Installation Guide - Compi Distributors Inc.

Transcription

Installation Guide
SS0319 Revised 7/13
Installation Guide
Contents
Introduction02
Safety/Precautions03
Contents
Handling/Storage05
Tools06
Job Planning10
Deck Seams11
Drop Edges14
Sinks18
Cutouts28
Conventional & Cove Backsplash
33
Thermoforming35
Finishing36
Installation38
Commercial43
Repair52
Product Information56
INTRODUCTION
Introduction
Any fabrication procedure or technique not contained within the Wilsonart®
Solid Surface Fabrication Manual will not be recognized by Wilsonart, LLC as
an approved method of fabrication. Deviations from these techniques must be
approved in writing by a Wilsonart Representative.
2
SAFETY/PRECAUTIONS
Safety/Precautions
General, Adhesive, Tooling
General Safety
Safety is a critical concern for any shop and key to a successful business. The following safety rules should be
incorporated into your safety program to help prevent an accident. Safety training, knowledge, product use and
environment is the responsibility of the facility owner and the shop employees.
CAUTION: Always follow product, equipment and/or tool manufacturer’s recommendations and instructions carefully.
• Read directions carefully before fabricating/installing Wilsonart® Solid Surface.
• Read and follow instruction manual before operating the different tools.
• Keep all guards in place and in working order.
• Insure all tools are properly grounded. Never remove the third prong.
• Keep work area clean, uncluttered and well lit.
• Don’t use electric power tools in a damp or wet work area.
• Keep visitors at a safe distance from the work area.
• Use the right tools. Don’t force a tool or attachment to do a job it was not
designed to perform.
• Always use safety glasses or approved eye protection and/or face shield, ear/
noise protectors and safety shoes. (FIG. 3A & 3B)
• Wear the proper apparel, no loose clothing or jewelry.
• Secure all work with the proper clamp or vise to a stable work surface.
• Don’t overreach. Keep proper footing and balance at all times.
• Maintain tools in top condition. Disconnect tools before servicing and when
changing accessories such as blades, bits, cutters, etc.
• Keep and use denatured alcohol, adhesives and materials in a safe, ventilated
place.
•Dust collection should be used when cutting, routing and sanding. Tools should
be used with dust collection at all times.
Figure 3A
Figure 3B
Wilsonart® Hard Surface Adhesive
• Wilsonart® Hard Surface Adhesive is for professional use only. Always follow the
manufacturer’s recommendations and instructions carefully. (FIG. 3C)
Figure 3C
• Warning: This seam kit contains the following hazardous ingredients: Methyl
Methacrylate, Benzoyl Peroxide, and Dibutyl Pathlate. Avoid prolonged breathing
of vapors. Use only in a well ventilated area. Keep out of reach of children. Eye
protection is always recommended. Motors and other equipment used in the
fabrication and installation process must be UL labeled explosion proof.
• For further information refer to Wilsonart® Hard Surface Adhesive Material Safety
Data Sheet available on request. Contact your local distributor or call 1-800-4333222 for immediate response to a question concerning Wilsonart® Hard Surface
Adhesive.
3
SAFETY/PRECAUTIONS
Safety/Precautions
Fabrication
Fabrication
• Do not use lacquer thinner, acetone or other solvents on Wilsonart® Solid Surface material.
• Colored or printed towels can leave a residue which will contaminate the seam material and
cause a weak or stained bond line.
• Refer to the Thermoforming Section when forming or bending Wilsonart® Solid Surface.
Wilsonart® Cityscape Collection are not recommended or approved for Thermoforming process.
Spot heating or cold bending is not approved and will introduce internal stress into the product.
• Thermoforming is not recommended or approved by Wilsonart for the Cityscape Collection,
please contact Wilsonart Technical Service Group at 800-433-3222 for further information.
• All edges should be sanded smooth and free of sharp corners and kerf marks which result in
stress points.
4
HANDLING/STORAGE
Handling/Storage
Handling, Storage, Inspection Selection
• Handling:
Carry Wilsonart® Solid Surface sheets vertically to
minimize flexing.
• Storage:
Store Wilsonart® Solid Surface sheet goods flat on
pallets or other suitable racks. (FIG. 5A)
Store Wilsonart® Sinks in their original shipping boxes
until ready to install. (FIG. 5B)
Store Wilsonart® Hard Surface Adhesive in cool, stable
refrigeration unit. The optimum temperature between
40º F and 60º F. The shelf life of the seam kits will
be greatly increased by refrigerated storage. (Do
Not Freeze). See Technical Data Sheet for additional
information.
Figure 5A
• Inspection:
Every effort has been made to supply high
quality materials, free of defects. However, you
the fabricator, must conduct a final (pre-cut)
inspection for color match, manufacturing defects
or damage to continue the quality control process
prior to fabrication.
• Sheet Selection Process:
Wilsonart® Solid Surface sheets are color matched by
lot numbers only. (FIG. 5C)
Figure 5B
Product information labels containing lot numbers are
adhered to the Wilsonart® Solid Surface panels. The
labels must be included on the Warranty Information
Label, B2B on-line warranty registration or Warranty
Registration Card in lieu of on-line registration.
Wilsonart, LLC requires this information to validate the
10-year installed warranty.
Figure 5C
5
Tools
Tool List
• The following suggested tool list is only a minimum requirement for professional and successful Wilsonart®
Solid Surface fabrication.
• Various woodworking and specialized solid surface fabrication tools are available in the market today. (See the Tool Supplier listing in the appendix).
Stationary Tools
Table or Panel Saw
Miter (“Chop”) Saw
Triple Chip Carbide Saw Blades
TOOLS
Hand & Power Tools
Routers (FIG. 6A)
- 3¼ HP with ½” (13mm) collet
- 3¼ HP Plunge base w/½” (13mm) collet
- 1½ -2½ HP w/½” (13mm) collet (edge details)
Figure 6A
General Router Bits
-½” (13mm) Straight cut
-½” (13mm) Bottom bearing flush trim bit
-1” (25.4mm) Top bearing flush trim bit
-Bottom bearing rabbeting bit
-Various profile bits
Sanders (FIG. 6B)-Random Orbital
-Dust collection system (suggested)
-Sanding Disks (Micron)
-Scotch-Brite® pads
Straight Edges (Phenolic or Aluminum)
Figure 6B
Clamps (FIG. 6C)
Bowl Bits
Contact 800-433-3222 or Wilsonart Technical Service Department for recommended bits.
Wilsonart® HD® Sinks
-Betterly Industries -TB690
½” X 4" Bottom bearing bit
Figure 6C
6
Tools
Tool List
Tools Not Recommended
•Jigsaws – Rout all cutouts. (FIG. 7A)
TOOLS
Figure 7A
•Auger type drill bits – Use hole saw/router for larger holes. (FIG. 7B)
•Belt Sanders – Do not use belt sanders at seam areas. (FIG. 7C)
Figure 7B
•ATB (Alternate Top Bevel) or ripping saw blades.
Use only triple chip or solid surface cutting blades.
(FIG. 7D)
Figure 7C
Figure 7D
7
Tools
Tool Manufacturers
TOOLS
Stationary Tools
•Powermatic 1-800-274-6848
www.powermatic.com
•Holz Her1-704-587-3400
www.holzher.com
•Delta 1-800-223-7278
www.detlamachinery.com
•Striebig1-781-585-4364
www.csaw.com
Hand Tools - Routers, Sanders, Bits, etc.
Router Bits
•Porter Cable 1-888-848-5175
www.portercable.com
•Amana Tool1-800-445-0077
www.amanatool.com
•Beaver Tools 1-800-365-6677
www.beavertools.com
•Velepec1-800-365-6636
www.velepectools.com
• Wesley Tools, Ltd. 1-800-397-6867
www.wesleytools.com
Sanding Equipment
•Fein 1-800-441-9878
www.feinus.com
•Dynabrade1-716-631-0100
www.dyabrade.com
•Festool 1-800-423-3531
www.festoolusa.com
•Master Power1-866-557-8316
www.masterpneumatictools.com
•Surcare 1-800-669-5519
www.surcare.com
•Gem Sander 1-800-447-4436
www.gem-industries.com
Sandpaper / Finishing Pads
Pipe and Bar Clamps
•3M 1-800-742-9546
Scotch-Brite & Trizact
www.3m.com
•Bessey1-800-828-1004
www.americanclamping.com
•Micro Mesh 1-908-788-5550
www.sisweb.com
•Norton 1-800-446-1119
www.nortonabrasives.com
•Mirka 1-800-843-3904
www.mirka-usa.com
•Sia 1-800-459-3534
www.sia-abrasives.com
9
Tools
Tool Manufacturers
Recommended Saw Blades
•
Amana1-800-445-0077
www.amanatool.com
•
Guhdo1-800-544-8436
www.guhdo.com
•
DML 1-800-242-7003
•
Forrest1-800-733-7111
www.dmlwoodworking.com
www.forrestsawblades.com
TOOLS
•
FS Tool1-800-387-9723
www.fstoolcorp.com
•
Leitz1-800-253-6070
www.leitz.com
Misc. Tools
• Fein Power Tools
1-800-441-9878
www.feinus.com
Dustless sanding system
• The Pinske Edge
1-800-874-6753
www.pinske-edge.com
Specialized solid surfacing tools
• Specialty Tools
1-800-669-5519
www.specialtytools.com
•
Perfect Seam1-770-463-8321
Vacuum base seam clamps
Vacuum base seam leveler
www.omnicubed.com
• Betterley Industries
1-800-871-7516
www.betterleytools.com
•
Align-Rite Tool Co.
1-888-624-1942
www.alignritetool.com
Fabrication tools
•A.M.P.S.
www.ampsedge.com
Straight edge
1-800-669-5519
•DeWalt
www.dewalt.com
1-800-433-9258
•Zip Wall
1-800-718-2255
www.zipwall.com
•
Wood’s Power Grip Co.1-800-548-7341
Dust containment
Vacuum base seam clamps
www.powergrip.com
• Sink Setter at Precision Works Sinksetter, Inc.
•Conprotec Inc.
1-603-893-2727
www.mixpac.com
Adhesive despenser repair parts
Sink Setter Brackets
Easy Leveling Shelf and Counter Bracket
www.sinkset.com
1-714-847-3396
10
Job Planning
Countertop Layout
JOB PLANNING
6
Seam
Seam
Radius all
inside corners minimum
1/2" (13mm)
Sink
Seam
1" min
(25.4mm)
Overhang
Offset seams
at least 1" (25.4mm) from corners
Dishwasher
Seam
Cooktop
3" min
(76.2mm)
Place seams no
closer than 3" (76.2mm)
from any cooktop cutout
or dishwasher
3" min
(76.2mm)
Seam
JOB PLANNING
Countertop Layout
PT Seam Locations
Miter Fold, Vertical and Stacked Edges
Figure 10A
Figure 6A
7
JOB PLANNING
Countertop Layout
7
Butt
Seam
3" min
Dishwasher
(76.2mm)
3" min
(76.2mm)
Place seams no
closer than 3” (76.2mm)
or dishwasher
3" min
(76.2mm)
Seam
Place seams no
3" min
closer than 3” (76.2mm)
(76.2mm)
or
dishwasher
Corner Support Block Requirements:
Figure 10B
Figure 7A
Profiles a 1/4" or less require:
• Minimum 1/2" x 1/2" block
Corner
Support
Blockradius
Requirements:
• Minimum
1/2"
inside corner
a 1/4"
or less require:
Profiles Profiles
larger than
1/4"require:
• Minimum
1/2" x 1/2" block
• Minimum
1" x 1" block
• Minimum
inside
corner radius
• Minimum
1" inside1/2"
corner
radius
Cooktop
Seam
Overhang
Minimum ½”inside corner
radius required
See Corner Block
Requirements below
Dishwasher
Seam
Seam
Minimum ½”inside corner
radius required
See Corner Block
Requirements below
Overhang
Si
nk
Butt
Seam
Seam
nk
Si
Butt Seam
Gibraltar® Solid Surface
Earthstone® Solid Surface
02/09/2007
Butt Seam
PT Seam Locations
Miter Fold, Vertical and Stacked Edges
Cooktop
JOB PLANNING
Countertop Layout
Wilsonart® Solid Surface Countertop Layout
Conventional Seam Locations
Conventional
(Figure 10A) & PT Seams (Figure 10B) Locations
Seam
11
Deck Seams
Conventional Seams
