installation instructions

installation instructions
installation instructions
Encore is a compression moulded,
reinforced, natural mineral filled
homogeneous nonporous acrylic. It has
colour consistency running throughout its
5mm surface.
Encore’s unique structure gives it some
great performance characteristics
including:
- the best stain resistance properties
compared to most other solid surfacing
materials.
- the most heat tolerant solid surfacing,
tested up to 240°C.
- the best scratch, chip, shatter and wear
properties.
- resistance to most chemicals ie:
solvents, acids, alkalis and many other
chemicals found in daily domestic use.
- hygienically easy to maintain and UV
resistant.
Encore comes with a 10 year
guarantee.
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product
data
Encore’s unique structure and 5mm surface gives it great performance
characteristics.
Composition
Splashbacks
5mm thick reinforced acrylic face.
5mm thick reinforced acrylic available in 2
sizes:
P3 grade environmentally preferred 38mm
thick chipboard PEFC certified.
Balanced with 0.8mm high pressure
decorative white laminate.
The unique edge construction is formed
using waterproof acrylic colour matched
adhesive.
The worksurface features a 3mm top
radius.
Worksurfaces
44mm thick available in 2 sizes:
- Worktop 4100mm x 650mm finished
front and both short edges, approx
weight 83kg.
-Breakfast Bar 2400mm x 900mm
finished all four edges, with a 1000mm
radius bow and a square end, approx
weight 67kg.
-Midway panel 4100mm x 600mm approx
weight 18kg.
-Hob panel 1200mm x 1200mm, approx
weight 10kg.
Upstands
12mm thick reinforced acrylic with 3mm
radiused top edge:
-3680mm x100mm, approx. weight 7kg.
Edging strips
5mm thick reinforced acrylic available in 2
sizes for on-site finishing:
-1350mm x 44mm.
-2400mm x 44mm.
Designers should consider the extra
thickness of Encore in comparison to
Bushboard laminate worksurfaces. Special
care should be taken when designing
kitchens with both tall housings and
worktop dresser units. Please seek advice
from your furniture supplier.
For advice call our Customer Service Team on 01933 232 242 or email us at [email protected]
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before
you start
When working with Encore and related materials we strongly recommend relevant
personal protection equipment is used.
Conditioning
Storage and handling
Health and safety
Prior to commencing installation ensure
Encore worksurfaces, splashbacks,
upstands and adhesives are brought up
to room temperature of around 18°C
(64.4°F).
Please consider the weight of Encore
worksurfaces before handling and
allocate adequate manpower. See
product data for weights. Where boards
are being carried manually, we advise that
they are held with the narrow side vertical
and the long side parallel to the ground.
Do not carry flat!
Encore is not known to be associated
with any hazards.
Colour compatibility
Encore is manufactured to strict colour
tolerances and factory finished to a linear
320 grit finish to reduce installation times.
However, colour compatibility of
components must be checked prior to
commencing installation. Simply peel
back the PVC protective film and lightly
sand a small area of each worksurface
using a fine Scotchbrite pad. Wipe off
any dust, then finish the area with a coat
of Countertop Magic. Compare colours
to satisfy yourself that installation can
commence.
Should the materials appear to have
an unacceptable colour variance,
please contact your supplier before
commencing work as claims for colour
incompatibility cannot be made after
installation.
The recommended storage method for
Encore worksurfaces is face up, flat, well
supported on batons 100mm in from
ends and at every 1000mm. You may
also store Encore vertically on its long
edge for short periods during installation.
The rest angle needs to be no more than
20° from vertical and where possible the
factory finished edge must not be against
the floor. For breakfast bars where no
choice is possible, ensure the edge on
the floor is protected against damage.
Encore worksurfaces must always be
stored in a ventilated, dry, enclosed area
within the recommended temperature
range of 10–20°C.
When working with Encore and related
materials we strongly recommend
relevant personal protection equipment
is used:
Dust mask – when cutting, routering,
gluing and sanding.
Safety goggles – when cutting,
routering, gluing and sanding.
