Seam Locations and Cutout Positioning. Material Review. Warehousing. Inspection

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1 HI-MACS Layout Before cutting the sheets you have ordered and received from your HI-MACS distributor, calculate the number, lengths, widths and elevation to double check the amount of material you will need to finish the entire project. If you calculate too closely, you may create yield problems and dye lot concerns if more material must be ordered. You must also remember to consider cutouts, backsplash materials and buildup strips. As you look at all of these factors consider the cutout sizes and locations, substructure requirements, seam locations, possible inlay issues and specialty fabrication, such as a cove backsplash or thermoformed surface requirement. Layout of HI-MACS Fabrication Warehousing Inspection Cutting Gluing Cutting and Staging Cutout Optimizing When making a cutout, remember to make them larger than the recommendations provided by the manufacturer. The recommendation is a 6mm gap around the countertop cutout and a 1/8 around the sink cutout. Do not make them too large. Cutting and Staging Overview Remember to avoid handling materials alone. Use two people to move the sheet into position for cutting. Cut the HI-MACS sheet materials for your job specifications. If you are using a table saw, make sure it has out feed supports. If using a vertical panel saw, remember to watch for errant materials after cutting. Place cut materials on your workbench and create the 13mm inside corner with the appropriate router and template. Remember that a 13mm bit creates only a 6mm radius. Stage your components and assemblies on a flat, rigid plane surface. If using more than one bench to stage your project, make certain these benches are of the same height! Your supporting work tables should have supports every 610mm. This will ensure a flat and safe working area as you assemble your tops. Save any extra materials or out falls for buildup strips, cutting boards and repair materials. Remember to leave a good size piece of color matched material at the jobsite in case of repair. A good spot to place this is under the sink cabinet. Pre-drill two holes in the material at your shop. During installation, place a screw into the drilled holes and position the piece to the side wall of the cabinet. Seam Locations and Cutout Positioning Keep seams mm from any inside or outside corners and mm from any cutout for stove, sink or other consideration of cutout. When having to layout and fabricate a countertop, remember to maintain the seam mm from the inside corners. General Fabrication Principles Q/C Store Warehousing Traditionally, solid seams are the hardest and leave the least amount for error. It is very important when seaming solids that you thoroughly clean the seams and prepare a precise mirror cut. Seaming with matrix colors, whether it be Sands, Pearls, Quartz or Granite series HI-MACS, are more forgiving, by virtue of the many colors of particulate. Waiting for Shipping Your best seam will typically be 2mm thick or less. Anything up to about 5mm is acceptable, but may be more visible depending on color used. Any seam greater than 5mm will be visible and produce a line the same color as the adhesive used. Since the adhesive is solid in color, it becomes very visible with colors containing particulate. Material Review Place materials on the work benches. Inspect dye lots and run numbers. Remove peel coat and inspect for color variation, match and defects. Review cuts and dry fit seams when applicable before cutting! Remember that this is a review and inspection process. Wet the edges between sheets to be seamed to help determine color match. Review all safety and shop procedures before cutting and machining the HI-MACS sheet materials. HI-MACS _ 20 HI-MACS _ 21