Deck Seams–Conventional
•Machine both edges to be seamed. (FIG. 11A)
DECK SEAMS
•Seams should fit tightly when dry fitted.
•Place a release material (such as clear packing tape) under the seam to prevent contamination of deck seam.
•Thoroughly clean areas to be seamed with denatured alcohol using clean white shop rag.
•Position sheets to be seamed 3/16” (4.8mm) to 1/4” (6.4mm) apart.
Figure 11A
•Prepare clamping materials
•Prepare seam kits.
Purge cartridge & tip to ensure proper mixture of
adhesive.
•Fill the seam to 1/2 full.
Damming the ends will make this easier.
•Slide the sheets together. Make sure there is
adhesive squeeze out along entire seam.
Figure 11B
•Clamp the seam together using bar or spring clamps.
(FIG. 11B)
•DO NOT OVERTIGHTEN clamps.
Over tightening will cause starved, weak seams.
•Remove adhesive squeeze out with router on “skis,” surface leveler, or random orbital sander.
(FIG. 11C)
Do not scrape, chisel or use belt sander on seam.
•All seams must be reinforced with a 4” (101.6mm) wide, 45° beveled Wilsonart® Solid Surface seam support adhered to the back of the panel. (FIG. 11D)
Reinforcement strip must be sanded smooth.
Reinforcement strip must cover length of seam.
Overlap seam support 2” (50.8mm) on each side.
Ensure complete adhesive coverage.
Figure 11C
•Sand the finished seam to job specifications.
(See Finishing Section, pages 36-37)
Figure 11D
12
Deck Seams
PT Seams
DECK SEAMS
Deck Seams–PT Seam
This method can be used with miter fold, vertical and
stacked edges. (See pages 14 & 15)
•Machine all edges to be seamed. (FIG. 12A)
•Thoroughly clean areas to be seamed with denatured
alcohol using clean white shop rag.
•Prepare clamping equipment.
Figure 12A
•Prepare seam kit.
Purge cartridge and tip to ensure proper mixture of
adhesive.
•Apply two 3/16” (4.8mm) beads of adhesive on the
edge of one panel to be seamed. (FIG. 12B)
Apply sufficient adhesive which will cover entire
drop edge and allow squeeze out along entire seam.
•Clamp the seam together. (FIG. 12C-12D. See page 9
for tooling information)
•DO NOT OVERTIGHTEN clamps.
Over tightening will cause starved, weak seams.
Figure 12B
Figure 12C
Figure 12D
13
Deck Seams
DECK SEAMS
PT Seams
• Adhere a Wilsonart® Solid Surface block into the inside corner and clamp in place. Block must cover entire length of seam from top of deck to bottom of drop edge. (FIG. 13A)
See page 16 for minimum requirements.
Squeeze out is required on both top and bottom of the seam and all sides of the corner block.
• Remove adhesive squeeze out with router on “skis,” surface leveler, or random orbital sander.
(FIG. 13B)
Figure 13A
Do not scrape, chisel or use belt sander on seam.
• Rout radius at inside corner. (See page 16 for
minimum requirements. (FIG. 13C)
• To accommodate face frame installs, a 1” minimum seam thickness is required over cabinet base, thus eliminating notching the cabinet base. (FIG. 13D)
• Sand the finished seam to job specifications.
(See Finishing Section, pages 36-37)
Figure 13B
Figure 13C
PT Seam For Faceframe Install
Support Block
No seam allowed in
front edge, radius
all corners at height
transition
Drop
Drop
Edge
Edge
Underside of Countertop
Figure 13D
14
Drop Edges
Stacked
Drop Edges - Stacked
• See page 15 for drop edge requirements for Melange, Sonata, Crystal, Riverstone Cityscape and Earthstone patterns.
DROP EDGES
• Sand backside of areas to be seamed.
• Dry fit edge strips and fasten hot melt blocks.
(FIG. 14A)
• Clean surfaces to be seamed thoroughly with
denatured alcohol and clean white shop rag.
• Purge cartridge and tip to ensure proper mixture of
adhesive.
Figure 14A
• Apply Wilsonart® Hard Surface Adhesive and clamp with spring
clamps at 2” - 3” (50.8 - 76.2mm) intervals.
(FIG. 14B)
• Make sure there is adequate glue squeeze out along
entire seam.
Check carefully for voids.
Figure 14B
• Do not sandwich other materials (wood, metal,
laminate, etc.) between Wilsonart® Solid Surface
edges. Use these type of inlays in a routed groove.
• Flush trim drop edge. (FIG. 14C)
• Rout requested edge profile.
Figure 14C
15
Drop Edges
Vertical
Drop Edges - Vertical
DROP EDGES
•Wilsonart® Solid Surface Solids, Global Gourmet, Global Spa, Crystal, Tempest and Mirage patterns - vertical and rebated vertical edge approved. (FIG. 15A-15C)
•Wilsonart® Solid Surface Melange, Spectra and Riverstone
patterns - vertical drop suggested with a 1/16" rebate. (FIG. 15A-15C)
•Wilsonart® Solid Surface Cityscape, Earthstone and Sonata patterns - rebated vertical edge required. (FIG. 15A-15C)
• Alternative Method: Miter Fold Drop Edge.
Figure 15A
Vertical Edge Fabrication • Inspect the edge of the Wilsonart® Solid Surface sheet for chip
distribution variation.
• Dry fit edge strips.
• See Both Edges below for remaining steps.
Rebated Vertical Edge
• Using a bottom bearing rabbeting bit or a router
with a straight edge, rout a 1/16” deep by 1/2”
wide rabbet into the bottom side of the sheet.
Amana, Superabbet™ part number 49360
For a Bull Nose, route a 1/16” deep by 1” wide
rebate to accept a double vertical stack. (FIG. 15D)
Pinske Rabbeting Solutions (See page 9 for details)
Figure 15B
Both Edges
• Clean surfaces to be glued thoroughly with denatured
alcohol and clean, white shop rag.
• Purge cartridge and tip for proper adhesive mixture.
• Apply Wilsonart® Hard Surface Adhesive and clamp with spring
clamps at 2” - 3” (50.8 - 76.2mm) intervals.
• Make sure there is adequate glue squeeze out along
entire seam.
Check carefully for voids.
Figure 15C
Figure 15D
16
Drop Edges
Inside/Outside Corners
DROP EDGES
Inside Corners
• Inside corners are subject to higher stress and
therefore, require special reinforcement.
dge
ed E
k
Stac
• One of the following reinforcement procedures must be used.
Corner block method: minimum 3” (76.2mm) x 3” (76.2mm) block. (FIG. 16A)
Vertical strips method: Corner block.
Figure 16A
(FIG. 16B)
Interlocking corner block method.
Solid Surface Deck
• The finished inside corner must be routed to a
minimum 1/2” (13mm) radius.
A larger radius is better.
1/2" x 1/2"
Support Block
1” Support Block
Outside Corners
• This method may be used up to 9” radius, requiring
1–3 strips placed on the angle. (FIG. 16C)
Min 1”radius for
1/4" or less profiles
Min 1”radius for
profiles larger than 1/4”
• For a radius larger than 9” refer to the Thermoforming Figure 16B
Section on page 35.
Figure 16C
17
Drop Edges
Miter Fold Drop Edges
Miter Fold Drop Edges
DROP EDGES
Wilsonart® Hard Surface Adhesive
• Place Wilsonart® Solid Surface face down on a solid, flat work surface.
• Remove corner block and trim hinge tape.
Hinge Tape
• Clean miter area thoroughly with denatured alcohol and clean with white shop rag.
• Apply a 1/16” bead of Wilsonart® Hard Surface Adhesive in
the entire length of the miter fold seam. Also apply
a 1/16” bead at one corner to be folded. (FIG. 17A)
Figure 17A
• Fold up drop edge and clamp into place. Cam action clamps are suggested. (FIG. 17B)
Clamps should be within 2" (50.8mm) from each corner and located every 12" (304.8mm).
Place clamps 1/4" (6.4mm) above the face of the panel to ensure proper pressure.
NOTE: Once drop edge is folded into place, do not allow the edge to separate from the deck.
Figure 17B
• Fold up the end caps and secure in place with spring clamps or 3 way clamps. Clamps should be placed every 2” (50.8mm). (FIG. 17C)
Place 3 way clamps 1/4” (6.4mm) above the face of the panel.
• Adhesive squeeze out is required along entire length of seam and at all corners.
• Allow seam adhesive to cure completely before machining.
Figure 17C
18
S I N K I N S TA L L AT I O N
Sinks
Sink Installation
Product Description –
Wilsonart® Solid Surface Sinks
Wilsonart® Solid Surface Sinks and Bowls are specially
shaped solid surface products commonly used as kitchen
sinks, bar sinks, and lavatory bowls. They may be bonded
to Wilsonart® Solid Surface panels with Wilsonart® Hard
Surface Adhesive to create a seamless appearance for
aesthetic appeal and easy maintenance.
Composition of the Product: The product is
composed of a proprietary mixture of resins and minerals.
Wilsonart® Sinks and Lavatory bowls are completely
homogeneous. The full-toned color has a consistent, uniform
pigment throughout the thickness of each bowl.
Wilsonart® HD® Sinks
Wilsonart® HD® Sinks are molded acrylic sinks and bowls
commonly used as kitchen sinks and lavatory bowls. They
®
may be bonded to Wilsonart® HD® Laminate and Wilsonart® Wilsonart Solid Surface Sink
Solid Surface with appropriate Wilsonart® Seam Adhesive to
create a seamless flow from countertop to basin.
Composition of the Product:
The product is composed of a 100% acrylic surface
combined with a fiber reinforced polymer (FRP)
backer. Wilsonart® HD® Sinks have a complete hygienic
surface that contains no fillers. This surface provides
superior resistance to stains, heat, impacts, bacteria,
scratches and thermal shock.
Wilsonart® HD® Sinks are not color matched to any solid
surface sheets in the Wilsonart® Solid Surface line. There will
be a slight variation in color when Wilsonart® HD® Sinks are
bonded to a solid color design in the Wilsonart® Solid Surface
line. This is considered normal and not a color issue.
Wilsonart® HD® Sink
Wilsonart Durasteel Sinks
®
™
Wilsonart® Durasteel™ Sinks and Bowls are specially
shaped stainless brush polished products commonly used as
kitchen sinks and bar sinks and lavatories. They are ideal for
Wilsonart® Laminate and Wilsonart® Solid Surface, as well as
granite, engineered stone and other countertop surfaces.
Composition of the Product: The product is
composed of 304 series alloy stainless, featuring the
highest quality 18/10 chrome-nickel formulation. Wilsonart®
Durasteel™ sinks and lavatory bowls have a complete
hygienic, rust-free, and extremely durable surface that is
made from heavy-duty, 18 or 20 gauge, non-porous material.
Wilsonart® Durasteel™ Sink
19
Sinks
Sink Installation
Wilsonart Solid Surface
Sink Installation Preparation
®
• Inspect sink for imperfections and verify color.
• Identify location
• Position sink using center-line dimensions.
(FIG. 19A)
Note: Integral Wilsonart® Sinks may be mounted
over a seam using the same techniques listed below.
Integral in conventional or PT Seams. (FIG. 19B)
Figure 19A
Conventional Seams
• Multiple bowl configurations are permitted;
however, special reinforcement guidelines are
required. (See Installation Section, page 38-41)
• Place wooden blocks with hot melt glue to position
sink securely during glue up. (FIG. 19C)
• Rout hole in countertop directly under sink drain hole.
Note: Make sure hole is large enough for pipe clamp.
• Thoroughly clean areas to be seamed with denatured
alcohol using a clean white shop rag.
4" bevel seam
support required for
length of seam
Figure 19B
Figure 19C
20
Sinks
Sink Installation
• Apply ample amount Wilsonart® Hard Surface Adhesive to
sink rim. (FIG. 20A)
• Clamp with pipe clamp through the drain hole.
