GetaCore processing and care instructions

Transcription

1 GetaCore processing and care instructions

2 Contents Product description Page 6 Page 7 Adhesives Page Sheet material Material structure Material properties Typical application areas Transport and storage Disposal/health & safety Behavior in fire Worktops Specification Substrate GetaCore surface Adhesive layer (surface bonding) Adhesive layer (edge capping) Transport and storage Handling and processing GetaCore worktops in case of fire Disposal Technical data GetaCore worktops and sheet materials 1.3 Quality features 2.1 Surface bonding 2.2 Bonding GetaCore to GetaCore 2.3 Unsuitable adhesives Required tools/materials Page 10 Page 10 Page Tools required for processing 3.2 Processing 3.3 Mechanical work 4 Processing recommendation Page 13 Page 18 Page 20 Page 21 Page 22 Page 33 Page 34 Page 35 Page 40 Page 42 Page Surface bonding of GetaCore 3 mm onto a substrate of 3 mm translucent GetaCore on acrylic glass of 10 mm GetaCore onto frame structure of 10 mm GetaCore on melamine-coated surfaces 4.2 Edge glueing Edge capping Edging under the top s surface 4.3 Corner joints and butt joints 4.4 Cut-outs for sinks and hobs 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted Installation of sinks from above Installation of stainless steel sinks Stainless steel sink undermounted Adhesive recommendation - installation of sinks 4.6 Sanding 4.7 Thermoforming 4.8 Renovation and repair 4.9 Upstand installation mm wallback panelling 4.11 Installation of 10 mm window sills 2

3 5 Care and cleaning Page 45 Page GetaCore Care Set, large Instructions for use for matt silk surfaces Instructions for use for high-gloss surfaces 5.2 GetaCore Care Set, small Instructions for use for matt silk surfaces 6 Further recommendations Page 48 Page 48 Page 48 Page 48 Page 48 Page 48 Page 49 Page 49 Page Choice of decor 6.2 Surfaces 6.3 Adhesive joints 6.4 Holes in general 6.5 Outdoor use 6.6 Installation of a kitchen waste shredder in GetaCore sinks 6.7 Handling/care 6.8 Special features of GetaCore -Star decors 6.9 Special features of GetaCore -Terrazzo decors 3

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5 Foreword GetaCore An excellent choice! You have chosen a very attractive material: The pleasant touch and seamless appearance - just to name a few advantages - are just some of the convincing selling points amongst many others. In addition, GetaCore is produced in matching colours so that we can guarantee you a colour match, irrespective of the thickness and product versions. The individual processing steps are explained in this booklet in order to recommend to you the optimum processing methods. Please follow these instructions carefully so that you and your customers can enjoy GetaCore products for a long time! If you have any further queries, please do not hesitate to contact your dealer or Westag & Getalit AG. 5

6 solid surface material 1 Product descriptions 1.1 Product description of GetaCore sheet material Material structure GetaCore is an acrylic-bound, homogeneous solid surface material. GetaCore consists of two main components: Aluminium trihydrate (ATH) filler Acrylic resin binder (PMMA, polymethyl methacrylate) with different additives A special characteristic of this material is its uniform colouring, which remains even all the way through the board. This solid surface material gives you a perfectly hygienic, long-lasting surface that is also resistant to impact and stains. It lies in the nature of the product that it may show minor scratches which can - and this is a major advantage of the product over other work (furniture) surfaces - be sanded away and which can even be repaired (see relevant chapters within this booklet). GetaCore material will be delivered in a wet-sanded version and can be individually processed to achieve a range of finishes from matt tomatt silk (Seidenmatt) and even high-gloss using an orbital sander (we recommend to use) Material properties Properties of GetaCore solid surface material: Non-porous Homogeneous Easy to clean Easy to care for Hygienic Can be processed similar as wood Thermoformable Seamless joints possible Food safe according to Recommendation EN 1186 and ENV Resistant to staining Water-resistant Highly resistant to impact Light-fast wool standard level 6 according to ISO 4892 Can be repaired Surface can be maintained by sanding Typical application areas Suitable applications for horizontal interior surfaces include e.g: Kitchen worktops for domestic applications. Worktops in clinics, doctors surgeries, schools, laboratories, dentists. Basin cabinets, basins in bathrooms. Counter tops in shops, public buildings, hotels or catering establishments. Suitable applications for vertical interior surfaces include e.g.: Wall-panelling in elevators, baths, showers. Partitions for changing rooms and solariums. Furniture panels in damp rooms such as in bathrooms or kitchens Transport and storage Transport: Boards delivered to your facility should always be unloaded with the aid of a fork lift truck or similar hoisting gear. If such equipment is not available, each solid surface material board must be carried upright by two people. To avoid scratching, boards should not be dragged off the stack. Wear protective gloves when carrying the boards. Boards should preferably be carried upright when transported by hand; when transported horizontally, the board must be suitably supported to prevent it breaking or cracking. Use suitable transport equipment such as lever-type grips, manual suction cups or panel transporters. Storage: Solid surface mouldings must always be treated with great care. The products are packed to ensure maximum protection during transport, for the mouldings are exceedingly susceptible to harsh knocks and bumps, especially at temperatures below 15 C. Solid surface sheet material/worktops must be stored in a flat, level position and supported over their full length to prevent warping or sagging. They must not be laid directly on the floor. The storage room must be dry and frost-free. The optimum temperature for storage is between 15 and 25 C Disposal/health & safety GetaCore dust is non-toxic. GetaCore dust can have a general irritant effect just like other non-toxic dusts. The dust concentration should be minimized by taking suitable precautions (air extraction, dust mask/dust limit value: 2 mg/m3). In persons with a tendency to suffer from allergies, direct contact can lead to irritation of the skin and respiratory tracts. GetaCore dust does not represent a specific explosion risk. GetaCore is a hardened acrylic resin composite material and can be disposed of as industrial waste. The following protective equipment is generally recommended for the respective activities: Sawing, cutting, chamfering: protective glasses, breathing masks if necessary. Glueing, cleaning: gloves Behavior in fire GetaCore sheet material behaves favourably in fires as a result of its material composition and it is classified as normally inflammable (DIN B2). No toxic materials such as heavy metals or halogens are released in case of a fire. The same fire fighting techniques can be used as for wooden construction materials. 6

7 1.2 Product description of GetaCore worktop Specification The information in this product data sheet applies to GetaCore elements consisting of a particleboard/chipboard substrate faced with an acrylic-bound 3 mm GetaCore solid surface sheet, a 0.24 mm balancer on the reverse side, a 10 mm GetaCore front edge and a cork strip serving as a flexible expansion joint between the front edge and the substrate Substrate The substrate is an E1 quality particleboard/chipboard according to DIN EN 312. It has a low formaldehyde emission potential in accordance with the requirements of the Chemicals Prohibition Ordinance and DIBt Directive 100 issued by the German Institute for Construction Technology, and officially certified for the use in interior rooms GetaCore sheet material - GetaCore surface The material described as GetaCore is a decorative acrylic-bound solid surface material. GetaCore solid surface materials mainly consist of acrylic resin binder (PMMA, polymethyl methacrylate) and the solid surface filler aluminum trihydrate (ATH). GetaCore is a homogeneous, non-porous solid surface sheet material which is suitable for interior fittings Adhesive layer (surface bonding) Special PVAc adhesives are used for bonding GetaCore 3 mm sheet material onto the substrate. The quality of the adhesives is >D3 (according to DIN EN 204). Please contact the adhesive manufacturer first if you intend to use different types of adhesive. Application rate: g/m2 Pressing pressure: N/cm2 Pressing temperature: Cold (max. 30 C) Balancer: GetaLit (0.7 mm laminate) Handling and processing Due to the possible presence of sharp edges, always wear protective gloves when handling these elements. When processing GetaCore worktops, make sure to select the correct tools and please make sure that the usual safety rules and processing principles for solid surface- and wood materials are observed. Wood dust (chiefly from softwood) is produced during the processing (sawing, cutting) of GetaCore elements. In conjunction with other organic constituents, this can lead to irritation of the skin and respiratory tracts. Long-lasting affects have not been discovered, provided the dust content in the air at workplaces remains within the statutory limits. Preventative measures are limited to regularly checking the workplace. Workplaces must be well ventilated. Loose dust must be cleaned away regularly using a vacuum cleaner or careful brushing. Compressed air should not be used for cleaning away dust. Wear suitable breathing masks in dusty surroundings, in order to reduce dust inhalation GetaCore worktops in case of fire Wood materials are used as substrates, therefore GetaCore elements behave similarly in fire as other wood products. When used as a construction material, they are classified as normally inflammable (B2 according to DIN 4102) without further evidence. In case of incomplete combustion, there may be toxic substances in the smoke as with any other organic material. If GetaCore worktops are involved in fire, it is possible to use the same fire fighting techniques as used for other wood-based construction products Disposal Waste material code according to the Waste Directory Ordinance: Construction and demolition waste (wood, glass and plastic) Adhesive layer (edge capping) GetaCore joint adhesive (two-component acrylic adhesive), colour-matched to GetaCore decors Transport and storage The basic principles in the General Processing Recommendations for GetaCore Sheet Material apply to transport and storage. Special safety precautions are not necessary. GetaCore worktops are not hazardous materials in the sense of the transport provisions. As a result, no identification is required. 7

