Fabrication Manual

Fabrication
Manual
And
Technical
Reference
Guide
2010
Written by Gordon Shell
Welcome to the world of
EOS™ 3cm Solid Surface
“The only “Solid” Solid Surface”
Click on title
to view
Video Clips
Introduction
• It started with a great idea...
Make a thicker solid surface
– Eos Solid Surface bridges the gap between seamless
solid surface and high-end laminate. Our patent
pending 3cm
(1 1/4") material offers all the advantages of premium
solid surface, in a thicker, more durable material at a
surprisingly low price.
– By eliminating up to 75% of the labor required for
traditional 1/2" solid surface, Eos combines the
massive look of granite with a lower price point and
faster delivery. The end result is a true value in the
classic sense a higher quality product at a competitive
price, offering you the flexibility to create the
countertop you have always wanted.
– In addition, 2cm (3/4”) EOS™ sheet goods offer
a great, low cost, low labor alternative to
laminate, cultured marble, and other materials
in the bath, window sill, hospitality, medical,
retail, etc. market.
Introduction
•
•
•
Eos offers you:
– The massive look of natural stone without conspicuous seams.
– A food safe, non-porous surface that is easy to clean and maintain.
– Seamless integrated bowls and backsplashes.
– Greater heat resistance.
– A 10-year transferable product warranty.
– A surface that is renewable and repairable.
– All the advantages of premium solid surface, at a surprisingly low
price.
Eos Solid Surface is ideal for both residential and commercial
applications. With a large color palette to choose from, unlimited
designer options, enhanced durability backed by a 10-year product
warranty, Eos is changing the solid surface industry.
We welcome you aboard the ever growing network of Eos Solid
Surface Fabricators. What you will find contained in this fabrication
manual is basic guidelines for the purpose of reference consisting of
proper use and handling of Eos materials to ensure a long-lasting
beauty and ultimate satisfaction for your customers.
Introduction
• FLEXIBILITY
– Custom Sheet sizes, thickness, and color
Regardless of the size, thickness, or color of your
project EOS™ Surfaces llc. can provide material
to fit your specification; our plant has the ability
to create sheets with custom length, width,
thickness, and/or color.
EOS™ Surfaces llc. has helped fabricators and
contractors save money by reducing labor,
reducing waste, and fulfilling color specifications
by providing custom material.
If you have a project that EOS™ Surfaces can
custom build to your spec contact your regional
manager ASAP, contact info is available @
www.eos-surfaces.com
Preface
•
This manual is supplied as a reference guide to the EOS™
fabricator/ craftsman.
•
EOS™ 2cm and 3cm sheet goods are intended for fabrication
by experienced solid surface fabricators and/or experienced
woodworkers.
•
The tools required to fabricate EOS™ are both powerful and
sharp and can be dangerous in the hands of inexperienced
individual(s).
•
For your safety and the safety of those around you, read and
understand the instruction manual and precautions for each
tool used in fabrication.
•
EOS Surfaces LLC assumes no responsibility for injuries that
occur during the fabrication of EOS™ sheet or shape products.
Table of
Contents
•
•
•
•
•
•
•
•
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Material handling, safety, storage, and inspection
Tools and accessories for EOS™
Cutting EOS™ 3cm Solid Surface
Seaming EOS™
Under-mounting bowls in EOS™
Finishing EOS™
Installing EOS™
Food Service and special applications
•
Chapter 9 Specifications
EOS™ Spec Web Page
• Chapter 10 Product Non-conformity guide
• Chapter 11 EOS™ warranty
To go directly to any chapter click on the desired chapter.
Return to this page at anytime by clicking on the EOS logo in the upper corner or the page
Material inspection,
handling Safety, and
Storage
• Inspection of Material
In order to ensure shipments arrive from your
Regional Distribution Center in good condition, it
is the responsibility of the fabricator to
conduct a visual inspection of the material being
received. Any visible damages must be notated
on the carrier’s paperwork upon delivery.
Carrier damage along with any concealed
damage for example color match, scratches or
any other problem must be immediately
reported to EOS™ Solid Surface Customer
Service Department 1-800-719-3671 ext. 4.
Material inspection,
handling Safety, and
Storage
•
Damaged or defective material
If it is determined that a shipment contains damaged or defective material, a
report should be filed with both the carrier and EOS™ Surfaces. Digital pictures
of the damage or defect can be sent to gordon@eos-surfaces.com or
hopem@eos-surfaces.com
Claims can also be called into EOS™Surfaces @ 1-800-719-EOS1
Upon receipt of claim, EOS™ Surfaces will offer either replacement materials or
credit for material to resolve claim.
Please refer to Chapter 10 for product non-conformity specifications.
INSPECT SHEETS AND SHAPE PRODUCTS CAREFULLY BEFORE BEGINNING
FABRICATION. EOS™ REPLACEMENT POLICY DOES NOT ALLOW FOR
REIMBURSMENT FOR LABOR COSTS ON DEFECTIVE MATERIAL.
Material inspection,
handling Safety, and
Storage
• Handling 2cm and 3cm EOS™ Palleted
Sheets
EOS™ Sheet goods are shipped flat on wooden or steel pallets, 3cm
sheets will be stacked to a maximum of 12 sheets per pallet, 2cm
sheets will be stacked to a maximum of 18 sheets per pallet. A forklift
with a minimum lifting capacity of 5000lbs and fork extensions are
recommended for moving complete pallets.
Material is shipped from EOS™ Distribution warehouse with steel
banding to safely secure the sheets to the pallet, Do not attempt to
move un-banded pallets. Always secure the sheets to the pallet with
“tie-down straps”, if the steel banding is not in place.
Material inspection,
handling Safety, and
Storage
• Handling individual EOS™ 2cm and
3cm sheets
•
•
•
•
•
•
EOS™ sheets are heavy and should never be carried by no less than 2
adults
3cm sheets 30”x121” weigh 285lbs each
2cm sheets 30”x121” weigh 195lbs each
Because of the weight and the sharp edges on EOS™ sheets, proper
shoes and gloves should be worn.
