duponttm corian condensed fabrication manual - cd:uk · condensed fabrication manual 4 duponttm...

DuPontTM Corian®

Condensed Fabrication Manual

www.corian.co.uk www.corian.com

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This booklet contains instructions for successfully fabricating DuPontTM Corian® in an efficient and safe manner.

It indicates the standards of workmanship requiredfor customer satisfaction.

The abridged fabrication procedures described in this booklet are recognized within the Europe, Middle East and Africa region and must be adopted during fabrication in order to comply with the DuPontTM Corian® ten (10) Year Limited

Installed Warranty.

For more detailed information on how to fabricate DuPontTM Corian®, please contact your DuPontTM Corian® supplier.

DuPont assumes no responsibilityfor the use of these techniques with any other products.

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A.WhAtisDuPont™CoriAn®_____________________________________________________P.4

B.EnvironmEnt__________________________________________________________________P.4

C.sAfEty________________________________________________________________________ P.4-5

D.toolsAnDACCEssoriEs__________________________________________________________

D.1 Saws and Blades ___________________________________________________________p. 6-7

D.2 Routers and Router Bits______________________________________________________ p. 7

D.3 Sanding Machines and Finishing______________________________________________ p. 7

D.4 Clamping Systems___________________________________________________________ p. 8

D.5 Templates____________________________________________________________________P. 8

E.insPECtionofDuPontTMCoriAn® ______________________________________________P.9

f.storAgEAnDhAnDling_______________________________________________________P.9

g.fABriCAtion_______________________________________________________________________

G.1 Cutting DuPontTM Corian® ____________________________________________________ p. 10

G.2 Positioning of Seams _______________________________________________________ p. 10

G.3 Seaming DuPontTM Corian®________________________________________________ p. 11-12

G.4 Edge details and Downturns___________________________________________ p. 13-14-15

G.5 Backsplashes ______________________________________________________________ p. 16

G.6 Shape Integration________________________________________________________ p. 16-17

G.7 Hob Cut-outs____________________________________________________________ p. 18-19

G.8 Frames and Support________________________________________________________ p. 20

G.9 Thermoforming ____________________________________________________________ p. 21

G.10 Wall Cladding_____________________________________________________________ p. 22

G.11 Finishing and Polishing _________________________________________________ p. 23-24

h.WArrAntyinformAtion _____________________________________________________P.25

i. Do’sAnDDon’ts______________________________________________________________P.26

tABlEofContEnts

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DuPontTM Corian® is a solid, non-porous surfacing material homogeneously composed of ± 1/3 acrylic resin (also known as PolyMethyl MethAcrylate or PMMA), and ± 2/3 Aluminium TriHydrate (ATH), a natural mineral filler obtained from bauxite.

DuPontTM Corian® is used as a decorative material in a variety of residential and commercial applications. It offers design versatility, functionality and durability.

Supplied in sheets and shapes, it can be fabricated with conventional woodworking tools into virtually any design.

DuPontTM Corian® is the original solid surface material only made by DuPont. It is widely accepted as a material for countertops, vanity tops, tub/shower walls, kitchen sinks, vanity basins, laboratory bench tops in numerous markets like: lodging, healthcare, banks, boutiques, restaurant and many others.

B.EnvironmEnt

Respect for environment is an asset for DuPont and all of its products. We have developed a series of initiatives that will help build a successful business without compromising the future generations by driving towards zero waste generation and zero emissions, preservation of energy and resources, material recycling, etc.

Also, DuPontTM Corian® can be considered a “green” material because it is:

Durable and renewable: it lasts long time and can easily be repaired and renewed. Because it is re-workable, DuPontTM Corian® generates up to 1/3 less waste than stone in fabrication process

Chemically inert and environmentally responsible: it doesn’t react readily with other chemicals or elements, therefore has low impact on the environment. DuPontTM Corian® also meets the most restrictive “food zone” standards. The pigments used to colour the material are all approved for food contact.

Non-toxic: at room temperature DuPontTM Corian® is non-toxic, with virtually no “off-gassing” of volatile organic compounds. In a fire situation, DuPontTM Corian® is clean-burning and produces an insignificant amount of smoke. Also, DuPontTM Corian® adhesives have extremely low VOC emissions during the curing process, well below US and EU standards.

C.sAfEty

Safety is a corporate value at DuPont.The safety consciousness from DuPont goes back to the early days of the company (1802) when it operated gun powder mills. Since those early days safety has become part of DuPont culture.Quality tools are used to fabricate and install DuPontTM Corian®.We recommend that you as a DuPontTM Corian® fabricator/installer would apply the safety guidelines included in this booklet.DuPont Surfaces is convinced that: “Safety is a key part of our business success”.

safetyguidelines1. For your own safety, read instructions manual before operating the different tools. Learn the tool’s

application and limitations as well as the specific hazards peculiar to it.2. Keep guards in place and in working order. Removing safety guards is illegal.3. Earth all tools. 4. Remove adjusting keys and wrenches. 5. Keep work area clean. 6. Don’t use in dangerous environment.