8 solid surface material 1.2 Product description of GetaCore worktop Technical data of GetaCore worktops and sheet materials Physical data of GetaCore Test standard Unit of measure Remarks* GetaCore worktop GetaCore 3 mm GetaCore 10 mm Dimensions: Length mm / /2040 Width mm 1250/ / /615 Thickness mm Tolerance: Length mm -0/+15-0/+15-0/+15 Width mm ± 1-0/+10-0/+10 Thickness mm ± 0,5 ± 0,2 ± 0,2 Density DIN EN 310 kg/m 3 (1) Weight kg/m 2 30,5 4,8 19,2 Coefficient of thermal expansion DIN K -1 (3) 5, , Flexural strength DIN EN 310 N/mm 2 (1) Modulus of elasticity DIN EN 310 N/mm 2 (1) Indentation hardness DIN ISO N/mm 2 (1) Impact resistance (small ball) DIN EN N (1) 70 Impact resistance (large ball) DIN EN mm (1) 2000 Scratch resistance DIN N (1) 1,4/4 D 1,4/4 D Tensile strength DIN EN ISO 527 N/mm 2 (1) Elongation at rupture DIN EN ISO 527 % (1) 0,7 0,7 Behav. when exposed to hot pans DIN EN 438 (180 C) (1), (9) Level 3 Level 3 Behav. when exposed to water vapour DIN EN (1), (9) Level 3 Level 3 Level 3 Stain resistance DIN EN (6), (9) Level 3 Level 3 Level 3 Behav. w. exp. to glowing cigarettes DIN (1), (7) 6 D 6 D 6 D Light-fastness DIN EN ISO 4892 gray scale (1) blue scale Temperature fluctuation resistance IHD-Werknorm 426 (-50 C/+60 C) (2) Passed Passed Passed Dimensionchange after exposure toheat DIN % (3) -0,2-0,1 Dimension change DIN EN 318 % (1), (8) 35/85% relative humidity Particleboard: D= 4.6%/L= 0.24% GetaCore surface, no change Other properties: Food-safeness ENV EN /109 and (4) Authorized 90/128/EWG Resistance to mold and DIN EN ISO 846 A, (5) Resistant bacterial attack BIB`, C Other information: Storage, handling, transport No hazardous substance as defined in the Hazardous Substance Ordinance Protective equipment Wear protective gloves and use suitable transport equipment when carrying Fire and explosivion protection None required as defined in the Hazardous Substance Ordinance Disposal EAK code Nr. (10) Processing: Workplace Usual health & safety measures (extraction, protective glasses, dust masks, etc.)/dust limit value 2 mg/m3 Explosion protection No particular precautions, dust explosion class St VDI 2263 Toxic effect in use None, solid surface materials are physiologically safe and permitted to be in contact with foodstuffs Formaldehyde emission DIN EN mg/h m2 <3,5 (gas analysis) Not measurable *Remarks (1) IHD-Dresden test certificate dated (2) IHD-Dresden test certificate dated (3) Test certificate no /02-1 SKZ-Würzburg (4) ISEGA Aschaffenburg certificate no U 01 (5) ISEGA Aschaffenburg certificate no. 550 GD 02 (6) DIN EN 438 resistance list is available on request. Solvents containing acetone, methylene chloride or trichloroethane, e.g. some stain removers and nail varnish remover, may damage the surface if left for a considerable long time on the surface. In accordance with our processing and care recommendations, such damage can be repaired using an appropriate surface treatment. (7) The yellowing can easily be removed using a Scotch-Brite scouring sponge and a mild scouring cream. A re-sanding of the complete work surface may be necessary. (8) Particleboard/chipboard composite element with 3 mm GetaCore surface and GetaLit 0.7 mm laminate balancer (9) Evaluation scale: Level 1: Surface damage and/or blistering Level 2: Major change in gloss level and/or colour Level 3: Moderate change in gloss level and/or colour Level 4: Slight change in gloss level and/or colour, only visible from certain angles Level 5: No visible changes (10) Disposal according to EAK code: : Wood, glass and plastic (construction and demolition wood) : Waste from mechanical processing of plastic All information given in this code of practice is based on the current status of technical knowledge, but does not represent a guarantee. The individual user of the products described in this code of practice is personally responsible for complying with the existing laws and regulations. 8

9 2 Adhesives 1.3 Quality features Food safe according to Recommendation ENV EN 1186 Heat resistant up to 180 C in accordance with DIN EN 438 Light-fast wool standard level 6 according to ISO 4892 Seamless joints possible Easy to clean Warm feel thanks to outstanding material properties Can be repaired and surface can be maintained by sanding Resistant to common household chemicals in accordance with DIN EN Surface bonding 3 mm sheet material PVAc adhesives and PUR adhesives are ideally suited for bonding GetaCore onto a wooden substrate. Contact adhesives may be used only with restrictions. 10 mm sheet material The 10 mm sheet material is glued onto the substrate floating (2 mm elastic adhesive joint). Suitable adhesive: MS polymer. If GetaCore is to be bonded onto a plywood-substrate, we recommend to use PUR adhesives (recommended: Sika Bond T54FC). 2.2 Bonding GetaCore to GetaCore When GetaCore materials are glued together, use the GetaCore adhesive specially developed for this material. IMPORTANT: Max. width of joint 0.1 mm to obtain a seamless appearance. Please note the following points before working with the 2-component GetaCore acrylic adhesive: Leave the GetaCore adhesive standing upright in its container for 24 hours at room temperature prior to glueing. Insert the GetaCore adhesive into the gun provided, screw on the mixing nozzles and press out a bead of adhesive of approx. 10 cm length to ensure the components are being properly mixed. Whilst doing this, check the hardener tube to see if any hardener is escaping. If there is any escaping hardener, do not continue to use this adhesive since an optimum mix of the adhesive components can no longer be guaranteed. After using the adhesive, remove the mixing nozzles and immediately seal the cartridge with the cleaned original cap so that the adhesive cannot react with the hardener component and cannot block the outlet hole. Minimum shelf life of the adhesive: 12 months (see filling date) 2.3 Unsuitable adhesives Rigid curing adhesives such as urea adhesives or epoxy resins are unsuitable for glueing GetaCore. 9

10 solid surface material 3 Tools/materials 3.1 Tools required for processing Veneer press Adhesive roller/toothed spatula Surface/bench router Trapezoidal flat tooth saw blades Router cutters Spring clamps/screw vices Edge clamps Adhesive gun Orbital sander - random Isopropanol alcohol or methylated spirit Sanding pads 3.2 Processing In addition to resins, the solid surface sheet material also contains mineral fillers. However, the same techniques can essentially be used as when working with wood. Although tool stress is not much greater, only carbide-tipped, well sharpened products should be used. Diamond-studded cutting tools can also be used for certain processing steps. Unfinished boards which are not glued to a wood substrate must always be processed on a plane, solid substrate. Care must be taken to ensure that the tools run smoothly and at an appropriate feed rate. Chipping and splintering of the material will result in notches; due to the notch sensitivity of the solid surface material, this will lead to crack formation under stress. 3.3 Mechanical work Drilling Holes up to 10 mm in diameter can be drilled in solid surface material using HSS, titanium, carbide and diamond-studded drill bits in handheld or pillar drills. It is advisable to use bits with a rooflike tip angled at 60. Carbide-tipped cup drills should be used to drill holes over 10 mm in diameter. Augers and gimlets must not be used to drill holes in solid surface material. Conventional hole saws with carbide-tipped cutters can be used to produce cutouts for socket outlets. Note: Splintering can be prevented by drilling the holes (through-holes) with little pressure and using a wood block. Where possible, the holes should be bevelled on both sides with a countersink. Drill holes in general Important: Holes drilled in GetaCore elements (e.g. washstands, worktops for installation of mixer taps) must always be sealed to prevent moisture penetrating inside the substrate. The sealing collar specially developed for Westag & Getalit AG can be used for this purpose (suitable for holes up to 35 mm in diameter); Height 29 mm: Art. No ; Height 39 mm: Art. No ; MS polymer adhesive can also be used for sealing. 10

11 Sawing 1. Before being cut, the solid surface material parts to be joined should be examined to ensure colour matching. Solid surface materials can be cut on panel and board sizing machines, as well as with a handheld circular saw with guide rail. Saw blades with negative trapezoidal flat teeth should be used for contouring. 2. Sharp saw blades are a prerequisite for high-quality cuts without scoring and offsets which would remain visible after bonding. Note: The saw blade should protrude approx mm beyond the material to be cut. Cutting speed m/s. The table opposite lists saw blades suitable for cutting solid surface sheet material. Saw Width Bore Number of teeth blade of cut, diameter approx. in mm in mm in mm 200 2, , * 3, , , , , A speed of rpm is recommended, for example, when using a panel sizing circular saw with this blade diameter. Ragged edges can be refinished by grinding or milling. Jig saws and similar saws must not be used for sizing or producing cutouts or recesses, as they cause notch stress in the solid surface material. 11

