blfa_fabricarea compacutlui

8/3/2019 blfa_fabricarea compacutlui

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Contents

1. Material specification

2. Application areas

2.1 Interior usage

2.2 Exterior usage

3. Transport and storage

3.1 Transport

3.2 Storage

4. Machining

4.1 General

4.2 Sawing

4.3 Routing and edge finishing

4.4 Drilling

5. Installation

5.1 Jointing HPL compact sheets together

5.1.1 Tongue and groove

5.1.2 Corner jointing

5.1.3 Bonded joints

5.2 Fixing to groundwork

5.2.1 Simple installation

5.2.2 Fixing panels with overlapping profiles

5.2.3 Fixing panels by face screwing or bolting


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1. Material DescriptionHPL Compact Sheets are decorative highpressure laminates over 2mm in thicknessand conforming to EN 438. They haverobust surface qualities with completelysealed homogenous structure to their cut

edges. One or both sides may have colour/ pattern effect and this can be eithersmooth or textured. They are available infull size boards.HPL Compact sheets provide the followingexcellent advantages.

Good dimensional stability and flatness.

Self-supporting ability.

Toughness resistance to impact andbreakage.

Especially high resistance to the effectof water and steam.

Insensitivity to temperature changes -

heat and frost. Non-corrosive and durable.

High colour fastness.

Easily cleanable.

Biologically harmless.

Meets the highest hygiene and sterilerequirements for both the surface andthe edge.

Little electrostatic build up no dustgathering.

Ease of installation variations ofdemountable systems offers room

saving possibilities. Simple to work and process.

Good fire performance little smokedeveloped and will not melt or drip. FRgrades can provide Class 1 SurfaceSpread of Flame and over certainthicknesses meet Class O requirements.

Further properties are set out in EN 438.

In thicknesses under 2mm, CompactSheets should be bonded to a rigidsupporting material. Materials up to 5mm

thick will need support from rigid closecentred framework.In greater thicknesses however, they areself supporting. Boards and panels over8mm are suitable for large horizontalusage with support at wide intervals.It is left to the user to decide the thicknessof the product that will meet the maximumrequirements of the intended application,including any special requirementsnecessary.

2. Application areas2.1 Interior UsageBecause of the outstanding materialproperties set out above, HPL CompactSheets can be unrestricted in its use ininterior areas. This applies especially for

areas where high demands will be madeupon the material.

Areas of use include:

A BChemists Counter TopsDoctors surgeries Lift LiningsVehicle Building Bathroom FurnHotels and Guesthouse Ceiling CladdingInterior installations Shower cubiclesHospitals Kitchen WorktopsCold stores Kitchen fronts

Laboratories FurnitureShopfitting fixtures ShelvingWet rooms Elevator liningsSanitary areas Sanitary cellsAbattoirs Circuit wiring bdsSchools PlinthsSports centres & baths PartitionsUnderground stations Tunnel claddingDoors Wall cladding

Note:HPL Compact Sheets with texturedsurfaces provide certain better properties

in their usage. The advice of HPLmanufacture should be sought regarding aparticular application.

2.2 Exterior usageHPL Compact sheets of standard qualitymay be installed in those areas where highstandards of weather resistance do nothave to be met. Examples of such areasare provided below but no formalendorsement of their suitability may betaken from this.

Clamping places InstallationsBus and tram sheltersInstallations in open air swimming poolsChildrens play groundsTravel and Information kiosksMaps and direction boardsDecorative balcony panels & dividingpartitionsBalustrade panels for bridges andfootbridges

In the course of time, through longexposure to weather the surface of the

Compact Sheets may become impairedand lose some of its colour and gloss. For


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this reason it is recommended that onlylight colours are chosen. Surfaces thathave become dull through weathering maybe restored by an application of lacquer.Note: This information sheet does notaffect Compact Sheets, which have been

endorsed for use in cladding facades.

3. Transport & storageHPL Compact Sheet is a dense heavymaterial and is also relatively expensive.For these reasons it is important toobserve the following:

3.1 TransportWhatever means of transport is used, it isessential that pallets of sufficient sizesupport the entire sheet. They should bestrong enough to support the load without

buckling or deforming.The surface of each board should be clearof any debris, grit or foreign bodies as theycan become embedded under the weightof the load, resulting in damage. Whenloading, boards must not be dragged overone another but lifted cleanly by hand orhoist. The stacked boards must be madesecure to prevent slippage.