A.WhAtisDuPonttmCoriAn®

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7. Keep children and visitors away. 8. Don’t force tools. 9. Use the right tool. 10. Wear proper safety gear. 11. Always use safety glasses or approved spectacle shields. Also use face or dust masks if cutting

operations are dusty.12. Secure work. Use clamps or a vice to hold work when practical. 13. Don’t overreach. Keep proper footing and balance at all times.14. Maintain tools in top condition. 15. Disconnect tools before servicing and when changing accessories such as blades, bits, cutters, etc. 16. Use recommended accessories. 17. Avoid accidental starting. 18. Never stand on tool. 19. Check damaged parts. 20. Never leave tool running unattended - turn power «off».21. Do not operate a tool while under influence of drugs, alcohol or any medication.

AND ESPECIALLY WHEN HANDLING DUPONT™ CORIAN® AND ITS ACCESSORIES:22. When carrying DuPontTM Corian® sheets, use two people, don’t flex sheets, wear heavy duty gloves and if

appropriate, use lifting straps.23. Don’t stack boxed products too high and in an unsafe manner.24. Keep denatured alcohol, adhesives and any other toxic or flammable materials in a safe ventilated place.

Material Safety Data Sheets for DuPontTM Corian® are available on the DuPont website (www.dupont.com) under “MSDS”:

When there is a medical incident, the European Medical Director can be contacted through telephone number +41 22 717 5131 (or fax nr +41 79 360 80 84).Provide name and telephone number of the medical doctors treating the patient and details on the incident.

The European Medical Director will contact this medical doctor in order to:

1. Get more details of what happened2. Discuss the best therapy with respect to the product involved

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D.toolsAnDACCEssoriEs

Most carpentry workshops will be equipped to work with DuPontTM Corian®. There is no absolute recommendation as to which brand you should use to work with DuPontTM Corian®. However DuPontTM Corian® requires that saw blades and router bits are of tungsten carbide composition and power tools should be powerful enough to assure quality fabrication and longevity of machinery.

Below is a selection of wood-working equipment to enable efficient and safe fabrication of DuPontTM Corian® sheets and shapes:

D.1. SawS anD BlaDeS

Any type of circular saw may be used for ripping and sizing DuPontTM Corian®.Most acceptable common varieties include:

Table saw bed with sliding tray Vertical panel saw Drop cut saw with 45-degree angle option Heavy-duty portable circular saw Radial arm saw Beam saw

Regardless of the type of circular saw, all saws must:

Be heavy duty Have triple-chip blades of tungsten carbide which should be used only for cutting DuPontTM Corian®

Have hook angle blades with pitch of -5 to +10 degrees and be described as “for cutting hard plastics” Have a quiet blade, small gullets, brass plugs and heavier blade stock Comply with the local safety standards.

Blades should be sharpened regularly with a 400 to 600 grit grinding wheel. Blades should have 6 teeth per 25 mm diameter.

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Refer to the table below for the most successful dry blades for cutting DuPontTM Corian®.

BLADE DIAM.mm

KERF WIDTHmm

PLATE THICKNESS mm

C-HOLEmm

N°. OF TEETHmm

PITCH mm

200 2.8 2.2 30 64 9.8

250 3.2 2.6 30 80 9.8

300 3.2 2.6 30 96 9.8

350 3.6 3.0 30 108 10.2

400 4.4 3.6 30 120 10.5

450 4.4 3.6 30 144 9.8

500 4.4 3.6 30 160 9.8

D.2. RouTeRS anD RouTeR BiTS

Router bits must be tipped with tungsten carbide. Polycrystalline diamond bits may be suitable in certain applications utilizing CNC machinery.

For day-to-day fabrication, you should have the following:

10 mm carbide tipped single flute with 12 mm (UK-12.7 mm) shank 10 mm carbide tipped double flute with 12 mm (UK-12.7 mm) shank Carbide tipped decorative bits 12 mm (UK-12.7 mm) shank with roller bearing (Profile bit or Trimming cutter)

Refer to the table below for an accurate guide to the use of router bits:

TASK TOOL/BIT

General Purpose Work:e.g. edge and seam trimming, cut-outs

10 mm carbide tipped double flute with 12mm* shank

Heavy Duty Work:e.g. bulk cut-outs, banjo cuts, coving

10 mm carbide tipped single flute with 12mm* shank

Detail Work:e.g. edge treatment Carbide tipped decorative bit

*12 mm (UK-12.7 mm)

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D.3. SanDing MachineS anD FiniShing

Finishing DuPontTM Corian® is a critical part of the end consumer’s perception of your ability to fabricate DuPontTM Corian®.

In day-to-day fabrication, you need to be well equipped and have the following:

Orbital sander Small hand sander Random orbital sander Stationery belt sander Portable belt sander Wide belt sander

D.4. claMping SySTeMS

Several types of clamps are suitable for use with DuPontTM Corian®. Those recommended include:

Spring clamps G-clamps Sash clamps Suction clamps

The table below shows which clamping systems are recommended for different applications.