12 solid surface material 3.3 Mechanical work Screwing Screw connections are unsuitable in solid surface material, as a number of measures must be taken into account to prevent subsequent damage (usually in the form of cracks). The diameter of the hole for screw connections in solid surface material must always be larger than the diameter of the screws used. Countersunk screws should not be used. It is advisable to insert elastic sleeves which need to be clamped softly. For screwing together solid surface parts with other materials, the same technique is used as when screwing glass. 1. Hole considerably larger than screw shank elastic sleeves rubber or silicone washer between board and screw head. Bonded anchors are also used for attachment. As a rule, the manufacturer should be consulted in this case. Solid surface materials must never be directly connected by self-tapping screws. Threaded inserts (e.g. plastic or roughened brass sleeves) must be used if a screw thread is required. 1. Milling Milling yields several advantages when working on solid surface sheet material: Subsequent processing is very much easier than, for example, after sawing (e.g. for rebating). The milling radius (minimum 4 mm) eliminates sharp corners especially in cutouts and the subsequent risk of cracking (all milled edges must be rounded when producing cutouts for hobs). Using sharp milling cutters produces cut edges of a quality suitable for subsequent bonding. Carbide-tipped woodworking tools should be used for milling solid surface material. The tools may have either fixed cutters or reversible cutters. Ensure that the cutters are sharp. Handheld routers and stationary milling machines should have a rating of W or 3-5 kw. Electronic speed control is advantageous. Standard routers (10 12 mm) with the desired profile are used for sizing and for cutouts. Profiling cutters (with the desired contour) with corresponding copying ring/roller bearing are used for profiling (copying ring with plastic sheath to protect the copying surface). Round-nose cutters with a radius of approx mm are recommended for cutting along wall outlets. The corresponding machine (round-nose router) is required for this purpose. Important: Ragged and/or scorched seams may result in poor glued bonds and/or discoloration in the adhesive joint. Joining IMPORTANT: Max. width of joint 0.1 mm to obtain a seamless appearance. 12

13 4 Processing recommendation 4.1 Surface bonding mm of GetaCore onto a substrate Suitable adhesives: All PVAc adhesives (D3 or D4) e.g. Rakoll GXL-3. Application rate: g/m² (depending on adhesive and application technique) Pressing with veneer press Pressing pressure: N/cm 2 Pressing time: Approx. 8 min. with subsequent curing for 24 hours under approx N/m² stack pressure or curing for 24 hours in the press with consistent pressure. Pressing temperature: Cold (room temperature) Required materials/tools: 3 mm GetaCore sheet material Particleboard/chipboard substrate ( 20 mm) 0.7 mm balancer Adhesive roller/toothed spatula PVAc glue with hardener Isopropanol alcohol 2. 3 mm GetaCore material is glued in a sandwich process. The substrate board is a particleboard/chipboard with a minimum thickness of 20 mm. A 0.7 mm balancer is required on the underside in order to balance expansion and contraction of the particleboard/chipboard substrate. 3. Before the adhesive is actually applied, clean the GetaCore material using isopropanol alcohol or methylated spirit. Then apply the adhesive. Apply the adhesive to the entire surface of the substrate board using an adhesive applicator roll or glueing machine. The adhesive can also be applied to surfaces up to 2 m2 using the toothed spatula or adhesive roller. Apply the adhesive to the reverse of the balancer in the same way. Now put the 3 materials together (panel material, substrate and balancer) and press them evenly. 4. Finished glueing Pressing with stack pressure Pressing pressure: 1000 N/m², corresponds to 100 kg/m² Pressing time: 24 hours curing under stack pressure 13

14 solid surface material 4.1 Surface bonding of 3 mm translucent GetaCore on acrylic glass Required materials/tools: 3 mm GetaCore translucent Transparent acrylic glass (min. thickness 6 mm) GetaCore adhesive, Color: Transparent Plastic spatula It is advisable to use 3 mm GetaCore material in order to obtain high translucence. A self-supporting board is obtained by bonding the 3 mm GetaCore sheet material onto transparent acrylic glass at least 6 mm thick. Before the adhesive is applied, the backing film must be removed from that side of the acrylic glass to which the sheet material is to be affixed and all surfaces must be cleaned with isopropyl alcohol. The adhesive has cured completely after about one hour. Joints and edges to be bonded must also be glued using the transparent 2-component acrylic adhesive. Use lamps with low heat output, e.g. LED lamps, or keep an appropriate distance between GetaCore and the lamp. IMPORTANT: Air bubbles can generally become visible, especially when directly backlit! The adhesive is applied to the acrylic glass in lines. It is then carefully spread with the aid of a plastic spatula. (Caution: the area worked on must not exceed 1.5 m² as the maximum processing time is minutes.) 3. The 3 mm GetaCore material is now laid on the pane of acrylic glass and pressed together. 3. Pressing: Pressing pressure: N/cm 2 Pressing time: not less than 30 Min. Pressing temperature: Cold (room temperature) 14

15 4.1 Surface bonding Surface bonding of 10 mm GetaCore onto frame structure: 1. Required materials/tools: 10 mm GetaCore GetaCore adhesive 100 mm wide strips for the frame structure Spacers MS polymer or PU adhesive GetaCore 10 mm panel material and the frame structure are glued using permanently elastic adhesives such as MS polymer or 1K- PUR. 2. Frame structures are suitable for surface glueing of 10 mm GetaCore. Use plywood or MDF boards for this. These should be cut into approx. 100 mm wide strips and glued as a frame. The distance of the frame should be based on the corresponding sub-structure, e.g. 600 mm (similar to cabinet carcasses). 3. Important: The frame is glued onto the GetaCore material floating (approx. 2 mm adhesive joint). 4. Securing the spacers with doublesided adhesive tape helps to maintain the distance of approx. 2 mm. 5. The adhesive is applied to the frame structure in beads or dots, as well as to the side which is to have GetaCore edging. 6. The required pressure is applied with the aid of clamps. 7. Joints or corner connections must be additionally reinforced with a substrate along the cut edges, for example to allow for cutouts for worktop connectors. In all other respects the bonding and assembly technique is almost the same as for the GetaCore worktop element. 8. The 10 mm material must be slotted with a biscuit groover so that the matching GetaCore tongue can be inserted with the 2-component acrylic adhesive. 9. Then apply PVAc glue to the substrate and coat the GetaCore edges as well as the tongue with sufficient 2-component acrylic adhesive. The two sides of the worktop can then be joined together. 100 mm

16 solid surface material 4.1 Surface bonding of 10 mm GetaCore on melamine-coated surfaces 1. Required materials/tools: 10 mm GetaCore 2 component acrylic adhesive Melamine-coated element (e. g. HPL worktop) MS polymer adhesive Rubber hammer Padded wood block Spacers Router GetaCore as renovation element: in this case, 10 mm GetaCore sheet material is glued onto an existing surface, such as an old HPL worktop. The following steps are required: Measure the worktop Remove the sink and hob Remove the mixer taps 2. The 10 mm sheet is cut in accordance with the actual dimensions. The GetaCore board must be rebated to apply the crossbar. IMPORTANT: 3-5 mm allowance, in case edges have to be affixed. Edges must be cut cleanly here. Cutouts for hob and sink (see 4.4) should generally be produced with a router. Remove sharp edges with a 3 mm radius cutter

17 3. The edging should now be applied. It is advisable to affix 10 mm edging material under the surface of the top. The surfaces to be glued must first be cleaned with isopropyl alcohol. Then apply a bead of the 2-component acrylic adhesive to the top of the edging strip. 4. Press the edging strip onto the rear surface material so that adhesive oozes out. IMPORTANT: Do not fit the edging strip flush with the surface material; it should be set back 3-5 mm so that the emerging 2-component acrylic adhesive does not run out of the joint. 5. Additional pressure should be applied to the bond with the aid of vices. 6. Let the adhesive cure and cut off the surplus surface material flush with the edge. 7. The surface bond with the melamine-coated element should now be prepared. All surfaces to be glued must first be cleaned. Then apply the MS polymer adhesive to the GetaCore element and edges in beads. A floating bond with an adhesive joint of 2 mm must be produced here. (Tip: Place two veneer layers between the adhesive beads to maintain the 2 mm height between GetaCore and HPL material.) 8. Then place the GetaCore material on the melamine-coated element. 9. Gently tap the GetaCore material into place with a rubber hammer and padded wood block (use a spirit level to ensure it is flat). After approx. 12 hours, the MS polymer adhesive has cured sufficiently for the GetaCore surface to be sanded. The sink and the hob can now be installed. The MS polymer adhesive has cured completely after 24 hours. IMPORTANT: As a rule, GetaCore should only be used to renovate melamine-coated surfaces not requiring corner connections, given that such connections are difficult to achieve properly. 17

