PROCESSING RECOMMENDATIONS Seta

Transcription

1 PROCESSING RECOMMENDATIONS Seta

2 PROCESSING RECOMMENDATIONS GetaLit Seta PRODUCT DESCRIPTION Decor Dekorpapier paper Kraftpapiere papers GetaLit HPL. High-pressure laminate to DIN EN 438. Type HGS = standard quality GetaLit Seta is a High Pressure Laminate (HPL) based on topquality impregnated paper sheets which are cured under high pressure and heat. HPL usually has a core of paper layers im- pregnated with dark phenolic resin and a decor paper treated with colourless resin. Seta has a surface finish with outstanding characteristics and a special visual appeal. Application Decorative laminate in SuperMat surface for indoor application. MATERIAL PROPERTIES General properties Fire behaviour: Type HGS: Building material class DIN 4102-B2 (normally inflammable) Material properties food safe to EN 1186 and EN resistant to common household chemicals steam resistant to EN 438 impact resistant to EN 438 heat resistant up to 230 C light-fast to EN 438 abrasion resistant to EN 438 scratch-resistant to EN 438 2

3 GetaLit Seta is a high-quality laminate with a very homogenous mat surface finish, characterized by a high scratch resistance >4N, a high abrasion resistance, a special appearance and pleasant haptics. In its essential features Seta is comparable with conventional HPL laminate; hence the standard processing methods and tools can be used for Seta as well. The Technical Data Sheet General Processing Tips for Decorative Laminates issued by the Professional Group for Decorative Laminates of the pro-k Association of GKV (The German Association of the Synthetics Processing Industry) on February 1, 2011 is valid both for Seta-HPL laminates and for compound elements with Seta-HPL. This processing guideline is available for download at unter technische datenblätter / pro-k dekorative schichtstoffplatten. Due to its special surface finish, GetaLit Seta features a slightly higher material hardness than conventional laminates. Because of this special property of the Seta-HPL laminate, the fitter has to use special procedures and care and observe the following special and additional instructions. Seta-HPL laminate can be used for surface and edge processing. Test DIN EN 438 Abrasion resistance classification number 3 Scratch resistance (N) 4 N* 1 Stain resistance degree 3 Hot pans test degree 3 Water vapour test degree 3 Damp heat degree 3 Impact resistance 20 N * 1 beige/cream-coloured decors might show minor values Abrasion classes Initial abrasion value Average value 3 (EN 438) Stains Test norm Unity Permissible fault degree Speckles, dirt or similar surface faults Westag & Getalit QA* visual inspection mm/m 2 1,0 mm 2 Fibres, fissures, scratches Westag & Getalit QA* visual inspection mm/m 2 10,0 mm * internal Quality Assurance Tolerances Test standard Unity Thicknesses 0,5 to 1,2 mm 1,2 to 2,0 mm 2,0 to 3,0 mm 3 (EN 438) EN 438 mm ± 0,10 Size accuracy Length/Width Type S EN 438 mm - 5 to +10 Rectangularity/Full size EN 438 mm 0,75 mm/m Permissible undersizes (quantity) none 3