The use of mechanical slab lifters is highly recommended (see
pictures and descriptions on following pages for suggestions), these
lifters are available thru stone and solid surface suppliers.
Hand cups provide a quick and convenient way to handle EOS™
sheets, confirm with the supplier that the cups that you purchase are
rated for the weight of each sheet. Always follow the instructions
provided, carefully.
Material inspection,
handling Safety, and
Storage
• Pinch lifters can be used to lift
individual sheets with
overhead crane systems or
can be adapted to fit most fork
lifts.
Material inspection,
handling Safety, and
Storage
• Vacuum lifting systems are a
great way to lift slabs directly
from the pallet to the saw or
work table.
Material inspection,
handling Safety, and
Storage
• When moving slabs or
completed projects long
distances the use of panel carts
or dollies is highly recommended
Material inspection,
handling Safety, and
Storage
•
It is recommended that EOS™ sheets are
stored on flat horizontal racks with proper
support not exceeding 48” span between
supports.
•
A good racking system optimizes the storage
area and efficiency of your operation,
providing many years of reliable service.
•
Racks should meet local OSHA safety
standards (see following slides for guidelines)
•
In order to easily verify material, EOS™ should
be stored by color and LOT number.
Material inspection,
handling Safety, and
Storage
• EOS™ Sheets should NEVER be
stored outside.
• EOS™ Sheets should NEVER be
stored in direct sunlight.
• EOS™ Sheets should be stored in a
dry, temperature controlled
environment, storage area temperatures
should not fall below 40° F (3°C).
EOS™ materials that are
stored out-doors are void of
any warranty coverage
Material inspection,
handling Safety, and
Storage
•
•
•
General Recommendations
“as written by OSHA on the safe handling of heavy slab material”
“
Employers who are engaged in the handling and storage of slabs must
prevent caught-by, struck-by, and/or crushed-by hazards in their
workplace. The following are general recommendations:
Pre-plan work to identify the hazards, safe work practices, and the
equipment that will be used to perform the work safely.
•
Develop and implement heavy stone slab handling procedures for
transporting, loading and unloading slabs from containers and storage
areas.
•
Provide mechanical handling equipment appropriate to the task.
•
Inspect material handling equipment before use to assure that it is in good
condition. Defective equipment must be immediately reported and repaired
or replaced before use.
•
Instruct and train employees on the proper material handling procedures.
•
Ensure that employees follow safe stone slab handing procedures.
Material inspection,
handling Safety, and
Storage
•
Recommendations for Storage of Heavy Slabs
The following recommendations will minimize the potential hazards associated with “Slab racks" and
other storage racks for storing heavy slabs:
•
Design storage racks to withstand the loads and forces imposed on them.
•
Design a storage rack system to secure slabs from shifting, sliding and collapsing, or provide
secondary bracing or a restraint system to secure slabs from shifting, sliding and collapsing.
•
Ensure that the "slab racks" are properly installed. Inspect each component to ensure that poles can
be inserted into the holes.
•
Maintain the rack, ensuring that no debris or other objects interfere with the insertion of the poles
used with "slab racks."
•
Develop and implement procedures for the placement and removal of slabs from the racks, keeping
employees out of danger zones.
•
Do not allow employees to use damaged storage racks.
•
Inspect the storage racks prior to loading. Ensure that the racks are properly installed. Look for:
–
–
–
–
–
–
•
Cracked welds;
Cracked structural members;
Deformed or bent structural members;
Splits in wooden supports;
Areas that show that the rack has been damaged or overloaded; and
Poles or other uprights not seated properly in sockets or holes.
Tools and accessories
for
EOS™
SOLID SURFACE
• Stationary power
tools
Table saw- A good quality 3 HP to 5 HP, 10” to 12” blade
diameter table saw with an accurate fence is essential. The
Table Saw is undoubtedly the most versatile machine in any
shop, and should be the woodworker's first machine purchase.
A good table saw becomes the centerpiece of the workshop,
as the woodworker uses it to rip, square, miter, groove, shape
and join pieces. A quality table saw will make completing
nearly any project easier. The table saw should have a cut
width of 24” to 36” and an out feed table to support 10’
lengths.
Panel Saw- Many shops have added a good quality vertical
panel saw such as a Streibig or Holtz – Her. A panel saw does
not replace a table saw, it compliments it. Panel saws make
very accurate vertical and horizontal cuts, they take up very
little space on a shop floor and handle large slabs easier than
a table saw.
Tools and accessories
for
EOS™
SOLID SURFACE
• Stationary power
tools
10”-12” Power Miter Saw- A miter saw will make
quick work of cutting backsplashes and smaller
work pieces to length.
A heavy duty model with dust collection port and all
safety guards intact is highly recommended.
All saw blades used on the previously
listed tools should be:
•
•
•
•
Rated “heavy duty”
Triple-chip Carbide tipped
Have hook angled blades with a pitch of -5° to +10°
Minimum of 6 teeth per 1” diameter.
Tools and accessories
for
EOS™
SOLID SURFACE
•
Stationary power tools
Solid Surface CNC Routers- While CNC routers do produce very fast,
accurate, and intricate cuts in EOS™, they are not required to cut
EOS™.
If your shop uses a CNC for cutting solid surface then EOS™Surfaces
makes the following recommendations:
1.
2.
3.
4.
5.
Make sure that your machine is balanced and in good working condition.
The use of pods over the use of spoilboards is recommended to hold EOS™
in place during cutting.
Using a carbide, 3/8”-1/2” diameter, single flute,
up-spiral router bit gives the fastest cleanest cut.
Spindle speed of 18,000 rpm
Cut rate of 70-80 ipm (depending on machine,
see mfg for their recommendations)
Tools and accessories for
EOS™
SOLID SURFACE
• Recommended Router bits for CNC
Model 63-735 Onsrud, single flute, upspiral, solid carbide, O-flute, 3/8” Collet.