18 solid surface material 4.2 Edge glueing Edge capping Adhesive joint Required materials/tools: Spring clamps/screw vices or edge clamps Flush/profile router wood blocks Isopropanol alcohol, or methylated spirit GetaCore acrylic adhesive Plastic spatula 2. Worktop edges can be lipped with 3 mm as well as 10 mm GetaCore edges. However, please note that the glue joint is then positioned (visible) to the face side of the board. 3. First, make a clean cut, it is recommendable to slightly sand the GetaCore from the surface. Clean all GetaCore surfaces with isopropanol alcohol or methylated spirit before glueing the edges. Now insert the GetaCore adhesive into the cartridge, screw on the mixing nozzle and make sure the components are being properly mixed. Do this by pressing an adhesive bead of approx. 10 cm length out of the mixing nozzle first. 4. Apply the adhesive to the edge strip and particleboard substrate and then spread it evenly over the edge using e.g. a spatula. 5. Then press the edge onto the substrate board until the adhesive is pressed out of the joint all the way along its length. Use a wooden block for fixing. 6. For fixing, secure with clamps and/or strong tape at intervals of cm including a wooden block, but only tighten them hand-tight and without applying a high contact pressure. 7.1 Remove the fixing elements when the adhesive has set after a drying time of minutes; you can test this with your fingernail Now mill the edge clean and flush, apply the profile and sand over the entire surface (see also 4.6 Sanding)

19 4.2 Edge glueing Edging under the top s surface Adhesive joint Required materials/tools: Spring clamps/screw vices or edge clamps Flush/profile router Wood blocks Isopropanol alcohol, or methylated spirit GetaCore acrylic adhesive Edgings in thicknesses of either 3 or 10 mm may be glued under the worktop s surface in order to achieve a seamless edging-joint. 2. Advantage: The glued joint is located on the front edge of the worktop (under the surface) Cut a rebate on the worktop in three stages. It should be 5-6 mm deep in the case of a 3 mm concealed edge band. Cut mm deep for 10 mm edging strips, because the cork strip also has to be inserted here in order to balance expansion and contraction of the particleboard substrate. Any adhesive residue on the underside of the GetaCore surface must be removed after cutting the rebate. Then clean the bonding surfaces with isopropanol alcohol or methylated spirit and let it dry off. 4. When applying the adhesive, make sure that the adhesive components are well mixed (see 2. Adhesives). Apply the adhesive to the board and the concealed edge band in wavy (zig-zag) beads. Now fit the cork strip onto the edge of the worktop. To ensure the flexibility of the cork, the adhesive should only come into contact with the cork and not with the 3 mm GetaCore surface. 5. Then press the edging into place until the adhesive oozes out of the joint. 6. Now fit the clamps at intervals of cm. Caution: Only tighten until finger- tight and without applying a high contact pressure. 7. The adhesive sets in minutes depending on the room temperature, and the fixings can be removed. Then cut and profile the edge clean. Following this, sand the entire surface (see point 4.6, Sanding). Seal the joint, the HPL balancer and the GetaCore edges using PU adhesive to make them water-tight. 19

20 solid surface material 4.3 Corner joints and butt joints Corner joints Required materials/tools: Router with 16 mm slot cutter 30 mm copying ring Template GetaCore corner joint set Biscuit cutter Groover Cut the worktops in three stages using a template (e.g. with a mitre jig template). 2. Then make cut-outs for the connection bolts on the reverse side of both worktop sides. Cut a biscuit groove as usual. 3. Now cut a groove approx. 4 mm wide (optimum groove width: 3.4 mm) and 12 mm deep under the 3 mm GetaCore surface to slide in the GetaCore tongue. Important: Remove all residual surface adhesive. 4. Bevel the edges with sandpaper in order to guarantee a seamless joint in the GetaCore surface. Then clean the GetaCore surfaces that are to be glued using isopropanol alcohol or methylated spirit and let it dry off properly. 5. Apply the colour-matched adhesive to the GetaCore tongue (to match the substrate: decor GC 7310) and a groove (ideally, use the matching GetaCore adhesive). Then insert the tongue. 6. Apply PVAc glue to the particleboard and insert the biscuits. Then apply GetaCore adhesive to the second groove and both sides of the GetaCore edges. Now join the boards and press until excess adhesive oozes out. Important: Make sure you prevent PVAc glue from getting onto the surface of the board. This is the only way to guarantee a nearly seamless joint. You can use clamps to apply additional (hand-tight) pressure. Also tighten the connection bolts. 7. Use a tooth pick, for example, to burst any air bubbles, which may occur when the adhesive emerges. Let the adhesive harden for about minutes depending on the room temperature. 8. Sand away the excess adhesive using GetaCore sanding discs, ensure that the area that is sanded has been blended into the wet-sanded finish to give a consistant finish overall. Then sand the entire board to give a seamless appearance (see Sanding) Butt joints First cut the joints accurately to the required shape. Remove excess chips from the core board by lightly sanding. Then follow the same procedure as for corner joints (see steps 2-8). 20

21 4.4 Cut-outs for sinks and hobs Furniture/kitchen standards stipulate a max. temperature load of 70 C in continuous operation. Care must therefore be taken to ensure that the appliances to be used comply with the standards! R Required materials/tools: Router with 16 mm slot cutter 30 mm copying ring Thermo tape Aluminum tape Template 2. Cut-outs for sinks and hobs can be made in GetaCore worktops similarly as in HPL-worktops. The hand router is quite a good tool for this job as well. Please note that jig-saws, hand-saws and trimming saws would leave rough cut edges. These can lead to cracks in the GetaCore material. Therefore, we recommend using the router in all cases. All corners should be rounded. Once again, all edges should be rounded/ sanded after cutting using a radius router R3 or, better, R5 mm. All cutouts should be sealed to prevent moisture ingress to the core material. 3. The first step is to fix the template. Use the hand router and the attached copying ring to cut the cut-out in three stages. Please remember to stick to the required minimum distance of 45 mm from the front edge of the worktop! 4. The corners of the cut-outs must have an internal radius of R 10! Again, please apply a radius to the 3 mm GetaCore material also using the radius router R3 or R5 followed by sanding, which prevents possible hairline cracks in the GetaCore material Cut-outs for hobs: We recommend using aluminum and thermo tape to seal the cut edges. Sequence: 1st aluminum, 2nd thermo, 3rd aluminum. Sealing offers adequate protection against temperature fluctuations. Cut-outs for sinks: All exposed chipboard edges in particular must be properly sealed, e.g. with MS polymer adhesive. The adhesive must be applied to the full surface of the open edges with the aid of a spatula and left to cure. 7. When securing hobs, ensure that a distance of at least 6.5 mm is maintained between hob and worktop. While the installation of hobs flush with the surface is technically possible (sealed with MS polymer adhesive), we do not recommend this type of installation due to the difficulties involved in obtaining a high-quality result. 8. Gas hobs can be installed in accordance with the installation instructions Cut-outs for hobs. However, a minimum distance of 50 to 130 mm (depending on the hob model and heat output, see 4.10 Wallback panelling) must be maintained between the gas hob and the wallback panelling behind it

22 solid surface material 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted (under the worktop s 3 mm GetaCore surface) Tools required for the following sink types: GC-R-450, GC-R-162, GC-RU-370, GC-OV-562, GC-SO-465/335 Diagram Name Notes/application 30 mm copying ring Preparation of the router (supplied with the router) i.e. mount 30 mm copying ring Aluminum slip-on ring AR For 1st step Put the aluminum slip-on ring onto the 30 mm copying ring. Router C or C D = 12 mm, L = 105 mm Speed approx. 20,000 rpm Full carbide metal, specially coated for double life Router C 16.2 with copying ring cutting the particle board Speed approx. 16,000 rpm max. Ideal speed approx rpm. 1st step Place the template onto the top surface of the GetaCore board and tighten using screw clamp. Now make the cut-out using the router (cut in 3 stages). 2nd step Turn over the GetaCore board (underside up). Make the cut-out into the substrate in three stages down to the GetaCore panel. Apply GetaCore adhesive to the GetaCore surface and the sink, insert the sink. 3rd step Seal in the sink at the back with a 2-component PU sealing compound (e.g. Biresin). Filling height approx. 15 mm. Pull the liquid compound upwards with a spatula to seal the chipboard. Slot profiling router R= 3 mm C 08.V3 with copying ring Speed approx. 21,000 rpm max. Ideal speed approx. 15,000 rpm 4th step Once the adhesive has set, turn over the GetaCore-board and cut off the GetaCore overhang. Now sand the entire area. Please refer to page 23 for further details and photo description 22

23 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted (under the worktop s 3 mm GetaCore surface) 1. Suitable templates as well as slot and forming routers are sufficient for installation using the router (see list). As a first step, slide an aluminum ring onto the copying ring. Then cut out the sink shape in three stages, working from the reverse side of the board. 2. Do not place the board directly on a full-surface support since the copying ring of the router does not have enough play. It is best to place 10 mm thick laths between the support and the board. Now cut the rebate in 3 more stages After removing all residual surface adhesive and cleaning the GetaCore overhang and the sink edge using isopropanol alcohol or methylated spirit, apply a full coat of GetaCore adhesive both to the GetaCore overhang and to the sink edge The adhesive must ooze out on the inside and outside when inserting the sink. 5. Apply clamps until hand-tight to hold the sink in place for about min. In addition, after setting, use a 2-component PU sealing compound (e.g. Biresin) to seal in the sink on the underside (15 mm deep). 6. Now finish the sink edges with a shank cutter (see list) and by sanding in order to get a harmonious joint between worktop and sink. All narrow edges of the substrate must be suitably protected (e.g. with one-component PU adhesive/sealant or MS polymer) against ingress of moisture