2 Using the Following Procedures Will Ensure a Great Seam Industry standards suggest that two acceptable methods will ensure a great seam. Mirror cut the two pieces to be seamed together and do so at the same time. This is performed by setting a straight edge in place on one of the pieces to be seamed and also clamping down the two pieces to be seamed. Maintain a gap approximately 6mm greater than the shank of the bit. It will take approximately 3mm off each of the pieces that will be seamed. A square base router will help the accuracy. With one controlled pass of the router, you will make these two mirror edges simultaneously. The two pieces will fit together exactly. You can also achieve extremely accurate cuts by using C.N.C., Vertical Panel Saws, or Auto V Groovers. If you scuff-sand the edges with a 90 degree block plane or right angle block and 60 grit sand paper, you will ensure a greater bonding surface than if you do not. Designed by Ron Arad. Fabricated by Rosskopf & Partner AG. Photographed by Cutting and Staging Make sure to clean the joining edges with denatured alcohol and a clean white rag. Apply a strip of box tape or packing tape to the underside of the area to be joined, half on each side of the two pieces. This will create a bridge. Leave about 3mm between pieces before applying the tape. Clamping Tips Remember clamping pressures. You do not want to use excessive pressure. If you do, you will create a dry seam. This is when you squeeze all the glue from the seam joint. Clamp pressures should be tight enough to allow a bead of adhesive to squeeze out. The adhesive will shrink slightly, so do not completely clean off the joint of excess adhesive. Look for glue voids and air pockets. Take care of this before the seam adhesive sets up. Inspect the seam to ensure a tight fit. Thermoforming Let the adhesive cure for a minimum of 40 minutes in normal conditions or until hard to your fingernail touch. Thermoforming Process per Thickness of Product Cooling Process of thermoforming Remove the excess adhesive by Leveling the seam with a router with a set of skis and a small leveling bit. Do not use a belt sander to perform this operation. Excessive heat will weaken the integrity or fail the seam all together. Finish sanding all surfaces to specified finish. When Top Mounting When Under mounting Sinks from Dissimilar Materials Lavatory Bowls Finish Considerations Matte Finish, Satin Finish, Gloss Finish Polishing Procedures Reinforcement Typical Standards Seam reinforcement materials should be comprised of 13mm HI-MACS materials. The reinforcement must be continuous along the entire seam. This 3 ± reinforcement strip must be beveled to 45 degrees and sanded smooth to reduce the stress riser. Avoid stress risers. A stress riser is a sharp or rough cut or corner that weakens over time as the top expands and contracts. This weakening effect will eventually fail the top and a crack in the countertop will occur. Locate reinforced seams where full support is available. Reinforcements can sometimes get in the way of the overall support structure. Keep the nearest edge of the seam support a minimum of 3 ± from inside corners. Note Do not place a seam over a dishwasher. Do not place a seam through a sink. HI-MACS _ 22

3 Mounting Sinks from Dissimilar Materials Sinks and Bowls to HI-MACS Sheet Materials. The most typical dissimilar sink or vanity will be comprised of Stainless Steel, Porcelain, Cast Iron, Ceramic or Glass. These sinks can be top mount, self rimming or under mount. When Top Mounting Cut the opening in the countertop approximately 2.5cm larger in length and width than the sink is to be mounted. Make this cutout with a router only! This opening should then be sanded to remove chatter to a smooth finish. Apply a 6mm bead of 100% silicone to the bottom edge of the self rimming sink flange and also to the edge of the routed cutout. Position the sink into the cutout so that the flange rests on the deck. Make certain to install the clips or clamps supplied, but remember not to screw anything directly into or onto the HI-MACS materials. Use a wooden block or shim block when necessary. Your distributor has or will direct you to the approved sources for sink clips that are appropriate to mount into the HI-MACS sheet materials. When Under Mounting Sinks from Dissimilar Materials Make a template if one is not provided of the required size for the cutout. Sand and finish the routed edges and chatter to provide a smooth surface. Invert or flip your HI-MACS countertop. Make certain your bench is flat and level. HI-MACS _ 24 Leave enough room at the back of the countertop for the faucet assembly, edge buildup backsplash, and respective sink flange. Apply a 6mm bead of 100% silicone to the top of the sink flange and to the bottom of the HI-MACS counter top at the flange perimeter edge. Position the sink equally around the cutout and install sink clips or clamps supplied, but remember not to screw anything directly into or onto the HI-MACS materials. Use a wooded block or shim block when necessary. Your distributor has or will direct you to the approved sources for sink clips appropriate to mount into the HI-MACS sheet materials. You can either bevel mount or under mount your HI-MACS sink or vanity to your HI-MACS countertop or vanity to create a monolithic appearance smooth to the touch and crisp and clean to the appearance. A seam mount in solid surfacing is gluing the top of the sink flange with adhesive to the bottom of HI-MACS sheet materials. For this reason, all typical bonding steps are performed on an inverted or flipped sheet, thus exposing the bottom of your countertop. Most fabricators will perform all steps in an inverted fashion, with the exception of final trimming with the router and finish sanding. It may be helpful to make sure you have a work table/bench that is open or wide enough in the center to flip the top into once the sink is installed for final trimming and finishing. Such a table/bench will provide proper support all around the sink and countertop. Mark the center location of the bottom of the sheet where the sink will also be centered in the sink base cabinet. Use an auger to scribe these marks. Once you dry fit the bowl into final position, use the same auger to draw an outline around the sink/bowl. Completely sand and then clean the surface of the sink flange and the area on the bottom of the sheet inside the auger outline that will have adhesive placed on it. Place the sink/bowl back into position inside your auger outline. Attach blocks made of wood or scrap HI-MACS material with hot melt glue against the outside edge of the flange. Once the glue has dried the sink will remain in position. At this point you can place a bead of adhesive on the flange of the sink or bowl and on the auger outline on the sheet. Place the bowl inside the positioning blocks and attach clamps or weights to ensure adequate and equal pressures as the adhesive is setting up. Depending on the bowl, it may be necessary or required to install sink clips or brackets to aid in the sink support. It can be noted that if you notch the positioning blocks to produce an "L" block, you can create you own support bracket. Once the adhesive is dry, carefully flip the top upright. Place your router in the center of the bowl and plunge an approximate 2.5cm hole through the sheet. Make sure you now put a bearing guide on the bit and follow the perimeter of the bowl as a guide. The bearing will follow it and the excess cutout material will be removed. Change your bit to a finish profile bit with a bearing guide and finish routing the final profile to the deck and bowl. It can be a smooth transition appearing as a monolithic top and bowl or a small bullnose to provide a transition lip. HI-MACS _ 25

