Avonite Fab Guide Final Revised April 2014.pub

Avonite Fab Guide Final Revised April 2014.pub
Fabrication Guide
This fabrication guide has been prepared to assist the fabricator and installer in the proper methods for seaming,
polishing, patching and handling Avonite Surfaces Studio
Collection TM and Foundations TM solid surface products.
Avonite Surfaces building and surfacing materials are warranted to be free from defects at time of manufacture. Any
materials found defective will be replaced promptly.
Avonite Surfaces Technical Services Department
1-800-428-6648 or
(505) 864-3800 Fax (505) 864-7790
1945 Hwy 304, Belen, NM 87002 USA
Information or references to application, code compliance
or specific standards are provided for convenience only.
The accuracy or suitability of any recommendations in this
guide must be verified by the user, Aristech Acrylics LLC
disclaims any legal responsibility.
Questions pertaining to any procedure detailed herein
should be addressed to the Avonite Surfaces Technical
Services Department.
Table of Content Link Page
Name : _____________________________________
Date of Seminar : _________________________________
Address : ___________________________________
Instructor : ______________________________________
___________________________________
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WHO WE ARE
Since 1983 we’ve been a pioneer in solid surfacing, known for our unbridled passion and spirited innovations. We’ve
been there, with many of you, from the beginning. For more than twenty five years, we’ve celebrated the relationship
between extraordinary product, design and craftsmanship. We are inspired by and committed to designers and fabricators with a passion for bringing forth original ideas and taking them beyond the ordinary.
HOW TO USE THIS GUIDE
We at Aristech Acrylics LLC hope you will find the following Fabrication Manual to be a useful tool. It was created to
help you discover the unlimited design possibilities, which will lead to wonderful solutions for you and your clients. Although many applications are covered in this guide, there will be new applications that may not be covered in detail.
Our fabrication guide is designed to provide you with the fundamental knowledge of fabrication. These fundamentals
can be adopted for many new applications.
If you have specific questions or requests, our friendly and expert technical staff is eager to help. Feel free to call your
regional representative or contact us at 1-800-428-6648.
Important updates such as Technical Bulletins published after the printing date of this manual are also
available for download. Certified fabricators should periodically check for updates and add them to this
guide. For additional copies of this guide or quick reference for your clients, the entire guide is available for
download at www.avonitesurfaces.com.
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Table of Contents
APPENDIX
SECTION 4: PATCHING AND INLAY
Current Product Listing
A.1
Patching
4.1
Joining Color Charts
A.2 - A.3
Color Inlay
4.2
Catalyst Ratio Chart
4.3
SECTION 1: INTRODUCTION
Product Introduction
1.1
Health and Safety
1.2 - 1.3
Wall Panels and Signage
5.1
Storage and Handling
1.4
Thermoforming
5.2
Color Matching
1.5
Repairs
5.3 - 5.4
Layout
1.6 - 1.9
Partitions and Wainscoting
5.5
Tooling
2.1 - 2.2
SECTION 6: SUPPORT MATERIALS
Machining Seams
2.3 - 2.4
Fabrication Support
6.1 - 6.4
Joining
2.5 - 2.6
Care and Maintenance
6.5 - 6.6
Clamping Seams
2.7 - 2.8
Warranty
6.7 - 6.8
Edge Build Ups
2.9
Clamping Edges
2.10
SECTION 5: SPECIAL APPLICATIONS
SECTION 2: FABRICATION
Machining Edges
2.11
Sanding and Polishing
2.12 - 2.17
SECTION 3: INSTALLATION
General
3.1 - 3.4
Wet Wall Panel System
3.5 - 3.10
Sinks and Pans
3.11 - 3.14
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Avonite Surfaces Colors
Crystelles
Metallics
A.1
Glass Series
K3-7725
Autumn Wheat
K3-8330
Cat Eye
K3-8560
Amber Glass
K3-7700
Aztec Brown
K3-8342
Chocolate Silk
K3-8455
Antique Glass
Cobalt Glass
K3-7100
Black Ice
K3-8570
Copper Canyon
K3-8485
K3-8000
Blue Pearl
K3-8495
Goldmine
K3-8480
Frosted Glass
K3-8100
Brazilian Blue
K3-8320
New Caldron
K3-8465
Sky Glass
K3-8425
Cement
K3-8580
Night Pearl
G3-1050
Midnight Sky
K3-8343
Pearl
K3-8500
Nougat
K3-8585
Silver Comet
K3-8575
Cozumel
K3-8340
Tusk
Recycled
Petals
Minerals
K3-8200
Kaleidoscope
K1-6638
Palm Desert
K3-8600
Sirocco
K1-6636
White Sands
K3-8601
Neptune
K1-6640
Back Roads
K1-6641
Brown Sugar
Dunes
Black Coral
Cairo
F1-9137
Casablanca
F1-9138
Fargo
F1-9117
Kokoura
F1-9119
Nordic
F1-9144
Palermo
F1-9146
Kona
Pediments
F1-7713
Algodon
Cottonwood
Crushed Lava
Cirrus
K3-8603
F1-9125
F1-9130
K1-6600
K1-6637
F1-9065
F1-9105
Recycled Recycled
Artica
Aspen
F1-4330
F1-4331
Honey Crunch
Khaki
F1-9033
Biscotti
F1-4310
Coastline
F1-7830
Bronze
F1-7553
Jungle
F1-9037
High Desert
F1-7552
F1-7810
Malt
F1-7554
Canary
F1-9036
Sandstorm
F1-7556
Shark Skin
F1-7820
Star Shine
F1-7557
Hazelnut
F1-9010
Stormy Gray
F1-7551
Ginger
F1-8206
Alpine Shimmer
F1-7555
Icecap
Symphony
Solids
F1-7921
Boardwalk
F1-8010
Bone
F1-7931
Cliffside
F1-8024
Crème
F1-8836
Marcato
F1-7735
Dark Roast
F1-8106
Ivory
F1-8844
Spianato
F1-7933
El Cajon
F1-8016
White
F1-8864
Fresco
F1-7710
F1-7711
Gulf Coast
Jurassic
F1-8026
Super White
F1-8812
F1-8820
Cadenza
Saltando
F1-7743
F1-7501
F1-7502
Red Rock
Moon Crystal
Avalanche
F1-8852
Arioso
F1-7503
Morning Tundra
F1-7715
Bayside
F1-777719
Urban Snow
©
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Joining Color Chart
A.2
Item Number Color Name
Adhesive
Item Number
Color Name
Adhesive
K3-8560
K3-8455
K3-7725
K3-7700
K1-6640
K3-7100
K3-8000
K3-8100
K1-6641
K3-8330
K3-8425
K3-8342
K3-8485
K3-8570
K1-6600
K3-8575
K1-6637
K3-8480
K3-8495
K3-8200
Icicle
Icicle
Wheat
Wheat
Galaxy
Galaxy
Icicle
Icicle
Slate
Icicle
Ash
Icicle
Icicle
Icicle
Polar
Polar
Ash
Icicle
Icicile
Polar
G3-1050
K3-8320
K3-8580
K3-8500
K1-6638
K3-8343
K3-8585
K3-8465
K3-8340
K1-6636
Midnight Sky
New Caldron
Night Pearl
Nougat
Palm Desert
Pearl
Silver Comet
Sky Glass
Tusk
White Sands
Icicle
Icicle
Icicle
Foam
Earth
Moon
Ash
Icicle
Icicle
Moon
NEW PETALS
K3-8603
K3-8600
K3-8601
Cirrus
Sirocco
Neptune
Icicle
Icicle
Icicle
©
Amber Glass
Antique Glass
Autumn Wheat
Aztec Brown
Back Roads
Black Ice
Blue Pearl
Brazilian Blue
Brown Sugar
Cat Eye
Cement
Chocolate Silk
Cobalt Glass
Copper Canyon
Cottonwood
Cozumel
Crushed Lava
Frosted Glass
Goldmine
Kaleidoscope
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Joining Color Chart
A.3
Item Number Color Name
Adhesive
Item Number Color Name
Adhesive Name
F1-7713
F1-9065
F1-9105
Algodon
Artica
Aspen
F1-7502
Avalanche
F1-9033
F1-9125
F1-7921
F1-8010
F1-7830
F1-9130
F1-9137
F1-7931
F1-8024
F1-7735
F1-7933
F1-9138
F1-7710
F1-9037
F1-8106
F1-7711
F1-9117
F1-7810
Biscotti
Black Coral
Boardwalk
Bone
Bronze
Cairo
Casablanca
Cliffside
Crème
Dark Roast
El Cajon
Fargo
Gulf Coast
High Desert
Ivory
Jurassic
Kokoura
Malt
F1-9144
F1-7743
F1-9036
F1-7820
F1-9010
F1-8016
F1-8026
Palermo
Red Rock
Sandstorm
Star Shine
Stormy Gray
White
Super White
Earth
Earth
Foam
Galaxy
Moon
Polar
Polar
F1-4330
F1-4331
F1- 7553
F1-7552
F1-7554
F1-7556
F1-7557
F1-7551
F1-7555
F1-4310
Honey Crunch
Khaki
Jungle
Tango
Canary
Shark Skin
Hazelnut
Ginger
Icecap
Coastline
F1-7501
F1-7503
Moon Crystal
Morning Tundra
F1-9119
F1-7715
F1-7719
F1-8206
F1-9146
Nordic
Bayside
Urban Snow
Alpine Shimmer
Kona
Polar
Polar
Moon
Crystal
Sand
Galaxy
Moon
Maple
Slate
Foam
Crystal
Earth
Crystal
Slate
Crystal
Sand
Crystal
Sand
Crystal
Foam
Polar
Crystal
Crystal
Ash
Polar
Moon
Crystal
Polar
Earth
©
New Recycled
F1-8812
F1-8820
F1-8836
F1-8844
F1-8864
F1-8852
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Symphony
Cadenza
Saltando
Marcato
Spinato
Fresco
Arioso
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Foam
Earth
Moon
Sunset
Maize
Ash
Earth
Moon
Crystal
Crystal
Foam
Crystal
Crystal
Slate
Foam
Foam
Avonite Surfaces Product Introduction
1.1
For over 25 years the debate of polyester versus acrylic solid surface has rumbled through fabrication shops. Avonite
Surfaces is in the unique position of offering both types of products. These product types share many common characteristics but some products from Avonite are so unique that they deserve special recognition for their applications and
fabrication techniques.
To Fill or Not to Fill
The majority of solid surface products are composed of polymer resins and a mineral filler called alumina trihydrate
(ATH). The resins are typically polyester, acrylic, or a blend of the two. Polyester resin is a thermoset polymer while
acrylic is a thermo plastic resin. To produce a solid surface product with acrylic resin, you must add ATH filler. Only with
the filler can you create an acrylic product that can be cut shaped and sanded. Without the filler the acrylic resin is too
soft . Solid surface products made from polyester resins do not require the ATH filler to be machined. Producers have a
choice of how much ATH filler to use.
ATH filler is a fine white powder that clouds the matrix. Products with high levels of ATH are opaque where as products
using small amounts can maintain their clarity and depth. This is where Avonite Surfaces stands alone. We are the
only major producer of solid surface that has chosen to create some products with minimum amounts of fillers to
achieve depth and clarity found in no other solid surface product.
PRODUCT SUMMARY
The Studio Collection features a wide variety of products that are unparalleled in their beauty and composition. From
dynamic colors and natural textures, to our series of recycled products and rich collections inspired by glass, concrete,
and metallics, no other company offers you more choices.
Standard Sheet Size is 36” x 120” x 1/2” (91.5cm x 304.8 cm x 12mm)
Custom colors are available.
These products are made in the USA at our Belen, NM facility.
The Foundations Advanced Acrylic products bring innovation to today’s most popular colors. Our production facility allow
us to produce acrylic solid surface up to 60” wide. This wide width can save you time and money by eliminating seams
and reducing labor costs. These savings can be even more dramatic using our custom size sheet capabilities. Go to
www.avonitesurfaces.com for details.
1/2” Standard Sheet Size is 30” x 144” x 1/2” (76.2cm x 365.7cm x 12mm)
1/4” Standard Sheet Sizes are:
36” x 96” (914mm x 2,438mm)
48” x 96” (1214mm x 2,438mm)
60” x 96” (1,518mm x 2,438mm)
These products are made in the USA at our Florence, KY facility.