Tools and accessories for
EOS™
SOLID SURFACE
•
Stationary power tools
Wet Stone CNC machinery“Quote from respected stone machinery manufacturer after running EOS™”
We have always been able to machine solid surface material on a
stone machine with the same diamond wheels and water that we use
for granite. The problem has been that the 1/2" thick material was not
rigid enough to machine with a typical pod set-up. The new EOS™
3cm material is very rigid and that allows us to use the same pod setups that we use for stone.
The same tooling is also used with exception of the polishers (which
are not used at all). Feed rates, except for the finger bit, are
approximately twice those for granite (based on the tool
manufacturer's recommended feed rates). For instance, the tooling
manufacturer recommends 59.1 ipm for both the medium and fine
diamond wheels. I would run both at 120 ipm in EOS 3cm. On finger
bits you will only be able to run about 25% faster than stone. You
can, however, substitute a collet style tool holder and use traditional
routerbits. Feedrates of 200 ipm should be reasonable, but it will
produce "chips" rather than fine dust that gets removed with the
water.
Overall, EOS™ 3cm requires about 1/4 of the machine time that the
same parts in granite require, assuming you take the granite all of
the way through polish. The edges produced by the last diamond
wheel (fine) very closely match the surface of the material. Also,
unlike granite, the solid surface material can be sanded on the top
surface.
Cover of Surface Fabrication
magazine showing EOS™
on stone machinery.
Tools and accessories for
EOS™
SOLID SURFACE
• Portable power tools
Heavy duty Circular or worm-drive saw- A good quality circular saw
with a solid surface blade will be used quite often in the shop and on
the job site for trimming, and ripping EOS™ to size.
A good quality “worm saw” works well on long cuts.
A saw with a dust-collection port works very well for indoor, on-site
work.
Regardless of the type of circular saw that you
choose, always use the proper saw blade. Never use
Jig saws, Hacksaws, ripping or combination blades
when cutting EOS™
Solid Surfaces.
Blades and Bits for
EOS™
• Circular saw blades– Tungsten Carbide
– Triple-Chip
– -5° to +10° hook angle
– Minimum 6 teeth per inch
– Described as “used for cutting hard plastic”
Blades and Bits for
EOS™
• Diamond saw blades
– Diamond blades can be used to cut EOS.
– Diamond Blades must be run wet with clean
water.
Blades and Bits for
EOS™
• Router bits for EOS™ 3cm Solid
Surface
Because of the bold thickness of EOS™ Surfaces the following
specialty bits are recommended:
• For flush-cuts off of straight edges
• For bowl cut-outs with over-hang
• For Full Bull-nose Edge Treatment
• For Bevel-edge into Solid Surface Bowl
• For Radius into Solid Surface Bowl
•Bits are available from many tool suppliers, bits pictured
can be found at www.wesleytools.com .
Blades and Bits for
EOS™
• Drill bits for EOS™ 3cm Solid Surface
– The only acceptable tools for boring holes in
EOS™ 3cm Solid Surface are:
• Drill bits-
Modified paddle-
• Hole Saws-
Diamond hole saw (wet)-
• Paddle bits-
Tools and accessories for
EOS™
SOLID SURFACE
• Hand Routers
– Plunge Router (Minimum 3 hp)…used for
plunge cuts of sinks, faucet holes, etc.
– Fixed Base Router (Minimum of 3hp)…Used
for creating seams, edge treatments, and
cutting shape.
– Trim Router (3/4 hp)…used for simple round
over of cut-outs, works well as a router on skis
for glue removal
Tools and accessories
for
EOS™
SOLID SURFACE
• Seaming Clamps– Gorilla Grips
– Seam setters
Tools and accessories for
EOS™
SOLID SURFACE
• Sanders– 6” Random Orbit Sander- With Hookit system
not PSA.) (preferably with Dust collection)
– Polisher (11-13” pad)- (preferably
with Dust collection)
Cutting EOS™ 3cm
Solid Surface
• Cutting EOS™ to “rough size” can be
done easily with any of the following tools– Panel Saw
– Table Saw
– Circular Saw
– CNC
– Water Jet
Cutting EOS™ 3cm
Solid Surface
• Cutting EOS™ 3cm to “Finished size” or
for seaming the following tools are the only
tools recommended– Router
– CNC
– Heavy Duty- calibrated Panel saw with very
sharp blade.
Seaming EOS™
3cm Solid Surface
Seaming EOS™
3cm Solid Surface
• Tools and Supplies needed–
–
–
–
–
–
–
–
–
–
3 hp router
Double fluted ½” router bit
C-clamps
Straight edge (s)
Solid Surfaces Adhesive and dispenser
Router on skis or low angle block plane
Clean white rags or white paper towel
Denatured Alcohol
Seam Clamps
Random orbit sander and sand paper
Seaming EOS™
3cm Solid Surface
• Seam Placement
– Inside Corners- seams near an inside corner must be offset
by 3X the radius of the corner Example: If you use the
minimum inside radius if ½” then your seam should be at
least 1.5” from the inside corner. (See 1-A and 1-B on
following pages)
– Butt Seams and/or square inside corners are not acceptable
in Solid Surface (see diagram 1-C following pages)
– Try to avoid seaming over Dishwashers and thru Cook-top
Cut-outs. If your design does not allow this contact EOS™
tech support for guidance. (See Diagram 1-D on following
pages)
Seaming EOS™
3cm Solid Surface
• Seam Placement
– Diagram
• 1-A
Seaming EOS™
3cm Solid Surface
• Seam Placement
– Diagram
• 1-B
Seaming EOS™
3cm Solid Surface
• Seam Placement
– Diagram
• 1-C
Seaming EOS™
3cm Solid Surface
• Seam Placement
– Diagram
• 1-D
Seaming EOS™
3cm Solid Surface
•
Preparing your seams– Edges to be seamed must be cut with a
clean sharp router bit.
1.
2.
3.
4.
5.
Secure sheets to work table or horses so that clamps will not impede the path of
the router.
Securely clamp straight edge to the edge to be routed, adjust straight edge so that
router bit cuts approximately ¼” off edge to insure a clean straight cut. (allow the
router to do the cutting, do not force the router thru the cut; applying baby powder
to the sheet and straight edge will reduce friction and allow the router to slide more
freely)
Inspect edge for router chatter, divots, etc. If any imperfections in the cut are found
re-route the sheet until the edge is perfect.
