Fabrication Guide - ESIcms.esi.info/Media/documents/Sylma_Fabrication_ML.pdf · 2016. 6. 21. ·...

This fabrication guide has been prepared to assist thefabricator and installer in the proper methods forseaming, polishing, patching and handling AvoniteSurfaces Studio CollectionTM and FoundationsTM solidsurface products.

Avonite Surfaces building and surfacing materials arewarranted to be free from defects at time of manufacture.Any materials found defective will be replaced promptly.

Information or references to application, code complianceor specific standards are provided for convenience only.The accuracy or suitability of any recommendations in

this guide must be verified by the user, Aristech AcrylicsLLC disclaims any legal responsibility.

Questions pertaining to any procedure detailed hereinshould be addressed to the Avonite Surfaces TechnicalServices Department.

Avonite Surfaces Technical Services Department1-800-866-TECH (866-8324) or

(505) 864-3800 Fax (505) 864-77901945 Hwy 304, Belen, NM 87002 USA

Name:

Address: Date of Seminar:

Instructor:

Fabrication Guide

Welcome

© Aristech Acrylics LLC • July 2007 • Avonite Surfaces Technical Services (800) 866-TECH • FAX (505) 864-7790 • www.avonitesurfaces.com

WWHHOO WWEE AARREE

Since 1983 we’ve been a pioneer in solid surfacing, known for our unbridled passion and spirited innovations.We’ve been there, with many of you, from the beginning. For more than twenty years, we’ve celebrated therelationship between extraordinary product, design and craftsmanship. We are inspired by and committed todesigners and fabricators with a passion for bringing forth original ideas and taking them beyond the ordinary.

HHOOWW TTOO UUSSEE TTHHIISS GGUUIIDDEE

We at Aristech Acrylics LLC hope you will find the following Fabrication Manual to be a useful tool. It wascreated to help you discover the unlimited design possibilities, which will lead to wonderful solutions for youand your clients.

The Avonite Surfaces Fabrication Manual has been recently updated to encompass a Quick Reference Appendixwith charts for Current Colors, Joining, Inlays, and Finishes.

Many of the documents and drawings included in this guide are available for viewing or downloading fromour website at www.avonitesurfaces.com. Future updates will also be found on the website.

If you have specific questions or requests, our friendly and expert technical staff is eager to help. Feel free tocall your regional representative or contact us at 1-800-866-TECH (8324).

This Fabrication Guide is also available online at www.avonitesurfaces.com

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SSEECCTTIIOONN 33:: IINNSSTTAALLLLAATTIIOONN

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SSEECCTTIIOONN 77:: PPOOSSTT IINNSSTTAALLLLAATTIIOONN

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Table of Contents


A.1Avonite Surfaces Colors


FOUNDATIONSTM

Solids

Bone F1-8010Creme F1-8024Ivory F1-8106White F1-8016

Dunes

Artica F1-9065Aspen F1-9105Biscotti F1-9033Black Lava F1-9020Bronze F1-7830Cypress F1-9085High Desert F1-9037Infinity F1-7845Malt F1-7810Mesa Brown F1-9040Night Shadow F1-9024Pumice F1-9032Raw Cotton F1-9016

River Moss F1-9058Sandstorm F1-9036Star Shine F1-7820Stormy Gray F1-9010

Minerals

Black Coral F1-9125Cairo F1-9130Casablanca F1-9137Cordoba F1-9234Fargo F1-9138Juneau F1-9116Kokoura F1-9117Nordic F1-9119Olivine F1-9154Palermo F1-9144

Pediments

Algodon F1-7713Arroyo F1-7936

Blue Moon F1-7745Boardwalk F1-7921Cliffside F1-7931Coastal Green F1-7734Dark Roast F1-7735El Cajon F1-7933Good Earth Red F1-7940Gulf Coast F1-7710Jurassic F1-7711Meadow Grass F1-7730Newcastle F1-7920Piñon F1-7912Quick Sand F1-7932Red Rock F1-7743Spanish Moss F1-7733Thunder Bay F1-7720Tuscan Gold F1-7725

Customer must specify matte, satin or gloss finish for their installation.

STUDIO COLLECTIONTM

Crystelles

Autumn Wheat K3-7725Aztec Brown K3-7700Black Ice K3-7100Blue Pearl K3-8000Brazilian Blue K3-8100Cement K3-8425Midnight Sky G3-1050Nougat K3-8500Pistachio K3-8450Saffron K3-8410Willow K3-7800

Metallics

Argent K3-8565Cat Eye K3-8330Chocolate Silk K3-8342Coppermine K3-8490Copper Canyon K3-8570

Cosmic Penny K3-8590Goldmine K3-8495Martian Sunset K3-8595Moss Frost K3-8310New Caldron K3-8320Night Pearl K3-8580Pearl K3-8343Silver Comet K3-8585Teal Steel K3-8341Tusk K3-8340Wasabi Shadow K3-8315

Traditions

Adobe Brown C1-1700Desert Ridge K1-6635Jicama K1-6625Limestone C1-1610Sandpiper K1-6200

Glass Series

Amber Glass K3-8560Antique Glass K3-8455Cobalt Glass K3-8485Frosted Glass K3-8480Ruby Glass K3-8420Sky Glass K3-8465

Recycled

Cottonwood K1-6600Cozumel K3-8575Crater K1-6639Crushed Lava K1-6637Kaleidoscope K3-8200Palm Desert K1-6638Summer C1-2900White Sands K1-6636

A.2 Joining Color Chart


Crystelles

Sheet Stock Code Adhesive

Autumn Wheat K3-7725 Clear

Aztec Brown K3-7700 Clear

Black Ice K3-7100 Jewel

Blue Pearl K3-8000 Clear

Brazilian Blue K3-8100 Clear

Cement K3-8425 Clear

Midnight Sky G3-1050 Jewel

Nougat K3-8500 Beige

Pistachio K3-8450 Cream

Saffron K3-8410 Cream

Willow K3-7800 Clear

Metallics


Argent K3-8565 Jewel

Cat Eye K3-8330 Clear

Chocolate Silk K3-8342 Brown

Copper Canyon K3-8570 Clear

Coppermine K3-8490 Clear

Cosmic Penny K3-8590 Clear

Goldmine K3-8495 Clear

Martian Sunset K3-8595 Clear

Moss Frost K3-8310 Clear

New Caldron K3-8320 Clear

Night Pearl K3-8580 Clear

Pearl K3-8343 Cameo White

Silver Comet K3-8585 Pearl Gray

Teal Steel K3-8341 Clear

Tusk K3-8340 Clear

Wasabi Shadow K3-8315 Clear

Traditions


Adobe Brown C1-1700 Brown

Desert Ridge K1-6635 Cameo White

Jicama K1-6625 Beige

Limestone C1-1610 Beige

Sandpiper K1-6200 Beige

Glass Series


Amber Glass K3-8560 Clear

Antique Glass K3-8455 Clear

Cobalt Glass K3-8485 Clear

Frosted Glass K3-8480 Clear

Ruby Glass K3-8420 Clear

Sky Glass K3-8465 Clear

Recycled


Cottonwood K1-6600 Glacier White

Cozumel K3-8575 Glacier White

Crater K1-6639 Clear

Crushed Lava K1-6637 Pearl Gray

Kaleidoscope K3-8200 Glacier White

Palm Desert K1-6638 Beige

Summer C1-2900 Pearl Gray

White Sands K1-6636 Pearl Gray

STUDIO COLLECTIONTM

A.3Joining Color Chart


FOUNDATIONSTM

Solids


Bone F1-8010 Beige

Creme F1-8024 Beige

Ivory F1-8106 Beige

White F1-8016 Glacier White

Dunes


Artica F1-9065 Cameo White

Aspen F1-9105 Pearl Gray

Biscotti F1-9033 Beige

Black Lava F1-9020 Jewel

Bronze F1-7830 Clear

Cypress F1-9085 Clear

High Desert F1-9037 Beige

Infinity F1-7845 Clear

Malt F1-7810 Beige

Mesa Brown F1-9040 Brown

Night Shadow F1-9024 Jewel

Pumice F1-9032 Pearl Gray

Raw Cotton F1-9016 Beige

River Moss F1-9058 Brown

Sandstorm F1-9036 Beige

Star Shine F1-7820 Jewel

Stormy Gray F1-9010 Pearl Gray

Minerals


Black Coral F1-9125 Jewel

Cairo F1-9130 Beige

Casablanca F1-9137 Beige

Cordoba F1-9234 Beige

Fargo F1-9138 Pearl Gray

Juneau F1-9116 Glacier White

Kokoura F1-9117 Glacier White

Nordic F1-9119 Cameo White

Olivine F1-9154 Clear

Palermo F1-9144 Pearl Gray

Pediments


Algodon F1-7713 Cameo White

Arroyo F1-7936 Pearl Gray

Blue Moon F1-7745 Pearl Gray

Boardwalk F1-7921 Pearl Gray

Cliffside F1-7931 Brown

Coastal Green F1-7734 Pearl Gray

Dark Roast F1-7735 Brown

El Cajon F1-7933 Beige

Good Earth Red F1-7940 Brown

Gulf Coast F1-7710 Beige

Jurassic F1-7711 Beige

Meadow Grass F1-7730 Pearl Gray

Newcastle F1-7920 Pearl Gray

Piñon F1-7912 Pearl Gray

Quick Sand F1-7932 Beige

Red Rock F1-7743 Pearl Gray

Spanish Moss F1-7733 Pearl Gray

Thunder Bay F1-7720 Pearl Gray

Tuscan Gold F1-7725 Beige

1.1Color & Sizes


CCOOLLOORRSSFor a complete list of current colors, please see TableA.1 in this manual, or visit www.avonitesurfaces.com.

SSIIZZEESSAvonite Surfaces Studio CollectionTM sheets are availablein 36" (91.5cm) by 120" (304.8cm) lengths.

Avonite Surfaces Foundation™ is available in 30"(76.2cm) widths by 144" (365.7cm) lengths. 1/4" is alsoavailable in 36" (91.5cm) by 96" (243.9cm), and 60"(152.4cm) by 72" (182.9cm). Custom sizes are availableon special order.

TTHHIICCKKNNEESSSSAll Avonite Surfaces sheets are available in standardthickness of 1/2" (12mm).

Foundation™ is available in 1/2" (12mm) and 1/4"(6mm) thickness.

CCOONNVVEERRSSIIOONN CCHHAARRTTMMuullttiippllyy BByy TToo OObbttaaiinnMeters 3.281 FeetMeters 39.37 InchesMillimeters .03937 InchesFeet 30.48 Centimeters

PPRROODDUUCCTT IIDDEENNTTIIFFIICCAATTIIOONNAll Avonite Surfaces color numbers not only identifythe product color, but also reveal other informationsuch as product category and fire rating.

KK33--77110000

PPrroodduucctt CCaatteeggoorryyF = Foundations™ AcrylicsC,G = Century Tradition SeriesK = Crystelle® Collection SeriesA,M = Gemstone Agate Series

FFiirree RRaattiinngg1=Class I Fire Rating3=Class III Fire Rating

1/4" solid surface must be adhered to anon-combustible substrate for a class 1 fire rating.

NNaammee//CCoolloorridentifies particular color offered

Custom colors are available on quotation.

**** GGEEMMSSTTOONNEE AAGGAATTEESS may have slight variations incolor pattern and veining. Color coordinationdeveloped from a sample chip should be verifiedwith sheet to be used. Avonite Surfaces StudioCollection should be color approved bbeeffoorreefabrication.

Product Category

Fire Rating

Product Name/Color

1.2 Health & Safety Information


FFOORR SSHHEEEETT AANNDD SSHHAAPPEEDD PPRROODDUUCCTTSS FFIIRRSSTT AAIIDD PPRROOCCEEDDUURREESS::

Avonite Surfaces solid surfacing material is non toxic;however, during fabrication such as sawing, routingand sanding, dust consisting of cured resin and filleris generated. This dust is classified as Nuisance Dust.

IINNHHAALLAATTIIOONN:: Nuisance Dust—Overexposure to dust may causeirritation of the respiratory tract. Should thishappen, remove affected individual to fresh air. Ifsymptoms persist, consult a physician. Styrene—Although no vapor build-up is expected,excessive inhalation of vapors can cause nasal andrespiratory irritation, dizziness, weakness, fatigue,nausea, headache and even asphyxiation. Removeaffected individual to fresh air. If symptoms persist,consult a physician.