TASK TYPE OF CLAMP

Attach downturn strips Spring clamps or Sash clamps

Hold templates or straight edges in place G-clamps or Sash clamps

Hold sheets together for seaming Sash clamps, suction clamps

D.5. TeMplaTeS

Templates should be made for all installations of DuPontTM Corian® that incorporate coved cut-outs.Store all templates in a way that keeps them in good condition and the leading edge true (such as in a vertical rack). This is essential in ensuring that cut-outs are clean and smooth, which means perfect seams for shape installation.There are several good e-template systems on the market. Each one has its own features and benefits that differ from the others. Careful investigation should be done before making a purchase, so that the chosen system fits with your way of working.

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E.insPECtionofDuPonttmCoriAn®

Inspect sheets and shapes products prior to fabrication.Do not work with substandard product which may greatly increase the amount of fabrication time required.DuPont’s replacement policy does not allow for compensation of labour on substandard product.Please refer to our DuPontTM Corian® product specifications or consult your DuPontTM Corian® supplier if you are unsure of the quality of the product.

An essential element to sheet inspection is checking for colour matching. The composition of DuPontTM Corian® produces slight colour variations between production cycles due to the complex blending of natural minerals and man-made acrylics. Colour variations are therefore inherent in the products (within 1 sheet or sheet to sheet of the same colour).

These strict guidelines below should therefore be followed to ensure the best possible colour matching of DuPontTM Corian®:

Step 1: Using sheets from the same pallet (same batch number);Step 2: Checking the code printed on each sheet and fabricating the sheets with the closest sequential

numbers when possible (example: 9063421 & 9063481);Step 3: Conducting a rapid check by gluing 2 small pieces together and visually checking the colour

matching result.In case where the ink-jet number or label is missing from a sheet within a complete pallet, it is most probable that the sheet may still be from the same batch as the others in the pallet. You may follow step 3 before commencing a job using this sheet.In case where a significant colour match difference is found to be unsatisfactory after following the 3 steps from the guidelines above, please contact your DuPontTM Corian® representative before commencing fabrication.

f.storAgEAnDhAnDling

Do not attempt to unload or carry DuPontTM Corian® sheet unaided.Do not carry sheets horizontally or unsupported, and do not handle sheets with bare hands when unloading.The product is fragile, heavy and must be handled with care to ensure that first-grade materials end up on the workbench.

Sheets must be stored so that the product is kept in a perfectly level condition, i.e. no warping. DuPontTM Corian® sheet is most effectively stored between 15 to 23° C and must be kept in a dry and well-ventilated area.

Shape should be stored to allow easy access and identification of the contents of the carton. Do not store heavy products on top of shape cartons. For safety, shapes should not be stacked more than six cartons high.

Under no condition should DuPontTM Corian® be stored outdoors.

If DuPontTM Corian® is exposed to extreme cold temperatures then it must be allowed to reach room temperature, approximately +18 to +20° C, before commencing working with the material.

DuPontTM Corian® Joint Adhesive should be stored in horizontal position, in a cool (in an area of constant temperature in the range of 12° to 16° C) and dark area.

All DuPontTM Corian® adhesives have a shelf life of two years. Please check expiry date before use.

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g.fABriCAtion

The following main fabrication techniques highlighted within this section will allow efficient fabrication of DuPontTM Corian® sheets and shapes.

This is a basic introduction to DuPontTM Corian® and if more complex fabrication techniques are required, please contact your DuPontTM Corian® supplier or consult our web-site for further information.

g.1. cuTTing DuponTTM coRian®

Prior to cutting, check carefully your drawing and prepare a cutting list. It is essential that you allow minimum 3 mm total tolerance to allow DuPontTM Corian® to expand and contract.

With all DuPontTM Corian® projects, allow a minimum 3 mm gap for expansion between walls.

Note: 4 / 6 mm DuPontTM Corian® sheets are to be used in vertical applications only. It is possible that a colour or pattern difference will occur between 4, 6, 12 and 19 mm DuPontTM Corian® sheets.

Do not mix DuPontTM Corian® from different production sites.

g.2. poSiTioning oF SeaMS

When examining plans of any installation of DuPontTM Corian®, the objective is twofold:

1. Placing seam positions in a manner that minimizes the use of the DuPontTM Corian® sheet and accessory material.

2. Placing seams in positions that maximize product performance.

All seams must be butt-seamed; i.e. seams must be placed either perpendicular or parallel to the length of the sheet. All seams in countertops must be reinforced. To select the best positioning of seams, follow the step by step process listed below.

1. Considerpositionofhoband/orheat-emittingappliancesWherever possible, (i.e. design and best use of economies) allow seams to be positioned parallel with the front edge of the hob or appliance. The minimum distance between countertop seams and hob is 250 mm. All DuPontTM Corian® reinforcing strips must be where heat appliances are situated.

2. ConsiderationofdishwasherSeams must not be positioned over a dishwasher.

Note: Always put insulating material directly over any dishwasher; between the dishwasher and the DuPontTM Corian® top.

3. ConsiderationofinternalcornersWherever possible, (i.e. design and best use of economies) allow reinforced seams to be positioned at a minimum of 35 mm from the internal corner.