24 solid surface material 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted (under 12 mm GetaCore sheet material). Tools required for the following sink types: GC-R-450, GC-R-162 Diagram Name Notes/application 30 mm copying ring Preparation of the router (supplied with the router) i.e. mount 30 mm copying ring Aluminum slip-on ring AR For 1st step Put the aluminum slip-on ring onto the 30 mm copying ring Router C oder C D = 12 mm, L = 105 mm Speed approx. 20,000 rpm Full carbide metal, specially coated for double life Router C 16.2 with copying ring cutting the particle board Speed approx. 16,000 rpm max. Ideal speed approx rpm 1st step Place the template onto the top surface of the GetaCore board and tighten using screw clamp. Now make the cut-out using the router (cut in 3 stages). 2nd step Turn over the GetaCore board (underside up). Use a Router to cut a 3 mm rebate in the substrate (to assist installation). 3rd step Apply GetaCore adhesive to the GetaCore surface and the sink, insert the sink and let the adhesive set. Conical flush router C 16.5 with copying ring Speed approx. 22,000 rpm max. Ideal speed approx. 18,000 rpm. 4th step Once the adhesive has set, turn over the GetaCore board and cut off the GetaCore overhang. Slot profiling router R= 3 mm C 08.V3 with copying ring Speed approx. 21,000 rpm max. Ideal speed approx. 15,000 rpm 5th step Cut the radius and sand the entire area. Please refer to page 26 for further details and photo description 24

25 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted (under 12 mm GetaCore sheet material) Tools required for the following sink types: GC-RU-370, GC-SO-465/335, GC-OV-562 Diagram Name Notes/application 30 mm copying ring Preparation of the router (supplied with the router) i.e. mount 30 mm copying ring Aluminum slip-on ring AR For 1st step Put the aluminum slip-on ring onto the 30 mm copying ring. Router C oder C D = 12 mm, L = 105 mm Speed approx. 20,000 rpm Full carbide metal, specially coated for double life Router C 16.2 with copying ring cutting the particle board Speed approx. 16,000 rpm max. Ideal speed approx rpm. 1st step Place the template onto the top surface of the GetaCore board and tighten using screw clamp. Now make the cut-out using the router (cut in 3 stages). 2nd step Turn over the GetaCore board (underside up). Use a Router to cut a 3 mm rebate in the substrate (radius 2 mm). 3rd step Apply adhesive to the GetaCore surface, insert the sink and let the adhesive set. Seal in the transition between the sink/board using Biresin. Slot profiling router R= 3 mm C 08.V3 with copying ring Speed approx. 21,000 rpm max. Ideal speed approx. 15,000 rpm 4th step Once the adhesive has set, turn over the GetaCore board and cut off the GetaCore overhang. Now sand the entire area. Please refer to page 26 for further details and photo description 25

26 solid surface material 4.5 Installation of sinks and basins Installation of GetaCore sinks Sinks undermounted (under 10 mm GetaCore sheet material) To undermount a sink under 10 mm GetaCore material, first make the cut-out in accordance with the template using the router, aluminum slip-on ring and copying ring (see list). Clean the surfaces to be glued using isopropanol alcohol or methylated spirit. Apply a full coat of GetaCore adhesive to the sink edge and the board until the adhesive oozes out of the joint. 2. Fasten the clamps until hand-tight to hold the sink for about minutes. 3. Finally, the board needs to be given the end-finish (milling/sanding)

27 4.5 Installation of sinks and basins Installation of GetaCore sinks Installation of sinks from above (flush-fit) into a GetaCore worktop (with 3 mm GetaCore/or into a 10 mm GetaCore sheet material). Tools required for the following sink types: GC-R-450, GC-R-162 Diagram Name Notes/application 30 mm copying ring Preparation of the router (supplied with the router) i.e. mount 30 mm copying ring Router C oder C D = 12 mm, L = 105 mm Speed approx. 20,000 rpm Full carbide metal, specially coated for double life Diagonal router 15 C 02.1 Speed approx. 24,000 rpm max. Ideal speed approx. 18,000 rpm 1st step Turn over the GetaCore board. Use screw clamps to tighten the template onto the board. Make the cut-out using the router (cut in 3 stages). 2nd step Fit the sink into the board using a diagonal router. Flat stepped router C 02.3 Speed approx. 24,000 rpm max. 3. 3rd step Apply adhesive to the sink, insert the sink from above and let the adhesive set. Carefully turn over the board with the sink and seal in the gap between the sink and the substrate board approx. 15 mm deep using 2-component PU sealing compound (e.g. Biresin) (only required if 3 mm GetaCore material is mounted on the substrate board). Turn the board and sink over so the good side is up-side. Now remove adhesive residue with a stepped router and sand the sink edge. Please refer to page 26 for further details and photo description 27

28 solid surface material 4.5 Installation of sinks and basins Installation of GetaCore sinks Installation of sinks from above (flush-fit) into a GetaCore worktop (with 3 mm GetaCore/or into a 10 mm GetaCore sheet material) Sinks are installed from above (flush-fit) in GetaCore worktops and 10 mm GetaCore material in the same way: First, the cut-out is made according to the template and using the aluminum slip-on ring - as usual in 3 stages. Then, in the second step, fit the sink into the board using a diagonal router. 2. Clean the surfaces to be glued on the board and the sink using isopropanol alcohol or methylated spirit and apply GetaCore adhesive to the board and the sink. 3. Insert the sink so the GetaCore adhesive is oozed out of the joint. 4. Leave to set for minutes, then sand off the adhesive residue (see Sanding)

29 4.5 Installation of sinks and basins Installation of stainless steel sinks Sinks undermounted (under the worktop s 3 mm GetaCore surface) Required materials/tools: GetaCore worktop Template Stainless steel sink MS polymer adhesive Quick-sealing resin Biresin 2. First position the template. 3. Slip an aluminum ring onto the copying ring. 4. Then cut the shape of the sink out of the composite material with 3 mm GetaCore board from above in three stages. 5. Sharp edges are removed with an R2 or R3 radius cutter. 6. Now cut a rebate from below in three further stages. 7. Then manually sand the radius to the desired final finish. 8. When all residues of the surface adhesive have been removed and both the overhang and the sink edge have been cleaned with isopropyl alcohol, the MS polymer adhesive is applied and the sink inserted

30 4.5 Installation of sinks and basins Installation of stainless steel sinks Kitchen sinks undermounted (under the worktop s 3 mm GetaCore surface) Secure the sink for 12 hours with the aid of screw clamps (hand-tight) and a wood block. 10. To stabilize the sink, the back is subsequently filled with Sika-Biresin 2-component quick-sealing resin. Ensure that the sealing compound is only applied to the sides of the sink. It must be sealed with adhesive or aluminum tape. 11. Remove the surplus adhesive from the top of the sink when the sealing compound has cured

31 4.5 Installation of sinks and basins Adhesive recommendation - installation of sinks Stainless steel sink installation from above into a GetaCore worktop (flush-fit) into the surface Clean all surfaces to be glued using isopropanol alcohol or methylated spirit and let it dry off. Glue in the sink using an MS polymer Remove the surplus adhesive compound from the front face of the worktop. Apply a moisture barrier to the narrow surface of the substrate material using materials such 1K PU adhesives/sealants or MS polymer. GetaCore-Beschichtung coating 3 mm3 mm 1 mm Adhesive Klebstofffuge joint 1 mm Particleboard Spanplattenträger substrate Stainless Edelstahlspüle steel sink Stainless steel sink undermounted - (under the worktop s 3 mm surface) Clean all surfaces to be glued using isopropanol alcohol, methylated spirit or acetone and let it dry off. Glue in the sink using an MS polymer 1*. Seal in the gap on the reverse side (approx. 15 mm deep) with a rigidly or flexibly hardening sealing compound (the holes/openings in the web on the back of the sink may have to be sealed with adhesive tape so that not the whole of the rear is filled with sealing compound). Remove the surplus adhesive compound from the front face of the worktop once the sealing compound has fully set. Apply a moisture barrier to the narrow surface of the substrate material using materials such 1K PU adhesives/sealants or MS polymer. 1,0 mm GetaCore-Beschichtung coating 3 mm3 mm Particleboard Spanplattenträger substrate Adhesive Klebstofffuge joint 0.1 0,1 mm 1* approx. ca mm Stainless Edelstahlspüle steel sink Sealing Vergussmasse compound (z. B. (e. Biresin) g. Biresin) 1* A sink fixing can also be used to assist mounting. Important: Tightening the screw too tight can damage the GetaCore surface. 31