SSKKIINN OORR EEYYEE::Nuisance Dust—May cause irritation. Wash skinand flush eyes with water for at least 15 minutes.Contact physician if irritation persists.

Styrene—Vapor concentration is expected to be toolow to cause irritation, but odor is recognizable.Excessive exposure can cause severe eye irritationand moderate skin irritation. Wash skin and flusheyes with water for at least 15 minutes.

EEXXPPOOSSUURREE CCOONNTTRROOLL MMEETTHHOODDSS

Provide sufficient ventilation and dust pick-up at saw,sander, drill or router to keep dust level below 10mg/m3 TWA (Time Weighted Average) for total dust, orprovide and make mandatory the wearing of NIOSHapproved fitted dust respirators.

Wear protective leather or cotton gloves, safetyglasses and safety shoes when installing orfabricating Avonite Surfaces solid surfacing material.

DDIISSPPOOSSAALL PPRROOCCEEDDUURREESS

Dust from fabrication operations is non-hazardous.Collect in impervious bags. Dispose of dust and scrapin accordance with local, state and federal regulations.

FOR MORE COMPLETE INFORMATION, REQUEST THEMATERIAL SAFETY DATA SHEET.

IINNLLAAYY RREESSIINNCCAAUUTTIIOONN: ■ FLAMMABLE COMPONENTS; AVOID HEAT, SPARKS

AND OPEN FLAME.■ WEAR SAFETY GLASSES AND PROTECTIVE GLOVES.■ FOR PROFESSIONAL USE ONLY.■ USE ONLY AS RECOMMENDED.

The Inlay Resin is a polyester resin used with MEKperoxide. These components and vapors may causeirritation of the skin, eyes, nose and throat. AVOIDCONTACT WITH EYES, SKIN AND CLOTHING. USE ONLYWITH ADEQUATE VENTILATION; AVOID BREATHINGVAPORS. WASH HANDS AFTER USE.

EEMMEERRGGEENNCCYY AANNDD FFIIRRSSTT AAIIDD PPRROOCCEEDDUURREESS::

In case the resin or catalyst contacts your skin, washwith soap and water, for at least 15 minutes. Foreyes, immediately flush with water for at least 15minutes. Contact physician if irritation persists. Incase of ingestion, immediately consult a physician oryour local poison control center, identifying thecatalyst as methyl ethyl ketone peroxide solution indimethyl phthalate containing a small amount ofhydrogen peroxide, and the resin as an unsaturatedpolyester in styrene monomer.

SSPPEECCIIAALL HHEEAALLTTHH EEFFFFEECCTTSS::

Excessive inhalation of resin monomer may aggravatepre-existing medical conditions such as, but notlimited to, chronic respiratory problems, skin diseaseand central nervous disorders.

There is a low health risk from inhalation of the fillerdust. Avoid inhalation or eye contact.

DDIISSPPOOSSAALL PPRROOCCEEDDUURREESS::

Un-reacted resin and hardener are classified ashazardous waste. All components should bedisposed by mixing so that they react and becomefully cured and solid. At this point, they can then bedisposed in accordance with local, state and federalregulations, as non-hazardous solid waste.

FOR MORE COMPLETE INFORMATION, REQUEST THEMATERIAL SAFETY DATA SHEET, or visit

www.avonitesufaces.com.

1.3Health & Safety Information


AAVVOONNIITTEE SSUURRFFAACCEESS SSOOLLIIDDSSUURRFFAACCEE AADDHHEESSIIVVEECAUTION■ FLAMMABLE COMPONENTS:

Avonite Surfaces Solid Surface AdhesiveComponent A contains acrylic resin andComponent B contains benzoyl peroxide. Theliquid and vapors may cause irritation to skin,eyes, nose and throat and may even cause anallergic skin reaction.

■ AVOID HEAT, SPARKS AND OPEN FLAME ■ USE ONLY AS DIRECTED ■ WEAR SAFETY EYE PROTECTION ■ AVOID CONTACT WITH EYES, SKIN AND

CLOTHING ■ HAVE ADEQUATE VENTILATION ■ AVOID BREATHING VAPORS ■ WASH HANDS AFTER USE

EEMMEERRGGEENNCCYY AANNDD FFIIRRSSTT AAIIDD PPRROOCCEEDDUURREESS::

If the Avonite Surfaces Solid Surface Adhesive resinor hardener contacts your skin, wash with soap andwater for 15 minutes. For eyes, immediately washthoroughly with plenty of water for 15 minutes andconsult a physician. In case of accidental ingestion,immediately consult a physician or your local poisoncontrol center, identifying the hardener as benzoylperoxide in plasticizer and the resin as acrylic resinin methyl methacrylate monomer.

NNootteess::

SSPPEECCIIAALL HHEEAALLTTHH EEFFFFEECCTTSS::

Excessive inhalation of resin monomer may aggravatepre-existing medical conditions such as, but notlimited to, chronic respiratory problems, skin diseaseand central nervous disorders and may cause nauseaand loss of consciousness.

DDIISSPPOOSSAALL PPRROOCCEEDDUURREESS::

Acrylic resin and hardener when disposed in liquidstate are hazardous waste but when mixed andpolymerized are non-hazardous solid waste. Disposeof used or unused Avonite Surfaces Solid SurfaceAdhesive by mixing components, allowing themixture to solidify and then disposing in accordancewith applicable local, state and federal regulations.

The information and statements herein are believed tobe reliable but are not to be construed as a warranty orrepresentation for which we assume legal responsibility.

FOR MORE INFORMATION REQUEST THE MATERIALSAFETY DATA SHEET, or visitwww.avonitesurfaces.com.

1.4 Storage and Handling


Avonite Surfaces material should always be storedFLAT and evenly supported. Figure A demonstrates aframed substrate. Figure B is an A-Frame storage bin.

Always carry sheets upright in a vertical position. Toavoid chipping and scuffing, do not drop or dragsheets. Fabricated sections with angles or seamsshould be handled carefully with support at theangled or seamed area. A carrying board should beused for tops with cut outs (Figure C).

Avonite Surfaces Studio Collection can betransported lying flat on an evenly supported andpadded surface. Large fabricated sections should betransported on edge. Pad the edges to preventdamage and brace to prevent movement (Figure D).When transporting Avonite Surfaces in an exposedvehicle, pieces should be wrapped to preventdamage from extreme temperature changes. Avoidexposing fabricated pieces to direct sunlight. Unevensolar heating will cause distortion of fabricated parts.Allow pieces to cool to room temperature at the jobsite prior to installation.

A.

B.

C.

D.

1.5Color Matching


Every Avonite Surfaces sheet has a sticker whichdisplays an identification number. When orderingmultiple sheets to be seamed, be sure that sheetscome from the same batch.

Please notify distributor of this fact when ordering.Advise that you need sheets with consecutive numbers.Although the Avonite Surfaces sheet has beeninspected prior to shipment, always remove peel coatand inspect for color consistency, surface blemishes,warping, and dimensional consistency.

Remove the protective peel coat and arrange thesheets in the manner they will be installed. Sand 12"-16" (305mm - 407mm) of the surface to verify colormatch. After sanding, wet material with alcohol orwater.

For Studio Collection, be aware that the pattern at theedge and end of the sheet may be different from thecenter of the sheet. This may not be noticeable whenlooking at a single sheet. Always plan to trim 1"-2"(25mm - 51mm) off an edge to be joined to anotherpiece. Aristech Acrylics LLC does not honor any claimsthat have migration due to not trimming the sides orends of the sheet when joining them together.

Gemstone Agates may have slight variations in colorand pattern. Color coordination developed from asample chip should be verified by fabricator and end-user on the sheet(s) to be used. Sheet-stock shouldbe color approved BEFORE fabrication.

120"

(30

4.8c

m)

120" (304.8cm)

36"(91.5cm)

36"(91.5cm)

TTHHEE LL TTEEMMPPLLAATTEEThe L-Template is a convenient way to fabricate theL or U shaped counter top.

The L-Template should be 10' (305cm) long by about30" (76cm) wide. The inside corner will have aminimum 1" (25.4mm) radius. The L-Template may bereversed and used for either side.

Clamp the L-Template securely to the AvoniteSurfaces material. Place some registration marks onthe back side and end of the template. Use a 3 HProuter and template guide for cutting. After cutting,turn the material bottom side up to bond on the dropedge and inside corner build up.

When the Avonite Surfaces Solid Surface Adhesivehas hardened, turn the material face up and re-clampthe L-Template. Using the registration marks, placethe template far enough back to remove the excessmaterial and Avonite Surfaces Solid Surface Adhesive.This will result in a clean and smooth edge requiringminimal sanding.

LLOOCCAATTIINNGG SSEEAAMMSSWhen you lay out your job, consider where you needto place the seams. Make as many seams as possiblein the shop and not in the field. All seams must besupported. Avoid placing seams in the followinglocations:1. Inside corners (Minimum 2" [50mm]).2. In cut outs.3. Over dishwashers or other heat producing appliances.4. When using dark colors, avoid placing seams in

direct sunlight.

MMiitteerrssThe distinctive vein patterns of Studio CollectionGemstone Agate colors usually require mitering at theinside corners. This should only be done using thewavey bit system and sufficient seam blocks. (SeeSeam Blocks)

SSEEAAMM BBLLOOCCKKSSThe use of seam blocks is REQUIRED for all seams. Seam blocks should be 4" (101mm) wide and be atleast 1/2" (12mm) thick. Join the seam block to theunderside using Avonite Surfaces Solid SurfaceAdhesive. Spread the Avonite Surfaces Solid SurfaceAdhesive over the entire surface so there are no voids.

SSeeaamm bblloocckkss aarree mmaannddaattoorryy.. SSeeaammss tthhaatt aarree nnoottbblloocckkeedd aarree nnoott ccoovveerreedd uunnddeerr wwaarrrraannttyy..

1.6 Layout


120" (305cm)

24"(612mm)

24"(612mm)

30"(762mm)

Minimum 1" (25.4mm) radius

4" (101mm)

1"(25.4mm)

1"(25.4mm)

1/2" (12.7mm)

One thickness exampleSeam Block

IINNSSIIDDEE BBLLOOCCKKSSAvonite Surfaces material requires a minimum 1"(25.4mm) radius on drop edge inside corners. Thisdiagram shows the recommended build up.After the buildup is made, use a template to cut thedesired radius (see L-Template).

EEXXPPAANNSSIIOONN AANNDD CCOONNTTRRAACCTTIIOONNLike all solid surface materials, Avonite Surfaces materialexpands or contracts with temperature variation.The following changes in length may occur with aswing in temperature of 55° F (31 ° C).Class I(Filled)—1/8" (3mm) for every 10' (304.8cm)Class III(Unfilled)—3/16" (5mm) for every 10’(304.8cm)Always leave appropriate clearances for expansionand contraction.

TTIILLEE BBAACCKKSSPPLLAASSHHEESSMust be siliconed where the tile meets the AvoniteSurfaces material and not grouted.

TTRRAANNSSLLUUCCEENNTT CCOOLLOORRSSGemstone Agates and Glass Series are translucent inareas and may require a seal coat of water basedinterior/exterior primer on back of the sheet toreduce shadowing effects. For more information callthe AAvvoonniittee SSuurrffaacceess TTeecchhnniiccaall SSeerrvviiccee DDeeppaarrttmmeenntt..

1.7Layout


Minimum 2"(51mm)

Minimum 2"(51mm)

Minimum 1"(25.4mm) radius

1/8" (3mm) clearance

1/16" (1.5mm) clearance

1/8" (3mm) clearance

DDEESSIIGGNNIINNGG AANNDD FFAABBRRIICCAATTIINNGG WWIITTHHAAVVOONNIITTEE SSUURRFFAACCEESS SSTTUUDDIIOO CCOOLLLLEECCTTIIOONNGGLLAASSSS SSEERRIIEESSThe unique translucent quality of Avonite SurfacesGlass products allows you to exercise a great deal ofcreativity. For this reason, it is expected that there willbe many new applications that will produceunanticipated effects. By all means experiment, becreative, and consult with us as you have questions.However, always make sure that the end result will meetyour expectations and those of your client by doing atest piece to demonstrate the effect you are trying toachieve. Should you develop special techniques fordealing with new applications, please give our TechnicalServices department a call at 800.866.8324

TThhee NNaattuurree ooff AAvvoonniittee SSuurrffaacceess SSttuuddiioo CCoolllleeccttiioonnGGllaassss SSeerriieessKeep in mind that dabs of silicone, supports, andunder-mount sink flanges will show through theseproducts like any typical glass. When the products arelaminated together for a thicker appearance, such as adrop edge or seam block, they will appear darker dueto reduced light transmission. These special effectscan be worked into the design for a unique aestheticeffect or application. Thermoforming of AvoniteSurfaces Studio Collection Glass products is notrecommended.