PRODUCT IDENTIFICATION: F= Foundations Acrylic / K= Crystelle / C,G= Traditions .The second digit represents the Fire Rating : 1= Class 1 /A 3= Class III/ C
Shaped Products
Fully integrated sinks provide a seamless bond between the counter and sink leaving no space for bacteria to gather. This
non-porous combination remains the wise choice for healthcare facilities and more.
Wet Wall Panel System
The Avonite Wet Wall Panel system includes our seamless wide wall panels with optional pans and accessories. The
standard wall panels are available in 36”, 48” and 60” widths and a full 96” high. These standard dimensions are stocked
in the eight popular colors, and are available in all Avonite Foundations products.
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Health and Safety Information
1.2
FOR SHEET AND SHAPED PRODUCTS
INLAY RESIN
FIRST AID PROCEDURES:
CAUTION:
Avonite Surfaces solid surfacing material is non
toxic; however, during fabrication such as sawing, routing and sanding, dust consisting of
cured resin and filler is generated. This dust is
classified as Nuisance Dust.
•FLAMMABLE COMPONENTS; AVOID HEAT, SPARKS AND
OPEN FLAME.
•WEAR SAFETY GLASSES AND PROTECTIVE GLOVES.
•FOR PROFESSIONAL USE ONLY.
•USE ONLY AS RECOMMENDED.
The Inlay Resin is a polyester resin used with MEK peroxide. These components and vapors may cause irritation of the skin, eyes, nose and throat. AVOID CONTACT
WITH EYES, SKIN AND CLOTHING. USE ONLYWITH ADEQUATE VENTILATION; AVOID BREATHING VAPORS.
WASH HANDS AFTER USE.
INHALATION: Nuisance Dust—Overexposure to
dust may cause irritation of the respiratory
tract. Should this happen, remove affected individual to fresh air. If symptoms persist, consult
a physician. Styrene—Although no vapor buildup is expected, excessive inhalation of vapors
can cause nasal and respiratory irritation, dizziness, weakness, fatigue, nausea, headache and
even asphyxiation. Remove affected individual
to fresh air. If symptoms persist, consult a physician.
SKIN OR EYE: Nuisance Dust—May cause irritation. Wash skin and flush eyes with water for at
least 15 minutes. Contact physician if irritation
persists. Styrene—Vapor concentration is expected to be too low to cause irritation, but odor
is recognizable. Excessive exposure can cause
severe eye irritation and moderate skin irritation. Wash skin and flush eyes with water for at
least 15 minutes.
EXPOSURE CONTROL METHODS Provide sufficient ventilation and dust pick-up at saw, sander, drill or router to keep dust level below
10mg/m3 TWA (Time Weighted Average) for
total dust, or provide and make mandatory the
wearing of NIOSH approved fitted dust respirators. Wear protective leather or cotton gloves,
safety glasses and safety shoes when installing
or fabricating Avonite Surfaces solid surfacing
material.
DISPOSAL PROCEDURES Dust from fabrication
operations is non-hazardous. Collect in impervious bags. Dispose of dust and scrap in accordance with local, state and federal regulations.
FOR MORE COMPLETE INFORMATION, REQUEST
THE MATERIAL SAFETY DATA SHEET.
©
EMERGENCY AND FIRST AID PROCEDURES: In case the
resin or catalyst contacts your skin, wash with soap and
water, for at least 15 minutes. For eyes, immediately
flush with water for at least 15 minutes. Contact physician if irritation persists. In case of ingestion, immediately consult a physician or your local poison control
center, identifying the catalyst as methyl ethyl ketone
peroxide solution in dimethyl phthalate containing a
small amount of hydrogen peroxide, and the resin as an
unsaturated polyester in styrene monomer.
SPECIAL HEALTH EFFECTS: Excessive inhalation of resin
monomer may aggravate pre-existing medical conditions
such as, but not limited to, chronic respiratory problems,
skin disease and central nervous disorders. There is a
low health risk from inhalation of the filler dust. Avoid
inhalation or eye contact.
DISPOSAL PROCEDURES: Un-reacted resin and hardener
are classified as hazardous waste. All components
should be disposed by mixing so that they react and
become fully cured and solid. At this point, they can
then be disposed in accordance with local, state and
federal regulations, as non-hazardous solid waste.
FOR MORE COMPLETE INFORMATION, REQUEST THE
MATERIAL SAFETY DATA SHEET, or visit
www.avonitesufaces.com.
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Health and Safety Information
AVONITE SURFACES SOLID SURFACE ADHESIVE
•FLAMMABLE COMPONENTS: Avonite Surfaces Solid
Surface Adhesive Component A contains acrylic resin
and Component B contains benzoyl peroxide. The liquid
and vapors may cause irritation to skin, eyes, nose and
throat and may even cause an allergic skin reaction.
•AVOID HEAT, SPARKS AND OPEN FLAME
•USE ONLY AS DIRECTED
•WEAR SAFETY EYE PROTECTION
•AVOID CONTACT WITH EYES, SKIN AND CLOTHING
•HAVE ADEQUATE VENTILATION
•AVOID BREATHING VAPORS
•WASH HANDS AFTER USE
EMERGENCY AND FIRST AID PROCEDURES:
If the Avonite Surfaces Solid Surface Adhesive resin or
hardener contacts your skin, wash with soap and water
for 15 minutes. For eyes, immediately wash thoroughly
with plenty of water for 15 minutes and consult a physician. In case of accidental ingestion, immediately consult a physician or your local poison control center, identifying the hardener as benzoyl peroxide in plasticizer
and the resin as acrylic resin in methylmethacrylate
monomer.
©
1.3
SPECIAL HEALTH EFFECTS:
Excessive inhalation of resin monomer may aggravate
pre-existing medical conditions such as, but not limited
to, chronic respiratory problems, skin disease and central nervous disorders and may cause nausea and loss of
consciousness.
DISPOSAL PROCEDURES:
Acrylic resin and hardener when disposed in liquid state
are hazardous waste but when mixed and polymerized
are non-hazardous solid waste. Dispose of used or unused Avonite Surfaces Solid Surface Adhesive by mixing
components, allowing the mixture to solidify and then
disposing in accordance with applicable local, state and
federal regulations. The information and statements
herein are believed to be reliable but are not to be construed as a warranty or representation for which we
assume legal responsibility.
FOR MORE INFORMATION REQUEST THE MATERIALSAFETY DATA SHEET, or visit
www.avonitesurfaces.com.
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Storage and Handling
1.4
Avonite Surfaces material should always be stored FLAT
and evenly supported. Figure A demonstrates a framed
substrate. Figure B is an A-Frame storage bin.
C
D
©
Always carry sheets upright in a vertical position. To
avoid chipping and scuffing, do not drop or drag sheets.
Fabricated sections with angles or seams should be handled carefully with support at the angled or seamed area. A carrying board should be used for tops with cut
outs (Figure C).
Avonite Surfaces can be transported lying flat on an
evenly supported and padded surface. Large fabricated
sections should be transported on edge. Pad the edges
to prevent damage and brace to prevent movement
(Figure D). When transporting Avonite Surfaces in an
exposed vehicle, pieces should be wrapped to prevent
damage from extreme temperature changes. Avoid exposing fabricated pieces to direct sunlight. Uneven solar
heating will cause distortion of fabricated parts. Allow
pieces to cool to room temperature at the job site prior
to installation.
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Color Matching
1.5
Every Avonite Surfaces sheet has a sticker which displays an identification number. When ordering multiple
sheets to be seamed, be sure that sheets come from the
same batch.
Please notify distributor of this fact when ordering. Advise that you need sheets with consecutive numbers.
Although the Avonite Surfaces sheet has been inspected
prior to shipment, always remove peel coat and inspect
for color consistency, surface blemishes, warping, and
dimensional consistency.
Remove the protective peel coat and arrange the sheets
in the manner they will be installed. Sand 12"16" (305mm - 407mm) of the surface to verify color
match. After sanding, wet material with alcohol or water.
For Studio Collection, be aware that the pattern at the
edge and end of the sheet may be different from the
center of the sheet. This may not be noticeable when
looking at a single sheet. Always plan to trim 1"2" (25mm- 51mm) off an edge to be joined to another
piece. Aristech Acrylics LLC does not honor any claims
that have migration due to not trimming the sides or
ends of the sheet when joining them together.
©
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Layout
1.6
LOCATING SEAMS
When you lay out your job, consider where you need to
place the seams. Make as many seams as possible in
the shop and not in the field. All seams must be supported. Avoid placing seams in the following locations:
1. Inside corners (Minimum 2" [50mm]).
2. In cut outs.
3. Over dishwashers or other heat producing appliances.
4. When using dark colors, avoid placing seams indirect
sunlight.
THE L TEMPLATE
The L-Template is a convenient way to fabricate the L or
U shaped counter top. The L-Template should be
10' (305cm) long by about 30"(76cm) wide. The inside
corner will have a minimum 1"(25.4mm) radius. The LTemplate may be reversed and used for either side.
Clamp the L-Template securely to the Avonite Surfaces
material. Place some registration marks on the backside
and end of the template. Use a 3 HP router and template guide for cutting. After cutting, turn the material
bottom side up to bond on the drop edge and inside
corner build up. When the Avonite Surfaces Solid Surface Adhesive has hardened, turn the material face up
and re-clamp the L-Template. Using the registration
marks, place the template far enough back to remove
the excess material and Avonite Surfaces Solid Surface
Adhesive. This will result in a clean and smooth edge
requiring minimal sanding.
SEAM BLOCKS
The use of seam blocks is recommended for all seams.
Seam blocks should be 4" (101mm) wide and be at least
1/2" (12mm) thick. Join the seam block to the underside
using Avonite Surfaces Solid Surface Adhesive. Spread
the adhesive over the entire surface so there are no
voids. The seam block should cover the entire length of
the seam.
Seam blocks are highly recommended. Seams are
not covered under warranty. The seam block provides you with the strongest seam possible.
Avonite Glass Series products require different
seam block methods. See section 1.8.
©
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Layout
1.7
EXPANSION AND CONTRACTION
Like all solid surface materials, Avonite Surfaces material expands or contracts with temperature variation. The
following changes in length may occur with a swing in
temperature of 55° F (31 ° C). Class I (Filled)—
1/8" (3mm) for every 10' (304.8cm) Class III (Unfilled)
—3/16" (5mm) for every 10’(304.8cm) Always leave
appropriate clearances for expansion and contraction.
TILE BACKSPLASHES
INSIDE BLOCKS
Avonite Surfaces material requires a minimum
1"(25.4mm) radius on drop edge inside corners. This
diagram shows the recommended build up. After the
buildup is made, use a template to cut the desired radius (see L-Template).
©
The transition from tile to Avonite should be silicone
sealed and not grouted.
TRANSLUCENT COLORS
Glass Series products are translucent and may require a
seal coat of water based interior/exterior primer on back
of the sheet to reduce shadowing effects. For more information call the Avonite Surfaces Technical Service
Department.
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Layout
1.8
DESIGNING AND FABRICATING WITH AVONITE SURFACES GLASS SERIES AND PETALS
The unique translucent quality of Avonite Surfaces Glass and Petals products allows you to exercise a great deal of creativity. For this reason, it is expected that there will be many new applications that will produce unanticipated effects.
By all means experiment, be creative, and consult with us as you have questions. However, always make sure that the
end result will meet your expectations. We recommend that you create a sample mock up to share with your customers.
The Nature of the Glass Series and Petals Product
Keep in mind that dabs of silicone, supports, and under-mount sink flanges will show through these products like any
typical glass. When the products are laminated together for a thicker appearance, such as a drop edge or seam block,
they will appear darker due to reduced light transmission. These special effects can be worked into the design for a
unique aesthetic effect or application. Thermoforming Glass and Petals Series products is not recommended due to
potential color shifts.
When these products are chosen for more typical applications, where less transparency is desired, the backsides of the
finished tops must be undercoated to hide any supports. For best results, we recommend undercoating with a white
latex paint. This brightens the top closer to the sample chip but magnifies the contrast to the darker edge. This effect
should be demonstrated to the end user. Avoid paints with non stick additives. Painting should be done after fabrication
to avoid painting areas where solid surface adhesive will be applied.