3.2 StorageHPL Compact Sheets should be stored inenclosed buildings where normal interior

conditions (18 240C and 50 60% RH)are maintained.

Boards will remain flat if stored in packs,horizontally with their edges flush to oneanother on a slightly oversized, perfectlyflat, stout base board, which has first beencovered with plastic sheeting and anabsolutely flat and substantial coverboard used to prevent their possibledistortion.

This procedure should be maintained

throughout their storage and reinstatedwhenever a sheet is removed.

fig. 1. Storage of sheets in stacks.

If boards are not stored flat for any lengthof time deformation can result. This will be

more difficult to rectify the thicker theboard. When a protective film is removed itshould be done on both sidessimultaneously.

4. Machining

In principle the instructions given in theGeneral Recommendations (Section 3) forHPL will apply. Additionally the followingspecial recommendations for CompactSheets should be observed.

4.1 GeneralThe increased thickness and density ofHPL Compact Sheets imposes greaterdemands on cutting tools and causesgreater wear. Tool manufacturers shouldbe consulted as to the type and quality oftungsten carbide tipping to provide the

best yield; especially where long runs ofproduction are contemplated and wherehigh quality finishes are required.Preliminary tests should also be carriedout.

In all machine processes, localisedheating caused by poorly maintainedcutting tools must be avoided. Equallyimportant is the removal of cutter swarf byan adequate dust extraction system duringmachining, as this can cause surfacemarking.

4.2 SawingWith HPL Compact Sheets, slower feedspeeds should be used than with HPLbonded boards and panels.Altering the exit angle of the saw blade byadjustments to its height can reducebreakout on the underside of CompactSheets.

Note: The higher the saw blade the betterthe top cut and the worse the bottom cutand vice versa.

fig. 2. Pre-scoring the underside of thesheet.


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Good results can also be obtained byusing a baseboard of plywood, hardboardor HPL beneath the Compact Sheet.

The best means of avoiding undersidebreakout is to use a scoring saw blade to

scribe the underside, prior to cutting withthe main blade.

These saws of smaller diameter operate inthe same parallel plane as the main sawblade but may revolve in the same, orcontrary, direction to it.

The rate of the feed speed essentiallygoverns the quality of the saw cut whensawing HPL Compact Sheets, having twodecorative faces. A speed of between 0.03and 0.05mms. per saw tooth has been

found the most successful.

The feed speed is obtained from thefollowing formula. When the rpm of thespindle is pre-regulated, the mostfavourable speed is obtained thus:

Feed speed per tooth: Sz ----S-----

mms/toothn x Z

Feed speed in mm/min S= Sz x n x Z(mms/min)

Or

No. of teeth required: Z = --------S

-----------n x Sz

Where : Sz = Feed speed in mm. per toothS = Feed speed in mm/minn = Spindle speed rpmZ = Number of saw teeth

Example: Number of teeth Z = 52Spindle speed n = 3500Feed speed/tooth

Sz=0.004mm

In the formula S = Sz x n x Z therefore

0.04 x 52 x 3500 = 7280mm/min =7.28m/min.

fig. 3 Feed speed per tooth (Sz)

4.3 Profile cutting and edge finishingThe sawn edges of HPL Compact Sheetsmay be machine finished by spindling orroutering. For good edge quality anallowance for this should be from 2-5mm.

For mass production, or where long runsare contemplated special cutter headshave been developed for machining HPLCompact Sheets.

For profile cutting, the use of diamondimpregnated cutting tools can berecommended in these instances.

Because of the higher cutting impact thework being machined must be securelyheld and firmly guided past the cutters.

In general, HPL Compact Sheets does notrequire any further protection bylacquering or veneering. Where the edgesof the board are seen, they can bemachine finished in a number of ways.

fig. 4 Various forms of machined edges.

Complete freedom from chatter marksfrom the cutter blades in spindle mouldingor routering is unavoidable. They may bereduced by feeding the work at a constantcontrolled speed (only by the use of amechanical power feed). In a subsequentfinishing process these can be removed byrubbing the edges with fine sandpaperfollowed by steel wool. If a furtherimprovement is required this can be donewith silicone free furniture oil.

Where necessary the exposed edges of

HPL Compact Sheets should be

Square cutting

Chamfering

Rebating

Profile shaping


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chamfered and corners softened to avoiddanger of injury.