(FIG. 20B)
Note: Use wooden spacers under clamp at sink flange and drain hole to prevent damage.
Note: Use clamp board (larger than the sink) under countertop to distribute clamping pressure.
Figure 20A
• Check for seam kit squeeze out around entire sink area.
• Remove pipe clamps after seam adhesive hardens.
• Rout sink opening(s) using:
Bowl flush trim bit (FIG. 20C)
Bowl profile bit (FIG. 20D)
See pages 8, 9 for Tool Manufacturers
• Sand inside of sink for proper finish (See Finishing Section, pages 36 & 37).
Note: Wilsonart® Solid Surface Sinks must be sanded to provide consistent finish. Failure to finish sinks
often leads to customer dissatisfaction.
Figure 20B
• Wilsonart® Solid Surface vanity sinks are equiped with
activated overflows. They are also available with
non-overflow by special order.
Figure 20C
Figure 20D
21
Sinks
Sink Installation
Recommended Fabrication Steps and Tooling
for HD® Sink/Bowl into a Solid Surface Top
Step #1: Make an outside template to remove center section sink
area in countertop.
•The template material should be constructed of flat, sturdy
material such as ¾” particle board.
•Pencil alignment cross hairs on the center of the template
material, both vertical and horizontal alignments.
•Place the bowl face down on the template material; align
registration marks on the sink with the pencil cross hairs.
•Using a pencil trace the outline of the sink leaving a 1/8” gap
between the pencil line and the flange of the sink.
Step #2: Using the maximum width dimension of the sink flange,
measure and pencil in a line inside of the previous one.
•Add ¼” for excess overhang (total approximately 1 ¼” ).
•Cut along the inner line drawn on the particle board using a
jig saw, thus creating an outside template of the sink.
Step #3: Take the outside template and clamp it to the top of the
solid surface where the sink is to be mounted.
•Use a 3 1/4 HP plunge router with a top bearing flush trim bit to
cut out the center section of solid surface.
•Make sure the bit is set to a depth to cut completely through the
solid surface and the bearing is riding along the template.
Figure 21A
Step #4: Flip top over and position the sink so there is ¼” of solid
surface extending past the sink flange.
•Hot melt blocks around the sink flange for positioning of sink.
•Remove the sink from countertop.
Step #5: Clean the top of the sink flange and solid surface with
denatured alcohol.
•Apply one 3/16” bead of Wilsonart® Hard Surface Adhesive 1/8”
from inside edge of sink flange.
•Place the sink in the cutout and use a pipe clamp for adequate
pressure.
Step #6: Once adhesive is cured, flip top over to finish routing.
•Use a 1 ¾ HP tilt base router from Betterley Tools (#TB690) with a Figure 21B
½” X 4” bottom bearing, double fluted flush trim bit to remove the
solid surface over the sink. (Figure 21 A and 21B)
•Set the angle of the base at approximately 35˚ to 40˚ for the first
pass and 45˚ to 50˚ for the second pass.
•Remember to set the bearing to run along bevel of sink and to
twist the router base in the corners to properly follow the radius
and eliminate router chatter.
Step #7: Sand the edge of the solid surface and sink wall with a
random orbital palm sander.
• Use 150 to 220 grit sandpaper.
• Finish sanded area with a gray 3M Scotch-Brite pad.
• Drill marked over flow with a 3/8” drill bit.
•Ease sharp edge of hole with 80 mic. or equivalent
sand paper.
22
Sinks
Sink Installation
Durasteel™ Undermount Sink Installation
Suggested Materials:
There are various methods to attach a Durasteel undermount sink to a hard surface countertop. Wilsonart suggests the
following materials and tools for conventional fabrication to
supply a properly installed stainless steel sink.
Sink Clip
For automated routing equipment, please visit the Wilsonart
B2B website or contact your local Wilsonart distributor
representative for Durasteel sink DXF files.
Materials
Support clip (FIG. 22A)
Sink clip base plate and wing nut (FIG. 22A)
- www.rotaloc.com
- www.specialtytools.com
100% Clear Silicone (FIG. 22B)
Seam Kit dispensing gun (FIG. 22B)
Tooling
Routers (FIG. 22C)
- 31/2 HP with 1/2” (13mm) collet
- 11/2 HP with 1/2” (13mm) collet
General Router Bits (FIG. 22C)
- 1” (25.4mm) Top bearing flush trim bit
- Round over bit ¼” (13mm) max.
Jig Saw (FIG. 22D)
Sanders
- Random Orbital (FIG. 22D)
- Dust collection system (suggested)
- Sanding Disks (Micron)
- Scotch-Brite® pads
Clamps
NOTE: You may require different, more specialized tools to
install this sink to countertop materials other than Wilsonart®
Solid Surface. Refer to countertop material manufacturers
recommendations.
Sink Clip Base Plate
Figure 22A
Figure 22B
Figure 22C
WARNING: When using electrical tools, please use caution to
prevent electrical shock.
CAUTION: Always follow product, equipment and tool
manufacturer’s recommendations and instructions carefully.
Figure 22D
23
Sinks
Sink Installation
™
Durasteel Undermount Sink Installation
Before You Begin
• Please refer to the Wilsonart® Durasteel Sink Warranty for complete coverage details.
• Observe all local plumbing and building codes.
• Prior to installation, unpack the new sink and inspect it for
damage. Return the sink to its carton until you are ready to install it.
• Plan the sink installation so future removal from underneath the countertop is possible without damaging the countertop.
• Multiple-bowl installations
A minimum distance of 3 3/8” (8.6 cm) is required between the cutouts.
Additional countertop support is required between multiple-bowl installations.
Sink Template (Conventional Fabrication)
TEMPLATE
MATERIAL
SINK LOCATION
REFERENCE LINES
Figure 23A
REVEAL OPTION
AFTER PERFORATED EDGE OF
PAPER TEMPLATE IS REMOVED
SINK
1 "
8
FLUSHMOUNT OPTION
ORIGINAL OUTER EDGE OF
PAPER TEMPLATE
• The template should be constructed of flat, sturdy material such as MDF or phenolic board.
• The length and width should be sized to adequately support a 3 1/4 HP router.
• Pencil alignment cross hairs on the center of the template Figure 23B
material.
Include both vertical & horizontal alignment marks. (FIG. 23A)
• Using the paper template provided in the sink box, select type of cutout desired. (FIG. 23B)
Flushmount installation, use paper template as provided.
Reveal type installation, remove the perforated outer edge.
• Align paper template with penciled cross hairs on the MDF or phenolic board template material and trace outer edge. (FIG. 23C).
• Cut along the penciled outline of the cutout. (FIG. 23D)
• Using 100 micron (150 grit) sand paper, smooth the edges Figure 23C
of the template.
SINK
S IN
K
CO
S CR
F AS
EW
S
U NT
ER
TO
P
TE
NE
R
U se
U se ou ts
ou ide lin
tsi de
e
U se
line for re
ve
fo r
Us ou ts
re ve al m
e ou ide
ou
al
tsi de line
mou nt cu
t:
line for re
nt
ou
c ut
ve
fo r
ts id
:
re ve al m
e lin
a l m ou nt
e fo
cu
ou
r re
nt c t:
ve al
ut:
m ou
nt
cu
t:
U se
ALIGNMENT
MARKS
CUTOUT
Figure 23D
24
Sinks
Sink Installation
™
TEMPLATE
MATERIAL
SINK
Sink Cutout
• Locate where sink is to be installed on the top side of the
countertop and draw reference lines. (FIG. 24A)
LOCATION
• Align the cross hairsSINK
of the
sink cutout template with the
REFERENCE LINES
reference lines on countertop.
Fasten template securely to the countertop.
• Index a 3 1/4 HP or 2 1/2 HP plunge router with a 1” x
1”1/2” top bearing flush trim router bit. (FIG. 24B)
• Rout along templates in the direction indicated.
(FIG. 24B)
• Once completed remove sink cutout template.
• Profile top side of cutout.
REVEAL OPTION
AFTER PERFORATED EDGE OF
radius
for 1/2” thickness.
Do not exceed 1/4” PAPER
TEMPLATE IS REMOVED
• Sand the edge of1 the cutout with a random orbital sander.
8"
(FIG. 24C)
FLUSHMOUNT OPTION
ORIGINAL OUTER EDGE OF
Begin with 180 grit (80u micron)
PAPER TEMPLATE
Continue with
220 grit (60u micron)
SINK
Keep sander moving to minimize the chance of dips
or over sanding one area.
• Finish sanded area with a gray 3M® Scotch-Brite™ pad.
Use only light to medium pressure in a
circular motion.
• Flip countertop over facing down.
COUNTERTOP
SINK LOCATION
REFERENCE LINES
Figure 24A
Top Bearing
Flush Trim Bit
Figure 24B
S IN
K
CO
S CR
F AS
EW
S
U NT
ER
TO
P
TE
NE
R
U se
U se ou ts
ou ide lin
tsi de
e
U se
line for re
ve
fo r
Us ou ts
re ve al m
e ou ide
ou
al
tsi de line
mou nt cu
t:
line for re
nt
ou
c ut
ve
fo r
ts id
:
re ve al m
e lin
a l m ou nt
e fo
cu
ou
r re
nt c t:
ve al
ut:
m ou
nt
cu
t:
U se
ALIGNMENT
MARKS
Figure 24C
CUTOUT
25
Sinks
COUNTERTOP
Sink Installation
™
Sink Installation
• Position and align sink over sink cutout.
• Locate sink clip bases around perimeter of sink flange and mark location with pencil. (FIG. 25A)
Equally space sink clip base plates along length
and width of sink flange.
Locate base plates to allow sink clips to contact
center of sink flange or closer to the sink well.
SINK LOCATION
REFERENCE LINES
• Clean under side of countertop around sink perimeter
with a nonabrasive cleaner. (FIG. 25B)
For solid surface use denatured alcohol and clean
white cloth.
Do not use lacquer thinner, acetone or other solvents.
Colored or printed towels will contaminate the seam
material and cause a weak or stained bond line.
For stubborn residue use a Scotch-Brite® pad and
denatured alcohol.
Figure 25A
• Apply Wilsonart® Hard Surface Adhesive where base plates
were marked. (FIG.25C)
• Place sink clip base plates into Wilsonart® Hard Surface
Adhesive. (FIG. 25D)
Insure Wilsonart® Hard Surface Adhesive completely
covers base plate.
Apply additional Wilsonart® Hard Surface Adhesive as
necessary to cover entire base plate.
• Allow adhesive to cure completely before continuing.
Figure 25B
WA
H
ard
Sea
mA
dhe
s
ive
Figure 25C
Figure 25D
26
Sinks
Sink Installation
Durasteel™ Undermount Sink Installation
Sink Installation
• Clean top of sink flange with denatured alcohol and clean white cloth.
Make sure the surface is smooth, clean and free of defects. (FIG. 26A)
• Apply a generous bead of 100% clear silicone to the top surface of the sink rim. (FIG. 26B)
To insure adequate seal, apply sufficient silicone to allow squeeze out around inside and outside sink perimeter. Figure 26A
• Reposition and align sink over sink cutout.
• Check the alignment of the sink with the cutout. Then securely tighten the clamps. (FIG. 26C)
Only hand tighten.
• Wipe away any excess silicone, and fill any voids as
needed.
• Allow the silicone to cure before proceeding.
Figure 26B
Figure 26C
27
Sinks
Sink Installation
General Sink Cutout Requirements (Porcelain, Granite, Cast Iron, etc...)
Helpful Tools
• Drill with 3/8” drill bit
• Jig Saw
• Long shank slotted screwdriver
• Pencil
• Caulking gun with 100% silicone
• 150 Grit sandpaper
• Safety glasses
• 3 1/4 HP Router
• 1" Flush Trim Bit with Top Bearing
• Refer to SINK MANUFACTURER’S INSTALLATION INSTRUCTIONS.
• All cutouts for all types of sink applications mounted in Wilsonart® Solid Surface must be routed using the correct