Frosted glass offers unique opportunities for painting the back different colors to achieve custom hues that transmit
through the sheet.
The translucent nature of these products allow light to travel through the sheet and sometimes show an interruption
such as a seam. Lighting conditions can sometimes mask or amplify this effect. In almost all conditions the 1/2” thick
edge of the top sheet will appear brighter because in fact it is gathering more light and transmitting that light to the
edge.
NEW SEAM BLOCK METHOD
BACKLIT APPLICATIONS
Previously the use of seam blocks on the translucent
Petals and Glass Series was not recommended. The
seam block location was apparent and back painting the
sheets prevented good bond strength for the seam
blocks. This challenge has been resolved by using adhesion primer for the back side painting. This high adhesion primer was developed for hard to paint surfaces
such as PVC, glass, and tile.
For backlit applications, you may use 1/2” (12mm)
acrylic to support larger spans. Using the 1/2” (12mm)
acrylic sheet as a solid substrate is recommended.
Frosted or white acrylic may be used to diffuse the light
source. When adhering the Avonite Surfaces glass product to the acrylic, we recommend small pieces of 3M
VHB double sided tape. If clear acrylic is used, it should
be sanded with 100 Micron to frost the surfaces. This
will help hide the adhesive tape. Always test a small
piece to judge appearance.
Recommended:
INSL-X Stix Waterborne Bonding Primer or
Sherwin-Williams DTM Bonding Primer
For the best results, continue preparing seams with the
Wavy Bit. Once the seam is complete, turn the sheet
over for the remaining fabrication. Clean the excess glue
where the 4”seam block will be applied. Paint the back
side with the adhesion primer. Two coats are recommended. Allow to dry completely.
The seam block must run the full length of the seam.
Apply a generous amount of adhesive to the seam block
and to the edge that meets the back of the buildup
edge. Uniform weight should be placed on the seam
block to assure even pressure as the adhesive is drying.
©
Backlit Applications that require deck seams or have
unsupported spans will require special consideration.
Please call Avonite Surfaces Technical Services
800.428.6648 as you have questions.
SEAMING THE NEW PETALS
The new Petals products should be fabricated the same
way as the original Glass Series. Because of the very
large petal shapes, these products will have more conspicuous seams. The Petal products are hand crafted
creating an organic patterns that have different petal
flake concentrations across the sheet. This too will effect
the appearance of seams in a completed top.
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Layout
1.9
Designing and Fabricating with Special New Metallic
The appearance and seaming qualities of these new special metallic colors is different than conventional solid surfaces.
These three products have a light reflective quality that provides an optical effect or “direction” that shows lighter or
darker depending on the angle from which they are viewed. This unique reflective quality allows patterns to be created
where sheets are joined together. All seams will show this inherent reflective quality and will be visible unlike standard
solid surface. The color will appear to change when viewed from different angles. These effects can be incorporated into
your designs.
These directional patterns are not detectable in single sheet applications where no seam is required. Seams made from
the same sheet will also be noticeable. Because of these conditions there will be no claims allowed for color matching of
these products.
Designers and fabricators must consider these characteristics when using these three products.
Contact Avonite Surfaces Technical Services for any questions.
1-800-428-6648
Silver Comet K3-8585
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Tooling
Avonite Surfaces material can be easily machined with
ordinary woodworking tools, such as routers, saws,
planers, lathes, drills, and sanders. All blades and bits
should be carbide tipped.
ROUTERS
For general purpose routing, a 1-1/2 to 2 HP router
maybe used. For heavier cutting of thick edges and cut
outs, a 3 HP router is recommended. A 1/2" (12.7mm)
shank carbide bit is needed to minimize chatter for all
routing with the exception of small details like a
1/4" (6.3mm)round over or a pin stripe inlay. Avonite
Surfaces material should be properly supported during
all phases of fabrication.
©
2.1
CUT OUTS AND CURVED CUTS
A template and a router is mandatory for all cuts. The
use of a saber saw will leave a rough edge where
stress cracks can occur.
Use a template for all inside and outside corner radiuses.
Helpful Tip
Two square feet of color matched material should be
left on the job site for future repairs. Material should be
placed under a bottom drawer or mounted to the inside
of the sink cabinet. Mark the material to identify it is
for potential repairs.
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Tooling
TABLE SAWS
A table saw with a minimum 2 HP motor can be used to
cut Avonite Surfaces materials. The sheets should be
cut face up. A good quality rip fence is necessary for
accuracy. A triple chip bevel saw blade is needed for a
clean cut with minimum chipping. A 10" (254mm) diameter blade should have 40 teeth with a 20° positive
hook. Raise the blade 1-1/4" (32mm) above the surface
of the material for the best results.
RADIAL ARM AND MITER BOX
A triple chip bevel saw blade should be used for clean
cuts. These saws require a 10" (254mm) diameter blade
with 60 teeth and a 5° positive hook.
TOOLING SUPPLIERS:
Forrest Manufacturing
1-800-733-7111
Monument Toolworks (Parallign)
(508) 644-2400
JCM Industries, Inc.1-800-669-5519
The Pinske Edge 1-800-T-PINSKE
Festool Power Tools 1-888-337-8600
Velepec (Router Bits)1-800-365-6636
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2.2
Seam Preparation
2.3
Use a good quality 1-1/2 – 2 HP router. Refit base with
square base. Two dimensions on base allow you to turn
base and remove an additional 1/16" (1.5mm). Always
use a 1/2" (12.7mm) double fluted carbide router bit.
Set the router flat against straight edge. Lubricate with
cornstarch to minimize friction between router base and
straight edge. Move router with even feed speed. Allow
router sound to indicate the rate of feed.
After routing edges, dry fit to assure a flat, true edge. In
the dry fit process, the seam should virtually disappear.
If the seam is not done correctly, redo by taking off an
additional 1/16" (1.5mm). Check by dry-fitting again.
After routing, check again for a quality dry fit. Only after
you have achieved a good dry fit should you proceed.
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Seam Preparation
2.4
With 100 grit sand paper on a hardwood block, lightly
score the edges to be seamed together. This step aids
the adhesion between the two surfaces. Make one or
two passes only. Be careful not to sand the top edge.
WAVY BIT SYSTEM
Another way to machine seams is to use the Wavy Edge
Router Base and Bit to make two interlocking surfaces
that fit snugly together. The seam edges align perfectly
and do not slip, and a wavy surface seam is stronger
because it has more adhesive area allowing better bonding. Here’s how: rout one seam edge with one side of
the stepped Router Base, then rotate the router 180
degrees and rout the other seaming surface. Use a high
-grade carbide bit with a reversible insert blade to cut
the wavy seam. Inserts eliminate re-sharpening and
ensure the accuracy of every cut. You save time preparing the seams, and the automatic alignment means
you will not do as much sanding to get a professional
finish.
MIRROR CUTTING
Mirror cutting is a method of machining seams which
cuts both edges to be seamed at the same time. Use
only a 1/2" (12.7mm) shank double fluted bit. Place the
two pieces to be seamed 1/4" (6.3mm) apart and secure
them firmly to prevent movement. Clamp your straight
edge to one side. The router must be fed through with a
continuous movement without stopping. The two pieces
will fit together exactly.
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Joining
2.5
AVONITE SURFACES Ultra-Bond G Adhesive
Our adhesive is a pre-measured and pre-tinted two part
adhesive. Ultra Bond G hardens in approximately 40
minutes and is available in 250 ml. cartridges. Ultra
Bond G is available in several colors and clear for excellent color matches. It is specially formulated to offer
superior bond strength for all Avonite products and is
Greenguard certified.
CARTRIDGES
Each cartridge contains 250 ml (10 oz.) of adhesive and
will adhere 35 to 45 feet (12.1M) of 1/2" (12.7mm)
seam. The adhesive flows through a static mixer tube
and is ready for use. Two mixer tubes are included with
each cartridge. To assure positive flow of activator, dispense a small quantity of adhesive before installing
mixer tube.
REFER TO MACHINING SEAMS SECTION
BEFORE APPLYING ADHESIVE
ADHESIVE STORAGE
It is recommended that Ultra Bond G be stored in a refrigerator for extended life. Ultra Bond G should be acclimated to at least 60° F or 15°C before being used. Store
cartridges in an upright position as shown in photo.
Storage at temperatures above 75°F or 24°C may affect
the shelf life, and could adversely affect proper curing of
the adhesive. All cartridges are dated with an expiration
date. Do not use expired adhesive.
FINAL PREP
After the dry fit is complete and you are ready to join
the seam, clean edges thoroughly with isopropyl alcohol.
Place separation paper under seam area. Have seam
blocks in place.
Scoring the top of the surface strengthens the bond of
the excess adhesive. This helps prevent the critical top
layer of the seam from pulling out when machined.
FABRICATION TIP
From time to time the bead of adhesive dispensed with the Avonite Surfaces Solid Surface Adhesive cartridge will not
contain the prescribed amount of hardener. This may arise for a variety of reasons, but the end result is that small
sections of the seam may not set up as rapidly as others. There are techniques that will reduce the variation in setup
time. Once the bead of adhesive has been dispensed, a popsicle stick applicator may be use to spread the adhesive
over the bonding surface. This serves to more uniformly blend the adhesive with the hardener and prevents variation in
the hardening time of the adhesive. Another helpful technique used frequently, is to dispense two thin beads as opposed to one thick bead. This method overlaps any possible gap in the hardener and prevents uneven hardening.
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Joining
2.6
DISPENSING OPTIONS
Ultra Bond G cartridges are designed to fit only
in a 10 to 1 ratio system. Our systems are available in both manual and pneumatic styles.
Unique Properties
•The activator is opaque and viscous, much like
a paste.
•The resin is similar to the viscosity of honey.
Manual
•The “clear” Avonite Surfaces Solid Surface Adhesive is “foggy” in appearance rather than
“water clear.”
For a complete list of current adhesive colors,
please see Tables A.2 and A.3 in this manual, or
visit www.avonitesurfaces.com.
©
Pneumatic
FABRICATION TIP
When a small amount is needed there is no reason to
waste a mixing tube. Simply remove the end plug and
squeeze the adhesive into a paper cup and stir for one
minute.
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Clamping Seams
CLAMPING METHODS
Before clamping seams, be sure to double check the
following:
1. Surfaces to be bonded are properly scuffed with 100
grit sandpaper.
2. Separation paper is in place.
3. Pieces are properly aligned and level.
4. Edges are clean.
Prepare some reusable glue blocks made from scrap
pieces of Avonite Surfaces material. They should be
1"(25.4mm) thick by 1-1/2" (38mm) w x 2" (51mm).
Bevel the edges and drill 1/4" (6.3mm) holes as shown
in Figure 1 so the isopropyl alcohol will penetrate and
release the hot melt bond when it is time to remove
them.
On a standard countertop, hot melt 3 pairs of blocks
about 6"(152mm) apart across the seam area (see Figure A). Bar clamps are then used to bring the joint together. Be sure the glue squeezes out to ensure a tight
seam. However, avoid using excessive pressure which
may cause too much glue to be squeezed out resulting
in a weak joint.
After the seam has hardened, remove the blocks by
applying isopropyl alcohol and allowing a few moments
for the hot melt to soften. Also apply alcohol in the
1/4"(6.3mm) holes to allow for penetration of alcohol in
the center of the block. Then place a chisel under the
beveled edge of the block and gently pry; do not use
excessive force. If the block does not free immediately,
apply more alcohol and allow to soak for a while longer.
Other effective clamping methods use the Pinske Power
Grips with brackets and turnbuckle, as shown in Figure
B, or the Parallign Clamps shown in Figure C (Available
through Monument Toolworks ).
Other innovative devices designed by independent suppliers may save time or simplify difficult tasks. If there is
any question regarding the use of such devices, please
contact Avonite Surfaces Technical Services at 1-800866-TECH.
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2.7
Finishing Seams
REMOVING THE FLASH LINE
Do not attempt to sand away the flash line with a belt
sander. Instead, attach two skis to the base of a router.
Use a flat bottom cutting bit and lower the cutter to just
over the surface of the sheet. Cutting the flash line off
this way eliminates sanding time.