4 PROCESSING RECOMMENDATIONS GetaLit Seta storage conditions and Handling The storage conditions of standard laminates are also valid for GetaLit Seta. Prior to processing, GetaLit Seta has to be conditioned for at least 8 days in the same environmental conditions that are expected for the future use. Storage The panels have to be stored horizontally and flush on a flat substrate, free of residual moisture or humidity, with the reverse sides facing each other. The substrate to be used for bonding with Seta-HPL laminate as a compound element should be stored in the same environment. In this way, all materials will have similar temperatures and moisture contents. Conditioning We recommend a space with a normal room temperature of C and a relative humidity of 50-65%. Materials that are stored in a moist environment tend to produce improper bonding, which may lead to tensions, cracking and warping. Edge damage may also lead to crack formation. Depending on storage conditions, the edge areas have to be particularly protected. GetaLit Seta must not be exposed for longer periods of time to direct sunlight or heat sources, which raise the temperature of the material on a defined area. For thermal insulation we recommend the use of heat tape in combination with aluminium tape or foil. Seta-HPL laminate must be handled with care, because of its harder and smooth surface finish. Protective foil Seta is supplied with a self-adhesive protective foil, which should remain on the HPL laminate during processing. The foil shall be removed only during edge processing, pressing and heat-processing. If the foil is removed before pressing, for example, it is recommended to apply a suitable foil for the further processing steps, if necessary. The suitability of the foil shall be determined through experiments. PROCESSING OF SETA-HPL Tools Due to Seta s special and somewhat harder surface finish, we generally recommend diamond-tipped tools, which are characterized by a long service life and produce an accurate and uniform cut. Carbide-tip tools are also suitable for smaller quantities and shorter cutting lengths. Cutting blades must always be kept sharp. It is important that Seta HPL is not heated excessively, as it may occur in the case of high-speed milling. Sawing Use diamond tools or carbide-tipped saw blades with circular table saws and with circular hand-held saws. In order to ensure chip-free cuts on both sides, it is recommended to use a scoring unit in combination with circular table saws. We recommend the use of a 1mm thick panel as a base to reduce the kerf and the risk of chipping. Milling Generally Seta-HPL laminates can be processed with stable, high-performance milling machines and diamond-tipped or carbide-tipped milling tools with a high concentricity. All tools must be sharpened at all times. To prevent chipping on the exit side, the feed speed of the drill should be reduced continuously. It is also advisable to work with a firm substrate that can be drilled. Drilling Drills for synthetic materials, with a tip angle of approx and a centering tip are recommended for piercing drills (hole-punching). To prevent chipping on the exit side, the feed speed of the drill should be reduced continuously. It is also advisable to work with a firm substrate that can be drilled. If no scoring unit is available, a thicker material, e.g. hardboard, can also be used. It is recommended to use saw blades with alternate tooth or trapezoidal flat tooth at a speed of 4000 rpm. (saw blade diameter 300 mm) and a feed rate of 10 m/min. For hand-held circular saws, a guide rail should be used. All tools must be sharpened at all times. Punching and shearing Punching and shearing are not recommended. 4

5 CREATING COMPOUND ELEMENTS WITH SETA-HPL Material As a substrate for compound elements, we only recommend high-quality chipboards and MDF panels with very good surface properties, because an unstructured matt finish requires more care than a textured surface finish. In the case of other materials, the fitter has to test them in order to make sure that they are suitable as substrates. Balancer A compound element with Seta-HPL must have a symmetrical construction with up to 25 mm thick substrates. Therefore, an identical Seta-HPL laminate of the same thickness has to be used as a balancer. It is important that the running direction and the grinding direction of the HPL laminate are equal on both sides. For thicknesses over 25 mm, different balancer materials can be used; their suitability has to be proven through tests conducted by the fitter. Bonding and pressing For the bonding of Seta-HPL we recommend PVAc dispersions (white glue) of D3 or D4 quality. The bonding pressure has to be chosen according to the instructions of the adhesive manufacturer but shall not exceed 3 bar. Seta-HPL has to be cold-pressed (at room temperature C), in order to avoid distortion. A uniform pressure and adhesive application must be provided throughout the entire bonding surface. Edge bonding The type of edge bonding can be blunt or mitred, according to the aesthetic, practical and functional requirements. Depending on the selected adhesive type, before bonding, all surfaces, except the surfaces to be bonded, should be protected with an adhesive tape against excessive glue (note: pay attention to the resistance of the adhesive used!). We recommend PVAc adhesive glue (D3 or D4). Butt joint bonding For butt joint bonding, proceed similar to edge bonding. This means that the surfaces should be protected in advance with a suitable adhesive tape against escaping glue. Processing of compound elements J Tools General rule for the processing of compound elements with Seta-HPL: due to Seta s special and somewhat harder surface finish, we generally recommend diamond-tipped tools, which are characterized by a long service life and produce an accurate and uniform cut. Carbide-tip tools are also suitable for smaller quantities and shorter cutting lengths. Cutting blades must always be kept sharp. J Formatting of compound elements For sawing see page 4. Depending on the application, a regrinding of the HPL edges should be conducted after formatting (see page 6, Final machining). Creating cutouts in compound elements A good conditioning of Seta-HPL laminate and substrate is very important for cutouts. Even small differences in moisture between Seta-HPL laminate and substrate may create tension, which can lead to crack formation at the inner corners, despite the specified minimum radius. Important: the larger the cutout, the greater the risk of crack formation. To avoid cracking, all corners of inner recesses and cutouts must be rounded off. The inner radius should be high (minimum 8 mm). J Hand router Inner recesses and cutouts can be made directly with the milling tool or can be pre-drilled at a corresponding radius before the cutout is cut from corner to corner. Sharp-edged corners are not material-friendly and lead to crack formation. In addition, all edges must be free of notches. The speed should be between rpm. A cutting speed of 10 m/s is recommended. We recommend as a first choice single-edged or double-edged diamond-tipped cutters and as a second choice carbide-tipped cutters. Seta s surface must be protected by taping or through other means. J Jigsaw Jigsaws with down-stroke blades for wood and plastic can be used for coarse cutouts, when cutting from the top. The pendulum should be set to medium strength. The top has to be protected against chipping, by using adhesive tape for example. J Table router Single-edged or double-edged diamond-tipped tools and sharp carbide-tipped tools are suitable for table routers at a cutting speed of max. 10 m/s and a feed rate of 5 8 m/min. 5