Protective gloves – when using
denatured alcohol and adhesives. (We
recommend use of powder free nitrile
gloves when gluing and using cleaning
agents).
Protective footwear – during general
installation.
Overalls – during general installation.
NB:
Cutting and sanding machines should be
fitted with adequate dust extraction.
Always use adequate extraction and
ventilation, especially when working in
enclosed rooms.
Use caution when working with
flammable cleaning agents.
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essential installation
tools & materials
The use of good tools will ensure a superior, professional finish.
Hand Router: to form straight cuts, mitre
joins and cut-outs, use at least 2000 watts
electrical power with variable rotation
speed facility.
Palm Sander: for finishing the front edge
use a good quality orbital palm sander with
at least 500 watts electrical power rating
and 2mm sanding stroke.
Router Cutters: use high quality double
flute tungsten carbide tipped cutters.
The router should be operated at around
18,000 RPM. Each cutter should cut
over 10m in length before replacement is
necessary.
Palm Sander Sanding Sheets: use
Clamps Type A: to apply end cap edge on site.
machines with a 80 x 130mm Hookit Sheet.
Clamps Type G: to secure jigs to worksurface,
Jig Saw: mainly for forming cut-outs, use
use screw type clamps.
a machine power rated to at least 650
Worktop Mitre Jig: to form 90º, 45º and 135º
watts with adjustable pendulum action for
mitre joints, to use as a straight edge to size
increased cutting performance.
Encore to length and for connector bolt cut-outs.
Jig Saw Blades: we recommend the use
Pencil: for marking out. Ensure that all marks
of BOSCH special blade T127D. Each
blade should cut up to 4m of Encore before are removed during the sanding process before
finishing with Countertop Magic.
replacement is necessary.
Hand Held Circular Saw: use a circular
saw with at least a 1600 watts power
rating and at least 65mm deep cut
capacity for rough sizing. Final sizing of
exposed edge must always be carried out
using a hand router. Allow at least 5mm
oversize for final routering.
Encore Colour Coded Seaming Adhesive: to
bond mitre joins and end cap edges. One 50ml
cartridge will form two 650mm deep joins or fix
two 650mm end caps, or one of each.
Edge Trimmer/Edge Profiling Machine:
to trim back edge overhang and to
replicate the 3mm factory edge profile
we recommend the use of a Makita 3703
laminate trimmer/profiling machine.
Scraper: use a card or laminate scraper with a
2mm 45° angle cut from one corner for scraping
excess adhesive from the inner front face of joints.
This will reduce sanding in this difficult to access
area.
Random Orbital Sander: to sand Encore,
use a good quality random orbital sander.
We recommend machines with 150mm
discs, a 5mm sanding stroke and at
least a 500 watts electrical power rating.
Operating the sander at 8500 RPM for
coarse grit, moving up to 11000 RPM
for finer grits. Use of an integrated dust
extraction system. Bushboard recommend
Festool random orbital sanders with dust
extraction for an excellent professional
finish. (www.Festool.co.uk)
Edge Trimmer Cutters: use a fixed tip
guide trim cutter. We recommend Titman
reference BGT90S .
Encore Pre-bond Cleaner (industrial denatured
alcohol, 200ml bottle): essential to thoroughly
clean both inner joint faces prior to bonding.
Edge Profiling Cutters:fixed tip guide
3mm profile cutter. We recommend Titman
reference ROCB3. (www.titman.co.uk)
Heat Reflective Tape 5m Roll: to minimise heat
transfer from hob to cut-out.
Random Orbital Sander Sanding Discs:
180 grit - bulk material removal from joints
240 grit - material removal from joints
320 grit - final stage sanding for overall
surface and joints.
Scotchbrite Ultra Fine Grey - for final finish
To obtain Bushboard approved sanding
discs with eight extraction holes contact
your distributor.
Biscuit Jointer Blade: use a blade to suit
no 20, 62mm x 23mm x 4.0mm biscuits.
Hand Held Circular Saw Blades: use
high quality TCT triple chip blades for a
fine finish cut.