SANDING SEAMS
The following procedure will efficiently finish seam areas
For illustration, please refer to Figure C.
1.
Trim the Avonite Surfaces Solid Surface Adhesive
flash line with router on skis or offset trim router
2.
The remainder of the flash line should first be sanded with 100 micron paper. It is important that
sanding extend on either side of the seam, without
concentrating directly on the seam, as illustrated by
Point A. The 100 micron sanding should extend to
about 6" (152mm) on either side of the flash line.
Concentrated sanding could cause a valley, or dip,
in the seam area.
3.
The next step is to sand with 80 micron paper. The
sanding area now extends to about 12" (305mm)
on either side of the flash line, as shown in Point B.
4.
Once the seam is sanded level, continue the standard finishing procedure by feathering out the finish
in the seam area to blend with the final finish of the
top, as shown in Point C.
Sanding should not concentrate directly on
the flash line, but extend on either side to
feather-in the finish.
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2.8
Edge Build Ups
2.9
GENERAL REQUIREMENTS
The construction of your edge build up is determined by the profile you wish to achieve. Strips are laminated together
to acquire the bulk for the design. Confirm that your construction provides a minimum 1/2” of bonding surface area
after the profile is cut. Larger bonding surfaces create stronger edges. The diagrams below demonstrate construction
methods referred to as Stacked Edges and Drop Edges. In general, Stacked Edges provide the greatest bonding surface
area and therefore are the preferred method. Stacked Edges also allow layers to be put on one at a time. This ensures
tighter joints and to offset the build ups at inside corners. Sand all surfaces to be glued with 100 grit paper sanding
block to enhance the bond. It is highly recommended that all edges have a minimum 1” bonding surface.
Stacked Edges laminate strips together for the desired thickness. SAND
BOTH SIDES of the strips with 100
grit. Laminate strips face to back.
Drop Edges use a single strip turned
vertically on edge. This is a common
method but is the weakest construction method due to the minimum
bonding surface area. This method is
also limited to small round over or
beveled profiles. Additional strips can
be used the increase bulk and
strength.
Any drop edges greater than 1 1/2”
tall require reinforcement. Figure C.
shows a typical skirted front vanity.
Note that the skirt is reinforced by
plywood. The plywood substrate is
also reinforced with brackets to prevent damage.
For added reinforcement we recommend gluing a 1/2” x 1/2” slice of
solid surface behind the skirt edge
joint.
V-Grooving edges is another form of
drop edge. Although the bonding surface is somewhat increased, any vgroove edges over 1 1/2” tall should
be reinforced.
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Clamping Edges
LAMINATING BUILD-UP DIRECTLY ON COUNTERTOPS
Edges should be straight and free of chatter-marks.
Clean bottom of sheet and fascias with isopropyl alcohol.
Light block sanding may be needed where edge is to be
applied.
Dry fit and mark where they go with arrows.
Hot melt some guide blocks along the backside of the
edge.
Glue and clamp one edge build up at a time, to prevent
glue from setting up before build up strips are applied.
Apply two small beads of adhesive to the surface.
Place the drop edge in the glue and make sure an even
flash line develops.
Hold the drop edge back 1/8" (3mm) to avoid any chip
out on seamed edge.
Place spring clamps 2" (51mm) to 3" (76mm) apart.
Keep clamps straight to avoid tilting the drop edge back.
The tips of the clamps should be in the center of the
drop edge.
After the Ultra Bond G has hardened, clamps may be
removed. The edge can now be routed to your final configuration.
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2.10
Machining Edges
Listen to your tools
By using a high quality router and reasonable feed
speed, detailed cuts can be easily achieved. Keep the
router steady and make a smooth pass with out stressing the motor as this can cause chatter and more labor
time. Heavier cuts, such as those for a 3" (76mm) bull
nose can be produced by laminating several pieces together and machining in two steps.
For Best Results...
Use a 1/2” shank profile cutter
Sharp cutters require less sanding
COMMON CONSTRUCTION METHODS FOR POPULAR EDGE PROFILES
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2.11
Sanding and Polishing
FINISHING
The final finish of your application must be specified and
understood by the end user. Most customers choose the
Satin or Polished finish.
All Avonite Surfaces sheets come from the factory with
minor linear sanding lines. These lines are 60 micron or
a 280 grit finish on the face. To obtain any of the possible finishes these sanding lines must be removed. This is
accomplished by starting the sanding process with 60
micron.
Using a 6" (152mm) or 8" (203mm) random orbital
sander will reduce your sanding time by HALF over conventional vibrating sanders, and will achieve a more
uniform finish.
Sanding Process
1. Move the sander in a back and forth direction.
NOTCIRCULAR.
2. Overlap each pass by 50%.
3. Sand at a slow and even pace, approximately
1"(25.4mm) per second.
4. Keep micron paper clean from sanding dust. This is
easily done by putting the sanding pad on a piece of
carpet while running and hold it down for a few seconds
(check paper frequently).
*Each sheet of micron paper will sand 10 sq. ft (about 1
sq. m) of Avonite Surfaces material.
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2.12
Sanding and Polishing
2.13
Matte Finish
After removing the linear sanding lines with 60 micron
paper, place a Scotch-Brite® pad, (#7447 Red) under
the sanding pad to even out the finish. The matte finish
is easily maintained and is usually the most suitable for
lighter colors. Make sure the customer understands the
required maintenance for the finish they have chosen.
Most solid surface samples are Satin finished and
likely will be what the customer is expecting.
Satin Finish
Sand with 60 micron paper, repeat sanding process with
30 micron paper. Place Scotch-Brite® pad (#7448 light
gray) under sanding pad. Sand with ScotchBrite®#7448 and soapy water. Homeowners may maintain this finish using a white Scotch-Brite® and SoftScrub.®
Polished Finish
After sanding with 60 micron paper, repeat the sanding
process with 30 micron paper. Use a 3M Super Buff
adapter to prevent the arbor of the polisher from damaging the surface. Dark colors with a high gloss finish
show wear very quickly. A dark color is not recommended for heavy use areas.
Coppermine K3-8490 and Goldmine K3-8495 are dark
colors that may require polishing for full impact. The
brilliance of the shine comes from the fact that these
products use real nonferrous metal in the ingot. The
nonferrous metal will:
1. Have no effect on your tooling.
2. Cause some oxidation during polishing, as exemplified
by blackening of the polishing pads. This is normal for
polishing metals.
Finishing Guidelines
You should become familiar with the different colors and
options you present to your clients. Most customers are
expecting the gloss level they have on the sample they
are choosing from. Download and print our document called Finishing Guidelines. Go over these
guidelines with your customers to help manage
expectations.
©
The buffer should be variable speed between 1000
-3000 RPM.
Best results are achieved at lower speeds.
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Sanding and Polishing * Paste
Step One
The first step of the polishing process uses 3M’s Marine
Paste Compound (White) #06039 with 3M’s Super Duty2
+ 2 pad (White). The Marine Paste Compound will remove 30 micron sanding swirls. It may be necessary to
repeat this step to remove all 30 micron swirls. Apply
enough pressure to deflect the pad as shown.
Step Two
Remove any compound residue by reversing the white
pad. DO NOT mix the compounds on the same pad. Repeat polishing the surface with 3M’s Finishing Material
#81235 (Quart) with 3M’s Super Buff Polishing Pad
(Yellow). This will remove the swirl marks left by Step
One and will produce a high gloss. Step Two takes about
half the time as Step One. Reverse the yellow pad for
final clean up.
Note: Keep the polisher moving to prevent overheating,
and assure that the buffing pad does not dry out.
A matte finish is not recommended for dark colors, a satin
finish provides a more even appearance.
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2.14
Sanding and Polishing * Dry Cut
POLISHING WITH THE AVONITE SURFACES DRY-CUT SYSTEM
Another effective polishing method involves the use of the Avonite Surfaces
Dry-Cut Finishing System abrasive bars. This is a three step system that
quickly and easily removes sanding scratches. Since the compound is a solid
it can be cleaner to use than 3M Marine Paste. Apply sparingly to the buffing
wheel and it stays there to efficiently create a high luster finish.
Step 1: (Brown Bar)
The first step in polishing with the Avonite Surfaces Dry-Cut Finishing System is
to use the brown bar (SM4036-A) with a 3M Super Duty 2+2 pad (white). Start
with the Avonite Surfaces material sanded to a 30-micron finish. The brown bar
must be applied directly to the buffing pad. With the buffing pad turned up and
buffer running, press the bar firmly against the pad allowing it to buildup on the
pad. Begin buffing the material, be sure to apply enough pressure to deflect the
pad as shown on page 2.14. Add material to the buffing pad if you feel you need
more to ensure you do not build up excessive heat by using a dry pad. Repeat
Step 1 as necessary to remove all of the 30-micron swirls.
Step 2: (Purple Stick)
This step will remove any marks left by the more aggressive cutting brown bar.
Reverse the white pad and apply the purple stick compound (SM4036-B) to the
pad. The purple stick must be applied directly to the buffing pad. With the buffing pad turned up and buffer running, press the stick firmly against the pad allowing it to build up on the pad. Add material to the buffing pad as you feel is
needed to ensure you do not build up excessive heat by using a dry pad. Repeat
Step2 as necessary until you have removed the buffing swirls resulting from Step
1. To achieve a high gloss finish, complete Step 3.
Step 3:
This is the final step in achieving a high gloss finish. Remove any residue from
the previous steps by buffing lightly with a clean 3M Super Duty 2+2 pad
(white). Use at the lowest power setting, gliding across the material until all the
material from Step 2 is removed. Repeat polishing the surface with 3M’s Finesseit Finishing Material (#81235) with 3M’s Super Buff Polishing Pad (yellow) at the
lowest power setting. This step will remove any swirl marks that may have resulted from Step 2, and produce a high gloss finish. Reverse the yellow pad for
final clean up.
WET VS. DRY
We have found this polishing method to give equivalent results to the Finesse-It
system, however the Finesse-It system is a little more forgiving and it is easier
to control surface temperature. The Avonite Surfaces Dry-Cut Finishing System
will give you a good polish if you are experienced and you will save some cleanup time.
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2.15
Finishing Guidelines
2.16
Avonite Surfaces Color And Finishing Guidelines
Avonite Surfaces offers a wide range of unique products that are used in many different applications. Some of these
products may not be suitable for high traffic applications due to their unique characteristics, dark hues and saturated
color. The color and finish guide below is intended as a general recommendation.
Choosing the Right Finish
The design flexibility of solid surface offers us limitless options for style. With so many choices it makes it difficult to
choose sometimes. One of the most confusing issues is the subject of finishing. Most manufac-turers present 3 options
commonly referred to as matte, satin, or gloss and ask the end user or designer to choose one of these. Quite often the
contractor’s quote assumes the least expensive matte finish as the default unless otherwise noted.
If the finish options are not discussed, most of the time customers are expecting to get the finish on the sample they are
looking at when they chose the color. Managing the customer’s expectations for finishing choices and overall performance
is critical.
Choosing the right finish requires consideration of the color, texture, and application. Where it may be easier for a manufacturer or contractor to advise against a polished finish in a kitchen because of the concern for maintenance, it should
not be the polished surface that causes concern but rather the color choice. Here is an example. Let’s compare two color
options both from the Foundations advanced acrylic solid surfacing for an average kitchen countertop: Casablanca (a light
neutral tan) and Dark Roast (a deep and rich brown).
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Finishing Guidelines
2.17
The light and neutral Casablanca will not easily show signs of everyday wear but the Good Earth Red may show early
signs of wear simply because of its color. This scenario would be true regardless of the finish chosen. A polished Casablanca countertop can go years without showing any wear.
Finishing Dark Colors
This is a good time to discuss what finishes are appropriate for dark and rich colors like Good Earth Red. There are some
of these colors in everyone’s sample box. When it comes to extra dark colors like these, the “matte” finish is a very poor
choice. Rough matte finishes on dark colors leave surfaces looking chalky and they easily smudge with fingerprints. All
dark colors should have a minimum “satin” finish. Manufacturers put a minimum satin finish on the samples in their sample boxes because all of the colors look much better and cleaner.