32 solid surface material 4.5 Installation of sinks and basins Adhesive recommendation - installation of sinks Stainless steel sink undermounted under 10 mm GetaCore Clean all surfaces to be glued using isopropanol alcohol or methylated spirit and let it dry off. Glue the underside of the stainless steel sink using a suitable glue (recommendation: MS polymer). Mechanical fixing is given by glueing pre-grooved GetaCore strips with GetaCore two-component acrylic adhesive to the sink s edge and GetaCore sheet. Remove the surplus adhesive from the inside of the sink. Do not continue work/processing until the adhesive has fully set (approx. 12 hours with MS polymer). Klebstoff Adhesive GetaCore mm GC-2-Komponenten two-component acrylic Acryl-Kleber adhesive Stainless Edelstahlspüle steel sink Ceramic sinks (Belfast sinks) undermounted (under a worktop s 3 mm GetaCore surface) Clean all surfaces to be glued using isopropanol alcohol or methylated spirit and let it dry off. Glue in the sink using a suitable glue (recommendation: MS polymer). Note: Due to the considerable weight of a ceramic sink, it should only be installed on-site. The sink must be statically supported from below in addition to glueing. Remove the surplus adhesive compound from the front face of the worktop. Do not continue processing until all adhesives have fully set (approx. 12 hours). GetaCore 3 mm 3 mm Particleboard/chipboard Spanplatte Ceramic Keramik-Spüle sink ca. approx. 3 mm 3 mm MS-Polymer/ polymer/ Kleb-Dichtstoff adhesive sealant 32

33 4.6 Sanding When sanding, pressure must be applied uniformly and in constantly changing directions. Do not start the random orbital sander on the worktop: always apply the rotating sanding plate to the worktop with its full area. Areas with adhesive beading should be sanded down first (with P180 sand paper). When these have been removed, the entire surface must be sanded, again using P180 sand paper. Then continue in accordance with the applicable sanding recommendation Special sanding pads are available which should be used to obtain the required surface finish. Generally all GetaCore solid surface materials are supplied with a 600 grain wet sanded finish ( pre-finish ). GetaCore sanding pads are compatible with commercial available random orbital sanders with 150 mm sanding plates. It is important to clean the surface with a microfiber cloth whenever the grain size is changed. Partial sanding (for instance, only around the adhesive join) is not recommended, as this does not produce a uniform finish. Glossy or high-gloss finishes are not suitable for surfaces in everyday use (e.g. worktops). Recommendation for matt silk finish: 1. Pre-sanding* Grain size P Sanding Grain size P End finish SG Cleaning STS-150 Recommendation for brilliant gloss finish: 1. Pre-sanding* Grain size P Sanding Grain size P Sanding P Sanding P End finish 9 m 6. End finish Felt pad** * Only necessary if the adhesive bead has not already been trimmed. ** To be used in combination with polishing milk MPA (Art. No ) Sanding duration per sanding pad: approx minutes/sqm 33

34 solid surface material 4.7 Thermoforming All GetaCore materials can be thermoformed, actually they can be formed to almost any shape. 2. The time required to heat through the material thoroughly and homogeneously depends on its thickness: minutes for 3 mm GetaCore material and about 30 minutes for 10 mm material, in both cases at C. The heating times may vary depending on the heat source, material thickness and decoration, therefore you should make some tests on the material first. If areas are not heated sufficiently, this can lead to cracks and breakages whereas overheating can lead to discoloration and bubbling. The minimum bending radii are 20 mm for 3 mm material and 70 mm for 10 mm material. 3. Complete surfaces are formed using positive/negative moulds irrespective of the material thickness. The workpiece is removed from the mould once the temperature has returned to approximately 50 C. 4. Final glueing of thermoformed edges should be done after the material has cooled down to normal room temperatures (see edge capping). 5. Instead of using positive/negative moulds, it is possible to adapt a 3 mm edge shape by fixing with masking tape, tensioning belts or edge clamps with a bond. Edges made from the 10 mm material can be adapted using positive/negative moulds, tensioning belts and edge clamps. 34

35 4.8 Renovation and repair The following parts are required ( numbers are picture numbers) Name Remark Application Router type C Shank diameter 12 mm, For cutting out the damaged area 1. Cutter diameter 12 mm of the worktop that is is to be repaired. Router 15 type C 02.1 Shank diameter 12 mm, For cutting the external contour 2. conical cutter in the worktop with a diagonal cross section. GC repair set Comprises a 340 mm contour For making the contour and 3. Diameter of the template, 340 mm machining machining out the damaged area repair piece 340 template, 340 mm disk template as well as cutting the repair and smoothing template disk and smoothing the surface. GC repair set Comprises a 260 mm contour For making the contour and 3. Diameter of the Stemplate, 260 mm machining machining out the damaged area repair piece 260 template, 260 mm disk template as well as cutting the repair and smoothing template disk and smoothing the surface. GC repair set Comprises a 180 mm contour For making the contour and 3. Diameter of the template, 180 mm machining machining out the damaged area repair piece 180 template, 180 mm disk template as well as cutting the repair and smoothing template disk and smoothing the surface. GC repair set Comprises a 50 mm contour For making the contour and 4. Diameter of the template, 50 mm disk machining out the damaged area repair piece 50 template and smoothing as well as cutting the repair No additional template disk and smoothing the surface. is required for machining out. GC template One template size for all four For smoothing the damaged area. 5. Surface smoothing template sizes of repair piece. External dimensions 480 x 200 mm. GC template External dimensions For cutting the contour 6. Contour cutting x 470 mm, hole diameter in the worktop. 359 mm for 340 mm diameter repair piece. GC template External dimensions For cutting the contour 6. Contour cutting x 470 mm, hole diameter in the worktop. 279 mm for 260 mm diameter repair piece. GC template External dimensions For cutting the contour 6. Contour cutting x 460 mm, hole diameter in the worktop. 199 mm for 180 mm diameter repair piece. GC template External dimensions For cutting the contour 6. Contour cutting x 330 mm, hole diameter in the worktop. 69 mm for 50 mm diameter repair piece. GC template With slot cutting in the surface, For machining out the damaged 7. Machining out the 340 mm template diameter 357 mm. area of the worktop that damaged area is to be repaired. GC template With slot cutting in the surface, For machining out the damaged Machining out the 260 mm template diameter 277 mm. area of the worktop that 7. damaged area is to be repaired. GC template With slot cutting in the surface, For machining out the damaged Machining out the 180 mm template diameter 197 mm. area of the worktop that 7. damaged area is to be repaired. GC template for cutting Diameter of the repair disk For cutting the 3 mm thick GC repair disk mm. Template diameter GetaCore repair disk mm. 35

36 solid surface material 4.8 Renovation and repair The following parts are required ( numbers are picture numbers) Name Remark Application GC template for cutting Diameter of the repair disk 260 mm. For cutting the 3 mm thick GC repair disk 260 Template diameter 242 mm. GetaCore repair disk. GC template for cutting Diameter of the repair disk 180 mm. For cutting the 3 mm thick GC repair disk 180 Template diameter 162 mm. GetaCore repair disk. GC template for cutting Diameter of the repair disk 50 mm. For cutting the 3 mm thick GC repair disk 50 Template diameter 32 mm. GetaCore repair disk. GetaCore D 3 mm 1000 x 300 x 3 mm For repair piece. GetaCore adhesive See colour recommendation for joint For glueing the GetaCore disk adhesive from Westag & Getalit AG. into the damaged area. Sanding pads See sanding and finish recommen- For smoothing the repair disk dation from Westag & Getalit AG. to the worktop. Double-sided fabric For fixing the template parts adhesive tape and fixing the 3 mm thick GetaCore repair material for cutting out the disk Screw clamps for router Router here: FESTOOL type OF 2000E/1 For all cutting work or equivalent router Copying ring with 30 mm Depending on the machine, For all cutting work external diameter, i.e. purchased by customer suitable for router For aforementioned router: FOR OF 2000 Diameter 30 mm Type KR-D30/OF2000 FESTOOL order no Recommendation: Before cutting the actual damaged part of the worktop, we recommend to test the entire repair procedure on a worktop offcut

37 4.8 Renovation and repair GetaCore can be repaired without leaving any signs of the repair. The following tools are required: Hand router with two matching copying rings as well as a corresponding T-grooverouter (see tools page 24). 1. Affixing the template onto the worktop Position the template over the damaged area Affix the template using screw clamps (recommended). Alternatively, secure with double-sided adhesive tape Preparing the router Mount the copying ring Insert the diagonal router Set the router to a cutting depth of 2.5 mm in the GetaCore worktop Important: Take account of the thickness of the template Cutting the outer contour of the worktop To prevent the router from tipping over, please use a support provided by the router manufacturer

38 solid surface material 4.8 Renovation and repair 4. Cutting out the damaged area of the worktop that is to be repaired Recommendation: In order to reduce tool wear, exchange the router for type C Cut with the round machining (slot) template Adjust the router as described under point 2. Router away the GetaCore area damaged as even as possible. Drill one or a few holes into the worktop See Figure Making the GetaCore repair disk Secure the 3 mm thick GetaCore repair material on a substrate (min. 10 mm) using double-sided adhesive tape (GC face side down). The tape is to prevent the disk from slipping. Additionally secure with screw clamps. 5.2 Use double-sided adhesive tape to secure the template onto the 3 mm thick GetaCore sheet material for cutting the GetaCore repair disk with an external diameter of e.g. 162 mm. 5.3 Insert the diagonal router into the router and set to cut 1 mm into the substrate. Important: Take account of the thickness of the template. Align the router horizontally and fit the support onto the router Cut out the disk Template 4.3 worktop machined-out area Substrate double-sided adh. tape milled surface