0710InstallationFinal2.indd 4
Biscuit Jointer: to form pockets for joint
alignment biscuits, use a good quality
biscuit jointing machine with 100mm
diameter blade capable of forming at least
20mm deep pockets.
Electric Drill: for general drilling operations
use a good quality variable speed drill with
1/2” chuck. Standard high speed drill bits
are suitable to drill Encore.
Adhesive Applicator: use a 50ml cartridge
with a 10:1 mix ratio to dispense colour
coded Encore adhesive.
High Modulus Silicon: to seal all exposed raw
core against moisture, such as sink cut-outs.
Connecting Bolts 150mm and Jointing
Biscuits: to clamp joints. To obtain sets of three
please contact your nearest distributor
Jointing Biscuits: use to strengthen joints and
produce a level final finish. Use no.20 – 62mm
x 23mm x 4mm biscuits. Use one biscuit per
connector bolt.
Countertop Magic Finishing Polish: for final
surface polish finish.
Microtex Wipes: for applying and polishing using
Countertop Magic.
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design &
planning
Designers should consider any effect on plinth or cornice lines where a design
includes both a tall housing and a worktop dresser unit.
Design considerations &
furniture preparation
Encore surfaces at 44mm are 6mm
thicker than laminate worksurfaces.
Designers should consider any effect on
plinth or cornice lines where a design
includes both a tall housing and a
worktop dresser unit. Advice should be
sought from the furniture manufacturer.
Encore must not be used to form Belfast
or Butler sink draining boards.
When installing Encore on either side of
an Aga or similar cooker, ensure a gap of
at least 50mm is left between the cooker
and the edge of the Encore worksurface.
Planning for joints
To achieve a secure and inconspicuous
joint ensure the carcasses are perfectly
aligned, levelled and secured.
Positioning of joints is important. The
designer and installer should consider the
following:
-Joints should not extend across any
hob or sink cut-outs and be offset by
over 100mm.
-Joints should ideally run away from a
sink rather than along its side.
-Joints must not be formed over heat
radiating appliances e.g. dishwashers
& tumble driers and not over washing
machines.
-800mm is the maximum span for an
unsupported Encore worktop between
walls or carcasses. Where possible
use leg supports or base end support
panels between machines to support
the surface.
-If forming a diagonal joint rather than
a butt and scribe joint, ensure the
undersides of both Encore worksurfaces
are fully supported along the full length
of the wall with batons.
-Consider using batons to support the
Encore worksurface along the enlarged
void where a standard 1000mm corner
base unit has been installed with an
oversized door.
-Joints must have biscuits applied in
every instance unless totally impractical
due to design considerations.
-Joints in 600-650mm surfaces should
be clamped using 3 -150mm connector
bolts. They should be easily accessible.
-Joints in 900mm surfaces should be
clamped using 4 -150mm connector
bolts. They should be easily accessible.
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cutting encore
worksurfaces
Encore is a hardwearing surface and as such the correct use of good quality
machinery and the correct sharp cutters will produce a professional finish.
Encore solid surface material is a
hardwearing surface and as such the
correct use of good quality machinery and
the correct sharp cutters will save time
and effort whilst producing a professional
finish. See recommended tools under
essential tools and materials.
Always commence the cut from the side
of the factory fitted edge. Never cut out
through the edge.
Time taken cutting carefully into the front
edge will help eliminate flaking or chipping.
Ensure that loose debris and sawdust is
thoroughly removed from the cut edge and
the cutting area, as dust and debris may
degrade the final adhesive bond and finish
of the joint.
General sizing
General sizing of Encore worksurfaces can
be carried out using either a fixed, slide
table dimension saw or portable hand-held
circular saw.
Ensure a good quality sharp triple fine
tooth tungsten carbide tipped blade is
used.
If using a fixed, slide table dimension saw
set the height to no more than 65mm off
the bed.
Use two cutting passes when using a
hand held circular saw:
-1st cut: set the saw blade depth at
15mm.
-2nd cut: set the saw blade depth at
50mm.
Preparing final size for jointing: on site
short edge finishing or the final cut to
run into a wall
All joint edges and final finished ends must
be cut using a hand router with a sharp
blade of the recommended type.