template (see Sink Manufacturer’s template recommendations/instructions).
• For undermount, profile top side of cutout and ease bottom side of cutout with random orbital sander
Do not exceed 1/4” radius for 1/2” thickness.
For self-rimming / top-mount applications ease top and bottom of cutout and sand with random orbital sander.
Minimum 1/4” or larger radius is required.
Support clips are required for all undermount sink applications with Wilsonart® Solid Surface.
Sink clip base, clip and wing nut are recommended
- www.rotaloc.com
- www.specialtytools.com
Adhere sink base clip to Wilsonart® Solid Surface using Wilsonart® Hard Surface Adhesive
Adhere sink to Wilsonart® Solid Surface using 100% clear silicone or refer to other sink manufacturer’s recommendation.
When installing heavy sinks such as cast iron, granite, etc., additional support is required.
Wilsonart® Solid Surface countertops with top mount/drop in-sink require adequate support.
Wilsonart® Solid Surface countertops with undermount sink applications require additional support for the bowl application within the cabinetry. For example, sink setters, wood support frame, etc. Support system must support entire sink.
28
Cutouts
Cutouts - General
General Cutout Requirements
CUTOUTS
These procedures are for cutouts that do not involve heat generating/producing appliances or items. See Cooktop
Cutout requirements on page 29-32 for cutouts involving heat generating items installed in or over a cutout.
• Cutouts must be performed with a router only.
12" x 12" or larger cutouts must be left on job site for color match repair material.
Secure cutouts to inside of sink base cabinet.
• Inside corners of all cutouts must be radiused.
Use 1/2" (9.5mm) or larger diameter bits.
See page 29-32 for Cooktop Cutouts requirements.
• Round over top and bottom edges of cutouts a minimum 1/16" (1.5mm) radius.
• Remove any roughness, nicks and/or router “chatter” with 150-grit (80 micron) or finer sandpaper.
• Allow at least 1/8" (3mm) clearance space on all sides for drop-in sinks.
• Allow at least 1/16" (1.5mm) clearance space on all sides for outlets.
• Web supports required within 3" (76mm), but no closer than 1" (25mm) from the edge of the cutout.
29
Cutouts
Cooktop Cutouts
Cooktop Cutouts
Cooktop
Adhere cutouts to inside of sink base cabinet.
• Inside corners of all cutouts must have a minimum
radius of 1/4” (6.4mm). (FIG. 29C)
• Corners of cooktop cutouts must be reinforced with 5”x 5” (128.5mm x 128.5mm) 45º beveled Wilsonart® Solid Surface corner blocks. (FIG. 29B & 29C)
Wilsonart® Solid Surface Countertop
9 mil Aluminum
Heat Tape
Figure 29A
mm"
• Roundover top and bottom edges of cutout minimum 1/16” radius and ease all edges of reinforcing blocks.
• Sand sides of cooktop cutout to be free of roughness, nicks and router “chatter” with minimum 150-grit or finer sandpaper.
• Wrap entire cooktop opening with Wilsonart® 9 mil aluminum heat reflective tape.
Place an additional layer of tape at all corners.
Inform cooktop installer that tape must not be removed.
Nomex® will assist with heat resistance.
Minimum
1/4" gap
5 (128.5
CUTOUT
• A minimum 1/4” (6.4mm) gap is required between edge of cutout and cooktop. (FIG. 29A)
5 (128.5mm"
Figure 29B
• Do not fold tape under the bottom of the cutout. (FIG. 29A)
Inside corners of all
cutouts must be radius minimum 1/4” (6.4mm)
• Tape must extend past the edge of cooktop flange. Trim excess (FIG. 29A & 29D)
• Never fasten cooktop to Wilsonart® Solid Surface with mechanical fasteners.
Use a wood block between Wilsonart® Solid Surface and cooktop fasteners.
Figure 29C
If minimum cutout dimension listed above cannot be met, follow requirements for cooktop mantle or stainless steel ring.
Figure 29D
30
Cutouts
Cooktop Mantle
Cooktop Mantle / Stainless Steel Ring
The following procedures are required in the event the
minimum 1/4” gap specification between the cooktop (heat)
box and the edge of the cutout cannot be met. (FIG. 30A)
• Minimum 1/2” (13mm) clearance required on all sides of the cooktop (heat) box.
• Minimum 1/2” (13mm) radius is required at inside corners of cutouts.
A larger radius if possible is preferred.
Minimum
1/4"
Figure 30A
mm"
• Corners of cooktop cutouts must be reinforced with 5”x 5” (128.5mm x 128.5mm) 45º beveled Wilsonart®
Solid Surface corner blocks. (FIG. 30B)
• Roundover top and bottom edges of cutout minimum 1/16” radius and ease all edges of reinforcing blocks.
• 1/2” (13mm) Wilsonart® Solid Surface cooktop mantle requires: (FIG. 30C)
Minimum 1-1/2” (38.1mm) width. (FIG. 30D)
Roundover all top and bottom edges minimum
1/16” radius. (FIG. 30D)
Rectangular rings should consist of four pieces mitered or butt jointed with silicone only. (FIG. 30C)
Round cutouts should consist of a two or four piece ring. (FIG. 30C)
If Stainless Steel Ring is used: 1/16”–1/8” (6.4mm) gap between ring and cooktop (heat) box.
Wilsonart® Solid Surface Countertop
Minimum
1/4"
9 mil Aluminum
Heat Tape
5 (128.5
CUTOUTS
Adhere cutouts to inside of sink base cabinet.
1/16" - 1/8" Gap
Cooktop
5 (128.5mm"
Figure 30B
Figure 30C
• Rout profile on edge of ring and ease inside edges. (FIG. 30D)
Profile Outer Edge
Ease Bottom Edge
1/16"–1/8" (6.4mm)
1 1/2" (38.1mm) Min
Figure 30D
31
Cutouts
Cooktop Mantle
Cooktop Mantle
CUTOUTS
• Adhere the cooktop mantle to the Wilsonart® Solid Surface using a continuous bead of silicone
and clamp in place with spring clamps until silicone has cured. (FIG. 31A)
Do not hard seam mantle.
• Apply Wilsonart 9 mil aluminum heat reflective tape around entire mantle. (FIG 31B)
Figure 31A
Ensure tape is in place after cooktop is installed.
®
Tape should hang straight down, do Wilsonart Solid Surface
Countertop
not fold under countertop.
1/16" - 1/8" Gap
Tape must extend past the edge of cooktop flange and be trimmed after cooktop installation.
Do not attach cooktop to ring with 9 mil Aluminum
mechanical fasteners.
Heat Tape
Apply a second piece of heat reflective tape in all corners to ensure adequate coverage.
Nomex® insulation can be used to ensure Figure 31B
added protection against excessive heat. (FIG. 31C)
Cooktop
Minimum
1/2"
Cooktop
1/16" - 1/8" Gap
9 mil Aluminum
Heat Tape
Nomex
Minimum
1/2"
Figure 31C
32
Cutouts
Cooktop Alternatives
Tile Cooktop Border
• Minimum 2” x 2” (50mm x 50mm) tile is required for this type of installation.
• Cutout must be performed with a router only.
Secure cutouts to inside of sink base cabinet.
CUTOUTS
• Opening must be large enough to accommodate the tile and tile support.
• Minimum 1/16” (1.5mm) gap is required between edge of cutout and the tile and tile support. • Inside corners of the cutout require minimum 3/16” radius (4.5mm).
• Roundover top and bottom edges of cutout minimum 1/16” radius.
Installation
• Attach necessary wood supports to cabinet base.
Must be level/flat
• Install Wilsonart® Solid Surface countertop per approved techniques.
• Install tile per the manufacturer’s installation procedures.
• Fill 1/16” gap between cutout and tile with silicone.
NOTE: Wilsonart® Solid Surface 10-year Residential Installed Limited Warranty does not include the tile or tile installation.
33
CONVENTIONAL BACKSPLASH
Conventional
Backsplash
Backsplash
• Use 100% silicone to adhere backsplash to countertop and wall.
Apply continuous bead to bottom of backsplash (FIG. 33A).
Dots of hot melt adhesive can be used to adhere backsplash to the wall while silicone cures.
• Remove excess silicone squeeze out, leaving only a small inside corner bead. (FIG. 33B)
Figure 33A
• On full height backsplash, apply all Wilsonart® Solid
Surface fabrication guidelines. (FIG. 33C)
1/4” (6.4mm) radiused inside corners
Space for expansion
Offset seams
Cutouts must be made with a router (FIG. 33C)
Attach backsplash with silicone. Do not
hard seam to countertop.
Figure 33B
Figure 33C
34
COVE BACKSPLASH
Cove
Backsplash
Cove Backsplash
• Cut Wilsonart® Solid Surface backsplash to desired height. (FIG.34A)
Allow 7/16” (11.3mm) for cove strip.
(FIG. 34A)
• Cut a 7/8” (22.23mm) strip for coving. (FIG.34A)
Bevel 7/8” (22.23mm) cove strip on a 45° angle.
This will reduce router chatter.
Backsplash
Cove Strip
• Cut 7/8” (22.23mm) x 1/16” (1.6mm) rebate into the Wilsonart® Solid Surface deck to accept cove strip.
(FIG. 34A)
Figure 34A
• Clean with denatured alcohol and clean white cloth.
7/8" Rebate
• Adhere cove strip and backsplash to countertop with Wilsonart® Hard Surface adhesive.
100% coverage is required.
Backsplash squaring block (FIG. 34B)
• Ensure cove strip is tight against front edge of rebate and clamp with spring clamps and bar clamps.
Squeeze out is required the entire length of all seams.
• After adhesive has cured completely, rout cove strip.
(FIG. 34C)
Figure 34B
• Sand to desired finish.
Figure 34C
35
THERMOFORMING
Thermoforming
Thermoforming
• To thermoform Wilsonart® Solid Surface material, an oven that will heat the material is needed.
(FIG. 35A)
• The sheet temperatures should be between 280° to 325°F (137.8° to 162.7° C) throughout the thickness during bending.
NOTE: Cold spots in the sheet will lead to cracks and whitening. Hot spots may cause blistering, discoloration, whitening and cracks.
• Thermoforming is not recommended or approved by
Wilsonart for the Cityscape Collection, please
contact Wilsonart Technical Service Group
at 800-433-3222 for further information.
Figure 35A
•Wilsonart® Solid Surface material has a minimum bending radius of 3” (76.2mm).
NOTE: Bending sheets to a smaller radius can
result in crazing, whitening, cracking, or reduction in impact resistance.
• For the best result, a set of male and female molds should be used to form the sheet into the desired radius shape (this is highly recommended for thermoforming 1/2” (13mm) sheets. (FIG. 35B)
Figure 35B
• Heat Guns, Torches and Cal Rods will cause failure with Wilsonart® Solid Surface countertops.
NOTE: Spot heating or localized heating will cause problems due to the temperature difference between the heated area and the unheated area. The stress build-up at the interface between the heated and unheated area will lead to cracking after the top is installed. (FIG. 35C)
Cool Down
• Allow the thermoformed sheet to cool down in the mold to less than 170° F (76.6° C) before removing from mold. Depending on the surrounding room Figure 35C
temperature, cool down will take approximately
20 to 40 minutes.
Seaming
• All seaming must be done after thermoforming.
36
Finishing
Procedures & Products
Procedures
• Wipe all sanding dust from countertop surface between grit changes.
FINISHING
• Darker colors will require more attention to obtain the desired final finish.
• Be careful when selling dark colors and/or semi-gloss or gloss finishes. Inform your customer of the possible extra care necessary to maintain a dark color and/or finishes higher than a standard Matte or Satin finish.
Products
Figure 36A
3M® Surfacing Abrasives – 1- 800-364-3577