39 4.8 Renovation and repair Do not remove the disk from the substrate. Measure the diameter of the disk. The diameter of the disk must be exactly 1 mm larger than the diameter of the cut-out in the worktop. If the diameter of the disk is too large, set the diagonal router gradually deeper in order to reduce the diameter. In case the size of the 3 mm repair disk is still too large, cut away step by step some material by adjusting the diagonal router in steps; try out a router. 5.5 Carefully remove the disk from the substrate (risk of breaking). 6.1 Drill 5 holes in the worktop at the repair area (hole diameter 5 mm) to allow excess adhesive and air to escape. 6.2 Positioning of the holes 7 Glueing in the disk into the worktop s surface Clean the surfaces thoroughly using isopropanol alcohol or methylated spirit and then leave to dry off completely. Apply GetaCore two-component acrylic adhesive to the repair area on the worktop and spread the glue all over the area using a spatula. Apply glue to the inside edge of the cutout. Insert the repair piece (slightly move it in when doing this with light rotatory movements), place the e.g. 162 mm template in the center of the repair area and place a weight of about 2 kg (4 lbs) onto it. 8 Now the repaired area in the worktop can be milled and sanded Place the milling (slot) template onto the contour template. Adjust the cutting depth of the router so that the excess glue and edge can be milled away. Process the repaired area step by step with the router. Important: Be careful not to cut into the contour template Also: Do not damage the whole repair by making a too deep groove into the just repaired area. You may as well»just«sand the complete repair area, then sand the worktop. Finally the entire worktop needs to be sandedto create an optically seamless joint. Please use the sanding sets and observe the sanding instructions. 39

40 solid surface material 4.9 Upstand installation Required materials/tools: Router or circular saw Spring clamps/screw vices Isopropyl alcohol 2-component acrylic adhesive 2. Cut a groove 18 mm wide and 1.9 mm deep along the rear edge of the worktop (e.g. using a router or circular saw). Take care to cut very cleanly in order to obtain a visually seamless connection. 3. Clean the upstand and 10 mm wallback with isopropyl alcohol at the points to be bonded and leave to dry off. 4. Place the 2-component adhesive in the applicator, screw on the mixer tip and ensure that the components are optimally mixed. This can be achieved by pressing a roughly 10 cm bead of adhesive out of the tip first. Now apply adhesive to the upper edge of the upstand and connect it to the 10 mm wallback. Secure with (hand-tight) screw vices and spring clamps at intervals of approx. 10 cm. 5. When the adhesive has cured after minutes (check with your fingernail), remove the clamps and trim down the surplus cured adhesive. The entire surface (10 mm thick wallback and upstand) is then sanded to the desired final finish. 6. The cut-out area of the worktop is now cleaned with isopropyl alcohol before the 2-component acrylic adhesive is applied here. Adhesive should be applied directly along the rebate and also in the middle of the cut-out area. The upstand 40

41 (with the bonded and sanded wallback panelling) is then positioned on the rear edge of the worktop. It is secured with screw vices and spring clamps at intervals of approx. 10 cm. 7. When the adhesive has cured (30-45 minutes), the clamps can be removed and the adhesive beading trimmed. The entire worktop including the upstand should now be sanded until the required final finish is obtained

42 solid surface material mm wallback panelling mm 1. Required materials/tools: 10 mm GetaCore sheet material MS polymer adhesive Spacers Supports The GetaCore wallback panel must not be applied to walls without expansion joints. 2. When installing gas hobs, a minimum distance of 50 to 130 mm (depending on the hob model and heat output) must be maintained between the gas hob and the wallback panelling behind it. Furniture/kitchen standards stipulate a max. temperature load of 70 C in continuous operation. Care must therefore be taken to ensure that all specified appliances comply with the standards. The following points must be noted in conjunction with the various substrates: Plaster/concrete substrate The substrate must be free of dust and grease. Proceed as described in step 3. Tiles: Old tiles must be cleaned thoroughly before installing the GetaCore wallback panel. Tiles must be free of grease, dust and dirt, as well as dry. Ensure that the substrate is as level as possible, without any major protrusions. The further procedure is described in step The panels are generally bonded with viscous PU adhesives or colored (filled) MS polymer applied in vertical beads at intervals of approx. 80 mm. Spacers approx. 2 mm thick must be fitted between the adhesive beads (e.g. with the aid of double-sided adhesive tape) to maintain a shadow joint between the wall and the GetaCore wallback. 4. The GetaCore wallback panel must then be secured to prevent it slipping or falling until the adhesive has cured (up to 24 hours). The joint between the wallback panelling and the wall must be sealed with MS polymer adhesive to keep out dirt and moisture. Gypsum plasterboard or wallpaper: The load-bearing capacity of the substrate must be assured. In most cases, it can be improved by treatment with a deep primer (preferably solvent-based). Continue as described below (see step 3) when it has dried off completely

43 4.11 Installation of 10 mm window sills Required materials/tools: 10 mm GetaCore material MS polymer adhesive and PU adhesives/assembly foam Router Spacers 10 mm thick GetaCore material can easily be used for window sills even without a substrate. The material's decisive advantage is that it is waterproof, meaning that additional protection against moisture is not needed. It is installed in accordance with the usual recommendations by bonding with elastic adhesives (e.g. PU adhesives, MS polymers or comparable products) or by insertion in PU assembly foam or by applying a bed of PU assembly foam. Optional installation with a singlecomponent PU adhesive: 2. Cut the 10 mm material to size in accordance with dimensions. IMPORTANT: Remember the required expansion joint*. Sharp edges must be bevelled or finished with a 3 mm radius router. 3. Finish the surface with the required final finish (see 4.6 Sanding ). 4. Before adhesive is applied, the substrate must be firm, clean and dry. Adhesive must be applied in beads at least 1.5 mm thick and at least 10 mm wide. The beads should be perpendicular to the length and not more than 80 mm apart. Spacers must be used if necessary to ensure that the minimum thickness of the adhesive layer is maintained. 5. When the window sill has been fitted, it must be lightly tapped into place with a rubber hammer and padded wood block (if necessary, use a spirit level to ensure it is level). 6. To ensure adequate stability, the window sill must be pushed under the window frame or secured to the latter, for example with a U-section or angle brackets. * Formula for expansion joints: Δl = ΔT x L x 5,6 x 10-5 [K-1] 4. 43

44 solid surface material 4.11 Installation of 10 mm window sills Adequately dimensioned expansion joints* must also be produced adjacent to the masonry at the sides. An overhang of more than 100 mm at the front should be avoided, as the material's load bearing capacity decreases with increasing overhang. 8. After approx. 12 hours, the MS polymer adhesive has cured sufficiently to permit further processing. It has cured completely after 24 hours. If the surface finish has been damaged during installation, it can be re-sanded in accordance with the instructions (see 4.6 Sanding). 9. The transition between the window sill and the wall or the window frame is sealed with MS polymer adhesive. The surface must be cleaned with isopropyl alcohol and left to dry off before it is sealed. Example: Max. load at the front of a properly installed window sill of 12 mm GetaCore sheet material: Overhang 100 mm: approx. 100 kg Overhang 150 mm: approx. 65 kg * Formula for expansion joints: Δl = ΔT x L x 5,6 x 10-5 [K-1] Example: Window sill: 2500 mm Temperature difference (Summer +40 C, Winter 0 C): 40 C Δl = 40 x 2500 x 5,6 x 10-5 [K-1] = 5,6 mm In other words, the expansion joints must be 2.8 mm wide on each side

45 5 Care and cleaning 5.1 GetaCore Care Set, large Instructions for use for matt silk surfaces Content: 1 microfiber cloth 1 sanding block 1 sanding pad SG sanding pad STS set of sanding pads 1 tube of GetaCore polishing paste 1 bottle of GetaCore polishing milk MPA bottle of GetaCore cleaner Areas of use: Everyday signs of use are normally unavoidable after a certain period of use. Slight surface scratches can be reduced and the appearance of the surface improved through regular use of the care set. General care instructions 1. Always clean the GetaCore surface with a mild, non-abrasive cleaning agent. 2. Do not use abrasive or acid cleaning agents. 3. Stains on the GetaCore surface should generally be removed as quickly as possible in order to maintain a uniform gloss. 4. Water/scale stains which have dried can still be removed without difficulty with white wine vinegar (5% solution) diluted 1:1 with water to produce a 2.5% concentrate. 5. Do not use wax polishes or cleaning agents containing oil/silicone. These will leave a greasy film on the surface which can only be removed with great difficulty. Fingerprints are also clearly visible when using such agents. 6. Chopping boards and pot stands should always be used to preserve the quality of the surface. If the GetaCore surface nevertheless shows signs of use, it can be repaired by appropriate treatment (see Application: Surface rejuvenation ) or re-sanded by a specialist. Application: Surface rejuvenation 1. First clean the area with a standard household cleaning agent. 2. Then attach the sanding pad SG 240 to the sanding block and apply it to the relevant area as follows: Grasp the sanding block and sand the relevant area with a circular movement and applying uniform pressure (not too much!). Remove the sanding dust with the microfiber cloth from time to time and examine the surface: have the signs of use been reduced to a minimum? Does the surface gloss of the sanded area match that of the remaining surface? If the improvement is not yet satisfactory, sand the area again with the sanding pad SG 240. Polishing paste can now be applied with the pad STS 150 or a cloth again with a circular movement in order to match up the degree of gloss. 3. Finally, clean the surface with the microfiber cloth. The procedure described above can generally be repeated several times on surfaces exposed to increased wear. 45