4 Lavatory Bowl (Under Mount Type) Step 1 Step 7 Drill Mark the center of product to install the bowl. Plunge a hole near the center of where the bowl is Auger to be mounted, using router. Step 2 Step 8 Exclusive adhesive Take the bowl and mark its circumference with auger. Apply the adhesive to the bowl flange. (Pencil or marker not recommended) Step 3 Cloth Step 9 Completely clean surface around circumference with Place and attach the bowl as shown. denatured alcohol. Step 4 Attach blocks as shown with quick-drying or hot melt adhesive in order to prevent the bowl from moving. Fixed scrap plate Step 10 Attach with clamps until the adhesive has hardened. Clamp Sand Paper Step 5 Step 11 Lightly sand the flange part of bowl with sand paper. Remove clamps after adhesive has hardened. Turn assembly over and route sink hole as shown. Cloth Step 6 Step 12 Apply denatured alcohol and clean the flange. A B C Various shapes are obtainable according to bit selection. HI-MACS _ 26 HI-MACS _ 27

5 Thermoforming CAUTION / The Volcanics Series is Not Thermoformable! Template to the shape required using plywood. Since materials other than plywood have inappropriate cooling times, it is recommended that only plywood be used. HI-MACS can be formed to tight radius by means of heating. The oven must heat the entire sheet for successful thermoforming operations. The sheets need to be heated to a temperature of , but should never exceed 200. Remove the protective film prior to heating. The minimum forming radius of 12 mm HI-MACS is 45 mm for Solids, Pearls and Sands and a minimum forming radius by 12 mm HI-MACS Quartz and Granite is 100 mm till 120 mm. But always be aware: the darker the colour, the smaller the radius will be, the more whitening there may be. The sheets should normally be heated for 15 to 30 minutes, depending on batch (manufacture date), heating temperature and pre-heated oven. Rebating the reverse side in the area to be formed can result in shorter heating times and smaller radius. Once heated to the required temperature remove workpiece with heat resistance gloves from the oven and place directly into a mould. Male and female mould are required. Allow heated material to shrink in the mould. Leave the sheet in the mould until the sheet has cooled down, ca. 60 at least, (typically minutes, depending on the material of the mold). Always wear heat-protection gloves for this operation. Never attempt any shock cooling as this can cause stress to the material. Attempting to bend HI-MACS at lower temperatures or shortening the heating cycles will often result in "whitening" or cracking of the edge. Normal sanding and finishing of the formed edge can be carried out once the sheet is fully rigid. Thermoforming Process per Thickness of Product Thickness of Product(mm) 6 Oven temperature( ) Heating Time(Minute) Minimum Curve Radius(mm) Cooling Never take out the product from the template before the temperature reaches 80. The shape of product is maintained at temperatures below 80, even if the product is not supported by the template. Thickness of Product(mm) 6 12 Cooling Time(Minute) 10~20 20~40 Note 160~ R50 160~ R Peel off the protective sheet, which is attached to the surface of product. 2. Be careful that the oven temperature does not exceed Heat 10~20 minutes, or more if you need the product with minimum curve R. 4. Please note with caution hat a whitening effect can be generated on the surface of the product if the temperature is too high or the heating is prolonged. 12 Finish Considerations HI-MACS sheet materials are factory sanded prior to peel coat application. The result of this superior quality factory finish offer fabricators less final sanding time in the shop or on the jobsite. is a very important part of the fabrication process. Be very sure to sell a finish that is right for the color and lifestyle of the customer. Do not oversell the performance of a specific finish, especially in a darker color selection and in a satin or gloss finish selection. Be forthright, in clearly expressing the performance of a finish option. The sanding and finishing process can also be the most time consuming and frustrating experience to the fabricator in the process of fabrication. HI-MACS would like to simplify the process as you take your countertop finish from a standard matte to satin to high gloss finish. Additionally, it can be confusing to the fabricator because of the multitude of sanding equipment, systems and sand paper companies available to the fabricator. As you decide the best equipment and sanding papers to incorporate into your fabrication process, remember to purchase good quality sanding equipment and sandpapers. Process The final process of manufacture of all HI-MACS elements is to sand (and/or to polish for special applications). Under normal circumstances, begin by sanding the entire element with 120 grit paper. In instances where there has been no prior fabrication of the sheet, it is possible to start with 280 or 320 grit. Always use dust extraction systems at all times when sanding, this will help pick up loose particles of grit and prevent unwanted scratches. Build up to finer and finer levels of grit size, taking care to clean down between each change with a damp cloth. Finish a 320 grit paper and than followed by Superpad S/G 1200 from Jost to reach a recommended semi-gloss level. To improve the gloss level of the surface use 1200/1500/1800 wet or dry, Scotch Brite pads, or polishing pastes available from 3M or other manufacturers. High-gloss finish level is very sensitive in maintenance and not recommended for normal use, but for art subjects acceptable. High-gloss finish Level is NOT covered under the 10-year limited installed warranty program. Keep the sander moving slowly in circles at all times, first in an East-West direction then North-South. Insure to use proper equipment, like a random orbital sander with a flat pad. For straight surfaces use a hard pad always. Soft or super-soft pads are recommended for curved surfaces. Never concentrate on one specific area, particularly near seam, as this can lead to dipping. After each sanding step, wipe off dust, then start with the next step. Be aware that some dark colours need more careful sanding than some other lighter colours. Thermoforming / Process of thermoforming HI-MACS Template Preparation Oven Heating Cooling Final Wooden Template Heating Forming Process Cooling HI-MACS _ 28 HI-MACS _ 29