There are 13 micron grades. Micron grade 100, the coarsest,
is approximately equal to a grade 150 in the U.S. standard
system. The .3 micron grade, one of the finest grades, is
equivalent to a 10,000 grit.
Scotch-Brite® by 3M® – 1- 800-364-3577
3M’s Scotch-Brite® Pad order of coarseness: 7447 Maroon
(Fine), 7448 Grey (Very Fine) and 7445 White (Ultra Fine).
3M® Trizact™ Abrasives – 1-800-742-9546 or
1-800-364-3577 in the U.S.A.
651-737-6501 outside the U.S.A.
May decrease the amount of sanding steps involved in
finishing a countertop. With the Trizact™ system, there is no
need to finish the top with 3M® Scotch-Brite® pads.
Figure 31B
Mirka Abralon Pads – 1-800-843-3904
Recommended for dark colors.
Sia -1-800-459-3534
www.sia-abrasives.com
Standards
• U.S. standard system: 16 grit (coarsest) to 2,000
grit (finest)
•Trizact™: 60mx (coarsest) to 20,000mx (finest)
• Micron system: 100 micron (coarsest) to .3 micron (finest)
• Abralon: Medium (coarsest) to mirror fine (finest)
37
Finishing
Sanding Steps
Abrasives
Sanding Steps
“Quick Steps” to Final “Finish”
FINISHING
For final finishing use the following steps located in the Abrasive Cross Reference Chart below:
Finish
Type
USA Grit
Scotch-Brite ™
3M ™ Micron
Scotch-Brite ™
Matte
180
80u
60u
7447
220
7447
Satin
Semi
Gloss
Gloss
Trizact ™
Film
268XA Green A35
268XA Blue A10/
7447
Mirka
Abralon
N/A
80u
60u
Medium 360
Sia**
120 Blue Disc
Standard Finish
180 Blue disk
Easy/Low Maintenance
280 Blue Disc
MAROON siafleece disc (wet)
WHITE siafleece disk (dry)
120 Blue Disc
180 Blue Disc
Soft Microhook Pad
280 Blue Disc
400 Blue Disc
GREY siafleece disc (wet)
Slightly More Difficult
Medium Maintenance
Requires special customer
instructions
180
220
280
7448
80u
60u
40u
7448
180
220
280
7445
7448
80u
60u
40u
7445
7448
268XA Green A35
268XA Blue A10
268XA Orange A5
80u
60u
40u
Medium 360
Super Fine 1000
120 Blue Disc
180 Blue Disc
Soft Microhook Pad
280 Blue Disc
400 Blue Disc
600 Blue Disc
1000 BlueDisc
GOLD siafleece pad (wet)
180
220
280
7448
7445
Buffer with
Polishing
Compound
80u
60u
40u
7448
7445
Buffer with
Polishing
Compound
268XA Green A35
268XA Blue A10
268XA Orange A5
568XA White CeO or
buffer with polishing
compound
80u
60u
40u
Medium 360
Super Fine 1000
Mirror Fine 4000
120 Blue Disc
180 Blue Disc
Soft Microhook Pad
280 Blue Disc
400 Blue Disc
600 Blue Disc
1000 BlueDisc
Sia Speed Fast Cut
Compound
N/A
Notes
Requires Fabricator to refinish
Recommended for vertical
surfaces only
Requires fabricator to refinish
The gloss finish is not recommended for high traffic areas. It requires a trained fabricator to maintain its finish.
** Use with Microhook Interface Pad
38
INSTALLATION
INSTALLATIONINSTALLATION
Jobsite
Jobsite Preparation
Preparation
29
29
Jobsite Preparation
Jobsite
Jobsite Preparation
Preparation
Jobsite Preparation
I N S TA L L AT I O N
• Install web supports as required.
• Install web supports as required.
• Install
webperimeter
supports as of
required.
Place
around
countertop and at
Place
around
perimeter
oforcountertop
at
1/2"
or
3/4"
MDF
particle boardand
recommended.
each cabinet support.
each
cabinet
support.
Place around perimeter of countertop and at each cabinet support.
•• Webbing
must be straight, flat and level after
Webbing must be straight, flat and level after
installation.
If shims
arebeused,
they
be installed
• Webbing
must
straight,
flat must
and level
installation.
If shims
are used,
they
must beafter
installed
installation.
If shims
used,
they must
between the
cabinet and
theareweb
frames,
notbe installed between the
cabinet
and
theand
web
notnot between
cabinet
the frames,
web
frames,
directly under
the the
countertop.
(FIG.
29A)
directly under
the
countertop.
(FIG.
29A)
directly under the countertop. (FIG. 38A)
Web Support
Web Support
Shim
Shim
Cabinet
Cabinet
• Do not install
Wilsonart
Solid® Surface
overover
a solid
• Do not
install Wilsonart
Solid Surface
a solid • Do not install
Wilsonart
Solid Surface
over a solid
substrate, except
at
overhangs.
(See
page
30)
Figure 38A
29A
Figure
substrate,
except
at
overhangs.
(See
page
39)
substrate, except at overhangs. (See page 30)
Figure 29A
• Supports required
everyin24".
• Certain unsupported
areas are
need of stronger
• Certain unsupported areas are in need of stronger
frame material. These include inside corner
frame material.
include
inside
• CertainThese
unsupported
areas
are in corner
need of stronger cabinets, especially
lazy Susans,
dishwasher
frame material.
These include
inside corner cabinets, especially
lazy Susans,
dishwasher
openings, sink
base especially
fronts, desks
and anywhere
else
cabinets,
lazy susan,
openings, sink
base fronts, desks
and dishwasher
anywhere else
openings,
sink base
fronts,
desks (FIG.
and anywhere
that the cabinet
is weaker
than
others.
29B) else that the cabinet is weaker than others. (FIG. 29B)
that the cabinet is weaker than others. (FIG. 38B)
Web Support
Web Support
Lazy Susan
Lazy Susan
Corner
Cabinet
Corner Cabinet
High Strength Support
High Strength Support
• Place web supports at both sides of all cutouts. Place
• Place web•supports
both sides
all cutouts.
Place
Place webat
supports
at bothofsides
of all cutouts.
Place supports no
closer
than
1"
(25.4mm)
and
no
further
closer
1” (25.4mm)
andfurther
no further supports nosupports
closer no
than
1" than
(25.4mm)
and no
than 3" ( 76.2mm)
from sides
cutout.
than 3” ( 76.2mm)
fromof
sides
of cutout.
than 3" ( 76.2mm)
from sides
of
cutout.
40 for additional
web support See
page 28See
forpage
additional
web support
See page 28 for additional web support
requirements.
requirements.
requirements.
Figure 29B
• Multiple bowl installations require special •• Multiple
bowl
installations
require
special
reinforcement
to provide
adequate
support.
Multiple bowl
installations
require
special
Reinforce unsupported area
Reinforce unsupported area
Figure
Figure 29B
38B
reinforcement
provide
adequate
support.
to
web support
along
both sides of the reinforcement
to Place
provide
adequate
support.
Place
web support
along both sides of the bowl
bowl
installation.
Place web support along both sides of the bowl
Place sink setters, solid wood, MDF or installation.
installation.
plywood solid
supports
between
eachorbowl.
Place
sink setters,
wood,
MDF
Place
sink setters,
wood,
MDF base
or
Supportssolid
must rest
on cabinet
plywood supports between each bowl. or be plywood
between
eachtobowl.
supports
attached to
cabinet base
alleviate flexing.
Supports must rest on cabinet base or be
Supports must rest on cabinet base or be
attached to cabinet base to alleviate flexing.
• Free standing
stoves
musttobe alleviate
set min. 1/16”
higher attached
to cabinet
base
flexing.
than surface of countertop.
06/01/2002
06/01/2002
Gibraltar®® Solid Surface
Gibraltar Solid Surface
Earthstone®® Solid Surface
Earthstone Solid Surface 39
INSTALLATION
INSTALLATION
Overhangs
INSTALLATION
Overhangs
Overhangs
Overhangs
Overhangs
Overhangs
30
30
30
INSTALLATION
• Additional support is required when the countertop
• Additional
is required
whenRefer
the countertop
overhangs support
the cabinet.
(FIG. 30A)
to the
• Additional
support
is
required
when
the
countertop
Overhangs
overhangs
the
cabinet.
(FIG.
30A)
Refer
to
the
following chart to determine support required:
overhangs
the cabinet.
(FIG. 30A)
Refer
to the
following chart
to determine
support
required:
following
chart to determine support required:
Overhangs
Overhang
Support Required
Overhang
Support Required
• Additional
when
the countertop
Overhang
Support
Required
0 - 6" support is required
None
0 - 6"
(0-152.4mm)
overhangs
the cabinet. (FIG. 39A)None
Refer to the following
0 - 6"to determine
Nonethe countertop
(0-152.4mm)
• Additional
support issupport
required
when
chart
required:
Brackets
(corbels)
6 - 12"
(0-152.4mm)
overhangs
the cabinet.(Under
(FIG.
30A)
Refer support)
to the
Brackets
(corbels)
web
frame
6 - 12"
(152.4mm-304.8mm)
Brackets
(corbels)
following
chart to determine
support
6 - 12"
(Under web
frame
support)
(152.4mm-304.8mm)
or required:
(FIG.
27A)
(Under
web
frame
support)
(152.4mm-304.8mm)
or
3/4" plywood underlayment
(FIG. 27A)
or
Overhang
Support
Required
(FIG.
27A)
3/4" plywood
underlayment
Bracketsunderlayment
(corbels)
12 - 18"
3/4" plywood
Brackets
(corbels)
12
18"
0
6"
None
(Under
web
frame
support)
(304.8mm-457.2mm)
Brackets
(corbels)
12(0-152.4mm)
- 18"
(Under
web
frame
support)
(304.8mm-457.2mm)
and
(FIG. 27B)
(Under
weband
frame
support)
(304.8mm-457.2mm)
Brackets
(corbels)
3/4" plywood
underlayment
(FIG. 627B)
- 12"
and
(FIG.
27B)
3/4"
plywood
underlayment
(Under
web
frame support)
(152.4mm-304.8mm)
18Figure
- 24"39B
Bracketsunderlayment
(corbels)
3/4" plywood
or
(FIG.
27A)
(457.2mm-609.6mm)
18 - 24"
Bracketsand
(corbels)
3/4" plywood(corbels)
underlayment
18 - 24"
(457.2mm-609.6mm)
andunderlayment
3/4"Brackets
plywood
(457.2mm-609.6mm)
and
Brackets
(corbels)
12 - 18"
3/4" plywood
underlayment
and
plywood
underlayment
(Under
web
frame
support)
(304.8mm-457.2mm) 3/4"
and legs
supporting
(Figure 39B)
and
and
supporting legs
(FIG. 27B)
legs
3/4" supporting
plywood underlayment
Overhangs
INSTALLATION
Overhangs
• When 18
brackets
used, place
them no
- 24" (corbels) areBrackets
(corbels)
• When
brackets
(corbels)
are
used,
place
them
(457.2mm-609.6mm)
more than 24" (609.6mm) apart. Inand
addition,no
place
• When
brackets
(corbels) areapart.
used,Inplace
them place
no
more
than
24"
(609.6mm)
addition,
plywood
underlayment
brackets 12" (304.8mm)3/4"
from
open ends
and against
more
than
(609.6mm)
apart.
Inand
addition,
place
brackets
12"24"
(304.8mm)
open
ends
and against
wall ends.
(FIG.
30B &from
30C)
brackets
12"
(304.8mm)
from
open
ends
and
against
wall ends. (FIG. 30B & 30C)supporting legs
wall ends. (FIG. 30B & 30C)
• When
(corbels)
are are
used,
placeplace
themthem
no more
•
Whenbrackets
brackets
(corbels)
used,
nothan
24” (609.6mm) apart. In addition, place brackets 12”
more than 24" (609.6mm) apart. In addition, place
(304.8mm) from open ends and against wall ends.
brackets 12" (304.8mm) from open ends and against
(FIG. 39B & 39C)
wall ends. (FIG. 30B & 30C)
Other recommended support items for sinks
and countertops.
• Sink Setter Brackets – support the sink under the counter and
also allow for adjustment in height of the sink, insuring proper
alignment with the bottom of the countertop.
• Easy Leveling Shelf and Counter Bracket – Brackets used to
support and level countertop, they have no cross brace, are
extremely strong, adjustable to level, and easy access to wall
anchor screws.
• For contact information see Tool Section in this manual.
30
Figure 30A
Figure 30A
Figure
Figure 30A
39A
Countertop
Countertop
Countertop
Web Support
Figure 30A
Web Support
Web Support
Cabinet
Cabinet
Cabinet
Countertop
Web Support
Figure 30B
Figure
Figure 30B
39B
Figure 30B
Cabinet
12" - 18"
(304.8mm - 457.2mm)
Figure 30B
12"
Maximum (304.8mm)
12"
Maximum
(304.8mm)
12"
Figure