4. Considerationofon-siteseamsandsizeoftransportablepartsGive careful consideration to the size and weight of transportable parts and their impact on non-preferred on-site seams. Use information from the site inspection to ascertain the ideal balance of these two conflicting issues.

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g.3. SeaMing DuponTTM coRian®

When seaming two pieces of DuPontTM Corian® in a standard countertop seam, it is important that the two pieces are a perfect fit.The ideal preparation for two edges to be seamed is the router pull-through method (mirror cut).This method entails using a standard double fluted router bit that is passed simultaneously across the leading edges of both pieces of DuPontTM Corian® to be seamed, as illustrated below:

Mirror cut method

Once the seam is routed, carefully sand both edges to be seamed using 150/180 grit sandpaper ensuring the top edges are not rounded.

Clean both edges of any contamination that may discolour the seam. Use clear denatured alcohol on a clean white cloth or paper towel. In ink printed numbers or text (e.g. pencil) that run through the seam zone, should be removed to avoid discoloration or stains in the seam.

Trial-fit both edges to check for perfect fit.

Place plastic release tape directly under the seam to allow DuPontTM Corian® to move. Adjust the sheets from underneath until face alignment is perfect. Set the two pieces to be seamed about 3 mm apart.

Use colour-matched DuPontTM Corian® Joint Adhesive to fill the seam. Push the sheets together and clamp up without over-tightening.

More detailed and comprehensive description of the DuPontTM Corian® fabrication and installation techniques are available at your DuPontTM Corian® supplier or in the complete DuPontTM Corian® Fabrication Manual.

All DuPontTM Corian® seams must be reinforced as per instructions detailed in this section to comply with the DuPont warranty program.

A reinforced seam will strengthen the seam to the actual strength of the DuPontTM Corian® sheet.The DuPontTM Corian® reinforcement strip must be the same thickness as the sheet being fabricated. The strip must be running the full length of the seam and the DuPontTM Corian® Joint Adhesive must be applied to the full width of the DuPontTM Corian® reinforcement strip.Adhere small blocks to each piece of DuPontTM Corian® with hot melt glue, and clamp on to these with G-clamps to provide seam pressure. Do not over-tighten.Ensure that a perfectly even bead of glue is emitted along the full length of the seam when clamp pressure is applied. Leave the adhesive cure for 45 minutes (room temperature 18° C), when the glue is dry and hard, remove surplus glue with a block plane.To finish the seam, take a random orbital sander or standard orbital sander using the techniques described in chapter G.11 finishing and polishing.

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Reinforce all seams with 12 mm DuPontTM Corian® strip from 50 mm wide.

Clean the seam with clear denatured alcohol and clean white cloth.

Apply DuPontTM Corian® Joint Adhesive to the reinforcement strip.

Joint Adhesive to fill the seam.

Push the sheets toward each other, leaving a 2 mm gap.

Use DuPontTM Corian® Joint Adhesive to fill the seam.

Push the sheets together to close the seam Clamp up without over tightening

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g.4. eDge DeTailS anD DownTuRnS

REBATING FOR THE EDGE DOWNTURN

One method recommended for edge downturn is the rebating of the downturn in the countertop. This provides additional strength in the seam, accuracy of the downturn placement and superior seam quality.

Since the underside of sheets of the particled colour families is uneven or has some air bubbles which will affect the seam quality, this procedure is suggested to eliminate the aforementioned problems.Tools Required:

Minimum 1400 W router Surfacing rebating bit (as illustrated below) or prepared with a C.N.C.

STEPS TO COMPLETION

1. Ensure that the countertop is finished to a stage where all countertop seams are complete and the countertop is accurately sized to 1.5 mm of its final dimension.

2. This requires that all pocket cuts are complete, especially in internal and external corners.

3. Fit the router with the rebate bit or in case of C.N.C. the appropriate router bit.

4. Rout a 13,5 mm x 2 mm rebate along all edges of the countertop that require downturn.

5. Turn the countertop over and finish off the router cut to assure an even surface.

helpfulhints:

The rebate bit allows the rebate to be completed on all straight and curves without turning the countertop over.Where possible, use a router with as large a base as possible, as this prevents any possible tilting during the cut.

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CONSTRUCTING THE STRAIGHT EDGE DOWNTURN

The straight edge downturns are as important as internal and external corners in terms of your ability to create a seamless finish. The straight edges are a more simple process, but are equally important to finish perfectly.

STEPS TO COMPLETION

1. Using material colour-matched to the sheet, create the required number of DuPontTM Corian® downturn strips,sufficient to make up the downturn depth. It is essential that downturn seams do not align with countertop seams. Careful planning is required at this point to ensure that the separation between seams is a minimum of 50 mm.

helpfulhints:

When clamping the downturns in place, be especially careful to ensure that they are perfectly aligned at 90 degree to the countertop.