Maintenance
Now let’s consider the question of long term maintenance for different colors and finishes. Regardless of which finish was
originally chosen, similar finishing steps must be applied to restore the surface to its orig inal finish. There are two steps
for a matte, three for a satin, and four steps for a high gloss. Because of the specialty equipment used to achieve a high
gloss, end users wanting a polished finish must be prepared to acquire this equipment and technique or contract their
installer to refinish their surfaces periodically every 4 or 5 years depending on the application. In most cases, countertops
that are used and cleaned everyday develop their own level of “patina”. Matte surfaces become more reflective with use.
It is generally agreed that the satin finish offers end users the best look with the minimum required maintenance. However maintaining a polished surface is only one more step than a satin finish. Overall hardness and scratch resistance of
all solid surfaces are relatively the same. Anything that is harder than the surface has the potential to scratch. Items
such as ceramic jars or stoneware for example should have felt protectors on the bottom to prevent scratching.
Texture
Texture refers to how much pattern you see in the color. Saturated colors with little texture will show wear easier than
full textured colors. Compare these two colors illustrated below. These are two very popular black colors from the Studio
Collection. Notice the texture or pattern of the Black Ice versus very little pattern in the Midnight Sky. The extra texture
in Black Ice will not show wear as easily as Midnight Sky or other saturated colors.
Special Exceptions
Some products in the Studio Collection from Avonite Surfaces create a few exceptions to these general finish guidelines.
Many of these products contain minimum levels of ATH filler. This allows the products to have a clear matrix that does
not show wear as easily as highly filled products. It is also this clear matrix that gives these products their depth and
unparalleled beauty compared to all other products. This depth and clarity is enhanced by the polished finish. The combination of a clear matrix and a full texture like Black Ice create a very durable polished surface.
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Installation
3.1
It is very important that the personnel installing
the Avonite Surfaces material be properly trained
and follow the recommended procedures. Improper installation may lead to problems in the future.
Failure to follow the recommended procedures will
void the warranty.
Substrates
Choosing the appropriate substrate for different applications should be considered. A solid substrate cannot be
used when heat sources are present, as in kitchen applications. The following methods demonstrate alternatives
to solid substrates.
Runner Method
The runner method uses 1" x 4" (25.4mm x 101mm)
supports that run parallel to the length of the top as
shown in Figure A. They are at the front, center and rear
edge of the counter top, adhered with dabs of silicone
every 18"-24" (45.7cm - 61cm). The cabinets must have
cross supports for the runners every 18"- 24" (45.7cm 61cm).
Clearances
Be sure to leave 1/16”-1/8" (3mm) between the edge of
the substrate and the back of the build up. Leave a minimum 1/16" (1.5mm) between the counter top and the
back wall. For wall to wall installations, allow clearance
on each end for expansion. Leave a 1/8” gap for Class I
products and 3/16” for Class III products. Allow as
much clearance as possible at cook tops and drop-in
sinks.
Securing Top to Cabinets
We recommend attaching substrate to the Avonite Surfaces top first and then fastening it to the cabinets. This
way if you ever need to remove the top, you may do so
without destroying it. Set tops on pre-leveled cabinets.
Put screws from all corner blocks on cabinets into substrate. Make sure screws do not go all the way through
substrates and into countertop. If screws are allowed to
contact the solid surface, they may start a crack at that
point. We recommend 100% silicone for bonding to
wooden substrates. NEVER USE LIQUID NAILS™ or other rigid adhesive which does not allow for expansion or
contraction of the top.
Adhering Material to Substrates
Dabs of silicone are placed in the front, center and rear
every 18"-24" (45.7-61cm) for all substrates. A dab of
silicone should be the size of your thumb nail.
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Installation
3.2
ALL CUT OUTS SHOULD BE MADE WITH A TEMPLATE AND A ROUTER AND HAVE A MIN.
1/4" (6mm) INSIDE CORNER RADIUS.
Corners of cook top cut outs must be reinforced by
bonding a 3" (76mm) x 3" (76mm) or larger piece of
Avonite Surfaces material to the underside.
Using the runner method substrate as pictured allows
for venting of heat.
COOKTOP AND BACKSPLASH CLEARANCE
Due to excessive heat generated from cook tops and
pans being heated, minimum clearances are required by
Avonite Surfaces material.
Standard 4"(102mm) tall splashes should have a minimum clearance of 2"(51mm) between the splash and
the cook top flange.
Note to homeowner:
Full height splashes within 2-1/2" (63.5mm) from the
cook top flange will not be covered under Avonite Surfaces’ 10 year warranty. Extensive use of large oversized pans that overhang the counter should be avoided.
Commercial type cook tops for residential use need to
be supported inside cabinet base, so that cook top is not
supported by countertop alone.
THERMO-FLOW TAPE
The use of Avonite Surfaces’ Thermo-Flow tape is REQUIRED for prevention of damage in cook top cut outs
and slide-in ranges due to excessive heat. The use of
any other tape voids the 10 year warranty. Thermo-Flow
is a 2-1/2" (63.5mm) wide heat conductive aluminum
tape with a glass backing that adds insulating properties. Install one layer of Thermo-Flow around the cut out
as shown in Figure A.
Commercial Food Service Hot Well Limitations
Avonite Surfaces does not warrant the use of Class III
products for use in commercial hot well unit applications. This restriction will continue in effect until appropriate design criteria have been developed. We will keep
you advised of any future developments in this area.
Guidelines for installation of commercial hot wells are
given on page 3.4.
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Installation
Making Field Seams
To insure that drop edges are properly aligned after
seaming, stop routing the profile a couple of inches from
the seam on either side. After removing the flash line of
the seam you may then route the profile across the
seam.
3.3
OVERHANGS
When installing overhanging countertops, support is
required for 1/2" (12.7mm) thick overhangs extending
more than 6" (152mm). Support is provided by plywood
underlayment and brackets which are equilateral right
triangles (anchor leg is equal in length to the support
leg). Brackets, when required, are placed no more than
24" (60.9cm)apart and should come to within
5" (127mm) of the countertop edge. Refer to the dimensions below for the type of support to use.
OVERHANG SUPPORTS
Up to 6” require no additional support.
6” - 12” require 3/4” plywood substrate or brackets
12” - 18” require brackets or metal frame
Overhangs more than 18” should be engineered to no
more than 1/8” deflection.
INSTALLATION CHECK LIST
1.
Before Seaming
a. Good dry fit (no gaps).
b. Seam Block in place
c. Separation paper.
d. Proper clearances.
e. Clean with isopropyl alcohol.
f. Prepared for clamping.
2. Support all seams
3. Substrate secured to cabinets
4. Level cabinets (3/32" in 48"(2.38mm in 120cm)
5. Cutouts—1/4" (6.3mm) radius
6. Thermo-Flow tape on cook top cutout
7. Inside corner radius
8. Silicone
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Installation
COMMERCIAL FOOD SERVICE AREAS
The following features must be included in a commercial
food service installation in order to be covered by Avonite
Surfaces’ 10-Year Material Warranty. Color must be selected from among Avonite Surfaces’ Class I fire rated products.
1.
Cabinet must be even and level with no protrusions to
cause cracking.
2.
Support tops every 18” (45.7cm). Cantilevers over
6” (15.2cm) require structural support. Provide support
within 3” (7.6cm) of all cut outs.
3.
Hot and cold units must be supported from below and
not rest on the Avonite top.
4.
Attach Avonite to support frame with dabs of silicone
every 18”-24” (45.7-61cm) ; do not use a continuous
bead.
3.4
7. Reinforce corners of rectangular cut outs with 6” x
6” (15.2x15.2cm) blocks of Avonite. Circular cut outs
must have a continuous ring of Avonite 2” (5cm) wide as
reinforcement.
8. Use a layer of Thermo-Flow tape to line the perimeter
of all hot and cold cut outs.
9. Hot well units must be covered with a layer of FlexSulation blended PVC foam sheeting. The foam may be
attached to the hot well with 3M® double sided aircraft
tape, or duct tape.
McMaster Carr Supply 562-692-5911
Part # 9349K1
10. Cabinets are to be ventilated by installing a fan near
the bottom to pull cool air into the cabinet and by providing vent slots near the upper edge of the cabinet to expel
the hot air. Temperatures in the cabinet must not exceed
170°F (78°C).
5. Separate tops containing hot sections from those with
cold sections. A soft (silicone) seam may be used.
11. Sneeze guards must be fastened to the cabinets or
the floor, not directly to the Avonite. Holes in the Avonite
to accommodate the sneeze guard supports must be cut
1/4” (.6cm) oversize in diameter to allow for expansion
and contraction.
12. Deck seams must be reinforced with a 4” (7.6-10cm)
seam block. Keep seams 3” (7.6cm) or more away from
cutouts.
6. Make cut outs with router and template and allow a
1/2” (1.2cm) radius in the corners. Cut and sand a
1/8” (.3cm) round over on top and bottom edge of cut out.
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Wet Wall Panel System Installation
3.5
Wet Wall Panels and Accessories
Please read the instructions carefully prior to installing the wall system. This document will give you basic instructions
for the installation of wet wall panels in a step-by-step sequence that will work in most types of installations. If you
have an installation that is not covered, please call Avonite Technical Services with any questions.
Warning—Please inspect all items and report any damage. Store panels in a flat area to avoid warping until the time of
installation. Allow panels to acclimate to room temperature before installing.
Recommended Tools and Supplies for Installation
• Circular Saw with Carbide Tip Blade
• Level
(24-40 tooth)
• Square
• Random Orbital Sander
• Jig Saw with Wood Finish Blade
• Belt Sander w/80 Grit Belt
• Compass or Scribe Tool
• 150-320 Grit Sandpaper & Scotch Brite Pad
• Denatured Alcohol
• Installation Kit or Hot Melt Gun & Glue Sticks
• Clean Shop Rags
• Drill, Hole Saw, 1/2” Diameter Bit (Sharp)
• 1x4 x 8’ Wood for Bracing (4 pcs.)
• Caulk Gun & Silicone
• Paintable Latex Caulk
Preparing the Site
• Prepare the area with moisture resistant dry wall, or tile backer board. Never install directly on any wall construction
that is, or may become, damp.
• When installing over ceramic tile, check for loose tiles. If you find any, correct the problem. Make sure that the area
to be covered is uniform in support. If not, build up the areas without tile. Remove the bottom row of tile and cut a
ventilation gap in the substrate.
• On every installation, make sure that there is a 1/2”-1” clearance between the top of the shower pan or tub deck and
the bottom of the substrate. This will allow for ventilation and keep water leaks from wicking up the substrate. (Figure
1)
Preparation for Accessories
Recessed Accessories
Make sure the accessories will fit near, but not in, a stud and closer to the center of the sheet. Make sure no electrical
wiring or plumbing is present before cutting out for the accessories. Make the cutout in the substrate to receive the
accessory.
Surface Mounted Accessories
If a surface mounted accessory, such as a grab bar, is going to be installed, make sure 2” x 6” wood blocking is installed behind the substrate where the surface mounted accessory will be located. This will insure that there is solid
backing for any screws that need to be used in the installation.
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Wet Wall Panel System Installation
Measuring for Installation
1. Determine your desired wall panel height. Allow for a
1/16” gap between the panel and shower/tub base for a
better silicone seal.
2. Panels should be installed in the following order, Back
wall, Side wall without plumbing and then the plumbing
wall.
3. You may need to draw level and plumb lines on the wall
to determine whether your shower pan or walls are out of
square. Using the reference line and measuring from the
lowest point on tub or widest point on the wall, determine
how your panels will need to be cut. Transfer this data to
the panels. (Figure 1)
4. Check your measurements and cut the panels
with a circular saw or jig saw. You may make final adjustments to your cuts with a belt sander.
Measuring and Making Cutouts
1. All inside corners of cutouts should have a
minimum 1⁄4” radius. Do not cut sharp inside corners.
2. Locate the location of the plumbing holes. Transfer the
data to the panels. Cut the holes a minimum 1⁄4” larger
than the pipe diameters. The cover plates for the plumbing
fixtures may allow for more variance. Consult the plumbing fixture installation instructions for templates and recommended hole cut out sizes. Check your measurements
and using a jig saw or standard bimetal hole saw, cut out
the plumbing holes.
3. Once the panels are cut to size, locate the caddie cutouts, marking the cut out locations. Cut the caddies out
after the panels have been installed.