When Glass products are chosen for more typicalapplications, where less transparency is desired, thebacksides of the finished top can be painted to hideany supports. We have found that most customers

prefer the brighter appearance when the backsides

are painted white.. The color you choose will affect thefinal appearance. Frosted glass offers uniqueopportunities for painting the back different colors toachieve custom hues that transmit through the sheet.Painting should be done after fabrication to avoidpainting any surface where Solid Surface Adhesive willbe applied (field seams, build up, etc):

SSeeaamm BBlloocckkssDue to the translucency of the glass products, on someoccasions the clear acrylic seam-blocks are noticeable.Therefore Avonite Surfaces has decided on thefollowing procedure for seams in the GLASS series.

The edges of the seams should be routed with thePinske Wavy Bit System. This allows for added gluearea & helps to align the surface better. After gluehas dried, sand seam, flip sheet and do remainingfabrication, edge build up, sinks etc. Clean up excessglue before it dries. Then paint the back of the sheetwith a flat latex paint (WHITE). After the paint hasthoroughly dried, attach the substrate. In the areawhere the seam is put a 4" wide piece of thesubstrate to act as a seam block using extra silicone.

For field seams, prepare edges as above, but stopsubstrate 2" from each edge of the seam and applythe 4" wide substrate “seam block” and attach whenmaking the field seam.

If there are seams in a top that is to be backlit, runa full sheet of 1/2" clear acrylic under the top beingsure to cover the seam. Do not glue a seperate 4"piece of the clear acrylic under the seam.

1.8 Layout


BBaacckklliitt AApppplliiccaattiioonnssFor backlit applications, you may use clear1/2"(12.7mm) acrylic to support larger spans. Using the1/2" (12.7mm) clear acrylic sheet as a solid substrate isrecommended. The clear acrylic will not appear whenlit. Counters must be supported every 24" (61.2cm)Frosted or white acrylic may be used to diffuse the lightsource. When adhering the Avonite Surfaces glassproduct to the acrylic, we recommend 100% siliconecontaining a matching translucent tint, such as AxiomSealants (Buffalo, NY 14215, phone: 716.894.1561 oremail at [email protected]), or equivalent. Anothermethod uses 3M VHB Clear Acrylic double side tape#4910 90065 287 N. Always test a small piece to judgeappearance. Backlit Applications that require deckseams or have unsupported spans will require specialconsideration. Please call Avonite Surfaces TechnicalServices (800.866.TECH [8324]) as you have questions.

1.9Layout


Avonite Surfaces material can be easily machinedwith ordinary woodworking tools, such as routers,saws, planers, lathes, drills, and sanders. All bladesand bits should be carbide tipped.

RROOUUTTEERRSSFor general purpose routing, a 1-1/2 to 2 HP router maybe used. For heavier cutting of thick edges and cutouts a 3 HP router is recommended. A 1/2" (12.7mm)shank carbide bit is needed to minimize chatter for allrouting with the exception of small details like a 1/4"(6.3mm) round over or a pin stripe inlay.Avonite Surfaces material should be properlysupported during all phases of fabrication.

CCUUTT OOUUTTSS AANNDD CCUURRVVEEDD CCUUTTSSA template and a router is mandatory for all cuts. Theuse of a saber saw will leave a rough edge wherestress cracks can occur.

Use a template for all inside and outside cornerradiuses.

Two square feet of color matched material must beleft on the job site for future repairs.

Material should be placed under a bottom drawer ormounted to the inside of the sink cabinet.

Mark the material to identify it is for repairs.

2.1Tooling


2.2 Tooling


TTAABBLLEE SSAAWWSSA table saw with a minimum 2 HP motor can be usedto cut Avonite Surfaces materials. The sheets shouldbe cut face up. A good quality rip fence is necessaryfor accuracy.

A triple chip bevel saw blade is needed for a cleancut with minimum chipping. A 10" (254mm) diameterblade should have 40 teeth with a 20° positive hook.Raise the blade 1-1/4" (32mm) above the surface ofthe material for the best results.

RRAADDIIAALL AARRMM AANNDD MMIITTEERR BBOOXX A triple chip bevel saw blade should be used forclean cuts. These saws require a 10" (254mm)diameter blade with 60 teeth and a 5° positive hook.

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MMoonnuummeenntt TToooollwwoorrkkss ((PPaarraalllliiggnn))((550088)) 664444--22440000

JJCCMM IInndduussttrriieess,, IInncc..11--880000--666699--55551199

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FFeessttooooll PPoowweerr TToooollss 11--888888--333377--88660000

VVeelleeppeecc ((RRoouutteerr BBiittss))11--880000--336655--66663366

Triple Chip Bevel

2.3Machining Seams


Use a good quality 1-1/2 – 2 HP router. Refit base withsquare base. Two dimensions on base allow you to turnbase and remove an additional 1/16" (1.5mm). Alwaysuse a 1/2" (12.7mm) double fluted carbide router bit.

Set the router flat against straight edge. Lubricate withcornstarch to minimize friction between router baseand straight edge. Move router with even feed speed.Allow router sound to indicate the rate of feed.

After routing edges, dry fit to assure a flat, true edge.In the dry fit process, the seam should virtuallydisappear. If the seam is not done correctly, redo bytaking off an additional 1/16" (1.5mm). Check by dry-fitting again.

After routing, check again for a quality dry fit. Onlyafter you have achieved a good dry fit should youproceed.

2.4 Machining Seams


With 100 grit sand paper on a hardwood block,lightly score the edges to be fused together. Thisstep aids the adhesion between the two surfaces.Make one or two passes only. Be careful not to sandthe top edge.

MMIIRRRROORR CCUUTTTTIINNGGMirror cutting is a method of machining seams whichcuts both edges to be seamed at the same time. Useonly a 1/2" (12.7mm) shank double fluted bit. Placethe two pieces to be seamed 1/4" (6.3mm) apart andsecure them firmly to prevent movement. Clamp yourstraight edge to one side. The router must be fedthrough with a continuous movement withoutstopping. The two pieces will fit together exactly.

WWAAVVYY BBIITT SSYYSSTTEEMMAnother way to machine seams is to use the WavyEdge Router Base and Bit to make two interlockingsurfaces that fit snugly together. The seam edgesalign perfectly and do not slip, and a wavy surfaceseam is stronger because it has more adhesive areaallowing better bonding.

Here’s how: rout one seam edge with one side of thestepped Router Base, then rotate the router 180degrees and rout the other seaming surface. Use ahigh-grade carbide bit with a reversible insert bladeto cut the wavy seam. Inserts eliminate resharpeningand ensure the accuracy of every cut. You save timepreparing the seams, and the automatic alignmentmeans you will not do as much sanding to get aprofessional finish.

AAVVOONNIITTEE SSUURRFFAACCEESS SSOOLLIIDDSSUURRFFAACCEE AADDHHEESSIIVVEEis a pre-measured and pre-tinted two part adhesive.Avonite Surfaces Solid Surface Adhesive hardens inapproximately 40 minutes and is available in 250 ml.cartridges. Avonite Surfaces Solid Surface Adhesive isavailable in several colors and clear. Avonite SurfacesSolid Surface Adhesive must be used to hard seamany Avonite Surfaces product.

CCAARRTTRRIIDDGGEESSEach cartridge contains 250 ml (10 oz.) of adhesiveand will adhere 35 to 45 feet (12.1M) of 1/2"(12.7mm) seam. The adhesive flows through a staticmixer tube and is ready for use. Two mixer tubes areincluded with each cartridge.To assure positive flow of activator, dispense a smallquantity of Avonite Surfaces Solid Surface Adhesivebefore installing mixer tube.

REFER TO MACHINING SEAMS SECTIONBEFORE APPLYING AVONITE SURFACES

SOLID SURFACE ADHESIVE

SSTTOORRAAGGEE OOFF AAVVOONNIITTEE SSUURRFFAACCEESSSSOOLLIIDD SSUURRFFAACCEE AADDHHEESSIIVVEEIt is recommended that Avonite Surfaces Solid SurfaceAdhesive be stored in a refrigerator. Cold weatherconditions will not affect Avonite Surfaces Solid SurfaceAdhesive, but it must be acclimated to at least 60° F or15° C before being used. Store cartridges in an uprightposition as shown in photo. Storage at temperaturesabove 75°F or 24°C may affect the shelf life, and couldadversely affect proper curing of the adhesive.

CCOOLLOORRSSFor a complete list of current adhesive colors, pleasevisit www.avonitesurfaces.com.

TTEECCHHNNIIQQUUEEFrom time to time the bead of adhesive dispensedwith the Avonite Surfaces Solid Surface Adhesivecartridge will not contain the prescribed amount ofhardener. This may arise for a variety of reasons, butthe end result is that small sections of the seam maynot set up as rapidly as others. There are techniquesthat will reduce the variation in setup time.

Once the bead of adhesive has been dispensed, apopsicle stick applicator may be use to spread theadhesive over the bonding surface. This serves to moreuniformly blend the adhesive with the hardener andprevents variation in the hardening time of the adhesive.

Another helpful technique used frequently, is todispense two thin beads as opposed to one thick bead.This method overlaps any possible gap in the hardenerand prevents uneven hardening.

2.5Joining


Store cartridgesvertically

AAPPPPLLYYIINNGG AAVVOONNIITTEE SSUURRFFAACCEESSSSOOLLIIDD SSUURRFFAACCEE AADDHHEESSIIVVEESand the top of the seam with 100 grit sandpaper toenhance the bond. Clean edges thoroughly with onlyisopropyl alcohol. Place separation paper under seamarea.

DDIISSPPEENNSSEERRSSThe dispenser will accept only cartridges (10 to 1 ratio)and is available in a manual or pneumatic system.

UUnniiqquuee PPrrooppeerrttiieess■ The activator is opaque and viscous, much like a

paste.■ The resin is similar to the viscosity of honey.■ The “clear” Avonite Surfaces Solid Surface Adhesive

is “foggy” in appearance rather than “water clear.”

For a complete list of current adhesive colors, pleasesee Tables A.2 and A.3 in this manual, or visitwww.avonitesurfaces.com.

2.6 Joining


Manual Dispensing Gun Pneumatic Dispensing Gun

HHeellppffuull HHiinntt:: When asmall amount isneeded there is noreason to waste amixing tube. Simplyremove the end plugand squeeze theAvonite Surfaces SolidSurface Adhesive intoa paper cup and stirfor one minute.

A.

B.

C.

CCLLAAMMPPIINNGG SSEEAAMMSSBefore clamping seams, be sure to double check thefollowing:1. Surfaces to be bonded are properly scuffed with 100

grit sandpaper.2. Separation paper is in place.3. Pieces are properly aligned and level.4. Clean.

Prepare some reusable glue blocks made from scrappieces of Avonite Surfaces material. They should be 1"(25.4mm) thick by 1-1/2" (38mm) w x 2" (51mm). Bevelthe edges and drill 1/4" (6.3mm) holes as shown in Figure1 so the isopropyl alcohol will penetrate and release thehot melt bond.

On a standard countertop, hot melt 3 pairs of blocks about6" (152mm) apart across the seam area (see Figure A). Barclamps are then used to bring the joint together. Be surethe glue squeezes out to ensure a tight seam. However,avoid using excessive pressure which may cause too muchglue to be squeezed out resulting in a weak joint.

After the seam has hardened, remove the blocks byapplying isopropyl alcohol and allowing a few momentsfor the hot melt to soften. Also apply alcohol in the 1/4"(6.3mm) holes to allow for penetration of alcohol in thecenter of the block. Then place a chisel under the bevelededge of the block and gently pry; do not use excessiveforce. If the block does not free immediately, apply morealcohol and allow to soak for a while longer.