When routering, the golden rule is to cut
into the factory fitted edge with waste
material to the right; the required work
piece on the left may be either face up or
down.
For straight end to end butt joints, use a
straight edge guide offset to suit the router,
to provide a clean square edge.
Mason mitre joints
Cut 90° and 135° joints using a
specialised purpose made jig. Refer to jig
manufacturer’s instructions for cutter &
guide bush combination, male mitre depth
allowance and setting method for both
male and female mitres.
Router cut in 3 stages in increments of
15mm depths each time.
Diagonal mitre joints
These are generally used to cope with
a variety of acute and obtuse angles or
diagonal 135° corner solutions. Diagonal
joins can also be used in a 90° corner, but
to minimise material waste we recommend
a mason’s mitre join.
Determine the angle of the corner.
Equally bisect the angle and transfer the
angle onto both worksurfaces and mark
with a pencil.
Final trimming should be made with a
router.
Using a straight edge guide offset to suit
the router, cut the diagonal butt jointing
edges.
Allow 5mm oversize to trim to the final size
with the router.
Router cut in 3 stages in increments of
15mm depths each time.
0710InstallationFinal2.indd 6
Cut-outs
Cut-outs can be formed using either a hand
router or a jig saw. Because Encore is reinforced,
it naturally only requires a 10mm radius on the
internal corner of cut-outs.
To form a cut-out using a hand router it will
be necessary to make a jig to suit the cut-out.
The size of the jig cut-out will depend on the
combination of the cutter diameter and the guide
bush being used.
Clamp the jig to the Encore worksurface and cut
round in 3 stages of 15mm depth increment.
When forming cut-outs offsite it is advisable to
form a blind cut-out leaving approx. 3-5mm at the
bottom. Once the worksurface is in place, this can
be more easily cut through using a jig saw.
To form cut-outs using a jigsaw, mark out the
desired size cut-out using a pencil.
Drill four 10mm diameter holes on the internal
corners of the marked cut-out. Using the holes
to introduce the jigsaw blade, carefully cut along
the inside of the marked line between the holes
leaving a radius on each corner.
Thoroughly remove loose debris and fine sawdust
from the cut-out edges and surfaces.
Sink cut-out edges
Bare edges must be carefully sealed using high
modulus clear silicon. Apply at least a 2mm thick
coat as silicon works best with thickness.
Hob cut-out edges
Apply 50mm wide heat reflective tape to bare
edges allowing equal overhang top and bottom
and tight round internal corners. Fold over the
overhang onto the top and bottom faces.
NB: Do not router to insert hob bars or heat studs
into Encore worksurfaces. Surface mounted
accessories are available from Unika
(www.unika.co.uk).
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edging end cap
on site
Both short ends of Encore worksurfaces are
factory edged. On occasion a design will call
for the installer to re-edge the product on
site. The operation is simple and produces an
excellent inconspicuous end cap. However, it
is much easier to complete a short end cap
return on a workbench before the worktop is
screwed in place.
short edges, 5mm from the edge to the bead
of adhesive, and finally one centrally.
Firmly apply edging strip and align flush to the
bottom so that approximately 1mm of edging
stands proud of the top face. Ensure that an
unbroken bead of adhesive is visible all round.
Prior to commencing work ensure all required
tools and installation items are to hand.
Secure the edging using ‘A’ clamps,
one at each end and the others spaced
approximately 100mm apart.
Measure and cut the required length of edging
strip.
Allow at least 40 mins adhesive cure time
before commencing further finishing work.
Please remember that applying an end cap
edge will increase the worktop length by 5mm.
Using a Makita hand trimmer with a Titman
BGT90SLP cutter, trim excess edge overhang.
Have the glue applicator gun loaded and
primed with Encore colour coded adhesive.
Using a Makita hand trimmer with a Titman
ROCB3 cutter, form a 3mm radius profile to
the trimmed short end, matching the factory
finish.
Have Super Plus ‘A’ Clamps (7 for 650mm- 9
for 900mm) at hand.