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3.6
Wet Wall Panel System Installation
Mounting the Panels (Figure 2)
1. Shim: Place shims (1/16” thick) at the base of where the
sheets will rest. This allows for better flow of the silicone.
Laminate chips make great shims. (Shims may not be
necessary if the slope of the pan creates a natural adhesion gap.)
2. Trial Fit & Scribe the Panels As Needed: Place the
panel on the shims where it will be installed and check the
fit. If necessary, scribe the panel for a better fit. Trim the
scribe with a belt sander.
3. Clean the Sheets and Installation Area: With denatured alcohol and a clean rag, clean the back of the sheets
and the substrate, along with any other area that will be in
contact with the silicone.
4. If using an installation kit, prior to applying the silicone adhesive, apply the butyl tape about 2” from the
edge, around the perimeter of the panel.
5. Apply the silicone adhesive, about 1” from the edge,
around the perimeter of the panel. Place quarter sized dots
of silicone adhesive every 8-10 inches apart over the surface of the panel. If Accessories are being used, on the
wall, place a bead of silicone around the cut out location.
6. Place the panel on the 1/16” shims, line up any
holes, and firmly press the panel in place.
7. If using a hot melt glue gun, apply the silicone as
stated in steps 4 & 5, apply hot melt along the back edge
of the panel where it will be attached to the substrate and
press the panel firmly into place. The hot melt will hold the
panel until the silicone sets up.
8. If you find the panel pulling from the wall, bracing may
be necessary. Use 1 x 4 boards, or other dimensional lumber, and brace the panels where needed as illustrated.
(Figure 3)
9. Allow the silicone to cure. Make all remaining cut outs.
Silicone between the panel and the substrate along the cut
out edge and install the accessory.
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3.7
Wet Wall Panel System Installation
3.8
11. Once the silicone is set up and the panel is secure, install the optional components.
12. Install any surface mounted items, such as grab bars, shower seats, etc, make sure that the screw hole drilled into
the panel is 1/16” larger than the screw so that the accessory is held in place by the wood blocking and not the panel.
If the accessory is to be ADA compliant, please refer to the ADA guidelines for the proper heights and locations.
Installing Optional Trim
• Trim should be installed using silicone adhesive. Hot melt glue should be used to tack the trim in place while silicone
cures. Clean all joints with denatured alcohol before applying silicone.
• Caulk all inside joints with the color matched silicone.
• Caulk outside joints with paintable caulk where wall surfaces are painted, or silicone if wall surfaces are unpainted.
• Clean up silicone with denatured alcohol while silicone is still wet.
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Wet Wall Panel System Installation
3.9
Surface Mounted Shelf Accessory
These instructions apply to the shelf accessories that are designed to rest flush against the corner of two wall panels
and not recessed within a wall panel.
1. For ease of installation, clean the mounting area of the panels with denatured alcohol.
2. Use the level and mark on each panel where the shelf unit should be placed. Hot melt or tape two indexing blocks
(small pieces of wood or solid surface) where the shelf unit will be mounted, using the marks from above. These blocks
will ensure that the mounting is level and will hold the unit in place until the silicone adhesive dries.
3. Apply silicone to the sides of the accessory that will be in contact with the wall panels. Leave several spots between
the silicone on the accessory to apply hot glue or tape.
4. Apply small amounts of hot melt or tape to the accessory in several places and immediately press the accessory into
the wall panels, making sure that it is straight and flush against the wall panels and index blocks.
5. Hold the accessory in place for 30 seconds or until the hot melt has cured. The holt melt should hold the accessory in
place until the silicone cures. Remove any excess silicone around the shelf accessory before it dries.
6. Once the accessory is securely in place, the index blocks can be removed if desired. Apply silicone to all edges of the
accessory that contact the wall panels. Let silicone cure for 24 hours in the dry environment before resting objects on
the shelf accessory.
Note: Never try to screw into the wall panel.
Recessed Shelf Accessory
These instructions apply to the shelf accessories that are designed to be recessed within a wall panel.
1. Make sure no electrical wiring or plumbing is present before cutting out the location for the accessory.
2. Measure, level and mark the panel for the location of the accessory. Place the accessory against the wall panel and
trace the outline of the back of the accessory unit against the wall panel.
3. Use the drill and hole saw to drill a hole inside the outline for the accessory item, to be used as starting point for the
jig saw to cut the opening. Use a jig saw with a fine to medium tooth blade to cut the opening for the accessory.
4. Dry fit the accessory to ensure a proper fit. The shelf accessory should fit tightly within the opening. If the accessory
does not fit, repeat step 4 until the proper fit is achieved.
5. Clean the mounting area of the panels and shelf accessory with denatured alcohol.
6. Apply silicone to the sides of the accessory that will be in contact with the shower panels.
7. Press the accessory into the opening, making sure that it is flush against the wall panel. Clean any excess silicone
from the wall panel or shelf accessory before the silicone dries.
8. Once the accessory is securely in place, apply silicone to all edges of the accessory that contact the wall panel. Let
silicone cure for 24 hours in dry environment before resting objects on the shelf accessory.
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Wet Wall Panel System Installation
3.10
Pan Installation
Please read the instructions carefully prior to installing the pan. These are the basic instructions for the installation of a
shower pan in a step-by-step sequence that will work in most types of installations. If you have an installation that is
not covered here, please call your Avonite Technical Services for additional information.
Warning—Please inspect the shower pan for breakage and report any damage to your Avonite representative. Allow the
shower pan to acclimate to room temperature before installing.
Tools and Supplies Needed for Installation
• Level
• Silicone/Plumber’s Putty
• Thin-Set Mortar & Water
• Shims
• Wrench
• 1/4” -1/2” Grooved Trowel
• Drain Fitting
• 5-gallon empty bucket
• Tool for mixing Thin-Set Mortar
Preparing the Installation Site
• Open shower pan and inspect the product for any damage.
• Clean and scrape the floor of the shower pan alcove.
This space must be free of any debris in order to
get a proper adhesion with the thin-set mortar.
• Measure the size of the alcove to insure that the pan and panels fit properly.
• Trial fit the pan in the alcove and make sure that the drain location lines up properly with the shower pan.
In a three wall application, the pan should slide in easily with approximately 1/16” - 1/8” spacing between the studs and
the pan. Placing a level on the pan, check that the pan sits level on the floor. If needed, use shims to level the pan in
the alcove. Note the shim locations before removing the pan. Lean the pan back or remove from the alcove.
Installing the Pan
• Install the drain fitting into the shower pan. Follow the installation instructions that came with the drain. Plumber’s
putty or silicone are acceptable to use with the drain.
• Mix and apply thin-set mortar to the floor, using the notched trowel. Spread the mixture to achieve a depth necessary
to fill the voids in the floor and enable the pan to sit level. A 50 lb. bag of thin-set should provide at least 45-50 square
feet of coverage. All supporting points should have contact with the thin-set mortar.
• After applying the thin-set, replace the shims (if necessary) in the proper location and set the pan into place. Make
sure the pan is resting level on the thin-set and shims and centered in opening.
• Clean the area at the threshold of any excess thin-set. Allow the thin-set and shower pan to cure for 24 hours before
working in the pan area. Be sure to protect the pan floor after installation, using card board sheeting or a like material,
until the complete project is finished.
• Before proceeding to install the wall system, flood test the shower pan for proper drainage.
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Sinks and Pans
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3.11
Sinks and Bowls
GENERAL SINK FUSED MOUNTING INSTRUCTIONS
Positioning and Preparation
Sinks are recommended for bonding to 1/2" (12.7 mm)
Avonite Surfaces sheet thickness. Turn the sheet backside up on a well supported surface. Position the bowl on
the sheet (Figure 1). Do not nick or scuff the rim of the
bowl. With a nail or screwdriver, etc., scratch a line on
the sheet around the perimeter of the bowl. Drill a 11/4" (31.4mm) pilot hole, with a hole saw, in the sheet
in line with the drain of the bowl (Figure 1). With a flat
sanding block and #80 grit sandpaper, sand the underside of the sheet where the bowl is to be bonded. This
removes factory sanding lines or scuff marks. With a flat
sanding block, scuff sand with #80 grit sandpaper the
top flange of the bowl. Do not round over or nick the rim
(Figure 2). Mark the location of 4 locating blocks as
shown in Figure 3. These blocks can be scrap pieces of
material 1" x 1-1/2" x 1/2" (25mm x 38mm x 12.7mm)
thick. Fasten the blocks to the back of the sheet using
Locktite 495, or equivalent. This will keep the sink from
sliding during bonding.
Bonding
Remove the bowl and clean the bonding area and the
bowl with isopropyl alcohol and let it dry. Apply the Ultra
-Bond G to the sheet fully coating the flange area. Always use adhesive to match the bowl or sink. Use allthread, two blocks of plywood and a wing nut to clamp
the bowl to the sheet as in Figure 4. Tighten the clamp
until the adhesive flashes out evenly and allow the adhesive to harden. Schock Sink colors available are
White, Crème, and Ivory. Use the following UltraBond G colors:
White = Polar, Crème = Biscuit,
Ivory = Biscuit
Mounting Brackets
Mounting brackets may be used to under mount sinks
other than Avonite Surfaces’. Drill a 1/4" (6mm) diameter hole by 1/2" (12.7mm) deep, 3/4" (19mm) from the
sink into the locating blocks as shown in Figure 5. Remove any dust and tap in the brass anchors slotted end
first. Set with Locktite. Mount hardware by first threading the wing nut well up on the screw near the head.
With washer and slotted clip in place, tighten screw securely to lock the brass anchor (Figure 5). Bond the
bowl to the sheet using silicone if it is a non-solid surface bowl. Swing clips on to the bowl lip and evenly
tighten the wing nuts until the bracket begins to deflect.
Recheck to be sure the bowl is in the proper position.
Allow the compound to harden. After adhesive cures, do
not remove under mount brackets.
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3.12
Sinks and Bowls
3.13
Shaping The Edge
Turn the top over and use the specially designed bowl
router bits to shape either a flush or bull nose bowl edge
trim. Cut the sheet material from the center of the bowl
area with the special straight router bit with an over
sized nylon bearing. Start from the pilot hole and rout
clockwise around the bowl. Hold the cutout steady as it
separates from the top to avoid damage to the edge
(Figure 6).A bull nose trim on the edge (Figure 8 and
10) of the sheet creates a shadow which can help hide
seams. The cutter slightly shaves the bowl edge and
removes all the seam compound. A round over bit on
the edge (Figure 7 and 9) of the sheet will produce a
smooth edge. The cutter slightly shaves the bowl edge
and removes all the adhesive. Different sheet thickness
and cutter heights can produce various edge profiles.
NOTE: The bowl bits shown have a 2 1/2" (64mm)
cutting diameter. Router base adjustments may be
needed.
For additional information contact Avonite Surfaces
Technical Services 1-800-866-TECH.
NOTE: WHEN POURING BOILING WATER INTO THE SINK
OR USING AN INSTANT HOT WATER DISPENSER, COLD
WATER SHOULD BE RUNNING INTO THE SINK SIMULTANEOUSLY. THIS WILL ELIMINATE ANY POTENTIAL THERMAL SHOCK CRACK. THE USE OF A GARBAGE DISPOSAL LARGER THAN 3/4 HP IS NOT COVERED UNDER
AVONITE SURFACES’ WARRANTY .
The bowl bit in Figure 10 is from Velepec
# SUBN-8-12 4VT
Velepec .
1-800-365-6636
Kitchen Sink Rounding Over Bit—Velepec 30-155
CRST10-8-8VTR 1/2” Radius for 1/2” thick top
Vanity Sink Rounding Over Bit—Velepec 30-140
CRST20-8-8VT 1/2” Radius for 1/2” thick top
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Sinks and Bowls
Color Matching Sheet to Bowl
Avonite Surfaces makes every effort to achieve a visual
color match between Avonite Surfaces Foundations
sheet products and bowls. However, we do not guarantee a color match between sheet and bowl of the same
name. When you are given an order to supply a fused
under mount sink in which the sink and the deck are the
same color, there is a distinct possibility that there will
be a visual color mismatch between the edge of the
deck and the wall of the sink. The likely color mismatch
problem is complicated by the fact that you cannot tell
how closely the sink and sheet match until the two are
joined and the edge of the deck is routed flush with the
sink. We do have a method of mounting a bowl in the
same color which will mask the color mismatch (See
illustration right) Using bit shown, sanding the seam
area between the bowl and the sheet and putting the
seam on the bottom side of the bull nose should hide
most color match problems. If you have any questions
regarding this procedure, please contact the Technical
Service Department at 1-800-866-8324.