The width of the strips can be calculated as follows: The countertop thickness minus thickness of the sheet plus the depth of the rebate = width of the strips, as illustrated below:

2. Sand the edge of the strips to be glued to the rebated edge to a smooth finish .3. Turn the sheet over and trial-fit all downturn strips.4. Apply a generous quantity of DuPontTM Corian® Joint Adhesive to the rebated area ensuring that the entire

rebated area has an even coating.5. Place the downturns in position hard against the rebate upturn and clamp in position using a small spring or

sash clamp placed every 100 mm.6. Ensure that the line of adhesive that forms at the rear edge of the seam is left intact and allowed to dry.7. Ensure that the line of adhesive that forms at the front edge of the seam is continuous and left intact.

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Allow DuPontTM Corian® Joint Adhesive to pool at both points x and y in the above Figure. If pooling is not continuous at point x, re-apply additional DuPontTM Corian® Joint Adhesive. Another method is to construct straight edge downturns without using the rebate method: Non-Rebated Edge Detail.Straight edges, butted directly against the underside of the DuPontTM Corian® sheet, are possible.When using this technique, be sure to check for defects to the underside of the sheet and always sand the downturn and the underside to the sheet prior to seaming.

Note: Stone-colours should also be included for this technique

WATERFALL EDGE

To construct a waterfall edge, unlike other edge details, a waterfall edge must be face-applied.To apply the edge detail, 3-way G-clamps or standard sash cramps can be used to apply pressure and enable the seam to be glued. One recommended method is to form a tongue on the DuPontTM Corian® sheet and a groove into the edge detail to allow for firm and accurate seaming to take place, see below picture (1).

The waterfall detail can be pre-shaped using a spindle moulder or alternatively can be done with a hand-held router using a waterfall router bit, as illustrated below (2).

1 2

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g.5. BackSplaSheS

G.5.1. BUTTED BACkSPLASH

The Butted Backsplash describes a return up the vertical wall behind the countertop that is seamed to the countertop with a simple butt seam. This method is a quick and simple method of adding value to a DuPontTM Corian® countertop, and can be glued using either DuPontTM Corian® Joint Adhesive or silicone.

G.5.1. COvED BACkSPLASH

A coved backsplash is created by inserting an additional piece in the seam between the countertop and the backsplash that is rounded to provide a seamless coved seam.One method for doing this is the Coved Countertop Insert Method:The Countertop Insert Method requires a block 12 mm x 22 mm to be rebated 2 mm into the countertop to form the base for the return of the backsplash to be mounted. This provides the additional material from which the cove, R 10mm between the countertop and the backsplash is formed.

g.6. Shape inTegRaTion

The installation of a DuPontTM Corian® shape product must be a precise and exacting process to ensure that a good fit is always created.

Using the correct tools is essential. In addition, the condition of all tools must be high quality, bits must be sharp and guards and fences accurate and precise.

These items are essential for all shape insertions: Undermount method

1. Strong level work bench that allows for the shape to be installed into the sheet.2. A minimum 1400 W router with a sleeve guide and a 12 mm collet.3. Accurate template for shape model being installed, or correct dimensions and angles for cutting on a C.N.C. 4. The recommended two router bits for undermount method

Coved backsplash

Butted backsplash

Coved Backsplash: Corner Detail. Using AK-8G from Albin Kraus or FRE317S from Virutex

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Plunge bit single flute, 10 mm Bowl cutter (See picture below)

For further information please contact your tool suppliers:

- www.titman.co.uk- www.albinkraus.at- www.festool.com- www.leitz.org

STEPS TO COMPLETION

1. Turn the sheet over and sand the area that the shape will be positioned on until smooth.2. Clamp the self-made template into position (sheet still upside down).3. Using a minimum 1400 W router fitted with a sleeve guide and a single flute cutting bit, rout the bowl cut-out.4. Remove the template and trial-fit the bowl. Glue bowl positioning blocks around the bowl flange if not

rebated. Centre the bowl in the cut-out using small hot-melt blocks.5. Sub mount DuPontTM Corian® bowls can be glued directly to the DuPontTM Corian® sheet without any

mechanical support provided the sheet and shape are sanded and cleaned prior to seaming.6. Inspect the rim face of the bowl for any imperfections (do a trial-fit).7. Clean the rim face and the areas to be glued with clear denatured alcohol.8. Take DuPontTM Corian® Joint Adhesive and put a thick bead around the internal perimeter of the bowl about 7

mm from the edge.9. Turn the bowl over and position it against stop blocks. Check for proper alignment.10. Press the bowl firmly in place.

11. Use bowl-clamping fixture (or similar device) to hold the bowl until the adhesive sets.

12. After the adhesive sets, remove clamping fixture and turnover.13. Using a router equipped with a round over bit (See “Examples of Router Bits”), trim excess sheet back to

the inside of the bowl14. Sand and finish the bowl and sheet in the normal manner.

Examples of Router Bits to finish DuPontTM Corian® Sinks and Bowls

Washer and wing Nuts

All Thread Bolt

Hex Nuts and Lock Washers

BOWL-CLAMPING FIXTURE

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g.7. hoB cuT-ouTS

DuPont highly recommends that hob cut-outs are done by the fabricator in the factory, as complicated techniques make it difficult for the installer to carry out the work on-site. Depending on the type of hob different hob cut-out methods must be used.