Using a lint-free bleached white cloth
thoroughly clean the jointing face of the
Encore solid surface and the scarified rear
face of the trimmed edging strip using Imanol
industrial denatured alcohol (avoid applying
Imanol to chipboard). Allow to evaporate dry
and assemble within a short time to prevent
recontamination.
NB: If the edge is to fit against a tall housing
or wall then profiling may not be needed to
ensure a tight square fit.
The edged worksurface is now ready to install.
Sanding will be completed as part of the final
finishing process.
Apply three beads of adhesive along the length
of the edging strip i.e. top, bottom and both
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jointing
Using bolts and biscuits to
assemble Encore joints
Dry Fit Trials and Sealing
Raw Edges
Using the correct number of bolts and
biscuits are a condition of the Encore
guarantee.
Carry out a dry fit trial prior to
commencing installation once all
components are cut and machined. It is
extremely difficult to resolve any problems
once joints are glued, secured and set.
Connector bolts
Recommended number of connector
bolts per joint:
-Up to 500mm depth – use two bolts
-Up to 700mm depth – use three bolts
-Up to 900mm depth – use four bolts
Using a connector bolt cut-out jig, router
the bolt cut-outs no deeper than 25mm
on the reverse face, 100mm in from ends
and spaced equally in the middle.
Jointing biscuits
Jointing biscuits must be used to achieve
a strong, perfectly aligned joint.
Using a biscuit jointing machine form
pockets to suit No.20 biscuits.
Cut pockets 20mm down from the top
face between bolt slots. Do not cut
pockets over bolt slots.
Use one biscuit between each connector
bolt,
0710InstallationFinal2.indd 8
End cap edges are easier to install on a
bench rather than after the worksurface
is screwed in place so consider which
edges will need capping.
It may also be useful to sand end caps to
a final finish prior to installation if they are
difficult to access – for instance against a
tall housing.
Prior to fitting ensure:
-Lengths are correct.
-Joints are a good fit - any gaps will
directly reflect on the joint quality.
that all edges that will remain raw and
exposed after installation are completely
sealed with at least a 2mm coat of silicon
e.g. sink cut-outs, rear edges and short
edges running into walls.
Encore is balanced with high-pressure
laminate which will prevent moisture
entering the worktop in normal kitchen
conditions. However it is good practice
to protect the consumer from costly
replacements with a few simple
measures:
-Install additional moisture protection
above dishwashers & washing
machines. Most appliances of this type
include protection within the installation
kit.
-It is also good practice to apply
additional moisture protection in front
of the sink to protect against overflow
situations. Silicon is again the ideal
sealant.
-Perfect horizontal worktop alignment.
-Hob and sink cut-outs are in correct
place.
Using Encore Adhesives
-Connector bolts are accessible.
Use only Encore adhesive to make joints
or cap short end returns. Any other
adhesive will invalidate the warranty.
-Biscuits can be easily applied and return
worktops moved into place.
Once satisfied with the dry fit ensure
The adhesive works as a filler, sealant and
adhesive on both the Encore solid surface
11/10/07 12:12:52
material and the chipboard core. It must
be applied with the correct applicator
gun to ensure a correctly metered mix of
adhesive and hardener.
-Sufficient connector bolts.
Load the adhesive cartridge into the glue
applicator gun.
-Card or laminate scraper.
Remove the protective cap (keep it safe
to recap the cartridge) attach the nozzle.
To reduce the risk of initial imbalanced
mix when using a new cartridge always
run off and dispose of 3-5 ml of mixed
adhesive.
Encore adhesive has a joint open time of
6-8 minutes which is useful for making
any final adjustments. However plan
on closing the joint within 5-6 minutes.
Encore adhesive is generally fully cured in
40 minutes. However on a warm day the
joint open time may be reduced, whilst on
a cooler day the curing time may need to
be extended.
-Biscuits.
-Spanner.
It is vital that the inner solid surface joint
faces only are cleaned thoroughly with
Imanol industrial denatured alcohol. This
ensures no contamination, particularly
essential in lighter colours. Do not use any
other solvents or degreasing cleaners.
Do not clean chipboard core with Imanol.