Repeat steps 1-3 for the second sheet to be seamed
Dry fit the seam (push the sheets together with out adhesive). The seam should be
inconspicuous with no voids; if the seam looks good then proceed to next step, if
not repeat step 1-3.
Dry fit seam
Seaming EOS™
3cm Solid Surface
•
Creating an inconspicuous hard seam
–
–
–
1.
2.
3.
**Always use the term “INCONSPICOUOS” when referring to solid surface seams, calling
the seams invisible can set false expectations and can be misleading.
Only proceed with these steps if you have an inconspicuous dry fit!
The following steps are used in the shop to create a shop seam, please see the chapter
on installation for additional precautions taken when field seaming.
Using Denatured Alcohol and a clean white rag or white paper towel, thoroughly
clean the seam and the surrounding areas, making sure to remove any ink, pencil,
or dust from the seam and surrounding areas. (do not use paper towel with print or
colored rags as there is risk of the ink bleeding into the adhesive)
Pre-set your seam clamps so that they are easily accessible and ready to apply to
your seam.
Select to proper adhesive color to match the EOS™ color that you are seaming
a. Remove the cartridge cap and set it aside for replacement later
b. Insert cartridge into applicator gun and push plunger forward
Continued in next slide……..
Seaming EOS™
3cm Solid Surface
•
Creating an inconspicuous hard seam (cont.)
3. continued….
c. On a clean rag or paper towel, purge a small amount of adhesive, out of cartridge to insure that
both adhesive and activator are flowing freely.
d. Insert the mixing tip and secure with threaded ring.
e. Squeeze approximately a glue tip’s length of adhesive out to make sure that adhesive and
applicator have time to mix.
f. With the sheets approximately ¼” apart begin applying the adhesive
in a continuous full bead, rest the tip on the top edge of the sheet to allow
the adhesive to flow down the seam surface.
4. Manually push the sheets together, looking for adhesive
squeeze-out along the entire length of the seam, no voids
or dry spots. (do not remove excess adhesive, doing so
could contaminate the seam and starve the seam)
5. Following the mfg instructions apply your seam clamps
(in this application we are using “Gorilla Grips”)
6. Check that your sheets are level and flat at the seam
(this can be done by running a clean razor blade or
tile shim through the adhesive to check levels, once you are
satisfied with seam tighten your clamps.
7. Allow adhesive to cure for 35-45 min
Seaming EOS™
3cm Solid Surface
•
Creating an inconspicuous hard seam (cont.)
4. After 35-45 minutes check to see that adhesive has cured, you
can check this by pushing your thumbnail into adhesive,
your thumbnail should not leave an imprint if the adhesive is
properly cured.
5. Remove the seam clamps.
6. Using a low angle block plane, direct drive rotary sander or
router on skis remove the excess glue bead (do not use a
belt sander! Belt sanders are overkill and can
heat the adhesive up leading to seam failure
and poor appearance.)
Do not use Belt Sander!
Low angle
block plane
Seaming EOS™
3cm Solid Surface
Seaming EOS™
3cm Solid Surface
•
Finishing the seam
1.
2.
3.
Using a random orbit sander with 100 micron abrasive remove the left over
excess adhesive from the seam and level any differences between the
sheets, be sure to feather out the seam area being careful not to create low
spots on the seam.
Once the seam has been leveled and adhesive removed, change to either a
60 micron or Green Trizact pad (wet), making sure to clean the surface
thoroughly
between grits.
Finally finish the seam area to match the
rest of the counter by proceeding to either
a blue Trizact pad (wet) or a maroon ScotchBrite® pad on a 12 inch sander.
(continue to the Finishing EOS section)
Under-mounting
bowls in EOS™
3cm Solid Surface
Under-mounting
bowls in EOS™
3cm Solid Surface
• This Chapter will cover the installation of the two most
common bowl applications with EOS™Solid Surfaces:
– Integrated Solid Surface Bowls
– Under-mount Stainless Steel
Under-mounting
bowls in EOS™
3cm Solid Surface
•
Installing an integrated Solid Surface Bowl:
1.
Using a CNC or Plunge-cut router, cut the proper sized opening for your bowl.
(save the bowl cut-out to be used as cutting board
or the required scrap piece to be left with customer)
2.
Check bowl fit before proceeding to next
step.
Under-mounting
bowls in EOS™
3cm Solid Surface
•
Installing an integrated Solid Surface Bowl:
3. With the bowl dry fit in place, hot-melt glue wood blocks into place around the bowl to
keep it from shifting after adhesive is placed on bowl.
Under-mounting
bowls in EOS™
3cm Solid Surface
4. With denatured alcohol and a clean white rag or white paper towel thoroughly clean the entire
bowl area, making sure to remove all ink, pencil lines, dirt, oil, etc
Under-mounting
bowls in EOS™
3cm Solid Surface
5. With Denatured Alcohol and a clean white rag or paper towel, thoroughly clean the entire bowl
flange, making sure that it is free of dust, ink, pencil, oil etc. If necessary use a clean Scotchbrite®
pad to remove stubborn material from the flange.
(during the cleaning process, be sure to inspect the entire flange for defects)
Under-mounting
bowls in EOS™
3cm Solid Surface
6. Apply a single, generous bead of adhesive around the entire perimeter of the bowl flange.
™ Do not apply a second bead of adhesive, this can act like a gasket and trap air
possibly leading to air bubbles or air pockets in your seam.
™ Use the adhesive that is a match to your bowl color as opposed to the color of the deck surface.
Under-mounting
bowls in EOS™
3cm Solid Surface
Simple bowl clamp that can be created from plywood, threaded rod,
nuts and washers.
(see next page for image of clamp in use)
Under-mounting
bowls in EOS™
3cm Solid Surface
7. Carefully place the bowl onto the sheet, between your glue blocks.
8. Place threaded rod of clamp thru the drain hole and tighten the wing-nut to secure the clamp and
bowl into place.