G.7.1. HIGH-STRENGTH CUT-OUT (MANDATORy METHOD FOR INSTALLING SqUARE HOBS)

The mandatory method for installing a square hob is using the high-strength cut-out. This technique is the best and strongest way known to avoid cracking around hobs. The technique described is patented only by DuPont.

(For a comprehensive explanation of this method please refer to our Fabrication Manual Chapter 8 ‘Cut-outs in DuPontTM Corian®’, or contact your DuPontTM Corian® supplier).

STEPS TO COMPLETION

1. The cut-out must be done with a router and a sharp minimum 10 mm straight carbide cutter; this is the only recommended tool for this procedure.

2. Always use the proper template for each flange size.3. Great care must be taken to sand all inside edges removing any chatter marks. The top and bottom edges

must be sanded to a minimum radius of 1,5 mm, until they are rounded and smooth.4. Particular care must be taken when sanding the corners as this is a vulnerable area. Therefore each corner

must be re-inforced with a second piece of DuPontTM Corian® and bonded with DuPontTM Corian® joint adhesives. Allow a minimum of 3 mm gap between the cut-out and the appliance. If more space can be given, then do so. See illustration below for details.

5. Apply 3M aluminium reflective tape (Scotch® Brand Tape 425/427) around the cut-out. The tape should be applied to the top surface where the hob flange rests and the remainder should be pushed down into the cut-out area.

6. All four corners should be doubly reinforced with the tape making sure all edges overlap

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Note: To avoid heat damage to the full height Corian® backsplash / wall cladding a minimum space of 100 mm is essential in case of a gas hob. This can be achieved by making a break front countertop.

This design will allow more width to the DuPontTM Corian® countertop where the hob is positioned.

unlessthehobisinstalledaccordingtotheabovementionedspecifications,theDuPontwarrantyisvoid.

Note: Flush-mounted hob units, integrated in a DuPontTM Corian® countertop, are not encouraged but will be covered by the DuPont warranty if the following procedures are followed:

STEPS TO COMPLETION

1. The cut-out must be done with a router and a sharp min.10mm straight carbide cutter. Always use a proper template to make the cut-out min. 3 mm bigger than the outside perimeter of the appliance.

2. Great care must be taken to sand all inside edges removing any chatter marks. Top and bottom edges must be sanded to min. radius of 1,5 mm until they are rounded and smooth.

3. Fix with a SMP polymer the profiled support of moisture resistant plywood or marine plywood to the DuPontTM Corian® countertop, all around the cut-out. Protect the support with 3M™ Scotch® aluminium reflecting tape.

4. Apply the foam tape supplied by the cooktop manufacturer; centre the appliance in the cut-out. Seal the 3 mm gap all around flush with heat resistant or with a MS polymer adhesive.

TO CHECk!

Install the hob as it is described in the hob manufacturer installation guide. Air ventilation is needed under the DuPontTM Corian® worktop if induction cook hobs are used. Check if all necessary insulation material is applied.

Note: Any modification of the hob cut-out done by non-authorised personnel after the installation could result in making the warranty void.

Minimum 3 mm gap. Seal with Silicon or MS

polymer adhesiveFoam tape (Supplied by cooktop manufacturer)

Moisture resistant plywood or marine plywood,

fix with a MS polymer adhesive

Cooktop

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g.8. FRaMeS anD SuppoRT

All DuPontTM Corian® countertops must be supported on a strong perimeter frame that will keep it levelled for the useful life of the top.Varying lay-outs and overhangs place different challenges on our support frames.The perimeter frame can be positioned on-site and the DuPontTM Corian® worktop placed over the frame.

A more commonly used technique is to create a perimeter frame in the workshop and bond it to the countertop with flexible adhesive. Installation and the creation of a perfect level is then completed by adjustment to frame and worktop as a whole unit.The perimeter frame must be attached to the DuPontTM Corian® sheet with silicone, neoprene panel adhesive or flexible polyurethane adhesive leaving 1,5 mm distance between the DuPontTM Corian® and the frame.

There are three types of materials that may be used in a DuPontTM Corian® frame support for kitchen countertops or other applications, these are: moisture resistant M.D.F. board moisture resistant particle board moisture resistant plywood

Applying front, back and side frame support is mandatory. The front and the back support must be continuous. Ideally work with two layers incorporated in the connection. Example: 12mm for the first layer and 16 mm for the second layer. Divisional supports should be added every max. 600 mm or to enhance fixing or additional strength.

A gap of minimum 1,5 mm between the DuPontTM Corian® edges is needed to respect the dilatation from different materials.

We do prefer frame support (see chart). However full underlayment will be covered by DuPont limited 10 year warranty if flexible adhesive is used to bond the full underlayment to the DuPontTM Corian® sheet.

Full underlayment still requires that the DuPontTM Corian® seam is re-inforced.

Note: All seams must be reinforced with DuPontTM Corian®. For countertops wider than 760 mm, put the seam in the overhang, not over the cabinet.