Ensure the joint is dust free and allowed
to evaporate dry.
It is essential that a clean lint free
bleached white cloth is used.
Dispense a small amount of adhesive in
the biscuit pockets on one side of the
joint and insert biscuits. Where possible
insert the biscuits into the female side of
the joint.
NB: See assembling joints for preparation
and cleaning.
Apply two beads of adhesive along the
entire length of the joint:
Assembling Joints
-The first bead to run just above the
biscuits at 20mm down from the top
face.
Prior to commencing work ensure all
required tools and installation items are
to hand:
-The second bead to be applied 5mm up
from the bottom face.
-Glue applicator gun loaded and primed
with Encore colour coded adhesive.
-Without delay, bring the worksurfaces
together leaving a 2mm gap.
0710InstallationFinal2.indd 9
Holding the dispensing gun slightly off
vertical, apply a final bead of adhesive
along the top surface and front edge. An
unbroken adhesive bead on the top and
bottom faces, as well as the front edge,
is the key to achieving an inconspicuous
and secure joint.
Bring the two worksurfaces together and
align the front inner faces. If assembling
a mason’s mitre ensure the short 45°
section is pulled together by ensuring the
male section is pulled fully forward. Insert
the connection bolts and tighten. Do not
over tighten - generally two to three full
turns after pinch point should be ample.
Using a card or laminate scraper with a
2mm 45° angle cut from it, scrape away
the squeezed out adhesive in the inner
front face of the joint. Use the angle cut
into the scraper to leave a neat bead
in the joint. This will save much time in
sanding this inaccessible area.
Do not attempt to remove any excess
squeezed out adhesive at this time as
it will shrink during drying. Adhesive
overspill elsewhere on the surface may be
wiped off using Imanol.
Allow at least 40mins adhesive curing
time before commencing finishing work.
11/10/07 12:12:56
final
finishing
The consumer should be left with an Encore care kit and advised to follow the
instructions with relation to care and maintenance.
Sanding
The use of a good quality random orbital
sander is vital to produce a professional
finish. Dust extraction is essential for
health and safety reasons and to ensure
the consumer’s home is not filled with
clouds of dust.
Ensure the sander is moved constantly
during sanding operations. Holding the
sander in one place can generate heat and
create a depression in the worksurface.
Ensure the worksurface is wiped clean
between each sanding operation to
remove debris and grit.
Sanding short ends (applied on-site)
To sand on-site applied short ends follow
the procedures as if sanding a joint.
However, depending on the quality of
trimming, sanding using 180 grit may not
be necessary.
worksurface, lightly hand buff and leave for 10
minutes.
Final all-over finishing
Once all joints and on-site applied short
ends are sanded, sand the complete
worksurface area using 320 grit discs.
The installer may also choose to apply
Countertop Magic using a random orbital
sander with ultra fine grey Scotchbrite, buffing
the worksurface in both depth and length until
the Countertop Magic is absorbed. Using this
method produces a superior, even finish.
Even with Encore being supplied to site
in a 320 grit linear finish it is important
that the entire surface is sanded by hand
with a random orbital sander to produce a
uniform all over finish. Failure to complete
this operation may lead to a difference in
the finish around joints compared to the
main surface areas, leading to a consumer
complaint.
You may decide to sand over again using
ultra fine grey Scotchbrite discs to ensure a
finer finish. This is often desirable for darker
colours.
Sanding joint
To obtain maximum use of sanding
materials, it is best to leave sanding until
all joints are formed.
Using a random orbital sander and
180 grit discs, carefully sand each joint
adhesive bead.
Further sand each joint using 240 grit
discs until they are flat taking care not to
over-sand and remove too much surface
material either side of the joint line.
0710InstallationFinal2.indd 10
Polishing
To achieve an even finish apply a moderate
amount of Countertop Magic to the
Apply a further moderate coat of Countertop
Magic and hand buff until it is fully absorbed.
Finally wipe using a Microtex microfibre cloth.
Ensure that all back edges are sealed to the
wall with a bead of silicon to prevent moisture
penetration.