Other effective clamping methods use the Pinske PowerGrips with brackets and turnbuckle, as shown in FigureB, or the Parallign Clamps shown in Figure C (Availablethrough Monument Toolworks 508-644-2400).

Other innovative devices designed by independentsuppliers may save time or simplify difficult tasks. Ifthere is any question regarding the use of suchdevices, please contact Avonite Surfaces TechnicalServices at 1-800-866-TECH.

2.7Clamping Seams


FFIINNIISSHHIINNGG SSEEAAMMSSThe following procedure will efficiently finish seam areas.For illustration, please refer to Figure C.1. Trim the Avonite Surfaces Solid Surface Adhesive flash

line with router on skis or offset trim router2. The remainder of the flash line should first be

sanded with 100 micron paper. It is important thatsanding extend on either side of the seam, withoutconcentrating directly on the seam, as illustrated byPoint A. The 100 micron sanding should extend toabout 6" (152mm) on either side of the flash line.Concentrated sanding could cause a valley, or dip,in the seam area.

3. The next step is to sand with 80 micron paper. Thesanding area now extends to about 12" (305mm) oneither side of the flash line, as shown in Point B.

4. Once the seam is sanded level, continue thestandard finishing procedure by feathering out thefinish in the seam area to blend with the final finishof the top, as shown in Point C.

Sanding should not concentrate directly on the flash line,but extend on either side to feather-in the finish.

2.8 Clamping Seams


flash

lin

e

A

B

C

C.


2.9Drop EdgesEdge treatment designs may be achieved bylaminating strips of Avonite Surfaces materialtogether for any desired thickness. A 3" (76mm)bullnose is illustrated here.

1. Overcut strips by 1/8" (3mm)

2. SAND BOTH SIDES to be laminated with 100 gritpaper.

3. Clean all surfaces with isopropyl alcohol.

4. Laminate pieces face to back.

5. Spread Avonite Surfaces Solid Surface Adhesiveover entire surface.

6. After stack is completed, roll the pieces up onedge and apply spring clamps every 3" (76mm).

7. Take the lamination and stand it on the ends ofthe clamps. The edges that were against thetable are now face up. This will allow the AvoniteSurfaces Solid Surface Adhesive to level itselfrelatively smooth allowing you to place that sideagainst the fence of your table saw.

8. After allowing sufficient hardening time, removethe clamps and cut your desired dimension onthe table saw (see Tooling Section).

LLAAMMIINNAATTIINNGG BBUUIILLDD--UUPP DDIIRREECCTTLLYY OONN CCOOUUNNTTEERR TTOOPPSSWhen applying the build-up on counter tops withinside corners, pieces should be put on one layer ata time, to ensure good butt joints and allowing youto offset inside corners.

Edges should be straight and free of chatter-marks.Clean bottom of sheet and fascias with isopropylalcohol. Light block sanding may be needed wheredrop edge is to be applied.

Dry fit and mark where they go with arrows. Glue andclamp one edge build up at a time, to prevent gluefrom setting up before build up strips are applied.Apply an even bead of Avonite Surfaces Solid SurfaceAdhesive to the surface. Place the drop edge in theglue and make sure an even flash line develops. Holdthe drop edge back 1/8" (3mm) to avoid any chip outon seamed edge.

Place spring clamps 2" (51mm) to 3" (76mm) apart.Keep clamps straight to avoid tilting the drop edgeback. The tips of the clamps should be in the centerof the drop edge.

After Avonite Surfaces Solid Surface Adhesive hashardened, clamps may be removed. The edge cannow be routed to your final configuration.


2.10 Stack Edges

GGLLUUEE SSUURRFFAACCEE AARREEAAIt is strongly recommended that built up front edgeshave a minimum 1" glue area.

This can be achieved by cutting strips 1" wide or widerand stacking two layers for a total thickness of 1.5"

If strips are cut 1" wide and stood on edge, you need2 pieces to achieve the 1" glue area.

Avonite Surfaces Top

Avonite Surfaces Top

Avonite Surfaces TopAvonite Surfaces

Top

SiliconeDabs

Avonite SurfacesSupport Block(1/2" x 1/2")

(12.7mm x 12.7mm)

SubstrateConstruction

Cross Section Views NOT DRAWN TO SCALE

3/4" (19mm) or 1" (25.4mm)Substrate Construction

1-1/2"(38mm)

greaterthan 1-1/2"

(38mm)

• Drop edgewider than1-1/2" (38mm)

• Drop edgeat 1-1/2"(38mm)

• Radius greater than1/4"(6.3mm) musthave Avonite Surfacesblock as shown ondrawing above

Radius no greaterthan 1/4" (6.3mm)

VV--GGRROOOOVVIINNGG TTEECCHHNNIIQQUUEESSAvonite Surfaces recognizes thegrowing industry of solidsurface fabrication techniquesconcerning V-Grooving. At thistime we would like to adviseyou of certain requirements forthose using the auto V-Grooving method. The sectiondrawing to the right demon-strates recommended rein-forcing methods for drop edgesgreater than 1-1/2" (38mm).


By using a high quality router and reasonable feedspeed, detailed cuts can be easily achieved.

Heavier cuts, such as those for a 3" (76mm) bullnosecan be produced by laminating several piecestogether and machining in two steps.

2.11Machining Edges

All Avonite Surfaces Studio Collection comes from thefactory with minor linear sanding lines. These linesare 60 micron or a 220 grit finish on the face. Toacquire any of the possible finishes these sandinglines must be removed. This is accomplished bystarting the sanding process with 60 micron.

Using a 6" (152mm) or 8" (203mm) random orbitalsander will reduce your sanding time by HALF overconventional vibrating sanders, and will achieve amore uniform finish.

SSaannddiinngg PPrroocceessss1. Move the sander in a back and forth direction.

NOT CIRCULAR.2. Overlap each pass by 50%.3. Sand at a slow and even pace, approximately 1"

(25.4mm) per second.4. Keep micron paper clean from sanding dust. This

is easily done by putting the sanding pad on apiece of carpet while running and hold it downfor a few seconds (check paper frequently).

* Each sheet of micron paper will sand 10 sq. ft.(about 1 sq. m) of Avonite Surfaces material.


2.12 Sanding and Polishing

ARP #8446-B6

Porter Cable #7336

Recommended Disc Sanders

AABBRRAASSIIVVEE GGRRAADDEE CCOOMMPPAARRIISSOONNMMiiccrroonn IInndduussttrriiaall FFEEPPAA oorr JJaappaanneesseeGGrraaddee UU..SS.. MMeesshh PP--GGrraaddee JJ1155 GGrraaddee EEmmeerryy100u #15080 18060 220 P240 #240

240 28040 280 320

320 P360 360360 P500 400 1/0

30 400 500 2/0500 P1000 600 3/0

15 600 1000800 1200

12 P12009 1200 2000 4/05 25003 40002 60001 8000

0.3

Festool #RO150E

MMaattttee FFiinniisshhAfter removing the linear sanding lines with 60micron paper, place a Scotch-Brite® pad, (#7447 Red)under the sanding pad to even out the finish. Thematte finish is easily maintained and is usually themost suitable for high use areas.

Make sure the customer understands the requiredmaintenance for the finish they have chosen.

Colors darker than Gibraltar Gray will require sandingwith 60 and 30 micron before using the Scotch-Brite®

pad. For best results, add water and a small amountof liquid detergent with Scotch-Brite® pad.

SSaattiinn FFiinniisshhSand with 60 micron paper, repeat sanding processwith 30 micron paper.Place Scotch-Brite® pad (#7448 light gray) undersanding pad.

For satin finish, use Scotch-Brite® #7448 and soapywater. Homeowners may maintain this finish using awhite Scotch-Brite® and Soft-Scrub.®

PPoolliisshheedd FFiinniisshhAfter sanding with 60 micron paper, repeat thesanding process with 30 micron paper.The polisher used should have 8-10 AMP and thecapacity to maintain 2500 R.P.M.Use a 3M Super Buff adapter to prevent the arbor ofthe polisher from damaging the surface.Dark colors with a high gloss finish show wear veryquickly. AA ddaarrkk ccoolloorr hhiigghh gglloossss iiss nnoott rreeccoommmmeennddeeddffoorr hheeaavvyy uussee aarreeaass..

Coppermine K3-8490 and Goldmine K3-8495 are darkcolors that may require polishing for full impact. Thebrilliance of the shine comes from the fact that theseproducts use real nonferrous metal in the ingot. Thenonferrous metal will:1. Have no effect on your tooling. 2. Cause some oxidation during polishing, as

exemplified by blackening of the polishing pads.This is normal for any material with metal in it.


Scotch-Brite® Pad

2.13Sanding and Polishing

TTHHEE ““FFIINNEESSSSEE IITT”” SSYYSSTTEEMMSStteepp OOnneeThe first step of the polishing process uses 3M’sMarine Paste Compound (White) #06039 with 3M’sSuper Duty 2 + 2 pad (White). The Marine PasteCompound will remove 30 micron sanding swirls. Itmay be necessary to repeat this step to remove all30 micron swirls. Apply enough pressure to deflectthe pad as shown.

SStteepp TTwwooRemove any compound residue by reversing thewhite pad. DO NOT mix the compounds on the samepad.

Repeat polishing the surface with 3M’s FinishingMaterial #81235 (Quart) with 3M’s Super BuffPolishing Pad (Yellow). This will remove the swirlmarks left by Step One and will produce a high gloss.Step Two takes about half the time as Step One.Reverse the yellow pad for final clean up.

NNoottee:: Keep the polisher moving to preventoverheating, and assure that the buffing pad doesnot dry out.

SSTTAANNDDAARRDD FFIINNIISSHHIINNGG SSTTEEPPSSMMaattttee SSaattiinn PPoolliisshh

1. 60 micron 1. 60 micron 1. 60 micron2. 30 micron 2. 30 micron 2. 30 micron3. Scotch-Brite® 7447 3. Scotch-Brite® 7448 3. Marine paste

soap and water soap and water compound with— OORR —— white padFor colors lighter than 4. Finesse-It withC1-1100 Gibraltar Gray yellow pad

1. 60 micron2. Scotch-Brite® 7447

dry

A matte finish is not recommended for very dark colors,

a satin finish provides a more even appearance.


2.14 Sanding and Polishing


PPOOLLIISSHHIINNGG WWIITTHH TTHHEE AAVVOONNIITTEE SSUURRFFAACCEESSDDRRYY--CCUUTT FFIINNIISSHHIINNGG SSYYSSTTEEMMAnother effective polishing method involves the use ofthe Avonite Surfaces Dry-Cut Finishing System abrasivebars. This is a three step system that quickly andeasily removes sanding scratches. Since thecompound is a solid it can be cleaner to use than 3MMarine Paste. Apply sparingly to the buffing wheel andit stays there to efficiently create a high luster finish.

AAvvoonniittee SSuurrffaacceess DDrryy--CCuutt FFiinniisshhiinngg SSyysstteemm SStteeppssSStteepp 11::((BBrroowwnn BBaarr))The first step in polishing with the Avonite SurfacesDry-Cut Finishing System is to use the brown bar(SM4036-50) with a 3M Super Duty 2+2 pad (white).Start with the Avonite Surfaces material sanded to a30-micron finish. The brown bar must be applieddirectly to the buffing pad. With the buffing padturned up and buffer running, press the bar firmlyagainst the pad allowing it to build up on the pad.Begin buffing the material, be sure to apply enoughpressure to deflect the pad as shown on page 2.14.Add material to the buffing pad if you feel you needmore to ensure you do not build up excessive heat byusing a dry pad. Repeat Step 1 as necessary toremove all of the 30-micron swirls.

SStteepp 22::((PPuurrppllee SSttiicckk)) This step will remove any marks left by the moreaggressive cutting brown bar. Reverse the white padand apply the purple stick compound (SM4036-51) tothe pad. The purple stick must be applied directly tothe buffing pad. With the buffing pad turned up andbuffer running, press the stick firmly against the padallowing it to build up on the pad. Add material tothe buffing pad as you feel is needed to ensure youdo not build up excessive heat by using a dry pad.Repeat Step 2 as necessary until you have removedthe buffing swirls resulting from Step 1. To achieve ahigh gloss finish, complete Step 3.