4.4 DrillingFor drilling holes in HPL Compact Sheets,drill bits as supplied for plastic sheets are

most suitable. These are special drills witha point angle of between 60-80 degreesinstead of the normal 120 fluting which isalso wider which provides more room forswarf.

For the avoidance of breakout on the exitside, the feed speed and pressure appliedshould be gradually reduced at this point.Most important is to support the workpiece with another piece of plywood orchipboard firmly in contact with the exitside of the sheet.

Best results for the through drilling withminimum breakout of the underside is apoint angle between 50-60 degrees.

For blind boring Fig 5, the depth of thehole should be such that no less than1.5mm remains at (a).

(a)

fig. 5 Drill holes made in Compact Sheets

When drilling parallel to the board surfacea minimum thickness of 3mm should beleft between the edge of the hole and thesurface of the board.

For simultaneous drilling andcountersinking a combined drill andcountersinking bit may be used.

Threaded holes in HPL Compact Sheetscan be produced with engineers screwcutting taps. Self-tapping screws may alsobe used.

5. InstallationThroughout their subsequent installation, itshould be borne in mind that HPLCompact Sheets alter in dimension withchanges in climatic conditions. In thisrespect the change in longitudinal directionis about half that of the transverse

direction.

For fastening or connecting boardstogether, several well tried methods areavailable, e.g. surface mounted orconcealed extruded retaining strips,tongue and groove joints or fastening byscrews or nails*. In areas subject to damp,

corrosion resistant fixings should be used.* Should it be necessary to bond HPLCompact Sheets the principles set out inGeneral Recommendations for processingHPL Chapter 4 Section 5, should beobserved.

For the mechanical fastening and jointingthe following information is recommend.

5.1 Jointing HPL Compact sheetstogether

5.1.1 Tongue and GrooveWhen two HPL Compact sheets are to bejointed together the width of the groove (a)and the thickness of the cheeks (b) shouldbe at least 3mm. Where the boardthickness allows, the cheek thickness (b)should always be greater than the groovewidth (a). The depth of the groove shouldbe kept as small as possible (max 10mm).The following guidelines should bemaintained:

Groove width (a) = 3mm

Thickness of cheeks = >3mm(=a)Depth of tongue =


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5.1.2 Corner jointingPrecautions should be taken where impactdamage is likely to occur on externalcorners. Angle brackets or full-lengthmetal strips should be used.

5.1.3. Bonded JointsJoints made with adhesive should be soarranged so that dimensional changes arenot restricted. It is essential that theseparate panels be assembled having thesame longitudinal and transverse directionto avoid incurring differential stresses.

5.2. Fitting to Groundwork

Metal grounds change their dimensionswith variations of temperature whereas thedimensions of HPL Compact Sheets are

essentially altered by changes in relativehumidity (see also Para 5).These differences of movement of HPLand metal can often be in differentdirections to each other.The assembly must therefore containsufficient play in their fastenings to allowfor their respective movements.

These dimensional changes whilststrongly influenced by temperature andmoisture conditions are also relative to thesize and thickness of the sheet.

Double Panel Single Panel

= Slip point = Fixed point

Fig 7 Example of pattern of fixed andslip points for securing sheets to subframing. There are approved methods oferecting sheets. A stable and secure,stress free, regular, level and in goodalignment structure, is of fundamentalsignificance for the success of aninstallation.

In regard to its cladding, it should be takeninto account that:

The stability of the cladding is

determined both by the sub framing andthe thickness of the cladding panels.

The sub framing must be protectedagainst the possibility of corrosionand/or decay.

The HPL Compact sheets must beprovided with ample allowance forpossible movement of both shrinkage

and expansion. A special advantage with HPL Compact

sheets is that where required, panelsmay be removed and/or replaced byusing jointing techniques and sufficientallowance for side movement of thepanels to accommodate thisrequirement.

5.2.1. Simple Installation

fig. 8 Simple securing of panels to walls.

The appropriate depth of the groove thatallows panels to be shifted sideways andtaken out and/or changed should be used.

Fig 8 shows a possible solution where thiscan be done. The gap is shown filled witha hygienic (for hospitals) type of seamfiller. Alternatively, a laminate insert cut tothe exact width can also be bonded in toprovide a matching or contrasting detail,however, this detail should only ever beused in dry areas.

