% + 2 mm , 35% + 2 mm - - Surface quality ISO CONFORMING CONFORMING CONFORMING CONFORMING % Water absorption ISO E < 0.5% <0.1% <0.1% <0.1% Rupture force in N ISO MINIMUM 1,000 >1700 >1700 >1700 5

11 INTRODUCTION SPECIFICATION Specs Test method ISO standard reference ISO Value CEMENT Test Result WOOD STONE BASALTINA Bending strength N/mm2 ISO MINIMUM 35 >40 >40 >40 Resistance to deep abrasion of unglazed tile ISO <175 MM3 <150 mm3 <150 mm3 <150 mm3 Thermal shocks resistant ISO REQUIRED RESISTANT RESISTANT RESISTANT Resistance to staining ISO Resistance to high concentrations of acids and alkali ISO see Manusfacturer Declaration UHA UHA UHA Resistance to low concentrations of acids and alkali ISO see Manusfacturer Declaration ULA ULA ULA Resistance to house and swimming pool chemicals ISO MINIMUM B UA UA UA Frost resistance ISO REQUIRED RESISTANT RESISTANT RESISTANT 6

12 INTRODUCTION PRODUCT FEATURES COTTO Grande collection is porcelain slabs made from natural materials such as feldspar, silica, and clay. Thanks to its state-of-the-art CONTINUA+Technology, COTTO Grand collection offers superior properties for numerous functions and usages such as kitchen countertops, floor and wall coverings and facade cladding. Technical features: 7

13 INTRODUCTION PACKAGING DETAILS Horizontal Pallet PALLET DIMENSIONS (cm) Finish Length (cm) Height (cm) Width (cm) GLAZED & UNGLAZED thickness 12 mm ( Packing number 7 slabs ) Vertical Pallet PALLET DIMENSIONS (cm) Finish Length (cm) Height (cm) Width (cm) GLAZED & UNGLAZED thickness 12 mm ( Packing number 22 slabs ) 8

14 INTRODUCTION HANDLING 9

15 INTRODUCTION HANDLING COTTO Grande collection slabs must be handled, loaded, unloaded and transported by a forklift, gantry crane or professional lifting machines. In every case of handling and transport, the slabs should be balanced considering Their center of gravity to prevent possible damages or slab breakages. Caution: 1. before handling slabs, please inspect conditions of machines to ensure their workability and make sure that weight of slabs do not exceed the weight limit of machines. 2. Clamps can be used for proper handling, while canvas slings are more suitable for handling multiple slabs at the same time. Given the hardness and sharpness of the material, there may be sharp edges on the slabs. Therefore, it is highly recommended to cover the canvas slings with protective covers to prevent possible accidents or damages to slabs. Please consult the sling manufacturers for details of proper covers. 3. Vacuum clamp is suitable only for slabs with flat surfaces. Using vacuum clamp with other rough surfaces may cause dangers in handling process. 10

16 INTRODUCTION HANDLING Handling Equipment A-Frame to free move Handeling device to free move Handling with Easy Move Double Suction Cup 115 MM 11

17 INTRODUCTION TRANSPORT AND STORAGE Slabs should be loaded for transport and stacked for storage on or in purpose built supporting frameworks and structures such as metal A frames and metal racking systems. Such load bearing and support frames should be coated to prevent rust or any other material from contaminating the load. On such frameworks additional protective surfaces of suitable wood, rubber or plastic should be provided with the purpose of inhibiting the effects of impact and abrasion during transport and any subsequent handling and storage activities. Separate the packs of slabs by inserting wooden battens that should be thicker than the ropes employed for lifting purposes. For storage, and especially for transport, the battens used to separate the slab packs must be centrally aligned with respect to the slab and spaced at a distance of approximately 47 in. Notwithstanding and as a precaution, the tops of slabs should be covered to protected from airborne pollutants such as grit, oil, grease, rust and fuel that are likely to be present in stockyards or standing areas. 12

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19 INSPECTION

20 INSPECTION PATTERN AND JOINT LAYING Laying pattern and the joints between the panel in the same plane Laying pattern and the joints between the sheets in a line - on the bottom or between the folds of the counter. Laying pattern and the joints between the panels in the side (L). 15