SStteepp 33:: This is the final step in achieving a high gloss finish.Remove any residue from the previous steps bybuffing lightly with a clean 3M Super Duty 2+2 pad(white). Use at the lowest power setting, gliding acrossthe material until all the material from Step 2 isremoved. Repeat polishing the surface with 3M’sFinesse-it Finishing Material (#81235) with 3M’s SuperBuff Polishing Pad (yellow) at the lowest powersetting. This step will remove any swirl marks that mayhave resulted from Step 2, and produce a high glossfinish. Reverse the yellow pad for final clean up.

We have found this polishing method to giveequivalent results to the Finesse-It system, howeverthe Finesse-It system is a little more forgiving and itis easier to control surface temperature. The AvoniteSurfaces Dry-Cut Finishing System will give you agood polish if you are experienced and you will savesome cleanup.

2.15Sanding and Polishing


It is very important that the personnel installing theAvonite Surfaces material be properly trained andfollow the recommended procedures. Improperinstallation may lead to problems in the future.Failure to follow the recommended procedures willvoid the warranty.

SSuubbssttrraatteessChoosing the appropriate substrate for differentapplications should be considered.A solid substrate cannot be used when heat sourcesare present, as in kitchen applications.The following methods demonstrate alternatives tosolid substrates.

RRuunnnneerr MMeetthhooddThe runner method uses 1" x 4" (25.4mm x 101mm)supports that run parallel to the length of the top asshown in Figure A. They are at the front, center and rearedge of the counter top, adhered with dabs of siliconeevery 18"-24" (45.7cm - 61cm). The cabinets musthave cross supports for the runners every 18"- 24"(45.7mm - 61cm).

CClleeaarraanncceessBe sure to leave 1/8" (3mm) between the edge of thesubstrate and the back of the build up. Leave aminimum 1/16" (1.5mm) between the counter top andthe back wall. For wall to wall installations, allowclearance on each end for expansion (see theExpansion and Contraction Section 1.10, for moredetails). Allow as much clearance as possible atcooktops and drop-in sinks.

AAddhheerriinngg AAVVOONNIITTEE SSUURRFFAACCEESSmmaatteerriiaall ttoo SSuubbssttrraatteessDabs of silicone are placed in the front, center andrear every 18"-24" (45.7-61cm) for all substrates. Adab of silicone should be the size of your thumb nail.

SSeeccuurriinngg TToopp ttoo CCaabbiinneettssWe recommend attaching substrate to the AvoniteSurfaces top first and then fastening it to thecabinets. This way if you ever need to remove thetop, you may do so without destroying it. Set topson pre-leveled cabinets. Put screws from all cornerblocks on cabinets into substrate. Make sure screwsdo not go all the way through substrates and intocountertop. If screws are allowed to contact the solidsurface, they may start a crack at that point.

We recommend Dow or GE 100% Silicone for bondingto wooden substrates. NEVER USE LIQUID NAILS™ orother rigid adhesive which does not allow forexpansion or contraction of the top.

3.1Installation

Figure A

Figure B


CCOOOOKKTTOOPP CCUUTT OOUUTTSSALL CUT OUTS SHOULD BE MADE WITH A TEMPLATEAND A ROUTER AND HAVE A MIN. 1/4" (6mm) INSIDECORNER RADIUS.

Corners of cooktop cut outs must be reinforced bybonding a 3" (76mm) x 3" (76mm) or larger piece ofAvonite Surfaces material to the underside.

Using the runner method substrate as pictured allowsfor venting of heat.

CCOOOOKKTTOOPP AANNDD BBAACCKKSSPPLLAASSHH CCLLEEAARRAANNCCEEDue to excessive heat generated from cooktops andpans being heated, minimum clearances are requiredby Avonite Surfaces material.

Standard 4"(102mm) tall splashes should have aminimum clearance of 2"(51mm) between the splashand the cooktop flange.

Note to homeowner:Full height splashes within 2-1/2" (63.5mm) from thecooktop flange will not be covered under AvoniteSurfaces’ 10 year warranty.Use of large oversized pans should be limited to frontburners only.

Commercial type cooktops for residential use need tobe supported inside cabinet base, so that cooktop isnot supported by countertop.

TTHHEERRMMOO--FFLLOOWW TTAAPPEEThe use of Avonite Surfaces’ Thermo-Flow tape isREQUIRED for prevention of damage in cooktop cutouts and slide-in ranges due to excessive heat. Theuse of any other tape voids the 10 year warranty.

Thermo-Flow is a 2-1/2" (63.5mm) wide heatconductive aluminum tape with a glass backing thatadds insulative properties.

Install one layer of Thermo-Flow around the cut out asshown in Figure A.

3.2 Installation

CCOOMMMMEERRCCIIAALL FFOOOODD SSEERRVVIICCEEUntil further notice, Avonite Surfaces does not warrantthe use of Class III products for use in commercial hotwell unit applications. This restriction will continue ineffect until appropriate design criteria have beendeveloped. We will keep you advised of any futuredevelopments in this area.Guidelines for installation of commercial hotwells aregiven on page 3.4.

Thermo-Flow Tape

Cooktop

Avonite Surfaces 1/2" (12.7mm)

Thermo-Flow Tape2-1/2" (63.5mm)

VVEERRTTIICCAALL SSUURRFFAACCEE

Wall cladding requires dabs of silicone every 8"-10"(200-250mm) across and down. Be sure the backs ofthe sheets are clean and dust free.

When vertical hard seams are requested such as aback wall or a tub surround, it is recommended tobond the panels together horizontally and float themup into place.

An alternative to bonding vertical seams might be tohave beveled edges with silicone seams like naturalstone. For best results, use the Wavy Bit System tokeep the panels aligned.

Vertical installations over 10' (304.8cm) in height mayneed mechanical fasteners.

Back splashes require dabs of silicone every 8"-10"(200-250mm). The use of hot melt glue can help holdthe splash in place until the silicone has set.

MMAAKKIINNGG FFIIEELLDD SSEEAAMMSSTo insure that drop edges are properly aligned afterseaming, stop routing the profile a couple of inchesfrom the seam on either side. After removing theflash line of seam you may then route the profileacross the seam.

IINNSSTTAALLLLAATTIIOONN CCHHEECCKK LLIISSTT1. Before Seaming

a. Good dry fit (no gaps).b. Wavy Bit System and Seam Block.c. Separation paper.d. Proper clearances.e. Clean with isopropyl alcohol.f. Prepared for clamping.

2. Support all seams3. Substrate secured to cabinets4. Level cabinets (3/32" in 48"

(2.38mm in 120cm)5. Cutouts—1/4" (6.3mm) radius6. Thermo-Flow tape on cooktop cutout7. Inside corner radius8. Silicone


3.3Installation

8"-10"(200-250mm)


CCOOMMMMEERRCCIIAALL HHOOTTWWEELLLLFFOOOODD SSEERRVVIICCEE CCOOUUNNTTEERRTTOOPPSSCommercial Hotwell Food service countertops willrequire different procedures for installation becausethey are exposed to much greater temperatures andstress than residential countertops.

The following features must be included in acommercial hotwell food service installation in orderto be covered by Avonite Surfaces’ 10-Year MaterialWarranty. Color must be selected from among AvoniteSurfaces’ Class I fire rated products.

1. Cabinet must be even and level with noprotrusions to cause cracking.

2. Support tops every 18" (457mm). Cantilevers over6" (152mm) require structural support. Providesupport within 3 inches (76mm) of all cut outs.

3. Hot and cold units must be supported frombelow and not rest on the Avonite Surfaces top.

4. Attach Avonite Surfaces material to supportframe with dabs of silicone every 18" to 24"(45.7cm-61cm), do not use a continuous bead.

5. Separate tops containing hot sections from thosewith cold sections. A soft (silicone) seam may beused.

6. Make cut outs with router and template andallow a 1/2" (13mm) radius in the corners. Cutand sand a 1/8" (3mm) round over on top andbottom edge of cut out.

7. Reinforce corners of rectangular cut outs with6" x 6" (152mm x 152mm) blocks of AvoniteSurfaces material. Circular cut outs must have acontinuous ring of Avonite Surfaces material 2"(51mm) wide as reinforcement.

8. A layer of Thermo - Flow tape is used to line theperimeter of all hot and cold cut outs.

9. Commercial Hot Well Food Service Units must becovered with a layer of Flex-Sulation® blendedPVC foam sheeting (McMaster Carr Supply Co.562-692-5911. Product #9349K1) The foam maybe attached to the hot well with 3M double sidedaircraft tape, or duct tape.

10. Cabinets are to be ventilated by installing a fannear the bottom to pull cool air into the cabinetand providing vent slots near the upper edge ofthe cabinet to expel the hot air. Temperatures inthe cabinet must not exceed 170°F (76°C).

11. Sneeze guards must be fastened to the cabinetsor the floor, not directly to the Avonite Surfacesmaterial. Holes in the Avonite Surfaces materialto accommodate the sneeze guard supports mustbe cut 1/4 inch (6mm) oversize in diameter toallow expansion and contraction.

12. Deck seams must be reinforced with 4" (76mm-102mm) seam blocks. Keep seams 3" (76mm) ormore away from cut outs.

If you have any questions, please call theAvonite Surfaces Technical Service Department

at 1-800-866-8324.

3.4 Installation

OOVVEERRHHAANNGGSSWhen installing overhang countertops, support isrequired for 1/2" (12.7mm) thick overhangs extendingmore than 6" (152mm).Support is provided by plywood underlayment andbrackets which are equilateral right triangles (anchorleg is equal in length to the support leg). Brackets,when required, are placed no more than 24"(60.9cm) apart and should come to within 5"(127mm) of the countertop edge.Refer to the chart below for the type of support to use.

OOVVEERRHHAANNGG SSUUPPPPOORRTTSSAAVVOONNIITTEESSUURRFFAACCEESSMMAATTEERRIIAALL LLEENNGGTTHH OOFFTTHHIICCKKNNEESSSS OOVVEERRHHAANNGG IINNSSTTAALLLL

1/2" (12.7mm) Up to 6" (152mm) No Additional Support

1/2" (12.7mm) 6" to 18" Plywood Underlayment(152mm - 457mm) and Brackets

1/2" (12.7mm) 18" or more Legs or Columns(457mm or more)


3.5Installation

3/4" (19mm) or 1"(25.4mm)Steel Tubing


3.6 Sinks and Bowls

Requires 36" cabinet base Requires 36" cabinet base

CAD drawings of sinks are available at www.avonitesurfaces.com


GGEENNEERRAALL SSIINNKK FFUUSSEEDD MMOOUUNNTTIINNGGIINNSSTTRRUUCCTTIIOONNSSPPoossiittiioonniinngg aanndd PPrreeppaarraattiioonnSinks are recommended for bonding to 1/2" (12.7 mm)Avonite Surfaces sheet thickness. Turn the AvoniteSurfaces sheet back-side up on a well supportedsurface. Position the bowl on the sheet (Figure 1). Do notnick or scuff the rim of the bowl. With a nail orscrewdriver, etc., scratch a line on the sheet around theperimeter of the bowl. Drill a 1-1/4" (31.4mm) pilot hole,with a hole saw, in the sheet in line with the drain ofthe bowl (Figure 1). With a flat sanding block and #80grit sandpaper, sand the underside of the sheet wherethe bowl is to be bonded. This removes factory sandinglines or scuff marks. With a flat sanding block, scuff sandwith #80 grit sandpaper the top flange of the bowl. Donot round over or nick the rim (Figure 2). Mark thelocation of 4 locating blocks as shown in Figure 3. Theseblocks can be scrap pieces of Avonite Surfaces material 1" x1-1/2" x 1/2" (25mm x 38mm x 12.7mm) thick. Fasten theblocks to the back of the sheet using Locktite 495, or equiv-alent. This will keep the sink from sliding during bonding.

BBoonnddiinnggRemove the bowl and clean the bonding area and thebowl with isopropyl alcohol and let it dry.Mix Avonite Surfaces Solid Surface Adhesive SeamingKit and apply it to the sheet fully coating the flangearea. (If the sheet and bowl are different colors, usebowl seam kit color.)Use all-thread, two blocks of plywood and a wing nutto clamp the bowl to the sheet as in Figure 4. Tightenthe clamp until the Avonite Surfaces Solid SurfaceAdhesive flashes out evenly and allow AvoniteSurfaces Solid Surface Adhesive to harden.