Under-mounting
bowls in EOS™
3cm Solid Surface
9. Allow Adhesive to cure for 35-45 minutes or as specified by the adhesive mfg.
10. Once adhesive has fully cured spay the hot-melt glue that is securing the wooden blocks
with Denatured Alcohol, allow to soak for approx 30-60 seconds, remove block with chisel
and wipe area dry.
11.Flip the countertop to the upright position and use a combination Router Bit with a Teflon
bearing, mounted in a fixed base router to complete the opening.
12. Using a 5” Random Orbit
palm sander and 100 micron
sand paper, sand the seam
and radius until smooth.
13. Continue to finer pads
to achieve desired finish.
Under-mounting
bowls in EOS™
3cm Solid Surface
• Installing a Stainless Steel bowl under
EOS™
Under-mounting
bowls in EOS™
3cm Solid Surface
•
1.
Installing a Stainless Steel bowl under
EOS™
Using a CNC or Plunge-cut router, cut the proper sized opening for your bowl.
(save the bowl cut-out to be used as cutting board
or the required scrap piece to be left with customer)
2.
Route the desired bevel or radius around the perimeter
of the bowl opening.
3.
Using a 5” Random Orbit
palm sander and 100 micron
sand paper, sand the bowl
opening smooth.
Under-mounting
bowls in EOS™
3cm Solid Surface
4. Apply a bead of clear silicone to the entire flange of the bowl.
Under-mounting
bowls in EOS™
3cm Solid Surface
3. Press bowl into place and use under-mount sink hardware to secure the bowl in place.
(Hardware shown below is available at www.integra-adhesives.com )
Apply epoxy to surface
Smooth epoxy and allow to cure
Press base of stud into epoxy
Secure bowl to stud with
clip and wing nut
Under-mounting
bowls in EOS™
3cm Solid Surface
• Under-mount sink optional hardware
PEEL'N STICK*
UNDERMOUNT SINK
CLIP
Epoxy mounted studs
and clips
There are many systems available on the market, search the
web, tradeshows, and workshops often for the best system for
you.
Finishing EOS™
3cm Solid Surface
The following slides will offer finishing
processes that many fabricators and
the EOS™ Tech Team have found to be
the most efficient, there are many
different processes available on the
market today; regardless of the
process that you choose, the final
project should have a uniform finish
free of scratches.
Finishing EOS™
3cm Solid Surface
•
Tools and supplies needed-
1.
2.
3.
4.
5.
6.
7.
8.
6” random orbit sander with papers (see following pages)
11” or 13” Polisher with pads (see following pages)
Spray bottle with water
Dish soap
Clean rags or paper towels
Water Bucket
Window Squeegee
Low angle lighting
Finishing EOS™
3cm Solid Surface
• Getting started– Fill spray bottle with clean water and add 2-3 drops of dish soap
and shake; you will use this water during the damp sanding steps
in the process, and also to clean our tops between grits (the soap
in the water keeps the water “wet” longer by slowing evaporation,
it also adds slight lubrication to the abrasives)
– Fill your water bucket with clean water and place your squeegee in
it; you will use this to squeegee the used water from the top
between grits (the water in the bucket is to rinse the squeegee;
change when water becomes to dirty)
– Because we are using wet sanding steps, be sure that your
sanders are powered by GFI protected outlets.
– Proceed to next page.
Finishing EOS™
3cm Solid Surface
• Abrasives– 3M™ 100 Micron discs
– 3M™ Trizact™ discs
– 3M™ Scotch Brite™ pads
• Maroon and Grey
– Abralon™ pads
Finishing EOS™
3cm Solid Surface
• Finishing basics–
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Your sander should run at least 6000 OPM (orbits per Min) and a stroke of at least
3/16”.
move the sander “east and west” along the length of the project overlapping each
path by a few inches.
move the sander “north and south” along the width of the project overlapping each
path by a few inches
You MUST clean the top thoroughly between each grit change otherwise you may end
up continuing to grind leftover grits into your top, never achieving a perfect finish
Placing lighting at a low angle, close to the height of the Countertop will produce more
natural lighting and highlight imperfections and swirls in your finish, do not trust
overhead shop lighting as your only light source; natural lighting at the consumers
location can highlight problems, its better to see and fix this in a controlled
environment . See next slide for example of using low angle lighting.
Allow the sander to do the work, do not apply to much pressure to the sander it will
impede the orbital action, slowing the finishing process and possibly creating an
inconsistent finish. (See trick of the trade on following pages)
Hook and Loop papers and discs are recommended over the use of Peel and Stick
(psa). Hook and loop pads will stay on your sander during damp sanding, they are
reusable, and they give a more consistent finish.
Finishing EOS™
3cm Solid Surface
• Using low angle lighting
Finishing EOS™
3cm Solid Surface
• Random orbit sander “trick of the trade”
Place 4 marks on the pads of your random orbital sanders. If you
have light colored pads, use a black magic marker, if you have
dark colored pads, use the old “white out” correction fluid you
can still get at office supply areas.
The marks should be placed evenly at north, south, east, and west
on the pad.
When using the sander with the correct amount of “arm pressure”,
you should see a strobe light effect from the marks.
With too much “arm pressure”, you will be able to see the 4
individual marks.
You will not be getting the true random orbital effect!
Finishing EOS™
3cm Solid Surface
• Different finishes– The following pages will outline the steps needed
to achieve the following finishes:
• Matte Finish- Standard finish in most lighter colors of
EOS™ Solid Surface, preferred finish for high traffic/use
surfaces.
• Semi-Gloss/Satin- Slight gloss that can be seen in low
angle lighting, this finish helps bring depth to darker
colors of EOS™
• High-Gloss- Very sensitive finish that requires constant
maintenance, not recommended for high traffic/use
areas such as Kitchens or reception area (if consumer
insists on this finish it is advised that you educate them
thoroughly and have them sign an acknowledgement that
they know the maintenance required to maintain the finish)
Regardless of the desired finish always clean the project
thoroughly between each grit change!!!
Finishing EOS™
3cm Solid Surface
STEP 4
1.