5.2.2 Fastening panels with overlappingprofiles.This type of fixing permits sufficientmovement of the HPL Compact sheets to

occur.

fig. 9 Securing panels with an Omegaprofile.


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5.2.3. Face fixing by screwing orbolting.When securing HPL Compact Sheets torigid sub structures such as metal framesor masonry, sufficient movement betweenthe components should be guaranteed by

the use of correspondingly oversizedscrew holes and:(a) washers under screw heads or bolt

heads(b) a slip foil between the back of the

Compact sheet and ground at its fixingpoint.

(a) (b)

fig. 10 Examples of through face bolting.

5.3 DoorsSmall sized doors of HPL Compact sheets(e.g. furniture) can be hung on one pair ofhinges.

Larger doors, (e.g. for changing cubicles),should be supported by more than twohinges. Not only should these be strongenough to support them withoutdeformation, but should contain sufficient

play to accommodate their dimensionalchanges. To keep these changes asminimal as possible the length of the doorshould be cut from the length direction ofthe sheet. The doorframe must besufficiently strong and must be erected ina flat and even plane to prevent stressesoccurring at the points of closure. Also theuse of rubber buffers and/or seals willdampen shocks from impact on closure inthis respect. The constant influence ofhigh humidity and/or high temperature onone side of the door can eventually cause

it to bow. It is therefore essential thatsufficient air circulation be provided toprevent this.

5.4 Fastening to Compact sheetsWhen securing rigid objects (e.g. fixinghook plates, profile strips or metal fittings)by bolting through the sheets as describedin Para 5.2.3, a clearance hole in thesheet should be used. When fixing into thesheet with bolts or screws that do notpenetrate right through the sheet (e.g.when using a spreader dowel or brass

bush inserts) a clearance hole in the fittingshould be provided. It is also

recommended that a slip foil between thetwo components be used.

5.4.1. Self-tapping screwsScrews with slow threads provide betterresistance to working loose than those

with fast threads. In all cases a pilot holeone-thread depth smaller than the outsidediameter of the screw must first be madein the sheet.

fig. 11 Bolting into Tap threaded holes.

5.4.2. Spreader Dowels (Brass inserts)The depth of the hole ought to be at least1mm deeper than the penetrating depth ofthe screw.

The highest screw holding is obtained bythe use of spreader dowels brass,threaded inserts which expand whenscrews are inserted into them.

fig. 12 Insertion of a spreader dowel

Dowel inserts should be plain sidedwithout grooves or ridges. At least 1.5mmshould be left between the bottom of thehole and the surface of the sheet.


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5.4.3 Through face fixingsHoles for this purpose should be drilled2-3mm larger than the diameter of thefixing screw or nail. The importantallowance for movement can also beachieved by the use of flexible insert

bushes (e.g. polyamide)

6. Cleaning and maintenanceHPL Compact Sheets are undemanding inthis respect and do not require specialmaintenance.

(a) Lightly soiled sheets may be cleanedwith a soft damp cloth.

(b) More heavily tarnished grime or stainscan be removed with warm soapywater or with a proprietary cleaningagent which does not contain any

abrasive material or strong alkaline (bleaching materials)

(c) Particularly hard dried deposits oflacquer or glue, ink from felt tipped orballpoint pens, lipstick and others mayin general be removed with a solventagent such as Methylated Spirits,Acetone or MEK etc. Where largescale quantity processing in whichlacquers and/or adhesives are used itis recommended that the producers ofthese products are consulted as towhich cleaning agent is the most

suitable for the removal of these andother spillages, such as deposits ofsynthetic resins (Urea, Melamine,Phenol or Resorcinol adhesives)together with reaction adhesives andlacquers based on Epoxy unsaturatedPolyester and Polyurethane after theyhave cured. Nitro Cellulose thinnersshould not be used as a cleaningagent because of their tendency toleave smears.After cleaning with solvents, anystreaks or smears may be removed

with a proprietary cleaning agent.Some solvents agents present adanger of flammability or if used inlarge quantities a health hazard.Windows should be opened and goodventilation should accompany suchprocesses.

(d) Paraffin and wax deposits must first ofall be removed, avoiding scratching ofthe surface and any remaining residuemay be ironed off over a layer ofblotting paper.

Polishing waxes or other polishes areunnecessary and should not be usedon HPL Compact Sheets.

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