MMoouunnttiinngg BBrraacckkeettss Mounting brackets may be used to undermount sinksother than Avonite Surfaces’. Drill a 1/4" (6mm)diameter hole by 1/2" (12.7mm) deep, 3/4" (19mm)from the sink into the locating blocks as shown inFigure 5. Remove any dust and tap in the brass anchorsslotted end first. Set with Locktite. Mount hardware byfirst threading the wing nut well up on the screw nearthe head. With washer and slotted clip in place, tightenscrew securely to lock the brass anchor (Figure 5). Bondthe bowl to the sheet using silicone if it is a non-solidsurface bowl. Swing clips onto the bowl lip and evenly

tighten the wing nuts until the bracket begins todeflect. Recheck to be sure the bowl is in the properposition. Allow the compound to harden. After adhesivecures, do not remove undermount brackets.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

(non solidsurface bowl)

AvoniteSurfaces Top

Avonite Surfaces Sheet

Bowl

3.7Sink & Bowl Installation

3/4" (19mm) Clearance Around Sink)

SSHHAAPPIINNGG TTHHEE EEDDGGEETurn the top over and use the specially designedbowl router bits to shape either a flush or bullnosebowl edge trim. Cut the sheet material from thecenter of the bowl area with the special straightrouter bit with an oversized nylon bearing. Start fromthe pilot hole and rout clockwise around the bowl.Hold the cutout steady as it separates from the topto avoid damage to the edge (Figure 6).A bullnose trim on the edge (Figure 8 and 10) of thesheet creates a shadow which can help hide seams.The cutter slightly shaves the bowl edge andremoves all the seam compound. A roundover bit onthe edge (Figure 7 and 9) of the sheet will produce asmooth edge. The cutter slightly shaves the bowledge and removes all the Avonite Surfaces SolidSurface Adhesive. Different sheet thickness and cutterheights can produce various edge profiles.

NOTE: The bowl bits shown have a 2 1/2" (64mm)cutting diameter. Router base adjustments may beneeded.

For additional information contact Avonite SurfacesTechnical Services 1-800-866-TECH.

NNOOTTEE:: WWHHEENN PPOOUURRIINNGG BBOOIILLIINNGG WWAATTEERR IINNTTOO TTHHEESSIINNKK OORR UUSSIINNGG AANN IINNSSTTAANNTT HHOOTT WWAATTEERR DDIISSPPEENNSSEERR,,CCOOLLDD WWAATTEERR SSHHOOUULLDD BBEE RRUUNNNNIINNGG IINNTTOO TTHHEE SSIINNKKSSIIMMUULLTTAANNEEOOUUSSLLYY.. TTHHIISS WWIILLLL EELLIIMMIINNAATTEE AANNYYPPOOTTEENNTTIIAALL CCRRAACCKK.. TTHHEE UUSSEE OOFF AA GGAARRBBAAGGEEDDIISSPPOOSSAALL LLAARRGGEERR TTHHAANN 33//44 HHPP IISS NNOOTT CCOOVVEERREEDDUUNNDDEERR AAVVOONNIITTEE SSUURRFFAACCEESS’’ WWAARRRRAANNTTYY ..


3.8 Sink & Bowl Installation

The bowl bit in Figure 10 isavailable from Velepec.1-800-365-6636# SUBN-8-12 VT

For fuse mounting KitchenSinks, use bowl bit #30-155 CRST-10-8-8 UTR as providedby Velepec, Inc or equal.

Figure 6

Figure 8Figure 7

Figure 10Figure 9

Avonite Surfaces makes every effort to achieve a visualcolor match between Avonite Surfaces Foundationssheet products and bowls. However, we do notguarantee a color match between sheet and bowl ofthe same name. When you are given an order tosupply a fused undermount sink in which the sink andthe deck are the same color, there is a distinctpossibility that there will be a visual color mismatchbetween the edge of the deck and the wall of the sink.The likely color mismatch problem is complicated bythe fact that you cannot tell how closely the sink andsheet match until the two are joined and the edge ofthe deck is routed flush with the sink. We do have amethod of mounting a bowl in the same color whichwill mask the color mismatch (See illustration right)Using bit shown, sanding the seam area between thebowl and the sheet and putting the seam on thebottom side of the bullnose should hide most colormatch problems. If you have any questions regardingthis procedure, please contact the Technical ServiceDepartment at 11--880000--886666--88332244..

NNOOTTEE:: AAVVOONNIITTEE SSUURRFFAACCEESS DDOOEESS NNOOTT WWAARRRRAANNTTYYCCOOLLOORR MMAATTCCHH BBEETTWWEEEENN SSAAMMEE CCOOLLOORR AAVVOONNIITTEESSUURRFFAACCEESS FFOOUUNNDDAATTIIOONNSS AANNDD BBOOWWLL..


BULL NOSE BITTO CUT AVONITE SURFACES UNDERMOUNT

LAVATORY BOWLS & KITCHEN SINKSwith VEL-VET TOUCH™ Bearing Guide Assembly

1/2" (12.7mm) Shank Diameter - 2 Flutes

1/2" AVONITESURFACES TOP

AVO

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3.9Sink & Bowl Installation


PPAATTCCHH KKIITTSS AARREE OONNLLYY AAVVAAIILLAABBLLEE FFOORR AAVVOONNIITTEESSUURRFFAACCEESS SSTTUUDDIIOO CCOOLLLLEECCTTIIOONN CCOOLLOORRSS..

PPRROODDUUCCTTSS NNEEEEDDEEDD FFOORR PPAATTCCHHIINNGG::a. Patching Resinb. Catalyst (sold separately)c. Stirring Stickd. Particulate Cane. Two Shading Vials

Minimal damage—lightly rough out area to 3/16"(5mm) depth. You may need to rout out the area tohold patching material. Be sure to serrate edges ofrouted area to help blend in the patch.

Clean area with isopropyl alcohol. Allow to drycompletely.

Mix particulate with patching resin in one largecontainer.Stir mixtures thoroughly together.Compare color by placing a puddle of water next tothe area to be patched. Add darker shading todarken, light particulate to lighten.The amount of catalyst to be added should bemeasured by the amount of resin used not the totalvolume of both containers. (see page 4.3)

Area has been masked off to contain patch material.Patch material is difficult to bring to the same glossas the sheet in a polished finish. A 100 watt lightbulb to post heat the patch will help. Larger areasshould be repaired with an insert of matching AvoniteSurfaces material.

PPaattcchh kkiittss aarree nnoott ttoo bbee uusseedd ttoo rreeppaaiirr aa bbaadd oorrbbrrookkeenn sseeaamm,, sseeee ppaaggee 55..44--55..55,, RREEPPAAIIRRIINNGG SSEEAAMMSS

4.1Patching

PPRROODDUUCCTTSS NNEEEEDDEEDD FFOORR IINNLLAAYY::Inlay Resin (same as Patching Resin)Sign paint*CatalystStirring StickWax Paper Cup

Route out slot for color inlay. Should be 1/8" (3mm)deep minimum. Contain overpour by placing maskingtape, Hot Melt, or 100% silicone around slot. Addcolor pigment to inlay resin. One drop per ounce.Add catalyst and stir thoroughly.

Pour mixture into prepared slot. Overpour by 1/8" (3mm) to eliminate low spots.Allow to dry thoroughly and finish. The hardeningtime is approximately 8 hours.

METAL INLAYS—Glue the metal to the bottom of thegroove with Super Glue. It may then be overpouredwith clear resin. Overpour should be a minimum3/32" (2mm) deep.

FFaabbrriiccaattoorr NNootteess::Inlay Resin is available in quarts. Particulate may alsobe special ordered in quart containers.When making large inlays, color enough material todo the entire job. Custom colors will be difficult tomatch later.

* Sign paint is a high pigment enamel paint such asChromatic® or One Shot® usually found at artsupply stores.


4.2 Color Inlay


DDEEPPEENNDDEENNTT OONN TTEEMMPPEERRAATTUURREE

Ratio of Catalyst: iinn ddrrooppss ppeerr oonnee oouunnccee ooff PPaattcchhiinngg//llnnllaayy RReessiinn..

EEXXAAMMPPLLEE:: one drop per one ounce ofPatching/lnlay Resin

Ambient temperature at 75° F (23.8’C)

Therefore: At an ambient temperatureof 75° F (23.8’C)

44 oouunncceess ((111133..44ggmm)) ooff PPaattcchhiinngg//llnnllaayyRReessiinn wwoouulldd ttaakkee 4400 ddrrooppss ooff ccaattaallyysstt..

4.3Catalyst Ratio Chart

5.1Wall Panel Installation/Signage


IINNSSTTAALLLLIINNGG SSCCRREEWWSS OORR BBOOLLTTSS IINNAAVVOONNIITTEE SSUURRFFAACCEESS PPAANNEELLSSIINNTTEERRIIOORR && EEXXTTEERRIIOORR AAPPPPLLIICCAATTIIOONNSSAvonite Surfaces realizes there are certain applicationsthat need additional vertical support.

Examples: Avonite Surfaces outdoor signage, AvoniteSurfaces steam showers or Avonite Surfaces ceilingsetc., and other similar applications. The propertechnique for installing screws or bolts throughAvonite Surfaces should be done according to thedrawing below.

Soft seams should be used for exterior applications

Important facts that you need to remember are:1. Hole should be 1/4" (7mm) oversize in diameter

minimum (for interior applications).2. Hole should be 1/2" (12.7mm) oversize in

diameter (for exterior applications).3. Rubber grommet/washer needs to be inserted in

hole to provide cushion for movement duringexpansion or contraction.

4. Do not over tighten screen or bolt; snug tightonly.

Outdoor ApplicationsAristech Acrylics LLC does not warrant countertopsfor exterior use or any object that has hard seams.As with any other solid surface products, dark colors

must not be located where they will receive direct

sunlight. The sunlight will cause an extremetemperature increase due to dark colors’ heatabsorption, accompanied by expansion of thematerial with potential distortion or cracking.

An Avonite Surfaces sign must not be located whereit will be periodically sprayed with water as from asprinkler system. Water spots will leave mineraldeposits which will buildup on the surface,eventually making it difficult to restore to the originalappearance.

Three dimensional structures with hard seams are notsuitable for outdoor applications in any color for anysolid surface products. Stresses are created when thesun warms part of the structure while another partjoined to it remains cool. Such stresses are likely tolead to failure of a seam or failure of the material itself.Avonite Surfaces material can be engraved byconventional carbide engravers and laser engravers.Letters or logos are easily cut out by computercontrolled routers.

Avonite Surfaces material can be sandblasted using amunument stencil like anchor Continental #111 or“Buttercut” by 3M.

Silicon carbide (80 grit) at 80 psi gives the bestresults for a sharp edge.

Not drawn to scale

AV

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AVONITE

SURFACES

MATERIAL

PLUG

5.2 Thermoforming


These Thermoforming Parameters are basic guidelinesfor fabricators to thermoform Avonite Surfaces. Theparameters listed below are recommendations, whichare a direct result of actual forming of AvoniteSurfaces. This testing was conducted by the AvoniteSurfaces Technical Service Department, but values areapproximate. We suggest re-testing for varyingconditions.

MMaatteerriiaall PPrreeppaarraattiioonnWhen preparing material to be formed, it isrecommended that material be cut to size. Then,remove all chips or scratches on the edge of thematerial. Any chip or scratch left on an edge maycause the material to tear during forming.

TThheerrmmooffoorrmmiinngg TTeemmppeerraattuurreeTemperatures given here are approximate andrepresent a starting point to establish the conditionsyou need for your project. If material is too cool ortoo hot it may crack or tear while bending.

Avonite Surfaces Studio Collection

When heating material for forming, it is important touniformly heat the entire thickness of the sheet. Spotheating or surface heating is not adequate to formthe sheetstock. To achieve this, it is recommendedthat an oven designed for solid surface be used. Beaware that heating in an oven may darken the colorof light colored Avonite Surfaces material. AvoniteSurfaces’ Glass series products are very difficult tobend and are not recommended for thermoforming.