21 INSPECTION MEASURING & INSPECTION Slabs Inspection Before fabrication or transformation of COTTO Grande collection slabs, it is highly recommended to clean the slab and inspect appearances of the slab thoroughly for: Color defects such as tonality and contaminations Physical defects such as chippings, blisters, cracks and fissures. Any other anomaly that might be considered a defect. Please note that no claims or complaints will be accepted of fabricated, transformed, or installed slabs that had defects upon delivery Working site Inspection 16

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23 FABRICATION

24 FEBRICATION FABRICATE WITH SAWBLADE Suggestions Aim copious quantities of water when cutting. Water jets must be accurately directed to the front and sides of the blade bit and as close as possible to the cutting area (as represented in the figure below). Make sure the workbench of the cutting machine is in good conditions and perfectly flat. If the milling bench is in poor condition, place a sheet of high-density technical rubber between the workpiece and the bench. 50% of cutting speed applied 150 mm 50% of cutting speed applied 150 mm Slow down the feed rate up to 50% for the first 6 inches inwards and the last 6 inches in outwards. To cut small-sized pieces, it is advised to firmly clamp the material in order to avoid movements during the cutting. 19

25 FEBRICATION MACHINING PRINCIPLES Before starting any processing, the slab has to be trimmed off longitudinally and transversally at a distance from the edge which is proportional to the slab thickness, all the following cuts will be performed starting from the rough side towards the trimmed side as indicated in the figure. Direction of following cuts Direction of following cuts Last cuts Warnings After each machining task, rinse the surface copiously with clean water before the workpiece has dry (better if in vertical position). The cutting direction must always be the same as the saw blade rotation direction. 20

26 FEBRICATION MACHINING PRINCIPLES 1. TRIMMING SCHEME Thickness 12 mm -Minimum trimming 20 mm 1600 mm 3180 mm Minimum actual dimensions 1580 mm 3200 mm 2. PROCESSING ORDER Example : cutting diagram for bridge milling 3rd cut 4th cut 1st drilled hole 2nd cut 6th cut Sequence of machining steps: 1. Core drilling (colour portions Blue) 2. Making through cuts (colour portion Orange) 3. Making interrupted cuts (colour portion Yellow) 5th cut 21

27 FEBRICATION MACHINING PARAMETERS FOR BRIDGE MILLING UNIT PRE-CUTTING DIAGRAM Specific measures: In the presence of one or more of the following condition, we recommend cutting in several passes: - Oversized flange not available - Low water flow rate - Saw blade is in poor condition - Resting base is not flat 1 st cut >1/2 saw blade 2 nd cut Caution Cutting this way it was not always smooth The thickness of the layer, therefor, require grinding tool. By grinding to use diamond grinding disc (GC60 or GC120) section view grinding with Handheld tool (please read grinding recommendation) 22

28 FEBRICATION MACHINING PARAMETERS FOR BRIDGE MILLING UNIT MULTIPLE PASS CUTTING DIAGRAM: 1 st cut 2 nd cut INCREMENTAL PASS CUTTING: Specific measures: In the presence of one or more of the following conditions, we recommend cutting in several passes: - Oversize flange not available - Low water flow rate - Saw blade is in poor condition - Resting base is not flat STRAIGHT PASS CUTTING Thickness mm Saw blade ø Spindle revolutions Feed rate Rim speed mm rpm mm/min m/sec INCLINED PASS CUTTING Thickness mm Saw blade ø Spindle revolutions Feed rate Rim speed mm rpm mm/min m/sec

29 FEBRICATION MACHINING PARAMETERS FOR BRIDGE MILLING UNIT Parameters START OF PLUNGE CUT Thickness mm Saw blade ø Spindle revolutions Feed rate Rim speed mm rpm mm/min m/sec STRAIGHT CUT Thickness mm Saw blade ø Spindle revolutions Feed rate Rim speed mm rpm mm/min m/sec INCLIENED CUT Thickness mm Saw blade ø Spindle revolutions Feed rate Rim speed mm rpm mm/min m/sec Warning: All data refer to discs marked COTTO Grande Any increased current draw of the spindle is an indicator that the saw blade requires dressing using an abrasive stone. 24

30 FEBRICATION Water Jet System is a new versatile fabrication system, which delivers high quality work. It is so flexible that it works with different materials and cutting patterns. 25