30C
24"
Maximum (609.6mm)
24"
Maximum24"
(609.6mm)
Figure 39C
Maximum (304.8mm)
Figure 30C
Figure 30C
12"
Maximum (304.8mm)
Wall
Wall
Wall
Maximum (609.6mm)
24"
Maximum (609.6mm)
Figure 30C
06/01/2002
06/01/2002
06/01/2002
Figure
Copy39D
for Illustrations
06/01/2002
12" - 18"
(304.8mm - 457.2mm)
12" - 18"
(304.8mm - 457.2mm)
12" - 18"
(304.8mm - 457.2mm)
Wall
®
®
Solid
Surface
Gibraltar
Solid
Surface
Earthstone
®
Solid
Surface
Gibraltar
®
Earthstone Solid Surface
Earthstone® Solid Surface 40
INSTALLATION
INSTALLATION
INSTALLATION
Web Support
Web Support
Layout
Web Support Layout
Web Support
Layout Layout
Web Support
Web Support Layout
Recommended
web support
material
includes:
Medium
Density Fiberboard
plywood,
hardboard
etc.
Recommended
web
support
material
includes:
Medium (MDF),
Density
Fiberboard
(MDF),
plywood, hardboard etc
Corners require extra strength supports
Sink Base
Sink Base
Seam
support
Seam
support
Dish
Washer
Dish
Washer
Corner
Corner
Seam
support
Seam
support
Support cutouts with
additional
Support
cutoutsside
with
supports from
1" (25.4mm)
additional
side to 3" (76.2mm)
from
sides
of
cutouts
supports from 1" (25.4mm) to 3" (76.2mm)
from sides of cutouts
Cooktop
Cooktop
OVERHANG
OVERHANG
Lazy
Susan
Lazy
Susan
Support at front
and back
of all
Support
at front
cabinets
and back
of all
cabinets
All ends require support
Figure 40A
(Option
1)
Figure
31A (Option
1)
Figure 31A (Option 1)
Lazy
Susan
Lazy
Susan
Dish
Washer
Dish
Washer
Sink Base
Sink Base
Support cutouts with
additional
Support
cutoutsside
with
supports from
1" (25.4mm)
additional
side to 3" (76.2mm)
from
sides
of
cutouts
supports from 1" (25.4mm) to 3" (76.2mm)
from sides of cutouts
Overhangs can
be supported
Overhangs
can
plywood
be with
supported
(See
"Overhangs")
with plywood
(See "Overhangs")
Corner
Corner
Cooktop
Cooktop
OVERHANG
OVERHANG
Recommended web support material includes: Medium Density Fiberboard (MDF), plywood, hardboard etc.
Support at front, middle
back of
all
Supportand
at front,
middle
cabinets
and back
of all
cabinets
Figure 40B
(Option
2)
Figure
31B (Option
2)
Figure 31B (Option 2)
06/01/2002
06/01/2002
Overhangs can
be supported
Overhangs
can
plywood
be with
supported
(See
"Overhangs")
with plywood
(See "Overhangs")
®
Solid
Gibraltar
41 SuS
®
Gibraltar Solid
®
Earthstone Solid
Earthstone® Solid S
INSTALLATION
Securing & Fitting
the Countertop
Securing the Countertop
• Use only 100% pure silicone to secure countertop to web frame.
No construction mastic
• Use dime sized dabs every 18” (457.2mm) to
24” (609.6mm).)
Secure all outside corners
Do not run continuous beads
Do not place silicone in the inside corners
• No mechanical fasteners should be used to fasten the countertop. Never screw, staple or nail into Wilsonart® Solid Surface.
Fitting the Countertop
• Provide minimum 1/8” (3.2mm) gap at all walls
for every 12 feet of countertop. )
• Scribe to wall as necessary.
42
Installation
Customer Satisfaction
Customer Satisfaction
Customer satisfaction is achieved by using a common
sense approach. Treat your customer fairly. Word of mouth
is the best and least expensive form of advertising. Quality
assurance in fabrication and installation is of the utmost
importance. The fabricator’s reputation hangs in the balance.
The following are mandatory:
• Warranty Information Label completed and affixed to Wilsonart in plain view under countertop or in sink cabinet base. (FIG. 42A)
Figure 42A
Wilsonart, manufacturer of decorative surfacing materials and adhesives for countertops and work surfaces
• Repair material affixed to cabinet under sink.
“Do Not Remove” should be written on material.
• Care and Maintenance information should be provided to end user. Information can be found at the Wilsonart
website, www.wilsonart.com. (FIG. 42B)
• Warranty Registration
On-line registration through the B2B website (FIG. 42C)
Legal Agreement
Privacy Policy
10/28/10 3:22 PM
Site Map
Site Search
Home
About Us
History
Environment
Media
Contact Us
Homeowners
Homeowners
Residential
Homeowners
Designers
To The Trade
Commercial
Designers
Enter Site
Retail
Welcome to Wilsonart International...
a world-leading producer of decorative surfacing products. No matter what
your budget or style, whether you are a design professional or a consumer, we
have a product to fit your needs. Where Great Ideas are Surfacing!
Figure 42B
©2010 Wilsonart International. All rights reserved.
No portion may be reproduced without written
permission of Wilsonart International.
http://wilsonart.com/
Notice to all users: Carefully read the following legal agreement before using this Web site. By
clicking the acceptance button or using this Website, you signify your assent to these terms of
use. If you do not agree , please disconnect from and do not use this Web site. Your privacy is
important to us, please review our privacy policy.
Page 1 of 1
Figure 42C
43
COMMERCIAL Commercial
Hot Bars and Cold Food Wells
Hot Bars & Cold
Food Wells
Hot and Cold Food Wells
• Base cabinets should be vented and contain a fan
for continuous air flow.
•Seams are not allowed through cutouts. (FIG. 35A)
a minimum
from(FIG.
all cutouts.
•Seams
Seams must
are notbeallowed
through 3"
cutouts.
43A)
Seams must be a minimum 3” from all cutouts.
• An 1/8" (3.2mm) flexible silicone seam is required
• Anhot
1/8”and
(3.2mm)
silicone(FIG.
seam 35A)
is required
between
coldflexible
food wells.
Required min. 1/8" (3.2mm) silicone seam
between hot and cold food wells
Largest Radius
Possible
3" (76.2mm) minimum between cutouts
½" (13mm)
radius
minimum at
each inside
corner
Hot
Cold
Seam must be 3" (76.2mm)
minimum away from cutout
Flexible Seam
between hot and cold food wells. (FIG. 43A)
Figure
Figure 35A
43A
•All cutouts must be routed.
• All cutouts must be routed.
mm"
•Minimum
1/2" 1/2”
(13mm)
gapgap
between
• Minimum
(13mm)
betweenedge
edgeof
of cutout
and heat
source.
(FIG.
35B)(FIG. 43D)
cutout
and heat
source.
• Minimum 1/2” (13mm) radius required on all
inside
corners
of cutouts.
(FIG.
43A) Prefer
• Minimum
1/2"
(13mm)
radius
required
on larger
all inside
radius
if
possible.
corners of cutouts. (FIG. 35A)
5"
5 (128.5
COMMERCIAL
Hot andshould
Cold Food
Wellsand contain a fan for
• Base cabinets
be vented
continuous air flow.
35
Prefer larger radius if possible.
• Inside corners of all hot well cutouts must be
reinforced with 5” x 5” beveled, Wilsonart® Solid
•Inside corners
hot well
cutouts must
be (FIG.
Surface, of
highallstrength
reinforcement
blocks.
reinforced
43B with
& 43C)5" x 5" beveled Wilsonart Solid
Surface high strength reinforcement blocks.
Ease&
top35C)
and bottom of all cutouts and
(FIG. •35B
)
mm
8.5
2
(1
5" (128.5mm)
450 bevel
5 (128.5mm"
Figure 35B
Figure 43B
reinforcement blocks.
•Ease top and bottom of all cutouts and reinforcement
• Sand cutouts free of roughness and router chatter.
blocks.
Minimum ½” radius required
on all inside corners
Inside corners of all
cutouts must be radius minimum 1/4” (6.4mm)
• A Mantle is required for all hot wells. (FIG. 43D)
•Sand cutouts free of roughness and router chatter.
• Wilsonart 9 mil heat reflective tape and Nomex®
insulation
is required
on hot
all hot
wells.(FIG.
The heat
•A Mantle
is required
for all
wells.
35D)
reflective tape must extend past flange of heat
source and then be trimmed. (FIG. 43D)
• Wilsonart 9 mil heat reflective tape and Nomex
insulation is required on all hot wells.
The heat reflective tape must extend past
flange of heat source and then be trimmed.
1" Minimum Typical
(25.4mm)
5"
(128.5mm)
Figure 35C
Figure 43C
Outer edge should match
front edge detail
1/8"
(3.2mm)
Roundover
Gibraltar Mantle
½"
(13mm)
1-1/2" Minimum (38.1mm)
Gibraltar Deck
Minimum 1/2"
Nomex insulation
9 mil Aluminum
Heat Tape
Wilsonart 9mil Aluminum Heat Tape
Figure 35D
06/16/2006
Figure 43D
®
Nomex
Gibraltar
Solid Surface
44
Commercial
COMMERCIAL
COMMERCIALFood
Food Bars
Bars
36
Always leave
expansion and
contraction space
Seal with silicone
Block up Sneeze Guard
Support with wood block
Hot
Cold
Provide 1/8" (3.2mm) silicone expansion
joint between hot and cold sides of food
bars to accommodate differing
rates of dimensional movement.
Silicone expansion joint can be
covered with a decorative
batten strip.
To provide longer
service and add design
flare, use stainless,
brass or steel rods.
Brace tray slides
as required, see page 39
27
for details.
06/16/2006
45
COMMERCIAL
COMMERCIAL
Wall
Cladding Installation
37
Commercial
Wall Cladding Installation
37
These instructions are for 1/4" and 1/2" thick Wilsonart Solid Surface.
These instructions are for 1/4" and 1/2" thick Wilsonart Solid Surface.
• The following are substrates which will allow proper support of Gibraltar wall cladding.
Substrates
- are
A-face
preferred
Drywall of Gibraltar
Cement board
• ThePlywood
substrates
willallow
allow
proper
support
wall wall
cladding.
•following
The following
are
substrateswhich
which will
proper
support
of Wilsonart® Solid Surface
Masonite
Tile
Plywood
Drywall
Cement board
cladding.- A-face preferred
Masonite
Tile
Plywood - A-face preferred Drywall Cement board
• Substrate surface must be sound, flat, smooth and free of dust or other contaminates during installation. Any
Masonite Tile
ceramic
tile must
must be
be sound,
removed
and
the void
level
to or
tileother
surface
with thinset
or above
substrates.
• loose
Substrate
surface
flat,
smooth
andfilled
free of
dust
contaminates
during
installation.
Any
loose• ceramic
must
beberemoved
the and
void
level
to tile
surface with
Substrate tile
surface
must
sound, flat,and
smooth
freefilled
of dust
or other
contaminates
duringthinset or above substrates.
installation. AnyAdhesives
loose ceramic tile must be removed and the void filled level to tile surface with
Recommended
thinset
or
above
substrates.
Recommended Adhesives
• 100% Silicone - All substrates and required expansion joints
•
Nails 933- -All
Wood
and drywall
substrates
• Liquid
100%Recommended
Silicone
substrates
and required
expansion joints
Adhesives
•
8215
Approved
hard
seams
• Liquid Nails 933 - Wood and drywall substrates
Siliconehard
- All substrates
• 8215•-100%
Approved
seams and required
1
8" expansion gap filled
with 100% silicone
expansion
joints
Installation
Requirements
- General
•
Liquid
Nails
933
Wood
and
drywall
substrates
Installation Requirements - General
• Minimum 1/8"® silicone filled expansion gaps are
1
with 100% silicone
• Wilsonart Hard Surface Adhesive - Approved hard seams
06/16/2006
06/16/2006
Framing
Sub-Wall
Framing
2"
2"
Framing
Framing
1
Sub-Wall
1
with 100% silicone
Sub-Wall
Sub-Wall
1
1
with 100% silicone
Figure45A
37A
Figure
Ceiling Framing
Figure 37A
Ceiling
Ceiling Framing
Ceiling
Min. 1 8" Silicone Filled Gap
Wall Framing
Wall Framing
• required
Minimumat:1/8" silicone filled expansion gaps are
• All inside
required
at: corners (Figure 37A)
• Between
floor
and ceiling
on full height
All
insidefinished
corners
(Figure
37A)
Installation