MMaatteerriiaall HHeeaatt--UUpp TTiimmeess ffoorr AAvvoonniittee SSuurrffaacceessSSttuuddiioo CCoolllleeccttiioonn

SShheeeett OOvveenn HHeeaatt UUpp TThhiicckknneessss TTeemmppeerraattuurree TTiimmee

1/2" (12.7mm) 270° F 20-25 Class III (132°C) Minutes

1/2" (12.7mm) 270°F 20-25Class I (132°C) Minutes

MMiinniimmuumm BBeennddiinngg RRaaddiiuuss FFoorr AAvvoonniittee SSuurrffaacceessSSttuuddiioo CCoolllleeccttiioonn

SSttuuddiioo MMiinn.. RRaaddiiuuss MMiinn.. RRaaddiiuuss CCoolllleeccttiioonn ffoorr 9900°° BBeenndd ffoorr 118800°° BBeenndd

1/2"(12.7mm) 8" 12" Class III (200mm) (300mm)

1/2"(12.7mm) 14" 18" Class I (350mm) (450mm)

NOTE: These minimums reflect radiuses in whichthere would be minimum to no breakage. Tighterradiuses can be achieved by either backsanding orkerfing the backside of the sheetstock as noted indiagrams below.

Avonite Surfaces Foundations

AAvvoonniittee SSuurrffaacceess FFoouunnddaattiioonnss HHeeaatt--UUpp TTiimmeess AAnnddBBeennddiinngg RRaaddiiuuss

SShheeeett MMiinniimmuumm OOvveenn HHeeaatt UUpp TThhiicckknneessss RRaaddiiuuss TTeemmppeerraattuurree TTiimmee

1/2" 2" 370°F 20-25 (12.7mm) (50mm) (187.7°C) Minutes

1/4" 1" 370°F 10-15 (6.3mm) (25.4mm) (187.7°C) Minutes

MMOOLLDD DDEESSIIGGNNWhen forming we recommend that male and femalemolds be made. The molds need to be designed sothey can accommodate clamps to hold them togetherwhile material is cooling.

CCOOOOLL DDOOWWNNAllow material to cool for a minimum of two hours toprevent the material from springing back. If materialis not allowed to cool adequately, it may spring backas much as 10% which will make any furtherfabrication of the application difficult.

FFAABBRRIICCAATTIIOONN:: FFIINNIISSHHIINNGG//SSEEAAMMIINNGGFinishing formed sheetstock is no different fromstandard finishing. However, it is important that anyseaming/joining be done after forming. The heat towhich the material is subjected will weaken theseamed areas of the pieces, which may result inseam failures.

5.3Thermoforming


5.4 Repairs


MMOOSSTT CCOOMMMMOONN RREEAASSOONNSSFFOORR SSEEAAMM FFAAIILLUURREE1. Excessive heat from belt sanding.

2. Too much clamping pressure.

3. Inadequate mixing of catalyst.

4. Insufficient catalyst from cartridge if voids notpurged by dispensing small quantity of AvoniteSurfaces Solid Surface Adhesive before installingmixer tube.

5. No seam block.

6. Unsupported seams.

7. Seams near heat source such as dishwasher orcooktop.

8. Seams placed at points of stress such as insidecorners.

SSEEAAMM AANNDD DDAAMMAAGGEE RREEPPAAIIRR1. The damaged area must first be bonded back

together. When the opening is wide enough,Avonite Surfaces Solid Surface Adhesive Clear canbe used. For tight cracks, a very thin cyanoacrylate (Loctite) should be used to fill the void.

2. After the glue has dried, route a groove about1/4" (6 mm) deep. See drawing.

3. Glue a matching piece of Avonite Surfacesmaterial into the groove. Always leave a piece ofmaterial on the job site for any future damage(perhaps on the floor beneath a bottom draweror mounted in the sink cabinet).

4. Material may then be routed level and sandedback to the original finish.

PPiiee SShhaappee RReeppaaiirr

Make a template large enough to encompass thedamaged area. The inside edges must besmooth and straight. Clamp the template to thecountertop and use a router to remove all of thedamage.

Cut out a matching piece of same thickness atleast 1" (25.4mm) longer than the pie cut usingthe same template and router. It will generally benecessary to trim the point of the replacementpiece to fit the radius of the pie cut. Dry fit thepiece until there are no large gaps.Glue a reinforcement block of Avonite Surfacesmaterial to the bottom of sheet when you glue inthe replacement piece, if possible.

Trim the repaired section with a router andtemplate to give an even surface, then sandsmooth.

5.5Repairs


Avonite Surfaces has created One Stop Shoppingconvenience by making available all of the necessaryfabrication products through your local distributor. Ifitems listed below are not available from yourdistributor, please notify Technical Services, 1-800-866-TECH.

AAvvoonniittee SSuurrffaacceess SSoolliidd SSuurrffaacceeAAddhheessiivvee CCaarrttrriiddggeeSM4161-**

DDiissppeennssee GGuunnSM4160-00 MANUAL/SM4150-00 PNEUMATICFor manual mixing gun repairs, please call;603-893-2727 or fax 603-893-3737 or write:Conprotec, Inc., 6 Raymond Avenue, NH 03079.

SSppaarree MMiixxiinngg TTuubbeessSM4162-01

IInnllaayy FFiilllleerr——QQuuaarrttSM4131A quart sized blend of particulate in any AvoniteSurfaces Studio Collection color. Mix with AvoniteSurfaces’ Inlay Resin to create beautiful inlay designs.

PPaattcchh KKiittssSM4021-**Color coordinated Patch Kits each include (1) 4 oz.(113.4gm) can of filler, toners, and (1) 4 oz. (113.4gm)can of patching resin. Patch Kits are available in allcurrent Avonite Surfaces Studio Collection colors. Thecatalyst hardener must be ordered separately(SM4001-10).

PPaattcchhiinngg RReessiinnSM4021 -PR

4 oz. (113.4gm) cans of untinted Patching Resin soldseparately. Also used for small inlays.

6.1Fabrication Support Material


IInnllaayy RReessiinn——QQuuaarrttSM4130-00Specially formulated inlay resin for creating customdetail designs in Avonite Surfaces material. Can be usedwith Avonite Surfaces Inlay Filler for an “intarsia” look.

6.2 Fabrication Support Material


AAvvoonniittee SSuurrffaacceess TThheerrmmoo--FFllooww TTaappeeSM4065-00

Insulates from excessive heat in cooktop cut outs.One roll of tape contains 18 yards (16.45m).

SSpprriinngg CCllaammppss——22"" oorr 33"" ((5500..88 -- 7766..22mmmm))SM4063-00SM4063-01

Needed for equal and consistent pressure to avoidopen joints. Standard equipment for every fabricator.

CCaattaallyysstt HHaarrddeenneerrSM4001-10The additive which causes inlay and patching resinsto harden. Available in 1 oz. (28.3gm) bottles only.

MMaarriinnee PPaassttee CCoommppoouunndd ((wwhhiittee))SM4059-00

6.3Polishing & Sanding Accessories


AAvvoonniittee SSuurrffaacceess DDrryy--CCuutt FFiinniisshhiinngg SSyysstteemmSM4036-A Brown barSM4036-B Purple stick

Polishing system.

SStteepp 11:: Brown bar. SM4036-A

SStteepp 22:: Purple stick. SM4036-B

SSuuppeerrbbuuffff AAddaapptteerrSM4044-00

Buffing pad adapter for grinder/polisher.

FFiinneessssee--IItt FFiinniisshhiinngg MMaatteerriiaallSM4058-00

Second step in polishing system.(1 quart - .95 liters)

SSuuppeerrbbuuffff 22 ++ 22 PPaadd ((WWhhiittee))SM4045-00

Polishing Pad used with Marine Paste compoundand Avonite Surfaces Dry-Cut Finishing SystemCompound.

6.4 Polishing & Sanding Accessories


DDiisscc PPaadd——66"" ((1155..2244ccmm))**SM4047-02SM4048-00

Cushion pad for micro finishing film. Specify Hookitor Silver Face Stikit.

66"" ((1155..2244ccmm)) IImmppeerriiaall MMiiccrroo FFiinniisshhiinngg FFiillmm**

Hookit backing PSA backing

30 micron SM4053-02 SM4053-01

60 micron SM4054-02 SM4054-01

80 micron SM4055-02 SM4055-00

100 micron SM4056-02 SM4056-00

3M uniform grit sanding material.

SSuuppeerrbbuuffff PPoolliisshhiinngg PPaadd ((YYeellllooww))SM4046-00

Polishing Pad used with Finishing Material.

* All discs and pads come withholes for dust recovery.

The final finish of Avonite Surfaces material should be specified in one of the following finishes: Matte, Satinor High Gloss. Each customer must receive Avonite Surfaces Care & Maintenance information to ensure theyunderstand the proper care and maintenance for the Avonite Surfaces installation and to register for the tenYear Limited Warranty, or the new Installed Warranty as appropriate.

The Avonite Surfaces Care & Maintenance information, as well as all warranty information is available onlineat www.avonitesurfaces.com

CARE AND MAINTENANCE GUIDELINES

MMAATTTTEE FFIINNIISSHHCClleeaanniinngg::

Soap and water will clean moststains. For more stubborn stainsuse a green Scotch-Brite® pad

and an abrasive cleanser.

SSccrraattcchheess::To remove scratches, start sanding

with 240 grit paper and thenclean with an abrasive cleanserand a green Scotch-Brite® pad.

RReemmeemmbbeerr ttoo ppeerriiooddiiccaallllyy ggoo oovveerrtthhee eennttiirree mmaattttee ssuurrffaaccee wwiitthh aaddrryy,, ggrreeeenn SSccoottcchh--BBrriittee®® ppaadd ttoo

rreettuurrnn tthhee oorriiggiinnaall ffiinniisshh..

SSAATTIINN FFIINNIISSHHCClleeaanniinngg::

Soap and water will clean moststains. For stubborn stains use awhite Scotch-Brite® pad and anon-abrasive cleanser, such

as Soft Scrub™.

SSccrraattcchheess::To remove scratches, start bysanding with 400 grit paper

followed by 600 grit paper. Thenclean the area with Soft Scrub™and a white Scotch-Brite® pad.You may choose to spray on a

light coat of Protect All orPlexus™ to enhance the luster.

HHIIGGHH GGLLOOSSSS CClleeaanniinngg::

Soap and water will remove moststains. Use a polishing compoundlike 3M Perfect-It and a soft clothto remove more stubborn stains.

SSccrraattcchheess::To remove scratches from a highgloss finish, start sanding with400 grit paper. The surface must

then be machine polished back to it’s original finish. Advisecustomer to contact the AvoniteSurfaces Fabricator if they do not

own or have access to thisequipment.

• Always use a hot pad or trivet under hot potsor heat producing appliances.

• Always use a cutting board.

• Never stand on your counters.

• Avoid harsh chemicals such as drain cleanersand paint removers.

• For high gloss counters, place felt protectors on thebottom of pottery or other hard objects. Avoidsliding hard objects across these glossy surfaces.

• Always run cold water when pouring boilingwater into Avonite Surfaces’ sinks.

DO’S AND DON’TS GUIDELINES

7.1Care & Maintenance


Use the Matte Finish cleaning and scratch removal procedures above.

To keep sink color bright, clean occasionally with liquid bleach and water. Fill the sink 1/4 full with water, add1 to 2 cups of bleach, wipe the sides of the sink and let stand for 15 minutes. Then drain the sink and rinse.

AVONITE SURFACES SINKS

7.2 Care & Maintenance (Español)


MMAATTEE

Del Final: El jabón y el agua limpiarán lamayoría de las manchas. Para

manchas más obstinadas utiliceuna pista escocesa verde del Britey una despedregadora abrasiva.

Rasguños: Para quitar rasguños, comience a

enarenar con el papel de 240arenas y después limpie con unadespedregadora abrasiva y unapista escocesa verde del Brite.

RReeccuueerrddee ppaassaarr ppeerriióóddiiccaammeenntteessoobbrree llaa ssuuppeerrffiicciiee mmaattee eenntteerraa ccoonnuunnaa ppiissttaa eessccoocceessaa vveerrddee sseeccaa ddeell

BBrriittee vvoollvveerr eell ffiinnaall oorriiggiinnaall..