Use the 100 Micron pads to remove all scratches and excess adhesive.
(this disc is ran dry preferably with a vacuum attachment)
2.
The Green Trizact™ disc is used to produce a uniform Matte Finish.
(keep this pad damp using the spray bottle with soap and water)
3.
The Blue Trizact™ disc is used to create a Matte Finish on darker colors.
(keep this pad damp using the spray bottle with soap and water) (For
light colors of EOS™ you can proceed to step #4)
4.
The Maroon Scotch Brite™ pad is the final step in the Matte Finish
process (keep this pad damp using the spray bottle with soap and water)
(for a swirl free finish an 11”-13” Buffer is the preferred tool)
Finishing EOS™
3cm Solid Surface
1.
Use the 100 Micron pads to remove all scratches and excess adhesive.
(this disc is ran dry preferably with a vacuum attachment)
2.
The Green Trizact™ disc is used to produce a uniform Matte Finish.
(keep this pad damp using the spray bottle with soap and water)
3.
The Blue Trizact™ disc is used to create a Matte Finish on darker colors.
(keep this pad damp using the spray bottle with soap and water)
4.
The Orange Scotch-Brite™ disc will increase the finish from a Matte to a
Semi-Gloss. (keep this pad damp using the spray bottle with soap and
water)
5.
The Grey Scotch Brite™ pad is the final step in the Semi-Gloss Finish
process (keep this pad damp using the spray bottle with soap and water)
(for a swirl free finish an 11”-13” Buffer is the preferred tool)
Finishing EOS™
3cm Solid Surface
1.
Use the 100 Micron pads to remove all scratches and excess adhesive. (this disc is ran dry
preferably with a vacuum attachment)
2.
The Green Trizact™ disc is used to produce a uniform Matte Finish. (keep this pad damp using
the spray bottle with soap and water)
3.
The Blue Trizact™ disc is used to create a Matte Finish on darker colors. (keep this pad damp
using the spray bottle with soap and water)
4.
The Orange Trizact™ disc will increase the finish from a Matte to a Semi-Gloss. (keep this pad
damp using the spray bottle with soap and water)
5.
The White Trizact™ disc is the final step in the High-Gloss Finish process (keep this pad damp
using the spray bottle with soap and water) (for a swirl free finish an 11”-13” Buffer is the
preferred tool)
Finishing EOS™
3cm Solid Surface
• Alternate Finishing systems– Abranet® andAbralon® Finishing pads
Some EOS™ customers have reported very positive results
With this system, you will find many systems on the market
Today, choose the one that gives you the best finish. The
Vacuum sander pictured and the Abranet System have
Preformed well in many shops.
Step One
Finish seams or level repair areas with Abranet®.
Use Abranet® P120 grit (125 micron) abrasive (dry) to
remove surface defects or repair areas.
Finishing EOS™
3cm Solid Surface
• Alternate Finishing systems– Abranet® andAbralon® Finishing pads
Step Two
Surface preparation with Abranet®.
Use Abranet P180 grit (82 micron) to P240 grit
(60 micron) abrasive (dry) to remove scratches and
prepare for final surface finishing.
Step Three
Final finishing with Abralon®.
Use Abralon 360 grit for matte finish.
For a satin finish, continue with 1000 grit.
For a gloss finish, continue with 2000 grit.
Finishing EOS™
3cm Solid Surface
• Solid Surface Sanders
– Random orbit sanders are the only sanders that are acceptable for
finishing EOS™ Solid Surface. Below are many versions of R/O Sanders
available on the market.
Finishing EOS™
3cm Solid Surface
• Conclusion– Finishing EOS™ Surfaces properly is one of the most
important steps in fabrication, great care should be taken in
the shop to ensure that the finish is perfect before
presenting to the consumer.
– It is good practice to pack the finished tops properly for
transport, protecting the finish, wrapping the tops with
cardboard, moving pads, foam wrap, etc will protect the
finish.
– EOS™ Surfaces llc. Does not warranty finishes, it is the
responsibility of the fabricator to provide a proper finish to
the consumer. Unless a problem is determined to be
defective material, ALL finish issues will be referred back to
the original installer.
Installing EOS™
3cm Solid Surface
Installing EOS™
3cm Solid Surface
• Installation requirements–
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The tops of all cabinets or structures must be true within 1/8” of flat surface.
Cabinets or structure must be strong enough to support the weight of EOS™ 3cm
(11.4lbs per sqft)
A minimum inside radius of ½ inch is required on all inside corners.
Aluminum “Heat Conductive” tape must be used around all “Hot” openings i.e. Cooktops, Buffet warmers, pasta boilers, insta-hots, etc.
All “Hot” openings require a minimum inside radius of ½ inch and the top and bottom
edge of opening must be rounded over and sanded smooth.
A color matched piece of EOS™ must be left on the job site for the consumer,
minimum size of piece is 10”x10”.
Use dabs of flexible adhesive, such as silicone, to fasten EOS™ to the structure.
Never rigidly adhere EOS™ to structure.
Never screw directly into EOS™, Brass inserts or surface mounted anchors are
acceptable.
Maximum unsupported overhang is 12”.
Maximum unsupported span is 24”.
An EOS™Care Kit with registration card inside must be left with
the consumer on every install.
EOS™Care Kits are available from EOS Surfaces.
Installing EOS™
3cm Solid Surface
• The installation of EOS™
– As with the fabrication, the simplicity and
thickness of EOS™ 3cm makes the installation
very simple and efficient. By eliminating a lot of
the requirements of ½” solid surface, such as
seam plates, additional substrate, etc, we have
made the process very simple.
– The following slides will give you some pointers
on installation.
– For additional installation guidelines contact
EOS™ Tech Support
Installing EOS™
3cm Solid Surface
• The installation of EOS™
– Adhering EOS™ to the cabinets• Using dabs of flexible adhesive to fasten EOS™
Installing EOS™
3cm Solid Surface
• The installation of EOS™
• Field Seams
– Extra care taken in field
Food Service and
Special
Applications
• Food Service
Food Service and
Special
Applications
• Food Service
– Hot and Cold service area and Cut-out guide lines:
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All openings must be sanded smooth, free of all cuts, kerf marks, router chatter, etc.