6 Matte Finish To achieve a matte finish, you can either use a grit or a micron system. Remember the numbering system or grades of papers between grit and micron systems are opposite to one another. First, use a 120 Grit or 100 micron abrasive. Once this step has been completed, remember to clean the top and switch papers to a 180 or 220 Grit or 60 Micron paper. Finally, clean the top once again and surface the top with a #7447 Scotch-Brite pad. If you are working with a dark or black color, you may have to add an additional third step in sanding. This will require a Grit or 30 micron paper. If this is done, you will then want to clean the top and then surface the top with a #7448 Ultra Fine Scotchbrite pad. Satin Finish If you wish to achieve a satin finish follow the same steps expressed to achieve a Matte Finish on a dark color. Use a 120 Grit/IOO Micron, then switch to a Grit/60 Micron. Remember to clean the top between steps. You will want sand the top using Grit/30 Micron paper. Clean the top. Finally, you will surface the top with a #7448 Ultra Fine Scotch-Brite pad. Clean the top once again and examine the final finish. Gloss Finish HI-MACS _ 30 Poggenpohi_Kitchen_United_Kingdom, designed by Poggenpohl, fabricated by Solidity, photographed by David Still Follow the steps to the Satin Finish specification, but do not use the #7448 pad yet. As you reach the Grit/30 Micron step, you will need to add a few additional steps. Sand the top using Grit/15 Micron paper. Thoroughly clean the top. Remember to check the loading of your paper during the process and replace it frequently as necessary to maintain a consistent finish. Make sure to remove excess adhesives with a surfacing router equipped with a system of skis. Avoid use of a belt sander as it generates a great deal of heat and can fail a seam. Furthermore, the belt sanding equipment is very aggressive and can remove material quickly. That being said you can create more problems for your countertop fabrication if more material is removed than is supposed to be. You want to maintain control in the sanding process. It is the final step of showcasing your work. An important step in the process of sanding is to thoroughly clean the top between steps or grit changes. You can do so with a spray bottle of water or preferably denatured alcohol and a clean white rag. Cleaning off sanding dust between steps allow for a more consistent and high quality finish. Apply equal pressure and overlapping coverage in both directions of the top. For example, left to right and front to back. Complete one direction before starting the other. Change or clean your sandpaper as you sand as it will get loaded and become less efficient. As you get to a more detailed finish the sandpapers will load more quickly. If care is not taken to keep the sandpaper loading to a minimum, it will impair your ability to achieve a high quality, consistent finish. In a gloss situation, you may never achieve it. Installation Overview Transporting Pre-Fabricated Materials Substructures Key Reminders to a Successful Installation Post-Installation Overview Kitchen Countertop Installation Troubleshooting Consumer Cleaning, Care & Repair HI-MACS Certificates

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