BULL NOSE BIT
TO CUT AVONITE SURFACES UNDERMOUNT
LAVATORY BOWLS & KITCHEN SINKS
with VEL-VET TOUCH™ Bearing Guide Assembly
1/2" (12.7mm) Shank Diameter - 2 Flutes
NOTE: AVONITE SURFACES DOES NOT WARRANTY
COLOR MATCH BETWEEN SAME COLOR AVONITE
SURFACES FOUNDATIONS SHEET AND BOWL.
©
3.14
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Patching
PATCH KITS ARE ONLY AVAILABLE FOR AVONITE
SURFACES STUDIO COLLECTION COLORS.
PRODUCTS NEEDED FOR PATCHING:
a. Patching Resin
b. Catalyst (sold separately)
c. Stirring Stick
d. Particulate Can
e. Two Shading Vials
Minimal damage — lightly rough out area to
3/16"(5mm) depth. You may need to rout out the area
to hold patching material. Be sure to serrate edges of
routed area to help blend in the patch. Clean area with
isopropyl alcohol. Allow to dry completely. Mix particulate with patching resin in one large container. Stir mixtures thoroughly together. Compare color by placing a
puddle of water next to the area to be patched. Add
darker shading to darken, light particulate to lighten.
The amount of catalyst to be added should be measured
by the amount of resin used not the total volume of both
containers. (see page 4.3)Area has been masked off to
contain patch material. Patch material is difficult to bring
to the same gloss as the sheet in a polished finish. A
100 watt light bulb to post heat the patch will help.
Larger areas should be repaired with an insert of matching Avonite Surfaces material.
Patch kits are not to be used to repair a bad or
broken seam, see page 5.4-5.5, REPAIRING SEAMS
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4.1
Color Inlay
Products Needed For Inlay:
Inlay Resin (same as Patching Resin)
Colorant—Sign paint*
Catalyst
Stirring Stick
Paper Cup
Route out slot for color inlay. Should be 1/8" (3mm)
deep minimum. Contain over pour by placing masking
tape or caulk around slot creating a damn about 1/8”
above the surface.
Add colorant to inlay resin. One drop per ounce. Add
appropriate amount of catalyst and stir thoroughly. Pour
mixture into prepared slot. Over pour by 1/8" (3mm) to
eliminate low spots and air bubbles.
Allow to dry thoroughly and finish. The hardening time is
approximately 8 hours.
METAL INLAYS—Glue the metal to the bottom of the
groove with Super Glue. It may then be over poured
with clear resin. Over pour should be a minimum
3/32"(2mm) deep.
Fabricator Notes:
Inlay Resin is available in quarts and 4 ounce cans.
When making large inlays, color enough material to do
the entire job. Custom colors will be difficult to match
later.
Patch Kits are often used for decorative inlays. Particulate may also be special ordered in quart containers.
Follow the same procedure above for inlay resin.
* Sign paint is a high pigment enamel paint such as
Chromatic® or One Shot® usually found at art supply
stores.
©
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4.2
Catalyst Ratio Chart
RATIO OF CATALYST DEPENDS ON TEMPERATURE
Ratio of Catalyst: Drops per one ounce of
Patching/lnlay Resin.
EXAMPLE: Ten drops per one ounce of Patching/lnlay
Resin
Ambient temperature at 75° F (23.8’C)
Therefore: At an ambient temperature of 75° F
(23.8’C)
4 ounces (113.4gm) of Patching/lnlay Resin would
take 40 drops of catalyst.
©
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4.3
Wall Panels and Signage
5.1
INSTALLING SCREWS OR BOLTS IN AVONITE SURFACES PANELS INTERIOR & EXTERIOR APPLICATIONS
Avonite Surfaces realizes there are certain applications
that need additional vertical support.
Examples: Avonite Surfaces outdoor signage, elevated
wall cladding or ceilings etc., and other similar applications. The proper technique for installing screws or bolts
through Avonite Surfaces should be done according to
Figure 1.
Soft seams should be used for exterior applications
Important facts that you need to remember are:
1.
Hole should be 1/4" (7mm) oversize in diameter
minimum (for interior applications).
2.
2. Hole should be 1/2" (12.7mm) oversize in diameter (for exterior applications).
3.
3. Rubber grommet/washer needs to be inserted in
hole to provide cushion for movement during expansion or contraction.
4.
4. Do not over tighten screen or bolt; snug tight
only.
Outdoor Applications
Aristech Acrylics LLC does not warrant exterior applications. As with any other solid surface products,
dark colors must not be located where they will
receive direct sunlight. The sunlight will cause an
extreme temperature increase due to dark colors’ heat
absorption, accompanied by expansion of the material
with potential distortion or cracking. A sign must not be
located where it will be periodically sprayed with water
as from a sprinkler system. Water spots will leave mineral deposits which will buildup on the surface, eventually making it difficult to restore to the original appearance. Three dimensional structures with hard seams are
not suitable for outdoor applications in any color for any
solid surface products. Stresses are created when the
sun warms part of the structure while another part
joined to it remains cool. Such stresses are likely to lead
to failure of a seam or failure of the material itself.
©
Figure 1.
Engraving and Sandblasting
Avonite Surfaces material can be engraved by conventional carbide engravers and laser engravers. Letters or
logos are easily cut out by computer controlled routers.
Avonite Surfaces material can be sandblasted using a
monument stencil like anchor Continental #111 or
“Buttercut” by 3M. Silicon carbide (80 grit) at 80 psi
gives the best results for a sharp edge.
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Thermoforming
5.2
These Thermoforming Parameters are basic guidelines
for fabricators to thermoform Avonite Surfaces. The
parameters listed below are recommendations, which
are a direct result of actual forming of Avonite Surfaces.
This testing was conducted by the Avonite Surfaces
Technical Service Department, but values are approximate. We suggest re-testing for varying conditions.
Material Preparation
When preparing material to be formed, it is recommended that material be cut to size. Then, remove all chips or
gouges on the edge of the material. Any chip or gouge
left on an edge may cause the material to tear during
forming.
Thermoforming Temperature
Temperatures given here are approximate and represent
a starting point to establish the conditions you need for
your project. If material is too cool or too hot it may
crack or tear while bending.
Avonite Surfaces Studio Collection
When heating material for forming, it is important to
uniformly heat the entire thickness of the sheet. Spot
heating or surface heating is not adequate to form the
sheet stock. To achieve this, it is recommended that an
oven designed for solid surface be used. Be aware that
heating in an oven may darken the color of light colored
Avonite Surfaces material. Avonite Surfaces’ Glass series products are very difficult to bend and are not recommended for thermoforming.
Oven Options
Below are thermoforming guidelines for conventional
and platen style ovens. Every oven is unique and calibrations may be necessary. Be sure the oven used is
large enough for the entire piece to be formed.
Product Group Conven onal Oven Temperature MOLD DESIGN
When forming we recommend that male and female
molds be made. The molds need to be designed so they
can accommodate clamps to hold them together while
material is cooling.
COOL DOWN
Allow material to cool for a minimum of two hours to
prevent the material from springing back. If material is
not allowed to cool adequately, it may spring back as
much as 10% which will make any further fabrication of
the application difficult.
FABRICATION: FINISHING/SEAMING
Finishing formed sheet stock is no different from standard finishing. However, it is important that any seaming/
joining be done after forming. The heat to which the
material is subjected will weaken the seamed areas of
the pieces, which may result in seam failures.
Platen Oven Time/Minutes Minimum Radius " Temperature Time/ Minutes Minimum Radius " Founda ons 12mm (1/2") 370 F / 187 C 20‐25 6" 302 F/ 150 C 15 6" Founda ons 6mm (1/4") 370 F / 187 C 10 to 15 3" 302 F/ 150 C 8 3" Studio Collec on C III 254 F /120 C 20‐25 8" 212 F / 100 C 10 to 12 8" Studio Collec on C I 270 F / 132 C 20‐25 14" 225 F / 110 C 10 to 12 14" Special No ce * Founda ons Recycled 13.5% 370 F / 187 C 20‐25 14" 302 F/ 150 C 10 to 12 14" * Sharkskin F1-7556, Tango F1-7552, Hazelnut F1-7557, Canary F1-7554, Icecap F1-7555, Jungle F1-7553, Ginger F1-7551
©
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Repairs
5.3
Most Common Reasons For Seam Failures
Seam and Damage Repair
1. Excessive heat from belt sanding.
1. The damaged area must first be bonded back together. When the opening is wide enough, Ultra Bond G can
be used. For tight cracks, a very thin cyano acrylate
(Super Glue) could be used to fill the void.
2. Too much clamping pressure.
3. Inadequate mixing of catalyst.
4. Insufficient catalyst from cartridge if voids not purged
by dispensing small quantity of Ultra Bond G before installing mixer tube.
5. No seam block.
6. Unsupported seams.
7. Seams near heat source such as dishwasher or cook
top.
8. Seams placed at points of stress such as inside corners.
©
2. After the glue has dried, route a groove about 1/4"(6
mm) deep. See drawing.
3. Glue a matching piece of Avonite Surfaces material
into the groove. Always leave a piece of material on
the job site for any future damage (perhaps on the
floor beneath a bottom drawer or mounted in the sink
cabinet).
4. Material may then be routed level and sanded back to
the original finish.
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Repairs
Pie Shape Repairs
The pie shape repair has proven to be one of the best
methods of repairing cracks and damaged areas. The
principal is to create a template large enough to encompass the damaged area. Clamp on the template and rout
out the area to be replaced.
Cut a matching wedge piece to fit using the same template and router. Check the dry fit and adjust until there
are no gaps. Glue the repair piece (s) in place with a
reinforcing block underneath whenever possible.
The methods and techniques have improved over the
years and today there are several companies that offer
repair templates and router bits that make repairs very
quick and accurate.
Circle Template Repairs
The circle template repair is recommended for damages
from heat producing appliances or hot pots that occur in
the center of the counter.
Templates By Andreas offers a selection solid surface
repair templates and tools.
www.andreascustomdesigns.com
Below is the 10 Degree Repair Kit available at
www.specialtytools.com
©
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5.4
Partitions and Wainscoting
5.5
General
When choosing solid surface for partitions, allowances for expansion and contraction must be considered. Avoid rigid
fasteners that that will not move. Rubber or nylon sleeves should be used for bolts going through the partition.
Toilet Partitions
Choose only Foundations 1/2” acrylic or Studio Collection Class I 1/2” thickness to be used.
It is recommended that all hardware should have rubber or nylon grommets between the hardware and Avonite surface.
1” thick pilasters are recommended for support post running floor to ceiling.
For added strength, construct a 1” x 4” build-up with a 1/2” channel for top and bottom rails.
Place no seams in stall doors.
Wall panels should be secured to back to walls with a full length “U” channel.
Partition hardware available at:
Bommer Industries
803-457-3301
Decolam
418-527-2544
Jacknob
888-231-9333
AVONITE SURFACES WAINSCOTING SYSTEM
This system utilizes our wide sheet Foundations 1/4” product with 1/2” base and trim. The Avonite Wainscoting system
provides stylish and durable wall protection. The panels can be custom sized to fit the application design.
The panels are adhered directly to dry wall. The wall surfaces and backsides of sheets need to be clean and free of
dust. Panels and trim can be adhered with silicone. Allow 1/8” gap between panels and fill with color matched silicone
for an inconspicuous soft seam.
©
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Fabrication Support Materials
Avonite Surfaces has created One Stop Shopping convenience by making available all of the necessary fabrication products through your local distributor. If items
listed below are not available from your distributor,
please notify Technical Services, 1-800-866-TECH.
Avonite Surfaces Ultra Bond G Cartridge
SM4164-**
** Refers to 2 digit color code.
Spare Mixing Tubes
SM4162-01
Dispensing Gun
SM4160-00 MANUAL
** Refers to 2 digit color code.
©
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6.1
Fabrication Support Materials
Inlay Resin—Quart
SM4130-00
Specially formulated inlay resin for creating custom detail designs in Avonite Surfaces material. Can be used
with Avonite Surfaces Inlay Filler for an “intarsia” look.