All inside corners must have a min. of a ½” radius
All top and bottom edges must be rounded over with a min. of 1/8” radius
All openings must be covered with Heat Conductive tape.
Food heating trays must not be in direct contact with or supported by EOS™ (contact tech
support for detailed drawings)
Food heating trays and or heating elements must not be in direct contact with EOS™
surface.
Heat trivets are recommended during the change-out of hot trays by buffet staff, do not
place hot pans directly on the surface of EOS™
– The surface temperature of EOS™ surfaces should never be allowed to exceed
150 degrees Fahrenheit (66 degrees Celsius). See Heat lamp bulletin on next
page.
– Because of the unlimited food service applications, technical drawings for food
service will be provided by EOS™ tech support upon request.
Food Service and
Special
Applications
• Heat lamps
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Heat lamps can generate extremely high surface temperatures and should
never be used to heat EOS™ surfaces. Most health authorities require food
to be kept a temperature of at least 165 degrees Fahrenheit (74 degrees
Celsius). This should be accomplished by positioning infrared bulb, rod or
wire heat lamps directly over and aimed towards the food. The lamp should
be a minimum distance of 20” (508mm) from the EOS™ surface, both in 2cm
and 3cm applications.
In no case should a heat lamp be placed over a seam in EOS™.
The surface temperature of EOS™ surfaces should never be allowed to
exceed 150 degrees Fahrenheit (66 degrees Celsius).
The use of lamps that produce UV (ultraviolet light) should never be used
over the surface of EOS™ Surfaces.
Due to the thermal expansion that can be caused, under prolonged use heat
lamps, EOS™ surfaces should be given a minimum expansion gap of at
least 1/8” on all sides (for aesthetics, this gap may be filled with a flexible
silicone).
Random testing of the surface should be performed to ensure that the
surface never exceeds the specified temperature of 150 degrees; if testing
proves that the surface is exceeding 150 degrees then the heat source
should be adjusted accordingly.
Food Service and
Special
Applications
• Coved splash
– EOS™3cm solid surface can
be easily converted into
Coved applications thru the
use of many shapers, coving
routers, and techniques in the
market.
– The easiest method is to glue
a ½”x ½” piece of EOS™into
the corner and use a Coving
router to mill out the radius.
Finish the process with some
hand sanding or a cove
sander.
Cove Sander
Coving Router
Food Service and
Special
Applications
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Window Sills
EOS™ 3cm Solid Surface is ideally
suited for window sill applications.
Adhere the sills using flexible
silicone adhesive.
Because of the extreme
temperature ranges in window sills
it is required to leave an expansion
gap of at least 1/8” for sills that are
trapped between walls, this gap can
be filled with color matched
silicone.
Leave a minimum of 1/16” gap
between EOS™ and metal window
frames due to the extreme transfer
of temperature thru these frames.
Food Service and
Special
Applications
• Inlays
– Thru the use of templates and
colored adhesive, you can
create unlimited designs to fit
your customers needs.
– Many aftermarket inlay kits are
available, be sure to follow the
mfg directions for each kit.
Food Service and
Special
Applications
• Drain Boards
– The 3cm thickness of EOS™
Solid Surface allows you
easily create drain-boards
that actually drain.
– Use a template tapered to the
sink edge and a fluting bit to
create the drain-board, finish
by hand, softening all sharp
edges.
– Drain-boards should not
exceed ½ the depth of EOS™
Product
Specifications
• The following pages will cover the product
specification, always visit
www.eos-surfaces.com for updated product
specifications and details.
If you are specifying EOS™ on a project
please click here to go directly to a Word
Document with Product specs.
Spec Document
EOS™ Spec Web Page
Product
Specifications
• Sheets
– 3cm x 121”x 30” …..286 lbs
– 2cm x 121” x 30”…..195 lbs
– Custom sizes and thickness available, call
representative for details.
Product
Specifications
• Solid Surface Bowls
• Colors
– White
– Bisque
Product
Specifications
• Stainless Steel Bowls
– 18 gauge
– Sprayed sound
insulation
– Sound pad under
drain
– Brushed finish
– Undermount only
Product
Specifications
Product NonConformity/Product
expectations
• Document Purpose
– EOS Surfaces is fully committed to the quality of its products.
This document will identify the difference between defective and
usable material. This document can be used by manufactures,
fabricators, and installers to inspect slabs prior to fabrication as
required by the General Terms page of the EOS Fabricator
Agreement. In addition this document will be used as a resource
for field inspections as a part of any warranty claim or dispute
resolution.
– This document identifies non-conformities that may appear
in EOS products when received from our manufacturing
facilities. This document is a reference document only and
is not indicative of the normal quality or consistency of EOS
products.
Product NonConformity/Product
expectations
• Product Description
• EOS Solid Surface is an acrylic/polyester
blended solid surface material sold to material
converters/fabricators for use in the construction
of but not limited to countertops.
• Slab sizes and usable area expectations
• EOS Solid Surfaces are currently available in the
following sizes;
• 3 CM Slabs
2 CM Slabs
30”x 121”
30”x 121”
Product NonConformity/Product
expectations
• Though EOS Surfaces produces slabs to be 100%
usable the are some unforeseen and uncontrollable
events that can occur during the loading, shipping and
offloading process.
• EOS 3 cm slabs can exceed 280lbs each, special care
must be used during the offloading process to prevent
the slabs from colliding with nearby pallets or other
objects that may cause chipping and breakage of the
slabs.
• The following are guidelines used to determine the
difference between acceptable material damage and
material which would require attention from EOS
management
Product NonConformity/Product
expectations
•
The following described damage must be documented and
photographed before the sheets are off loaded by fabricator
personnel. If it is obvious that damage occurred during shipping
please file appropriate paper work with truck driver and forward to
EOS Surfaces for processing.
• Chips
– Chips from the outer, factory saw-cut, edge should
not exceed 1 inch into the width of the sheet.