Requirements
- General
wall
cladding.
(Figure
37B)
• Between finished floor and ceiling on full height
• Every
10’-12’
of (Figure
wallfilled
length/height.
wall cladding.
37B)
Minimum
1/8” silicone
expansion gaps are required at:
• 1/8"
finished
floor for all
Everyminimum
10’-12’ ofoffwall
length/height.
wainscoating.
•
All
inside
corners
(Figure
45A)
• 1/8" minimum off finished floor for all
•wainscoating.
Between finished floor and ceiling on full height wall
• A combination
of hard
cladding. (Figure
45B)seams and silicone seams can
•
Every
10’-12’
of
wall
length/height.
be
utilized
for
wall
cladding
installations.
• A combination of hard seams
and silicone seams can
•
1/8”
minimum
off
finished
floor for all
wainscoating.
•
See
Wall
Cladding
Seam
Option
Drawings
on
be utilized for wall cladding installations.
•
A
combination
of
hard
seams
and
silicone
seams
can be
pages
42-44.
• See
Wall
Cladding Seam Option Drawings on
used for wall cladding installations.
pages 42-44.
• See Wall
Cladding
Seam to
Option
• Panels
must
be routed
size,Drawings
no saw on
cuts.
pages
50-51.
• Panels must be routed to size, no saw cuts.
• Panels
must
be routed
to size, no
saw
cuts.
• All
seams
must
be flat/level
and
well
supported by
•
All
seams
must
be
flat/level
and
well
supported
by a
substrate.
• aAllsound
seamsrecommended
must be flat/level
and well supported
by
sound recommended substrate.
a sound recommended substrate.
• Allhard
hard seams
seams must
release
material
between
• All
musthave
have
release
material
between
the
substrate
and
the
seam
adhesive.
Do
Not
seam
the
substrate
and
the
seam
adhesive.
• Alltohard
seams must have release material between
substrate.
Do
Not seam
to
the
substrate
and
thesubstrate.
seam adhesive.
• All cutouts must
be routed.
Do
Not
seam
to
substrate.
• Allow minimum 1/16” expansion gap around entire cutout.
• All cutouts
must
beradius
routed.
• Minimum
1/4”
required at inside corners of cutouts
•
Allow
minimum
1/16" expansion gap around entire
• All cutouts must be routed.
• cutout.
Allow minimum 1/16" expansion gap around entire
• cutout.
Minimum 1/4" radius required at inside corners of
• cutouts.
Minimum 1/4" radius required at inside corners of
cutouts.
(continued next page)
(continued next page)
Gibraltar Wall Panel
Sub-Wall Sub-Wall
Commercial
Substrates
These instructions are for 1/4” and 1/2” thick Wilsonart® Solid Surface.
Substrates
Gibraltar ®
Wall
Panel
Wilsonart
Solid
Surface
Finished Floor
Figure 37B
Finished Floor
Figure45B
37B
Figure
SolidSurface
Surface
Earthstone
Gibraltar® ®Solid
®
Earthstone Solid Surface
46
Commercial
COMMERCIAL
Installation Requirements - General
• Ease all edges including inside of all cutouts.
• Accessories like hand rails, grab bars, seats, etc., must be supported by wall framing.
• Oversize all holes for accessories 1/8” larger than attaching hardware to be used.
• Do not over tighten.
• All accessories applied to the face of the Wilsonart® Solid Surface must allow for expansion and contraction.
• Apply LN933 flexible wall panel adhesive to wall, not on panels.
• Ensure back side of wall panel has been scuffed or sanded to remove gloss.
• Final finish to be provided by fabricator. See Finishing Section in Wilsonart® Solid Surface Fabrication Manual.
Safety Notes and Suggestions:
Maintain all local, county, state and federal work area safety requirements. Always use
personal protective equipment including eye, ear (sound) and face protection, safety shoes
and hand protection. Read and follow the manufacturers’ application and safety instruction
information for LN933 flexible panel adhesive, silicone adhesive sealant and Wilsonart® Hard Surface Adhesive.
Ensure adequate ventilation before applying adhesives or caulking materials.
47
Commercial
COMMERCIAL Wall Cladding Installation
39
Size Panel
Size Panel
• Check corner to see if vertically plumb.
• Check corner to see if vertically plumb.
• Measure width and height of area where wall panel
• Measure width and height of area where wall panel
is to be installed.
is to be installed.
• Allow for min. 1/8” gap at floor, ceiling and corners
as indicated on page 41. (Figure 47A)
• Allow
fornon-plumb
min. 1/8"corners,
gap at floor,
corners
• For
scribe ceiling
the side and
of panel
to
as indicated
on
page
34.
(Figure
39A)
be placed at the corner so that the opposite edge of
panel is plumb.
• For non-plumb
the
of panel
• Trim panel tocorners,
size withscribe
a router
andside
a straight
edge.
to be
placed
at the
corner
the to
opposite
• Place
shims
on floor
and so
drythat
fit panel
wall.
edge
of panel
is plumb.
• With
a pencil,
outline the edge of the panel on the
wall to indicate area to accept wall panel adhesive.
• Trim panel
size with a router and a straight edge.
(Figureto
47B)
Measure
Measure
Measure
COMMERCIAL
Min. 1 8" Gap
Corner
Measure
Min. 1 8" Gap
Min. 1 8" Gap
Corner
Pencil Outline
of Wall Panel
• Place
shims onApplication
floor and dry fit panel to wall.
Adhesive
• With• aApply
pencil,
outline the
of silicone
the panel
the
a continuous
1/4”edge
bead of
3/4”on
inside
wall to
indicate
area
to
accept
wall
panel
adhesive.
the perimeter of the panel outline. (Figure 47C)
(Figure
39B)
• Apply
a continuous 1/4” bead of silicone or flexible
panel adhesive every 6”- 8” inside the perimeter
bead.(Figure 47C)
Adhesive
• PlaceApplication
panel on shims and press to wall. Apply firm
pressure from the center of the panel working
• Apply atoward
continuous
1/4" bead of silicone 3/4" inside
the edges.
the perimeter
of
the
panel
outline.
(Figure
39C)
• Dabs of hot melt on
the wall
will assist
to hold
panel in place.
• Apply•aUse
continuous
bead oftool
silicone
orpressure.
flexible
a J-roller or1/4"
comparable
to apply
Brace panel
as necessary
until adhesive
has set.bead.
panel•adhesive
every
6"-8" inside
the perimeter
(Figure(Figure
39C) 47D)
• Remove all excess silicone.
• Place panel on shims and press to wall. Apply firm
pressure from the center of the panel working towards
the edges.
• Dabs of hot melt on the wall will assist to hold panel
in place.
• Use a J-roller or comparable tool to apply pressure.
Finished Floor
Figure 47A
38A
Min. 1 8" Gap
Figure 38B
47B
Figure
Finished Floor
Silicone / Flexible Panel Adh.
Pencil
Outline
Corner
Silicone
Perimeter Bead
Finished Floor
38C
Figure 47C
Min.1 8" Gap
Corner
Bracing
• Brace panel as necessary until adhesive has set.
(Figure 39D)
Min. 1 8" Gap
• Remove all excess silicone.
38D
Figure 47D
06/16/2006
Finished Floor
48
Commercial
Multiple Panel Installation
COMMERCIAL
• Refer
to pages
50-51 in this section for seam options
Multiple
Panel
Installation
• With firm pressure towards the seam, press panel to
wall and apply firm pressure to entire surface of panel
as described on page 39.
Silicone / Flexible Panel Adh.
Pencil Outline
1s
A tW
dh a
er ll P
ed a
t o ne l
W
al
l
COMMERCIAL
and requirements.
• Refer •toPrepare
pages as
42-44
this as
section
manyin
seams
possiblefor
in seam
shop. options
and requirements.
• All edges to be seamed must be routed.
• Refer to the Deck Seams Section of this manual for
preparation
• Prepare seam
as many
seams techniques.
as possible in shop.
• After sizing the second panel, dry fit and mark outline
of to
second
panel onmust
wall. (Figure
48A)
• All edges
be seamed
be routed.
• Apply wall panel adhesive as described on previous
• Refer to the Deck Seams Section of this manual
page. (Page 47, Figure 47C)
for •seam
techniques.
Applypreparation
release tape on
wall if Wilsonart® Hard Surface
Adhesive is used to make an inconspicuous seam.
®
• After sizing
second
panel,
dry fit
and mark
• Applythe
sufficient
seam
adhesive
(Wilsonart
Hard
outline Surface
of second
panel
on wall.along
(Figure
Adhesive
or silicone)
edge 40A)
of panel, lap
joint and/or batten to provide 100% coverage and
adhesive
out along
entire seam.
48B)
• Apply wall
panelsqueeze
adhesive
as described
on (Figure
previous
•
Place
second
panel
on
shims
and
angle
panel
to
allow
page. (Figure 40B)
only areas to be seamed to come into contact.
(Figure 48B)
• Apply release
tape on wall if WA8215 adhesive is
• With firm pressure towards the seam, press panel to
used to make an inconspicuous seam.
wall and apply firm pressure to entire surface of panel.
• Clamp seam together and insure seam is level.
• Apply •sufficient
seam
adhesiveuntil
(WA
8215has
or set.
silicone)
Brace panel
as necessary
adhesive
along edge
of panel,
(Figure
48C) lap joint and/or batten to provide
100% coverage
and adhesive
• Remove excess
adhesive.squeeze out along entire
®
seam. •(Figure
Wilsonart40B)
Hard Surface Adhesive - Refer to page 11
of the Conventional Deck Seam Section in this manual
for approved
• Place second
paneltechniques.
on shims and angle panel to
•
Finish
seam
specification.
allow only areas to tobejobseamed
to come into contact.
•
Refer
to
pages
36-37
of the Finishing Section of this
(Figure 40B)
manual for finishing steps.
40
Min.18" Gap
Finished Floor
Silicone
Perimeter Bead
Figure
Figure 48A
40A
Pencil Out Line
Apply Seam
Adhesive
1st Panel
Adhered to Wall
Silicone / LN933
Flexible Panel Adh.
Angle 2nd Panel
Finished Floor
Figure
Figure 48B
40B
Min. 1 8" Gap
Bracing
1st Installed
Panel
• Clamp seam together and insure seam is level.
• Brace panel as necessary until adhesive has set.
(Figure 40C)
Min. 1 8" Gap
Finished Floor
Figure
Figure 48C
40C
• Remove excessive adhesive.
• WA8215 - Refer to the page 10 of the Deck Seam
Section in this manual for approved techniques.
• Finish seam to job specification.
• Refer to pages 27-28 of the Finishing Section of
this manual for finishing steps.
49
Commercial
COMMERCIAL
41
Molding Installation
Molding
Installation
•
•
of moldings. (Figure 41A-41C)
4"
or 1 2" Wilsonart Solid Surface
Silicone / Flexible Panel Adhesive
Silicone
Wilsonart Solid Surface Base Molding
Sub-wall
•
1
Framing
COMMERCIAL
•
• Adhere baseboard moldings and/or crown moldings as
with 100%
silicone
only. crown moldings as
Adhere needed
baseboard
moldings
and/or
•
Do
Not
hard
seam
molding
needed with 100% silicone only.
• Provide min. 1/8” silicone gap at all inside corners.
• Apply a continuous bead of silicone to top and bottom
Do Not hard seam molding
of moldings. (Figure 49A-49C)
• Apply small dabs of hot melt to hold moldings in place
Provide until
min.silicone
1/8" silicone
gap
at all
inside corners.
has cured.
(Figure
49A-49C)
• Locate moldings on wall and press in place.
Apply a• Remove
continuous
beadsilicone.
of silicone to top and bottom
all excess
Hot Melt Adhesive
1
8" Silicone
Fill Gap
1 "
16 Silicone
Fill Gap
Finished Floor
Figure
Figure 49A
41A
Wainscot Molding Installation
until silicone
cured.moldings
(Figureand/or
41A-41C)
• Adherehas
baseboard
chair rail moldings
Flexible Panel Adhesive
Silicone
Silicone
Wilsonart Solid Surface Shoe Molding
1 " Silicone
8
Filled Gap
Filled Gap
Finished Floor
Figure
Figure 49B
41B
Ceiling
Fill
Expansion Gap
Hot Melt Adhesive
Sub-wall