Gap of min. 1,5 mm

Gap of min. 1,5 mm

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g.9. TheRMoFoRMing

Due to the composition of DuPontTM Corian®, it can be thermoformed following the instructions highlighted in this section.

DuPontTM Corian® should be heated to between 160°C and 165°C prior to bending for the majority of DuPontTM Corian® colours. If the thermoforming temperature is too low, it may be too stiff to form and may degrade the product. High temperatures, in access of 170° C, may blister or discolour DuPontTM Corian® to an unacceptable level.

Heat-up times will vary depending on oven design and the size of the piece to be formed. Platen ovens will work quicker and more efficient.

Note: The Illumination translucent DuPontTM Corian® colours require lower thermoforming temperatures due to its unique characteristics.These colours perform best at 145°C to 150°C. This temperature will minimise any decolourisations.

Refer to the table below as a guide to heating times in an oven:

SHEET THICKNESS OVEN TEMPERATURE HEAT-UP TIME*

6 mm 160°C -175°C 15-30 min

12 mm 160°C -175°C 25-45 min

19 mm 160°C -175°C 35-50 min

For more details, please check our DuPontTM Corian® Fabrication Manual 2012 or contact the Technical Department.

Note: Oven temperatures exceeding more than 175° C may overheat the surface of the sheet before the inside of the sheet reaches thermoforming temperature. Do not exceed this temperature.

Before thermoforming starts, a test must be run to calibrate your oven to find the best time/temperature for thermoforming.

Proper material preparation is essential for successful thermoforming.An essential part of successful thermoforming is the radius of the bend.Refer to the table below as a guide to the minimum inside radius permitted when thermoforming standard DuPontTM Corian® thickness sheet material:

SHEET THICKNESS MINIMUM INSIDE RADIUS

6 mm 25 mm

12 mm 50 mm

19 mm 127 mm

However, using the radius rebate technique, we can reduce the radius below these recommended guidelines.Minimum radiuses will be different according to the type of colour used (e.g. particled colours). For more details check the fabrication manual.

* Approximate time depending on heating equipment

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g.10. wall claDDing

4 / 6 mm DuPontTM Corian® sheets are to be used in vertical applications only. The 10 year limited installed warranty applies only to vertical applications of the 4 / 6 mm DuPontTM Corian® sheets.An essential element of any vertical application is that the DuPontTM Corian® sheet must conform to the dimensions and angles of the existing wall.idealsupportsforverticaladhesionare: Water-resistant gypsum board Moisture-resistant plywood M.D.F. board Any sound tile surface Plasterboard sheeting Plywood

STEPS TO COMPLETION

1. Cut all wall cladding pieces and trial fit. An expansion space of 3 mm minimum should be allowed (1mm per linear meter) in order to comply with the DuPont Warranty.

2. Clean the reverse side of the Corian® wall cladding with clear denatured alcohol and a clean cloth.3. Apply elastic P/U adhesive or silicone to the reverse side of the DuPontTM Corian® sheet in the following manner:

• Apply a continuous bead of adhesive around the DuPontTM Corian® sheet• Approximately 25 mm from the outside edge• Then apply dabs approximately 30 mm in size, equally spaced, at approximately 200 mm centres, within

the inside area. Any cut-outs i.e. electrical sockets require a continuous bead of silicone, 20 mm around the cut-out.

• To eliminate the need for bracing the DuPontTM Corian® wall cladding, hot-melt glue can be applied to the reverse side of the sheet shortly before adhering it to the wall.

• Press the Corian® wall cladding firmly against the wall, use a straight edge to check for any deviation.

Caution: Do not fix DuPontTM Corian® in saunas, swimming pools or steam rooms as described above. Due to the influence of constant exposure to moisture and humidity, the coefficient expansion and contraction are impossible to control. Applications as such are not covered by

DuPont warranty. Special sub-construction and fixing methods need to be foreseen.

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g.11. FiniShing anD poliShing

Finishing DuPontTM Corian® is a critical part of the end consumer’s perception of your ability to fabricate DuPontTM Corian®.To prepare a DuPontTM Corian® surface prior to sanding, remove all dust and dirt particles using a damp cloth and a soap/water solution:Finish may vary according to customer requirement.However, to achieve a finish which is easy to maintain in daily use, a mattorsemi-glossfinish is recommended.

Gloss level Matt Semi Gloss High-gloss

solid and veined colours

all non-solid and non-veined

coloursall colours

DuPontTM Corian®

colour families

Genesis, Venaro& Design

Portfolio (Solid)

Sierra, Summit,Magna, Jewel,

Lustra & DesignPortfolio

(Patterns)

all families

Steps to follow

Step 1 100/80 µ 80/100 P 100/80 µ 80/100 P 100/80 µ

Step 2 60 µ 120 P 60 µ 120 P 60 µ

Step 3

Maroon 3MScotch-Brite™

7447 orsimilar pad

180 P 30/40 µ 180 P 30 µ

Step 4

Maroon 3MScotch-Brite™

7447 orsimilar pad

Gray 3MScotch-Brite™

7448Or Jöst Use-it™

SuperPad S/G 600 or

Abralon® or similar

240 P 15 µ

Step 5 Paper towel 320/360 P 9 µ

Step 6

Gray 3MScotch-Brite™

7448Or Jöst Use-it™

SuperPad S/G 600 or

Abralon® or similar

Solid surface polish

Festool or similar

Step 7 Paper towel

Having established the correct starting grade, use a sanding sequence from coarse to fine, cleaning the dust from DuPontTM Corian® between different grades.