46 solid surface material Instructions for use for high-gloss surfaces General care instructions High-gloss surfaces require special treatment. The enclosed sanding set is needed, among other things, for maintaining high-gloss surfaces. Although a detailed description of the sanding process is enclosed with the set, this should be done by a specialist firm, as a high-gloss surface of uniform brilliance can only be obtained with special sanding machines. However, you can also freshen up small areas of the surface yourself as follows: 1. First clean the area with a standard household cleaning agent.. 2. Then attach the sanding pad STS 150 to the sanding block and apply it to the relevant area as follows: Before you pick up the sanding block and sand the relevant area with a circular movement and applying uniform pressure (not too much!), apply a small amount of MPA polishing milk to the surface. Remove the sanding dust with the microfiber cloth from time to time and examine the surface: have the signs of use been reduced to a minimum? Does the surface gloss of the sanded area match that of the remaining surface? If the improvement is not yet satisfactory, polish the area again with the pad STS 150 and polishing milk. 3. Finally, clean the surface with the microfiber cloth. Note that this is only a freshening up proces. As already mentioned, a thorough renovation of the highgloss surface requires a specialist firm. Application: Stain removal The GetaCore cleaner removes stubborn stains without altering the surface gloss. Simply spray the affected area with GetaCore cleaner and wipe off with a damp cloth and clear water. Leave the cleaner to take effect (approx. 30 minutes) when removing more stubborn stains. Further application notes can be found on the label on the back of the cleaner. 46

47 5.2 GetaCore Care Set, small Instructions for use for matt silk surfaces Content 1 microfiber cloth 1 sanding block 1 sanding pad SG sanding pad STS 150 Areas of use: Everyday signs of use are normally unavoidable after a certain period of use. Slight surface scratches can be reduced and the appearance of the surface improved through regular use of the care set. General care instructions 1. Always clean the GetaCore surface with a mild, non-abrasive cleaning agent. 2. Do not use abrasive or acid cleaning agents. 3. Stains on the GetaCore surface should generally be removed as quickly as possible in order to maintain a uniform gloss. 4. Water/scale stains which have dried can still be removed without difficulty with white wine vinegar (5% solution) diluted 1:1 with water to produce a 2.5% concentrate. 5. Do not use wax polishes or cleaning agents containing oil/silicone. These will leave a greasy film on the surface which can only be removed with great difficulty. Fingerprints are also clearly visible when using such agents. 6. Chopping boards and pot stands should always be used to preserve the quality of the surface. If the GetaCore surface nevertheless shows signs of use, it can be repaired by appropriate treatment (see Application: Surface rejuvenation ) or re-sanded by a specialist. Application: Surface rejuvenation 1. First clean the area with a standard household cleaning agent. 2. Then attach the sanding pad SG 240 to the sanding block and apply it to the relevant area as follows: Grasp the sanding block and sand the relevant area with a circular movement and applying uniform pressure (not too much!). Remove the sanding dust with the microfiber cloth from time to time and examine the surface: have the signs of use been reduced to a minimum? Does the surface gloss of the sanded area match that of the remaining surface? If the improvement is not yet satisfactory, sand the area again with the sanding pad SG Then clean the surface with the microfiber cloth. 4. Attach the pad STS 150 to the sanding block and work on the affected area with a circular movement as described above. 5. Finally, clean the surface with the microfiber cloth The procedure described above can generally be repeated several times on surfaces subject to major stress. 47

48 solid surface material 6 Further recommendations 6.1 Choice of decor GetaCore decors with intensive colours and particularly the plain decors require more intensive care. Since they contain more colour pigment, these decors are more susceptible to wear. Highly pigmented GetaCore decors should therefore only be used for vertical surfaces subject to little stress in both residential and commercial properties. 6.5 Outdoor use of GetaCore GetaCore can conceivably be used out of doors in protected locations for several years. Use of 10 mm thick material is generally recommended on account of its self-supporting nature. However, no independent test certificates for outdoor use of GetaCore have been obtained to date. 6.2 Surfaces Note that the more glossy a surface, the more susceptible it is to everyday signs of use. High-gloss surfaces are therefore only recommended for use in private bathrooms, e.g. in the washstand. Matt silk surfaces are recommended for use in public areas and for kitchen worktops. 6.3 Adhesive joints GetaCore can be bonded with invisible joints. The joint must be not more than 0.1 mm wide if a seamless joint is to be produced. The color of the adhesive should also match that of the decor! 6.4 Holes in general Important: Holes drilled in GetaCore elements (e.g. washstands, worktops for installation of mixer taps) must always be sealed to prevent moisture penetrating inside the substrate. The sealing collar specially developed for Westag can be used for this purpose (suitable for holes up to 35 mm in diameter); Height 29 mm: Art. No ; Height 39 mm: Art. No ; MS polymer adhesive can also be used for sealing. 6.6 Installation of a kitchen waste shredder in GetaCore sinks GetaCore sinks are suitable for installation of kitchen waste shredders. Description The device is easily installed under virtually any sink with standard 3.5" (approx. 90 mm) drain. It is roughly 3 cm high, has a diameter of cm and is installed between the drain and the stench trap under the sink. A power supply is required for operation. Detailed installation instructions are enclosed with every device. Function Organic kitchen waste is finely shredded with motor assistance when the water is running and discharged via the ordinary wastewater pipes and sewers to the sewage treatment plant. Permit European standard DIN EN , No. 4.6 contains the following reference with regard to permission: National and regional rules and regulations may permit the use of waste shredders. The regulations of the local sewage company must therefore be observed before using the kitchen waste shredder. 48

49 6.7 Handling/care Always clean the GetaCore surface with a mild non-abrasive cleaning agent. Ordinary washing-up liquid is perfectly adequate. Scale should be removed with vinegar essence diluted 1:2 with water (i.e. one part vinegar essence to two parts water). Rub the scale stained area with a cloth soaked with this mixture and then wipe off with a dry cloth. Repeat the process or leave the liquid to take effect for a few minutes if the stains are more stubborn. Always use a chopping board to protect the worktop. Hot pots and pans should not be placed directly on the GetaCore surface. Use a pot stand. Signs of use are easily removed from the GetaCore surface with GetaCore polishing paste (Art. No ). Simply apply a little paste to a clean cloth or fine sponge and rub into the surface with a circular movement. Then clean the surface with water and cleaning agent. Important: the polishing paste is a care agent which has been specially developed for GetaCore surfaces. Please do not use any similar substances instead. Hartnäckige Flecken (wie z. B. Kaffee, Tee, Haarfärbemittel, etc.) entfernen Sie einfach mit dem GetaCore-Cleaner (Art.-Nr ): Der GetaCore-Cleaner entfernt hartnäckige Flecken, ohne den Oberflächenglanzgrad zu verändern. Einfach die zu behandelnde Stelle mit dem GetaCore-Cleaner einsprühen und mit einem feuchten Lappen und klarem Wasser entfernen. Bei hartnäckigeren Flecken den Cleaner längere Zeit einwirken lassen (ca. 30 Min.). Weitere Anwendungshinweise entnehmen Sie dem rückseitigen Etikett des Cleaners. 6.8 Special features of GetaCore -Star decors GetaCore -Star decors contain particles of glitter which produce particularly attractive effects. However, there are a number of special features to be observed in conjunction with these decors which must also be made known to the customer. 1. For reasons associated with production, the glitter particles in the board can produce a striped effect. 2. The glitter particles have a flake-like appearance which, for reasons associated with production, can line up in a certain direction in the board and thus possibly change the appearance of the decor, depending on the incidence of light. 3. GetaCore-Star decors are most effective with high-gloss final finish. These surfaces consequently require more intensive care. Due to these special features, GetaCore -Star decors should only be used to a very limited extent in horizontal applications subject to major stress, as the usual signs of wear such as scratches and smears are more easily seen, especially on high-gloss dark decors. Complaints of this kind consequently cannot be accepted on account of this information. Further information on handling and care of GetaCore can be found on our website: Special features of GetaCore -Terrazzo decors Due to the very coarse structure of the decor, adhesive joints may be more difficult to bond seamlessly, as the cut edge of the coarse granules is easily seen. 49

50 solid surface material Notes 50

51 Notes 51

52 WESTAG & GETALIT AG Postfach Rheda-Wiedenbrück Germany Tel. +49(0) 5242/ Fax: +49(0) 5242/ Internet: Plywood/Shuttering Doors/Frames Laminates/Elements Order No September 2009