Patch Kits
SM4021-**
Color coordinated Patch Kits each include (1) 4 oz.
(113.4gm) can of filler, toners, and (1) 4 oz. (113.4gm)
can of patching resin. Patch Kits are available in all current Avonite Surfaces Studio Collection colors. The catalyst hardener must be ordered separately(SM4001-10).
This is MEKP-9 catalyst and is usually available locally.
Spring Clamps—2" or 3" (50.8 - 76.2mm)
SM4063-00
SM4063-01
Needed for equal and consistent pressure to avoid open
joints. Standard equipment for every fabricator.
Avonite Surfaces Thermo-Flow Tape
SM4065-00
Insulates from excessive heat in cook top cut outs. One
roll of tape contains 18 yards (16.45m).
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6.2
Sanding and Polishing Accessories
Marine Paste Compound (white)
SM4059-00
First step in polishing system.
Finesse-It Finishing Material
SM4058-00
Second step in polishing system.(1 liter)
Superbuff Adapter
SM4044-00
Buffing pad adapter for grinder/polisher.
Avonite Surfaces Dry-Cut Finishing System
SM4036-A Brown bar
SM4036-B Purple stick
Polishing system.
Step 1: Brown bar. SM4036-A
Step 2: Purple stick. SM4036-B
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6.3
Sanding and Polishing Accessories
Superbuff 2 + 2 Pad (White)
SM4045-00
Polishing Pad used with Marine Paste compound and
Avonite Surfaces Dry-Cut Finishing System Compound.
Superbuff Polishing Pad (Yellow)
SM4046-00
Polishing Pad used with Finishing Material.
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6.4
Care & Maintenance
6.5
The final finish of Avonite Surfaces material should be specified in one of the following finishes: Matte, Satin or High
Gloss. Each customer must receive Avonite Surfaces Care & Maintenance information to ensure they understand the
proper care and maintenance for the Avonite Surfaces installation and to register for the ten Year Limited Warranty, or
the new Installed Warranty as appropriate. The Avonite Surfaces Care & Maintenance information, as well as all warranty information is available online at www.avonitesurfaces.com
CARE AND MAINTENANCE GUIDELINES
Matte Finish
Satin Finish
High Gloss
Cleaning
Cleaning
Cleaning
Soap and water will clean most stains.
For more stubborn stains use a green
Scotch-Brite® pad and an abrasive
cleanser.
Soap and water will clean most stains.
For Stubborn Stains use a white
Scotch-Brite® pad and non-abrasive
cleanser such as Soft Scrub™.
Soap and water will clean most
stains. Use a polishing compound
like 3M Perfect-It and a soft cloth to
remove more stubborn stains.
Scratches:
Scratches:
Scratches:
To remove scratches, start sanding
with 240 grit paper and then clean
with and abrasive cleanser and a
green Scotch-Brite® pad.
To remove scratches, start sanding
with 400 grit paper followed by 600
grit paper. Then clean the area with
Soft Scrub™ and a white ScotchBrite® pad.
To remove scratches from a high
gloss f nish, start sanding with 400
grit paper. The surface must then be
machine polished back to it’s original
f nish. If you do not own or have
access to this equipment, you should
contact you local Avonite Surfaces
fabricator for assistance.
Remember to periodically go the entire
matte surface with a dry, green Scotch
Brite® pad to return the original finish.
Avonite Surfaces Sink Care
Use the Matte Finish cleaning and scratch removal procedures above. To keep sink color bright, clean occasionally with
liquid bleach and water. Fill the sink 1/4 full with water, add 1 to2 cups of bleach, wipe the sides of the sink and let
stand for 15 minutes. Then drain the sink and rinse.
Do’s and Don’ts Quick Reference
x
x
bottom of pottery or other hard objects. Avoid sliding
hard objects across these glossy surfaces.
Always use a hot pad or trivet under hot pots or heat
producing appliances.
x
Always use a cutting board.
x
Never stand on your counters.
x
Avoid harsh chemicals such as drain cleaners and
For high gloss counters, place felt protectors on the
x
Always run cold water when pouring boiling water into
Avonite Surfaces’ sinks.
paint removers.
x
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Care & Maintenance (Español)
MATE
Del Final:
El jabón y el agua limpiarán lamayoría
de las manchas. Paramanchas más
obstinadas utilice unapista escocesa
verde del Brite y unadespedregadora
abrasiva.
Rasguños:
6.6
LIMPIEZA DEL FINAL
DEL SATÉN
ALTA LIMPIEZA
DEL LUSTRE
El jabón y el agua limpiarán lamayoría
de las manchas. Para lasmanchas
obstinadas utilice una pistaescocesa
blanca del Brite y unadespedregadora
que no senabrasiva, tal como suavidad
friega.
El jabón y el agua quitarán lamayoría
de las manchas. Utilice uncompuesto
que pule como los 3m Perfect-It y un
paño suave paraquitar manchas más
obstinadas.
Rasguños:
Para quitar rasguños, comience aenarenar con el papel de 240 arenasy
después limpie con unadespedregadora abrasiva y una pistaescocesa verde
del Brite.
A quitar rasguños, comienceenarenando con 400 de papel de laarena seguida por el papel de 600arenas. Entonces limpie el área consuavidad
friegan y una pistaescocesa blanca del
Brite. Ustedpuede elegir rociar una
Recuerde pasar periódicamentesobre
la superficie mate entera conuna pista capaligera del protege todos para realescocesa verde seca del Brite volver el zarel lustre.
final original.
Rasguños:
Para quitar rasguños de acabe delustre alto, comience el enarenar conel
papel de 400 arenas. Entonces lasuperficie debe entonces sermáquina
pulida de nuevo a su finaloriginal.Aconseje al cliente que contacteal
fabricante de Avonite Surfaces si no
poseen ni tienenacceso a este equipo.
FREGADERO DE AVONITE SURFACES:
Utilice la limpieza mate del final y rasguñe los procedimientos de retiro arriba.Para mantener color del fregadero brillante, limpie de vez en cuando con el blanqueo líquido y riegue. Llene elfregadero 1/4 por completo de agua, agregue 1
a 2 tazas de blanqueo, limpie las caras del fregadero y deje elsoporte por 15 minutos. Después drene el fregadero y
aclárelo.
LAS QUIAS DE CONSULTA DE QUE HACER Y NO HACER
x
Utilice una pista o un trivet caliente bajo loscrisoles
calientes o caliente siempre producer aplicaciones.
x
Siempre utilice una tabla.
x
Nunca se pare sobre en sus contadores.
x
Evite los productos químicos ásperos tales comoproductos de limpieza de discos deldren y removedores
de pintura.
©
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10 Year Limited Warranty
Aristech Acrylics LLC (the “Company”) warrants to the
original purchaser of any of the Company’s Avonite Surfaces
solid surface products that the Company will at its option
repair or replace, without charge, such product if it fails due
to a Company manufacturing defect during the first ten
years after initial installation. This includes reasonable labor
charges needed to repair or replace the product covered
hereunder.
This warranty applies to any Avonite Surfaces solid surface
product purchased after August 22, 2005 that is put into
residential or commercial use and maintained in the manner
recommended by the Company in its publications relating to
care for a permanent installation. A copy may be obtained,
free of charge, from your dealer or by writing directly to the
Company.
This warranty does not apply to the Company’s Acrystone®
solid surface 1/8” product, which is covered by a separate 1
year limited warranty.
This warranty does not cover damage caused by:
1.Failure to follow Company recommended procedures for
fabrication and installation.
2.Physical abuse, structural movement, damage from excessive heat, or breakage not due to a Company defect in the
manufacture of the material.
3. Failure of any adhesive, caulk, or other finishing or
maintenance accessory, or failure of any caulked or filled
joint or seam.
This warranty applies only to Avonite Surfaces products:
1.Purchased for use in the United States and all other countries where Avonite Surfaces is distributed, fabricated and
installed by an Avonite Surfaces authorized fabricator/
installer.
2.Which fail due to a manufacturing defect; and
3.Which have not been moved from their original place of
installation.
For coverage under this warranty, request a registration card from your dealer or contractor and mail the
card to the company. The Company will assign a warranty registration number. To obtain service under this
warranty, write to the dealer/contractor from whom you
purchased the product or alternatively write to Aristech
Acrylics LLC at the address given below.
Include the phrase “Avonite Surfaces Products, 10YearLimited Material Warranty”, your name, address, a
description of the problem and your warranty registration number. A response will be sent within 60 days.
The Company’s obligation hereunder is limited solely to
the repair or replacement, including necessary labor
charges, of the Avonite Surfaces product purchased
hereunder. The Company’s obligation to repair or replace shall further be limited to repair or replacement
with colors and styles of product that are available at
the time of repair or replacement. No implied or express warranty of merchantability or fitness for a
particular purpose is granted by this warranty.
Except as provided herein, the Company shall not be
liable in either tort or contract for any loss or direct,
consequential or incidental damage arising out of the
use or inability to use Avonite Surfaces residential or
commercial products hereunder. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion
may not apply to you.
This warranty gives the purchaser specific legal rights;
other rights may also be available which may vary from
state to state or in Canada from province to province.
This warranty is not transferable or assignable.
Any questions under this warranty should be addressed
to the local Avonite Surfaces distributor or Aristech
Acrylics LLC.
This warranty is for applications such as countertops, vanities and vertical applications and does not apply to installations in mobile environments such as recreational vehicles,
marine crafts and airplanes. This warranty does not cover
material exposed to weather conditions or exterior applications such as grill tops & exterior counters. This warranty
does not cover color. If during or after installation you decide that you do not like the color selected due to sample
chip variance, website or printed literature representation or
Aristech Acrylics LLC
1945 Highway 304
Belen, NM 87002
1.800.428.6648
www.avonitesurfaces.com
Effective as of 8/22/05
other reason replacement is not covered by this warranty.
©
6.7
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Warranty Claims Processing
FILING CLAIMS
To resolve warranty claims, we ask that our Distributor
Representatives prepare a Warranty Claim Report. You can
help us expedite the processing of warranty claims and
achieve improved customer satisfaction by assisting in the
following areas:
1. Warranty Claim Report Form - Please fill form out
completely so that the information needed to make decisions is readily available for us. This information helps us
tremendously in the processing of the claim.
2. Quality Inspection Checklist -We ask your assistance
in completing this form in detail, as this helps us to identify how the defect occurred. Your help in this area in the
past has led to the advanced fabrication procedures that
now exist in the solid surface industry, further improving
our industry’s reputation.
3. Job Layout -Include a detailed diagram of the job,
complete with all measurements, including distances to
seams and seam locations. This helps us to accurately
estimate the cost of fabrication and material, thereby reducing errors and allowing us to validate a repair/
replacement quote.
4. Photos -Take three to four photographs (Polaroids are
fine) of the defective area and a photograph of the overall
kitchen.
5. Quotation -Submit a written quotation on the repair or
replacement of the job. Repair is encouraged over replacement. However, if repair is not possible, a quote of the job
replacement is needed.
Warranty claims that are submitted with complete information will be resolved within two weeks of receipt of the
claim. Without this information, the processing of a claim
will be delayed. We ask for your continued cooperation and
thank you for your assistance.
AVONITE SURFACES
TECHNICAL SERVICE DEPARTMENT
1-800-428-6648
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6.8
IMPORTANT NOTICE
The information and statements herein are believed to be reliable but are not to
be construed as a warranty or representation for which we assume legal responsibility. User should undertake sufficient verification and testing to determine the
suitability for their own particular purpose of any information or products referred
to herein. NO WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE.
Nothing herein is to be taken as permission, inducement or recommendation to
practice any patented invention without a license. Any information or suggestion
concerning applications, specifications or compliance with codes and standards is
provided solely for your convenient reference and without any representation as
to accuracy or suitability. Aristech Acrylics LLC disclaims any responsibility. The
user must verify and test the suitability of any information or products for his
specific application.
Aristech Acrylics LLC
7350 Empire Drive
Florence, KY 41042
All Rights Reserved. © Aristech Acrylics LLC
1-800-354-9858 www.avonitesurfaces.com
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