31 FEBRICATION MACHINING PRINCIPLES 3. WORKPIECE ORIENTATION Make the holes for sinks or hobs toward the center of the slab and get the folded edges on the outer sides of the slab Incorrect machining Correct machining 26

32 FEBRICATION MACHINING PARAMETERS FOR BRIDGE MILLING UNIT SINK CUTTING: Specific instructions If one or more of the following conditions apply, follow this cutting diagram: - Non-flat resting base - Islands measuring not more than mm - Sinks measuring not more than mm 30 mm Cut 1 Piercing 1 Cut 2 Piercing 2 50 mm 50 mm Warning After each machining task, rinse the surface with clean water before the work piece has dry. 27

33 FEBRICATION MACHINING PARAMETERS FOR WATER JET MACHINE WATER JET Parameters piercing Thickness Pressure Speed Abrasive mm Bar mm/min kg/min Suggestions When possible, make the entry hole outside the slab. Alternatively, make the entry hole a few inches away from the cutting perimeter and never less than 7-32 in away. Water level in WATERJET TANK : It is good practice to keep the water equal to the 0 bench surface Slab Water level Metal slats 28

34 FEBRICATION FABRICATE WITH CNC MACHINE CNC MACHINE Parameters (Driller CNC) Thickness mm Feed rate mm/min Spindle revs rpm Parameters (Pofilling Polishing CNC) Thickness mm Feed rate mm/min Spindle revs rpm

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36 FEBRICATION FABRICATION WITH HANDHELD TOOLS Cutting Tools Using professional fabrication tools in high quality fabricated output. It is recommended to use electric tools and diamond-bits cutting blade for cutting high-strength materials such as porcelain slabs. Cutting blade can be categorized into 2 types 1. Diamond blade size 4 "for cutting tiles. The blades have been around some teeth. Tiles can be cut to a minimum disintegration. By cutting both dry and water. 2. Diamond blade size4 "for cutting granite. The blades are thick around the teeth. Tiles can be cut with thick, but must use the cutting speed and cutting water use. 31

37 FEBRICATION Piercing tools It is recommended to use electric drill and hole saw in wet cutting only. Piercing tools are suitable for making holes on countertops for faucets, taps, and washbasins. Grinding tools and Polishing tools Polishing Tools polishing a rough guide as to the number and the number of sanding respectively. It is recommended, or granite blades (4 ) diamond grinding disc (GC60 or GC120) which could be used both in dry and wet cutting. However, it is recommended to be used by skillful fabricators to prevent possible damages. In case of cutting long slabs, it is recommended to use cutting guide, as it helps improve cutting quality and reduce possible damages. 32

38 FEBRICATION CUT-OUT RECOMMENDATION Cutting with electric hand-held tools 1. Make sure that working space is clean and perfectly flat, then plan cutting pattern of slabs into smaller pieces. 2. Attach COTTO slab on working space/desk. It is recommended to place a layer of wooden plank below the slab to prevent possible damages. 3. Start cutting from edges around slab with lower cutting speed. continue cutting line until it reached 1/3 of slab length, then stop and start cutting from opposite side of the slab until it reaches previous cutting mark. This is to prevent possible breakage of slabs. It is also important to make sure consistent cutting force during cutting process. 4. Recheck the output to ensure the right designed size. Trim and polish with polishing disc (number ) to remove sharpness of the slab. 33

39 FEBRICATION CUT-OUT RECOMMENDATION Cautions and recommendation 1. Cutting with water feeding is highly recommended to reduce friction and potential damage during fabrication. 2. For cutting with water feeding, please feed water both from above and below the blade to increase cutting efficiency. Recommended cuts should start by cutting down to just half a sheet. Cut again to the Slab is cut off. 3. Damage of fabrication tools might be a result of; Slab feeding speed is too fast Too high friction 4. Damage of slabs might be a result of; Slabs are too hard for cutting blades or machines. It is not recommended to lower cutting speed, as cutting blades might be damaged. Weight of slabs is not balanced, or not equally distributed. It is recommended to use double suction cup or the free more to lift and handle slabs. 34

40 FEBRICATION CUT-OUT RECOMMENDATION Piercing with general tools Piercing holes on COTTO Grande collection slabs can be achieved by general piercing tools in different shape such as circle and rectangular to serve different purposes. Piercing circular holes by hole saw 1) Make sure that working space/desk is clean and flat, and match hole size with proper hole saw. 2) Pierce with electric drill, clean dust and in spect work quality. *To ensure flatness and roundedness, use Stone Wet Polishing Kit with Diamond Pads 35