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24

Avoid excessive pressure. The best technique is to set the machine in motion and to guide it over the surface of DuPontTM Corian® using equal pressure everywhere.When you start sanding follow the direction “North – South – East - West” for each sanding step in small circular motions overlapping the edges, but without rounding the edges (2 patterns per sanding step is recommended = minimum 3 times in each direction per sanding step).

Move the sander in small circular motions through “North – South” - and “East - West” rows so that the sanding areas overlap sufficiently each time. Always clean the sanding disc and the DuPontTM Corian® surface after each step:

Note: For sanding with 100 or 80 μ or 100 P-grid paper, use the extender sanding mode if an option. For finer sanding discs use the polish mode.

When it comes to the fine sanding: change your pattern to random 8-movements, changing from the “North – South – East - West” direction to diagonal. Use the same method with the paper towel.

importantremarks: Do not apply too much pressure while sanding Use equal pressure Use equal speed Use correct tools Change sanding discs when worn For horizontal surfaces without profiles, a hard backer pad is recommended

DuPontTM Corian®


25

h.WArrAntyinformAtion

DuPont offers two levels of warranty protection for DuPontTM Corian®: Product and Installed.The “Product Warranty” is standard for all DuPontTM Corian® products and ensures that they will be free of manufacturing defects for a period of 10 years after purchase.A higher level of coverage, the “Limited Ten (10) Year Installer Warranty”, is only available when fabrication and installation is done through a Quality Network DuPontTM Corian® fabricator. This Limited Installed Warranty expands the Product Warranty and also ensures that the fabrication and the installation of the finished product will be free of defects.For further information please contact your local authorised distributor.

This is a courtesy translation of the original documentation prepared in English.Please consider that only the original version in English has legal value and is valid until superseded.

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DO’s

Always allow DuPontTM Corian® to move freely.

Always allow a minimum of 3 mm total tolerance to allow DuPontTM Corian® to expand and contract.

Always radius corners as solid surface material are vulnerable to stress at inside corners.

Always sand smooth any nicks or cuts from edges.

Always use flexible adhesive when applying substrate to DuPontTM Corian®.

DOn’ts

Don’t screw directly into the DuPontTM Corian®.

Don’t use jig saws to cut DuPontTM Corian®.

Don’t use substitute adhesive to seam DuPontTM Corian® together.

Don’t put DuPontTM Corian® seams through heating appliance locations.

Don’t use full underlayment in any application where heating.

For further information please contact your local authorized distributor or your Quality Network Assistant.

General Fax +32 24 03 53 44General Email [email protected]

Country Free Phone Numbers

Austria 0800 28 15 55 Belgium 0800 95 165France 0800 91 73 69Germany 0800 18 17 228Ireland 1800 511 716Italy 800 785 521Luxemburg 0800 23 784Spain 900 963 241Switzerland 0800 83 57 85The Netherlands 0800 02 32 165UK 0808 23 40 576

The information contained in this brochure is given free of charge by E.I. du Pont de Nemours and Company Inc. or its affiliated companies (collectively, “DuPont”). It is based on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at their own discretion and risk. DuPont assumes no responsibility for results obtained or damage incurred from the use of the information contained in this brochure either in whole or in part by the fabricator, the architect, or the designer, or the owner, or the user of DuPontTM Corian® sheets nor shall DuPont be liable in case of non-compliance with the applicable government regulations or in the event that DuPontTM Corian® sheets are applied in violation of the applicable government regulations. More specifically, we do not approve or disapprove any designs or drawing submittals or assume any liability for the design selected. Any and all liability for a design rests with the architect, or the designer, or the owner, or the user, based on whatever contractual arrangements have been made. Moreover, the information in this brochure does not contain any warranties, except to the extent expressly provided otherwise herein. We believe all information in this publication to be correct at the time of printing. It is intended as information concerning our products and their application possibilities and is therefore, not intended as any form of warranty with regard to any specific product characteristics, except to the extent expressly provided otherwise herein.

DPS-00-1870-14 - The DuPont Oval logo, DuPontTM, Endless Evolution, the Endless Evolution logo, DeepColourTM and Corian® are registered trademarks or trademarks or copyrighted material of E. I. du Pont de Nemours and Company or its affiliates. Only DuPont produces Corian®. Copyright © E. I. du Pont de Nemours and Company or its affiliates. All rights reserved. This document is protected by all applicable laws. Other logos, registered trademarks and trademarks are property of their respective owners.

Photo credits: Kitchen in private apartment; worksurfaces made with DuPontTM Corian®, in Glacier White colour; photo DuPontTM Corian®, all rights reserved.

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