– Chips from the outer, factory saw-cut, edge should
not exceed 1.75 inches into the length of the sheet.
• Cracked/broken sheets
– Sheets that are broken thru the width of the sheet will
be credited based on the remaining usable area of
the sheet. Digital photos must be submitted for credit.
Product NonConformity/Product
expectations
• Thickness
– EOS slabs are classified as a nominal Thickness of 2.0cm or
3.0cm. EOS slabs do have a tolerance range for each thickness
classification as follows:
• Nominal Thickness
Tolerance
2.0cm
19.5-20.5mm
3.0cm
29.5-30.5mm
• Sheet Contamination/Foreign material
– Materials found in EOS slabs that are determined to be not an
acrylic/polyester solid surface such as; Metal, rubber, wood, etc.
are considered foreign material. If the foreign material cannot be
safely removed and repaired during fabrication it must be
photographed and reported immediately to EOS Surfaces
management.
Product NonConformity/Product
expectations
• Off colored particulate contamination
– Off colored particulate found in the sheet i.e.; black particulate in white
EOS™ should be drilled and filled with corresponding adhesive color
during fabrication.
– Off colored particulate that is determined to be un-repairable should be
photographed and reported to EOS™ management immediately.
– Off colored particulate exceeding the proximity standard of five pieces per
five linear Ft. should be reported to EOS™ management immediately.
• Slab Warp
– Though we take every precaution to avoid slab warp, warping can
occur during shipping and if slabs are stored improperly.
– Slab warp must be reported immediately after it is found during
delivery inspection.
– The following chart outlines the limits of slab warp.
Product NonConformity/Product
expectations
• Warping caused by improper storage of
material in fabricator facility is not covered
by EOS Surfaces.
• NOTE:
– Because of the fact that EOS is a solid surface
material most minor warp can be removed by placing
the slabs on a flat surface in a warm area, the slabs
should go back to tolerance level that can be easily
fabricated and installed.
Product NonConformity/Product
expectations
•
Factory Finish
– The EOS manufacturing facility uses state of the art machinery to create a
consistent finish on the slabs. The finish delivered to the fabricator is a
“Factory finish” it is not a final finish. The fabricator is required to use
standard solid surface finishing steps to create the desired final finish for
their end customer.
– Because of the weight of EOS, slabs can easily be damaged by foreign
material between the sheets. The fabricator should take care in material
handling. The use of vacuum lifters are recommended to minimize
dragging of sheets over one another.
– The machinery used by EOS manufacturing can sometimes cause a
swirling finish effect, this is merely a by-product of the finishing process
and is easily removed by using standard solid surface finishing
techniques.
Warranty
•
Residential 10-year Warranty
– Eos warrants through the fabricator to the original owners of
installed Eos products for a period of ten (10) years from the date
of installation that the Eos material will be free from manufacturing
defects. If a manufacturing defect occurs during the warranty
period, Eos will, at its option, replace the defective Eos products at
no cost to the end user. The fabricator of the countertops reserves
the right to repair the defect in a workmanlike manner should they
judge that the material is repairable.
•
What this Limited Warranty Covers
– Eos obligation under the 10-year warranty covers only the
provision of replacement material for the failed product.
– This limited warranty covers Eos solid surfaces that have been
permanently installed in your residence.
– This limited warranty covers products that have been maintained
according to the Eos surfaces care and maintenance guide
provided free of charge at the time of installation, or upon request,
by the Eos installer or by Eos.
Warranty
•
What this Limited Warranty DOES NOT Cover
– This limited warranty does not cover thermal shock, chemical abuse or
defects by fabrication, misuse or improper fabrication.
– This limited warranty does not cover any additional or supplemental
repairs or modifications, such as tile or wall surface modifications, that
may be necessary to repair or replace the Eos product covered under this
limited warranty; such other repairs and modifications shall be the
responsibility of the customer.
– This limited warranty does not cover products that have not been paid for
in full.
– This limited warranty does not cover uses for products exposed to outside
weather and climate conditions, abnormal use or conditions, or abuse in
any way. “Abnormal use or conditions” includes, but is not limited to,
damage from mishandling or misuse, damage from excessive heat or
uneven exposure to weather conditions, exposure to ultraviolet light,
physical or chemical abuse, and damage from improper care and
maintenance.
– Eos is not responsible for damage or injury caused in whole or in part by
acts of God, job site conditions, architectural and engineering design,
structural movement, acts of vandalism or accidents.
Warranty
• Warranty Registration
– To register for this limited warranty, you or the Eos Authorized
Installer must fill out the warranty registration card or call or write
Eos at the phone number or address below to obtain a
registration form. Or you may register right now.
• To Obtain Service Under this Warranty
•
– To obtain the best service under this limited warranty, contact
the source from whom you purchased Eos. For more information
about this warranty, please contact Eos directly by writing or
calling:
Warranty Registration cards can be
Eos Surfaces
found in the EOS™Care kit
P.O. Box 4146
Portsmouth, VA 23701
Attn: Warranty Department
800-719-3671
Available from EOS Surfaces
Warranty
•
•
•
•
•
In order to obtain service under this limited warranty, you must permit
your Eos Authorized Installer or Eos authorized agents to inspect your
Eos product at your residence. Also, you must reasonably cooperate
with your installer and Eos’ agents in the efforts to service this limited
warranty.
Except as provided in this limited warranty, Eos shall not be liable in
either tort or contract for any loss of direct, consequential or
incidental damages arising out of the use or inability to use the
product in residential applications covered by this warranty. Some
states do not allow the exclusion or limitation of incidental damages,
so the above limitation or exclusion may not apply to you.
Eos makes no other warranty, representation or guarantee, express or
implied, with respect to its products, except as expressly stated
herein. Some states do not allow limitation on how long an implied
warranty lasts, so the above limitation may not apply to you.
This warranty gives you specific legal rights, and you may also have
other rights which may vary from state to state or, in Canada, from
province to province.
This is the only warranty offered by Eos. No one other than Eos is
authorized to make any warranty promise with respect to Eos solid
surfaces.
Thank You!
Your
business is
appreciated