6 PROCESSING RECOMMENDATIONS GetaLit Seta Corner joint milling Corner joint millings, e.g. for kitchen worktops, shall be created according to the usual procedure (see Hand router, page 5). The HPL laminate cutting edges and the cutting surfaces of the substrate panel of the corner joint have to carefully reground. Final machining Use carbide-tipped bevel or square cutters (end mills) with a very high concentricity for deburring or chamfering. To avoid chipping, reduce feed rate at corners and intersections. Extremely careful edge processing with trimming and deburring is very important for Seta-HPL laminates and Seta elements. Edge processing by hand: Choose sandpaper over file and use broaches instead of draw blades. For manual regrinding use abrasive paper not coarser than 240 grit. Basin fitting Drop-in basins can be fitted into a Seta compound element in accordance with the manufacturer s assembly manual. Recessed ceramic basins require a support structure. Carry out the cutouts as described in chapter Cutouts. For sealing we recommend sealants based on polyurethane or silane-modified polymer (MS polymer). Cleaning The surface finish of Seta HPL laminates is unstructured, which means it is highly resistant and homogenous. Light stains can be removed with a damp soft cloth. Heavy dirt can be removed with warm soapy water or with a commercially available cleaning agent (see SETA cleaning recommendation). Particularly heavy stains, such as paint and adhesive residues can be removed carefully with a solvent, such as acetone. Avoid hard rubbing and long exposure times. 6

7 SETA cleaning recommendation Country Cleaning agent Fingerprints Coffee Black tea Red wine Dry ketchup Ink Nettoyant Multi-Usage Spray + o + o o France St. Marc Multi-Usages Anti Bacterien + o o o + La Pierre Du Draguiste o o o Vigor Ultra Degraissant au Savon Noir o o o o + Glassex Nr.1 Glas und Multi Spray o + Mr. Muscle Keuken Lemon Spray + o + + o + The Netherlands/ Belgium Cilit Bang Power Cleaner Spray o o o o + Cif Power Cream Keuken Spray o o + + o + Cif Ultra White Cream schuurmiddel + o + + o + Cif Cream Citrus schuurmiddel + o o Dreft Dishwasing Detergent + o o o + Bref Power Fat Solvent + o o + Germany Frosch Citrus Abrasive Milk + o o + o + Sidol Kitchen Power + o + o + ATA Abrasive Milk + o o Finland Kiilto Keittio Puhdistaja Spray o o + o + good cleaning results o modest cleaning results no visible cleaning results ADDITIONAL INFORMATION Seta-HPL laminate is not suitable for postforming or for use outdoor. Tentativeness note Technical Product Data Sheets are issued to the best of our knowledge and with special diligence. We assume no liability for printing mistakes and errors. Technical changes may occur as a result of the continuous development of GetaLit Seta laminates and of the amendment of standards and documents of public law. For this reason the contents of these Processing Recommendations cannot serve as an instruction manual or as a legally binding document. 7

8 status: june 2012 Plywood/Formwork Doors/Frames Laminates/Elements Westag & Getalit AG Postfach Rheda-Wiedenbrück Germany Tel Fax