Framing
1 " Silicone
16
of moldings. (Figure 41D)
until silicone has cured. (Figure 41D)
Hot Melt Adhesive
1 " Silicone
16
• Do Not hard seam molding
• Provide min. 1/8" silicone gap at all inside corners and
between top of panel and molding. (Figure 41D)
Wilsonart Solid Surface Base Molding
Sub-wall
Framing
as needed.
•
Do
Not hardonseam
• Locate moldings
wallmolding
and press in place.
• Provide min. 1/8” silicone gap at all inside corners and
top of panel
and molding. (Figure 49D)
• Remove between
all excessive
silicone.
of moldings. (Figure 49D)
Wainscoat
• ApplyMolding
small dabs of Installation
hot melt to hold moldings in place
until silicone has cured. (Figure 49D)
• Adhere• Locate
baseboard
moldings
and/or
rail moldings
moldings
on wall and
presschair
in place.
•
Remove
all
excess
silicone.
as needed.
Wilsonart Solid Surface Wall Cladding
Crown Molding
Silicone
Wilsonart Solid Surface Panel
Figure
Figure 49C
41C
• Locate moldings on wall and press in place.
Silicone
Wilsonart Solid
Surface Cap Molding
Sub-wall
Framing
• Remove all excessive silicone.
Hot Melt Adhesive
Silicone
Figure
Figure 49D
41D
50
Commercial
Wall Cladding
COMMERCIAL
COMMERCIALSeam Option
Wall Cladding Seam Options
42
Wall Framing
Subwall
Wilsonart
Solid
Surface
Eased Edges
Silicone
Silicone Butt Joint
Figure
Figure 50A
42A
Wall Framing
Subwall
Wilsonart
Solid
Surface
Gibraltar ®Batten
Wilsonart
Solid Surface Batten
Silicone
Silicone Joint w/ Batten Strip
Figure
Figure 50B
42B
06/16/2006
51
Commercial
COMMERCIAL
Wall Cladding
COMMERCIAL
Option
Wall Cladding Seam
Seam Options
44
Wall Framing
Subwall
Wilsonart
Hard Surface
Color
Matched
Seam
Adhesive
Adhesive
®
Silicone
Wilsonart
Solid
Surface
Hard Seam Butt Joint
Figure 51A
44A
Figure
Figure 51B
06/16/2006
52
Repair
Plug
REPAIR
Plug (Pie) Repair
Plug
(Pie)Repair
Repair
Plug
(Pie)
45
Nut
• Tools required: Plunge router, repair template, double stick
tape, random orbital sander and a 1/2” beveled cutter with
a snap
ring template
repairrepair
set (FIG.
52A) available
• Tools
required:
Plungeguide
router,
template,
from:
double stick tape, random orbital sander and a 1/2"
* Specialty
Tools
1-800-669-5519
beveled
cutter
with
a snap
ring template guide
* Betterley Industries 1-800-871-7516
Router Base
Template Guide
Snap Ring
Rubber Keeper
repair set (FIG. 45A) available from:
* Specialty Tools 1-800-669-5519
• Make a template from 1/4” (6mm) material to the size and
* Artnecessary
Betterleyto remove
1-800-871-7516
shape
damaged area of countertop.
• Make
a template
1/4"
material
the or
• Locate
template from
over the
area(6mm)
to be repaired
andtoclamp
R E PA I R
(Pie) Repair
in place.
size hot
andmelt
shape
necessary to remove damaged area of
countertop.
1/2" (13mm)
Beveled Repair
Bit
Figure
Figure52A
45A
Remove area to be repaired
• Make an alignment on the template and countertop to
ensure proper fit.
Template
• Locate template over the area to be repaired and
clamp
hotring
melt
in place.
• Withorsnap
in place
index plunge router to completely
cut through countertop and rout along perimeter of
template.
(FIG. 52B &
• Make
an alignment
on52C)
the template and countertop
Countertop
to ensure proper fit.
• Apply double stick tape under the repair material and
press on to flat work surface. The tape will secure repair
• With snap ring in place index plunge router to
material in place while cutting.
completely cut through countertop and route along
perimeter
template.
(FIG.
45Buse
&sink
45C)
• For colorofmatched
repair
material
or cooktop
cutout section.
Figure
43A
Figure52B
45B
• Apply double stick tape under the repair material
• Clamp
overwork
repairsurface.
material. Remove snap ring
and
press template
on to flat
andThe
indextape
plunge
router
to
cut
through
the repair
will secure repair
material
in material
place
and rout along perimeter of template. (FIG. 52D) Rout
while cutting.
Remove area to be repaired
Template
slowly to ensure exact cut.
• For color matched repair material use sink or
Countertop
cooktop cutout section.
• Clamp template over repair material. Remove snap
ring and index plunge router to cut through the
repair material and route along perimeter of
template. (FIG. 45D)
Rout slowly to ensure exact cut.
Figure 52C
Figure
45C
Plug
Template
Repair material
Figure
Figure52D
45D
06/16/2006
Tape
53
Repair
REPAIR
Plug (Pie) Repair
Plug (Pie) Repair
46
Plug (Pie)
Repair
Plug (Pie)
Repair
• Make an alignment on the plug and countertop to
ensure proper fit. Ensure alignment mark does not
• Make ancome
alignment
on with
the seam
plug adhesive.
and countertop to
into contact
ensure proper fit.
Insure
does
notfit.come
into
• Dry fitalignment
repair plug tomark
ensure
proper
The repair
plug should
about
1/32” (.79mm) above the
contact
withrest
seam
adhesive.
deck.
PLUG
215
WA8
COUNTERTOP
R E PA I R
• Dry fit repair plug to ensure proper fit.
• Clean both the repair plug and cutout with
The repair plug should rest about 1/32"
denatured alcohol.
(.79mm) above the deck.
• Adhere seam support under repair area extending
• Clean both
the repair
plug
and
cutout with denatured
a minimum
2” either
side
of seam.
alcohol.
• Apply Wilsonart® Hard Surface Adhesive and set
repair plug
into place.
53A) area
100%extending
coverage a
• Adhere seam
support
under(FIG.
repair
is
required.
Squeeze
out
is
required
along
entire
minimum 2" either side of seam.
top and bottom of seam.
• Apply color matched WA8215 seam adhesive and set
• Allow seam adhesive to cure completely.
repair plug into place. (FIG. 46A)
100%
coverage
required.
• Remove
adhesiveissqueeze
out with router on
Squeeze
out
is
required
along orbital
entiresander.
top and
“skis,” surface leveler, or random
bottom
of
seam.
Do not scrape, chisel or use belt sander to remove
Figure
Figure 53A
46A
COUNTERTOP
seam adhesive.
• Allow seam adhesive to cure completely.
• Sand to existing finish. (FIG. 53B) Follow
finishingout
procedures
locatedon
on “skis,”
• Remove recommended
adhesive squeeze
with router
pages
36-37
in
this
manual.
surface leveler, or random orbital sander.
Do not scrape, chisel or use belt sander to
remove seam adhesive.
Figure
Figure 53B
46B
• Sand to existing finish. (FIG. 46B)
Follow recommended finishing procedures
located on pages 27-28 in this manual.
54
REPAIR
Plug (Pie) RepairRepair
Plug (Pie) Repair
Plug (Pie) Repair
47
Plug (Pie) Repair
Tools required: Plunge router, 1/2" (13mm) cutter,
repair template, double stick tape and random orbital
Tools
required:
Plunge router, 1/2” (13mm) cutter,
sander and
disk
sander.
repair template, double stick tape and random
sander
and disk
• Make a orbital
template
from
1/4"sander.
(6.4mm) material (i.e.
hardboard or phenolic) with a hole saw or butterfly
Make a template from 1/4” (6.4mm) material
circle •cutter.
REMOVE AREA TO
BE REPAIRED
TEMPLATE
COUNTERTOP
(i.e. hardboard or phenolic) with a hole saw or
butterfly circle cutter.
clamp in place. (FIG. 47A)
clamp in place. (FIG. 54A)
R E PA I R
• Using a plunge router, 5/8" (15.9mm) template guide
and 1/2"
(13mm)
cutter,
the Gibraltar.
• Using
a plunge
router,remove
5/8” (15.9mm)
template
(FIG. 47B)
guide and 1/2” (13mm) cutter, remove the
Figure 54A
Figure
47A
Wilsonart® Solid Surface. (FIG. 54B)
• Remove template and place on Wilsonart Solid
®
Surface• Remove
repair material
andplace
pencil
exact template
template and
on Wilsonart
Solid
shape. (FIG.
47C)
Surface repair material and pencil exact template
For
color
matched
repair material
shape.
(FIG.
54C)
use sink or cooktop cutout section.
• For color matched repair material use sink or
(continuedcooktop
next cutout
page) section.
REMOVE
COUNTERTOP
Figure
Figure 54B
47B
TEMPLATE
PLUG MATERIAL
Figure 54C
Figure
47C
06/16/2006
55
Repair
REPAIR
Plug (Pie) Repair
Plug (Pie) Repair
48
Plug (Pie) Repair
(continued)
• Rough
cut the
penciledshape
shapeleaving
leaving about
• Rough
cut the
penciled
about1/8”
1/8"
(3.2mm)
around
perimeter.(FIG.
(FIG. 55A)
(3.2mm)
around
perimeter.
48A)
• Using
a disk
sander,
slowlysize
sizeplug
plugto
to fit
• Using
a disk
sander,
slowly
fitcutout.
cutout.
(FIG.
55B)
(FIG. 48B)
• Make an alignment mark on the plug and countertop
R E PA I R
• Make an alignment mark on the plug and countertop
to ensure proper fit. (FIG. 55C) Ensure alignment
to ensure proper fit. (FIG. 48C)
mark does not come into contact with seam
Insure alignment mark does not come into
adhesive.
contact with seam adhesive.
Figure 55A
48A
Figure
• Slightly bevel bottom side of plug to allow proper
• Slightly
bevelbetween
bottomcountertop
side of plug
to allow
proper
bonding
and plug.
Take care
not
bonding
between
countertop
and
plug.
to touch top edge of plug.
Take care not to touch top edge of plug.
• Dry fit repair plug to ensure proper fit. The repair
should
resttoabout
1/32”
(.79mm)
• Dry fitplug
repair
plug
ensure
proper
fit.above the
deck.
The repair plug should rest about 1/32"
(.79mm) above the deck.
• Clean both the repair plug and cutout with denatured
• Cleanalcohol.
both the repair plug and cutout with
denatured alcohol.
• Adhere seam support under repair area extending a
minimum 2” either side of seam.
Figure 48B
55B
Figure
• Adhere seam support under repair area extending a
minimum 2" either side of seam.®
• Apply color matched Wilsonart Hard Surface
Adhesive and set repair plug into place. (FIG. 55D)
• Apply100%
colorcoverage
matchedis required.
WA8215Squeeze
seam adhesive
and set
out is required
repairalong
plug entire
into top
place.
(FIG.
46A)
and bottom of seam.
100% coverage is required.
Squeeze
is required
entire top and
• Allow
seamout
adhesive
to curealong
completely.
bottom of seam.
• Remove adhesive squeeze out with router on “skis,”
• Allowsurface
seam adhesive
to cureorbital
completely.
leveler, or random
sander. Do not
scrape, chisel or use belt sander to remove seam
adhesive.
• Remove
adhesive squeeze out with router on “skis,”
surface leveler, or random orbital sander.
• Sand
to existing
recommended
Do not
scrape,finish.
chiselFollow
or use
belt sander to
finishing
procedures
located on pages 36-37 in this
remove
seam adhesive.
Figure 48C
55C
Figure
PLUG
manual.
• Sand to existing finish. (FIG. 46B)
Follow recommended finishing procedures
located on pages 27-28 in this manual.
215
WA 8
COUNTERTOP
Figure 55D
48D
Figure
06/16/2006
56
PRODUCT INFORMATION
Product Information
Patterns & Products
57
Wilsonart, LLC
2400 Wilson Place
P.O. Box 6110
Temple, TX 76503-6110
800.433.3222
SS0319
Revised 7/13
Wilsonart, LLC. Copyright © 2013, All Rights Reserved

Installation Guide - Compi Distributors Inc.

Transcription

Similar documents

LOKWELD Wood Glue

yellow wood glue

Wilsonart HD High Definition Laminate Brochure

Wilsonart HD High Definition Laminate Look Book

November 2012 - Harry Warren, Inc.

Haunch preparation - The Deer Initiative

RÉSoNANSS: a regional contribution to

see the Wilsonart Laminate Brochure

RC3017

PrimeFilm 1800 AFL Low-Cost 35mm Slide/Film Scanning Through