Hobs and sinks can be installed at this point.
Follow the manufacturer’s sealing instructions to
prevent moisture passing under the sink or hob.
The consumer should be left with an Encore
care kit and advised to follow the instructions on
care and maintenance. We advise the consumer
to apply Countertop Magic daily for the first
week, then every week as part of their normal
cleaning process.
Tiling
Never tile directly onto worksurfaces. Use a
5mm MDF strip laid as a guide on the surface
to tile down onto. The resulting gap can be filled
with a robust and neat bead of silicon before
grouting. This final finish is waterproof and will
last much longer than grouting or a thin layer
of silicon across the front of the tiles. It also
simplifies removing the surfaces whilst leaving
the tiles intact should it be necessary.
Upstands
Encore upstands are factory finished to 320 grit
linear sand finish.
11/10/07 12:12:57
Once sizing is complete, prior to
installation, final finish using grey
Scotchbrite.
Upstands can be customised using a mitre
saw, router and jigsaw.
Measure, cut or mitre upstands to length.
Any exposed cut edges will need to be
finished now.
The Encore splashback is factory finished
to 320 grit linear sand finish.
Once sizing is complete, prior to
installation, final finish using grey
Scotchbrite.
The Encore splashback must be well
supported during machining operations.
Wipe clean the back of the splashback using a
damp cloth and allow to dry. Ensure the wall is
dry and free of any loose debris.
Apply blobs of silicon to the back of the
splashback, approximately 20-30mm in
diameter and at least 10-15mm thick. The
silicon blobs are best staggered and spaced at
least 125mm apart.
Offer the splashback into place; firmly press
back and down to worksurface.
Dry fit upstands.
The splashback can be customised using a
portable circular saw for straight concealed
edges, a jigsaw to form cut-outs and a
hand router for both straight cuts and
cut-outs.
Wipe clean back of upstand using damp
cloth and allow to dry.
Measure and cut the splashback panel to
suit.
In such cases the splashback with the 3mm
wide rebate should be adhered to the wall first.
Ensure the wall is dry and free of any loose
debris.
Any exposed cut edges will need to be
finished now.
Using a clean, lint-free, bleached white cloth,
thoroughly clean the jointing faces of both
Encore splashback rebates using Imanol
industrial denatured alcohol.
When butting up two upstands, router the
butting edges.
Apply 3 beads of clear silicon along the
length, approx.15mm in from edges and
one centrally.
Offer the upstand in place, firmly press
back and down to worksurface.
Wall
3 mm
Apply a small bead of acrylic adhesive centrally
along the length of the 5mm wide rebate.
5 mm
Mid way splashback
If necessary the join between upstand and
worksurface can be sealed using clear
silicon.
Splashbacks
The 4100mm x 600mm x 5mm
splashback panel should be handled with
care.
Where boards are being carried manually,
we advise that they are held with the
narrow side vertical and the long side
parallel to the ground. Do not carry
flat! This will help eliminate flex-related
damage.
0710InstallationFinal2.indd 11
5 mm
Hob splashback
Face
Rebated butting edges can be glued together
using acrylic adhesive.
5 mm
When butting up splashback panels, to
achieve a well aligned join it’s best to rebate
the butting edges. Using a router and
straight edge to rebate the butting edges.
Refer to drawing above for rebate details.
Dry-fit the splashback panels.
Apply silicon blobs and offer the splashback into
place, aligning the rebate joins, pressing back
and down to the worksurface.
As it can be difficult to sand and finish vertical
surfaces, we recommend overspills of acrylic
adhesive are carefully cleaned off using Imanol.
If necessary, the joins can be temporarily pulled
together using good quality duck tape until the
adhesive is set.
If necessary, the join between the splashback
and worksurface can be sealed using clear
silicon. Clean any silicon overspills from the
surface immediately.
11/10/07 12:12:57
For technical support on Bushboard products, please
contact the Customer Service Team on:
tel: 01933 232 242
fax: 01933 232 286
email: [email protected]
or log onto www.bushboard.co.uk
0710InstallationFinal2.indd 12
11/10/07 12:12:57
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