LLIIMMPPIIEEZZAA DDEELL FFIINNAALLDDEELL SSAATTÉÉNN

El jabón y el agua limpiarán lamayoría de las manchas. Para lasmanchas obstinadas utilice unapista escocesa blanca del Brite yuna despedregadora que no sen

abrasiva, tal como suavidad friega.

Rasguños: A quitar rasguños, comience

enarenando con 400 de papel dela arena seguida por el papel de

600 arenas. Entonces limpie el áreacon suavidad friegan y una pistaescocesa blanca del Brite. Usted

puede elegir rociar una capaligera del protege todos para

realzar el lustre.

AALLTTAA LLIIMMPPIIEEZZAADDEELL LLUUSSTTRREE

El jabón y el agua quitarán lamayoría de las manchas. Utilice uncompuesto que pule como los 3mPerfect-It y un paño suave paraquitar manchas más obstinadas.

Rasguños: Para quitar rasguños de acabe delustre alto, comience el enarenar

con el papel de 400 arenas.Entonces la superficie debe

entonces ser máquina pulida denuevo a su final original.

Aconseje al cliente que contacteal fabricante de Avonite Surfaces

si no poseen ni tienenacceso a este equipo.

FREGADERO DE AVONITE SURFACES:

Utilice la limpieza mate del final y rasguñe los procedimientos de retiro arriba.

Para mantener color del fregadero brillante, limpie de vez en cuando con el blanqueo líquido y riegue. Llene elfregadero 1/4 por completo de agua, agregue 1 a 2 tazas de blanqueo, limpie las caras del fregadero y deje elsoporte por 15 minutos. Después drene el fregadero y aclárelo.

LAS QUIAS DE CONSULTA DE QUE HACER Y NO HACER

• Utilice una pista o un trivet caliente bajo loscrisoles calientes o caliente siempre produciraplicaciones.

• Siempre utilice una tabla.

• Nunca se pare sobre en sus contadores.

• Evite los productos químicos ásperos talescomo productos de limpieza de discos deldren y removedores de pintura.

Aristech Acrylics LLC (the “Company”) warrants to the

original purchaser of any of the Company’s Avonite

Surfaces solid surface products that the Company will at

its option repair or replace, without charge, such product

if it fails due to a Company manufacturing defect during

the first ten years after initial installation. This includes

reasonable labor charges needed to repair or replace the

product covered hereunder.

This warranty applies to any Avonite Surfaces solid

surface product purchased after August 22, 2005 that is

put into residential or commercial use and maintained in

the manner recommended by the Company in its

publications relating to care for a permanent installation.

A copy may be obtained, free of charge, from your dealer

or by writing directly to the Company.

This warranty does not apply to the Company’s

Acrystone® solid surface 1/8” product, which is covered

by a separate 1 year limited warranty.

This warranty does not cover damage caused by:

1. Failure to follow Company recommended procedures

for fabrication and installation.

2. Physical abuse, structural movement, damage from

excessive heat, or breakage not due to a Company

defect in the manufacture of the material.

3. Failure of any adhesive, caulk, or other finishing or

maintenance accessory, or failure of any caulked or

filled joint or seam.

This warranty applies only to Avonite Surfaces products:

1. Purchased for use in the United States and all other

countries where Avonite Surfaces is distributed,

fabricated and installed by an Avonite Surfaces

authorized fabricator/installer.

2. Which fail due to a manufacturing defect; and

3. Which have not been moved from their original place

of installation.

This warranty is for applications such as countertops,

vanities and vertical applications and does not apply to

installations in mobile environments such as recreational

vehicles, marine crafts and airplanes. This warranty does

not cover material exposed to weather conditions or

exterior applications such as grill tops & exterior counters.

This warranty does not cover color. If during or after

installation you decide that you do not like the color

selected due to sample chip variance, website or printed

literature representation or other reason replacement is

not covered by this warranty.

For coverage under this warranty, request a

registration card from your dealer or contractor and mail

the card to the company. The Company will assign a

warranty registration number. To obtain service under this

warranty, write to the dealer/contractor from whom you

purchased the product or alternatively write to Aristech

Acrylics LLC at the address given below.

Include the phrase “Avonite Surfaces Products, 10-

Year Limited Material Warranty”, your name, address, a

description of the problem and your warranty registration

number. A response will be sent within 60 days.

The Company’s obligation hereunder is limited solely

to the repair or replacement, including necessary labor

charges, of the Avonite Surfaces product purchased

hereunder. The Company’s obligation to repair or replace

shall further be limited to repair or replacement with

colors and styles of product that are available at the time

of repair or replacement. No implied or express warranty

of merchantability or fitness for a particular purpose is

granted by this wwaarrrraannttyy. Except as provided herein, the

Company shall not be liable in either tort or contract for

any loss or direct, consequential or incidental damage

arising out of the use or inability to use Avonite Surfaces

residential or commercial products hereunder. Some

states do not allow the exclusion or limitation of incidental

or consequential damages, so the above limitation or

exclusion may not apply to you.

This warranty gives the purchaser specific legal rights;

other rights may also be available which may vary from

state to state or in Canada from province to province.

This warranty is not transferable or assignable.

Any questions under this warranty should be

addressed to the local Avonite Surfaces distributor or

Aristech Acrylics LLC.

Aristech Acrylics LLC

1945 Highway 304

Belen, NM 87002

1.800.428.6648

www.avonitesurfaces.com

Effective as of 8/22/05

7.310 Year Limited Warranty


Aristech Acrylics LLC (the “Company”) warrants to the

original purchaser of any of the Company’s Avonite Surfaces

solid surface products for residential or commercial use that

the Company will at its option repair or replace, without

charge, such product if it fails due to any Company-

manufacturing, fabrication, or installation defect during the

first ten years from initial installation, except for damage

caused by physical or chemical abuse, damage from

excessive heat, damage from fire or emergency, or damage

resulting from a natural disaster. This warranty covers seam

performance but not appearance. The warranty includes

reasonable labor charges to the extent necessary to repair

or replace the product covered hereunder.

This installed warranty is transferable within the 10-

year period ONLY when the new owner sends Avonite

Surfaces a written request to register the installation under

the new owner’s name. Upon receipt of such notification,

the warranty will continue for the balance of the original 10-

year period.

The installed warranty applies only to PERMANENTLY

INSTALLED Avonite Surfaces products:

1. Purchased for residential or commercial use in the

United States or Canada;

2. With a Registration Tag affixed to the installation and

which were fabricated / installed by an Avonite

Surfaces Certified Master Fabrication / Installation

(CMF/I) Source;

3. Which have not been moved from their original place of

installation; and

4. Which are maintained according to Avonite Surfaces

Care & Maintenance guidelines. A copy will be

provided, free of charge, by your Avonite Surfaces

Certified Master Fabrication / Installation Source or by

contacting Aristech Acrylics LLC.

This warranty is for applications such as countertops,

vanities and vertical applications and does not apply to

installations in mobile environments such as recreational

vehicles, marine crafts and airplanes This warranty does not

cover material exposed to weather conditions or exterior

applications such as grill tops & exterior counters. This

warranty does not cover color. If during or after installation

you decide that you do not like the color selected, due to

sample chip variance, website or printed literature

representation or other reason, replacement is not covered

by this warranty.

This warranty does not apply to the Company’s

Acrystone® solid surface 1/8” product, which is covered

by a separate 1 year limited warranty.

For coverage under this warranty, request a registration

card from your Avonite Surfaces CMF/I or write directly to

the Company. Your Avonite Surfaces CMF/I must fill out a

portion of the warranty registration card. To register your

warranty, mail the card to Aristech Acrylics LLC. To obtain

service under this warranty, contact the source from whom

you purchased your Avonite Surfaces product, or

alternatively contact Aristech Acrylics LLC.

Installations not fabricated / installed by an Avonite

Surfaces Certified Master Fabricator / Installer, are

warranted only against product manufacturing defects for a

period of 10 years from the date of initial installation as

stated in Avonite Surfaces 10 Year Limited Material Warranty.

To determine if a fabricator is a CMF/I call the Company’s

Technical Service department at 1-800-866-8324.

The Company’s obligation hereunder is limited solely to

the repair or replacement, including necessary reasonable

labor charges, of the Avonite Surfaces solid surface product

purchased hereunder. The Company’s obligation to repair or

replace shall further be limited to repair or replacement

with colors and styles of product that are available at the

time of repair or replacement. No implied or express

warranty of merchantability or fitness for a particular

purpose is granted by this warranty. Except as provided

herein, the Company shall not be liable in either tort or

contract for any loss or direct, consequential, or incidental

damages arising out of the use or inability to use Avonite

Surfaces solid surface products hereunder. Some states do

not allow the exclusion of incidental or consequential

damages, so the above limitation or exclusion of damages

may not apply to you.

This warranty gives the purchaser specific legal rights;

other rights may also be available which may vary from

state to state or in Canada from province to province.

Avonite Surfaces’ 10 Year Limited Installed Warranty

coverage is your ultimate assurance of lasting quality. If we

can answer any further questions regarding this warranty,

please contact your local Avonite Surfaces distributor or

contact Aristech Acrylics LLC directly by writing or calling:

Aristech Acrylics LLC

1945 Highway 304

Belen, NM 87002

1-800-428-6648 or 1-505-864-3800

www.avonitesurfaces.com

The Avonite Surfaces Installed Warranty is offered

by Certified Master Fabricators/Installers only.

To become a Certified Master Fabricator,

please contact the distributor in your area.

Effective as of 8/22/05

7.4 10 Year Installed Warranty



WWAARRRRAANNTTIIEESS::

To resolve warranty claims, we ask that ourDistributor Representatives prepare a Warranty ClaimReport. You can help us expedite the processing ofwarranty claims and achieve improved customersatisfaction by assisting in the following areas:

1. WWaarrrraannttyy CCllaaiimm RReeppoorrtt FFoorrmm - Please fill form outcompletely so that the information needed tomake decisions is readily available for us. Thisinformation helps us tremendously in theprocessing of the claim.

2. QQuuaalliittyy IInnssppeeccttiioonn CChheecckklliisstt -- We ask yourassistance in completing this form in detail, asthis helps us to identify how the defect occurred.Your help in this area in the past has led to theadvanced fabrication procedures that now existin the solid surface industry, further improvingour industry’s reputation.

3. JJoobb LLaayyoouutt -- Include a detailed diagram of the job,complete with all measurements, includingdistances to seams and seam locations. This helps

us to accurately estimate the cost of fabricationand material, thereby reducing errors and allowingus to validate a repair/replacement quote.

4. PPhhoottooss -- Take three to four photographs(Polaroids are fine) of the defective area and aphotograph of the overall kitchen.

5. QQuuoottaattiioonn -- Submit a written quotation on therepair or replacement of the job. Repair isencouraged over replacement. However, if repairis not possible, a quote of the job replacement isneeded.

Warranty claims that are submitted with completeinformation will be resolved within two weeks of receiptof the claim. Without this information, the processing ofa claim will be delayed. We ask for your continuedcooperation and thank you for your assistance.

AAVVOONNIITTEE SSUURRFFAACCEESSTTEECCHHNNIICCAALL SSEERRVVIICCEE DDEEPPAARRTTMMEENNTT

11--880000--886666--TTEECCHH((11--880000--886666--88332244))

7.5Warranty Claims Processing

IIMMPPOORRTTAANNTT NNOOTTIICCEEThe information and statements herein are believed to bereliable but are not to be construed as a warranty orrepresentation for which we assume legal responsibility. Usershould undertake sufficient verification and testing to determinethe suitability for their own particular purpose of any informationor products referred to herein. NO WARRANTY OF FITNESS FOR APARTICULAR PURPOSE IS MADE.

Nothing herein is to be taken as permission, inducement or recom-mendation to practice any patented invention without a license.

Any information or suggestion concerning applications,specifications or compliance with codes and standards is providedsolely for your convenient reference and without any representationas to accuracy or suitability. Aristech Acrylics LLC disclaims anyresponsibility. The user must verify and test the suitability of anyinformation or products for his specific application.

Aristech Acrylics LLC7350 Empire DriveFlorence, KY 41042

All Rights Reserved. © Aristech Acrylics LLCItem #SL4009-07. Printed in U.S.A. 07/07

1-800-354-9858www.avonitesurfaces.com

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