41 FEBRICATION CUT-OUT RECOMMENDATION Piecing large holes for sink or basins 3) Polish the slab by following instruction in Polishing tools 36

42 FEBRICATION CUT-OUT RECOMMENDATION Manual machining Warning During any type of manual processing the workpiece should be adequately supported with a flat resting base in good condition, preferably made of wood. For any type of machining process, always use high water flow rates. Suggested sequence The sequences described are subject to possible variations due to ongoing research into improvements in product fabrication. We recommend contacting your dealer or the COTTO Grande technical service department for any details you may require. 37

43 FEBRICATION DESIGNING PRINCIPLES Suggestion for sink cut the Countertop 1st Drille holes 0 Suggested core drill bit 35 mm 5th cut 4th cut 3rd cut 50 mm The saw blade cut must be tangential to the circumference and must not proceed beyond the circumference 50 mm Specific instructions If one or more of the following conditions apply, follow this cutting diagram: - non-flat resting base - islands measuring not more than mm - sinks measuring not more than mm 4th cut 1st Drill holes 2nd cut 6th cut 3rd cut 5th cut 7th cut 0 Suggested core drill bit 35 mm 38

44 FEBRICATION DESIGNING PRINCIPLES Internal Angles and Sink Hole All internal angles must follow a minimum radius of 5 mm. A greater radius imparts greater structural strength to the material (see figure 1), while any non-radius angle will create a stress point on the top (see figure 2 and 3). Figure 1 Figure 2 Figure 3 Minimum Distance Between Edge and Sink Hole The minimum recommended distance between the sink hole and the outer edge of the workpiece is 50 mm. 50 mm 50 mm We recommend supporting the top adequately with the reinforcement in slab, or using material having the same thermal expansion coefficient (e.g granite). 39

45 FEBRICATION DESIGNING PRINCIPLES Minimum Distance Between Slab and Wall The recommended minimum distance between Slab and the wall is 2 mm. Slab Thickness 12 mm. 2 mm Minimum Distance Between Slab and Wall The recommended minimum distance between Slab and the wall is 2 mm. Sink Over Worktop Slab Thickness 12 mm. Flush-fitting sink 2 mm Slab Thickness 12 mm. 2 mm 2 mm 40

46 FEBRICATION DESIGNING PRINCIPLES Minimum Distance Between Slab and Induction Hob The recommended minimum distance between Slab and the induction hob is 2 mm. Over Worktop mounted induction hob Slab Thickness 12 mm. 2 mm Flush-fitting induction hob Silicone or seal > 5 mm Slab Thickness 12 mm. 2 mm 2 mm Minimum Distance Between Slab and Gas Hob The recommended minimum distance between Slab Grande top and the gas hob is 2 mm. Over Worktop mounted induction hob SlabThickness 12 mm. 2 mm 41

47 FEBRICATION GRINDING ANDPOLISHING RECOMMENDATION Grinding by general tools 42

48 FEBRICATION JOINT TO PROFILE 45 RECOMMENDATION Step up the joints between the pieces are beautiful. You can do the following: 1. workpiece profile 45 recommendations made chamfer at least 1 mm. 2. Buffering two pieces together using epoxy joints. chamfer at least 1 mm. Use epoxy filler Polishing Apply the polish with a polishing sanding number 50,150,300 and Apply the polish with a polishing resolution number and 3000 respectively. 43

49 FEBRICATION OVERHANG SAFETY For more information on the safety of COTTO Grande handling, processing and disposal, we invite you to download the Safety Sheets from download area in our site. Parameters (high pressure) Material required support Thickness 12 mm Sketch No additional support required Recommended A<150 mm A Static Laod Without Impact Max weight 130 Kg 350 mm A A A A A A A A A A 44

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51 INSTALLATION

52 INSTALLATION PREPARING THE STRUCTURE 12 mm 8 mm 47

53 INSTALLATION PREPARING THE STRUCTURE The process of preparation Structural plywood counter. 12 mm 8 mm 48

54 INSTALLATION INSTALLATION OVER CONCRETE KITCHEN CABINET it is recommended to install with cement glue by sandwich technique by following process; 1. Mix cement glue with clean water in ratio of 1 bag of cement and 5-6 liter of water 2. Mix until the paste is homogeneous, and leave 10 minutes before mixing again. 3. Use U-shaped trowel to apply cement paste over installation areas, make sure constant application over the whole area. 4. Use V-shape trowel 3 mm to apply cement paste on the back of slabs consistently. 49

55 INSTALLATION INSTALLATION OVER CONCRETE KITCHEN CABINET 6. Clean slab surface to remove stain and dust 8. Leave epoxy grout for 24 hours 50

56 INSTALLATION INSTALLATION OVER PLYWOOD KITCHEN CABINET The counter surface plywood paneling 1. The surface material is enclosed sheet Cement Bonded / Particle Board recommended installing concrete structure in the same way. Adhesive Bonding Cement with over 1.0 N / mm2 We recommend using glue, nails and modified silicone material as the adhesive. With this installation procedure 2. Fires tack adhesive and modified silicone. The point spread over the entire surface area of the installation. The adhesion spread evenly across the plate. 3. Epoxy grout the joints with colors like Grande sheets before mixing with Hardener accelerator, and immediately the grout.various joints Be careful not to stain the surface, leaving the Epoxy Seth 5-10 minutes, then trim the seam beautifully. Then leave it for about 24 hours before use. 51

57 INSTALLATION QUALITY CONTROL After installation of countertops, installers should inspect quality of finished work to ensure the best quality work, or to fix minors problems which may occur during installation. Quality control should cover following issues; 1. Overall visual look and touch 2. Correct dimension and sizes 3. grouting and joint 4. Flatness and seamless joints 5. Clean surface without stains 6. Physical damage such as chipping, cracks, blisters 7. Consistent level of shininess from polishing 52

58 INSTALLATION CLEANING & MAINTENANCE General cleaning instruction 1. Clean your COTTO Grande collection countertop regularly by using soft cloth or a microfiber cloth to remove dust and stain from the surface. 2. COTTO Grande collection countertops can be washed and cleaned with warm water. Household detergent or cleaning agents can be used for better cleaning effects in the dose recommended by the manufacturer. (Avoid products containing hydrofluoric acid and its derivatives) Rinse with warm water and dry with a cloth or similar. 3. In case of spilled liquids or stains, it is highly recommended to clean and dry it as soon as possible. Leaving stains on the surface may cause difficulties in removing them. 4. Some of the detergents or household cleaning agents may contain waxes or polishing additives which can leave an oily film on the surface after repetitive use. 53

59 INSTALLATION CLEANING & MAINTENANCE COTTO Grande ars non porous [due to their high quality raw materials, stringent production parameters and state of the are technology], hence any dust or deposited waste cannot penetrate the surface. But its is necessary to remove the from the surface. For most cases only a damp cloth is sufficient for cleaning. Regular cleaning highlights the aesthetic features of the surface gives it exceptional shine. For highly aggressive cleaning caused by some common food and substances followthe table below. TYPE OF STAIN CHEMICAL PRODUCT EXAMPLE Cement Acid Hydrolic acid Oil ISO Solvent Ammonia Coffee Alkaline - Solvent Ammonia or Bleach Rubber ISO Solvent Alcohol Rust Acid Hydrolic acid Ink ISO Oxidant Solvent Alcohol Candle wax Solvent Alcohol 54

60 DISCLAIMER The aim of this manual is to offer some helpful guidelines and suggestions about machining, laying and maintaining the COTTO Grande slabs. Information contained herein reflects the state of art of the Producer s technical, scientific and operational knowledge at the time of its publishing; it is therefore highly advised to keep up with the latest version available on the site in the download area. However, since it is a sintered ceramic material, we highly recommend the user not to restrict himself to the indications herein but to consult the wide technical, scientific and operational literature available on this subject, as well as to refer to professionals for the various machining and laying phases of ceramic products. Since no complaint will be accepted on installed materials with defects existing at delivery, it is advisable to check the color shade, thickness and surface finish at delivery. In case of complaints it is advisable to contact COTTO technical team, addressing your to cotto@scg.co.th ; our technicians will be at your disposal. 55

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62 Thai Ceramic Co., Ltd. 1 Siam Cement Rd., Bangsue, Bangkok 10800, Thailand.

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