Latest Revision-2/1/05

Fabrication Guide

2/1/05 The information and data contained within this document pertain to the properties of Lumicor base acrylic material only. We believe this information to be reliable, and offer the information in good faith without guarantee, as conditions and methods of use are beyond our control. We recommend prospective buyers perform their own testing of edge sealing, cutting, thermoforming, fastening, glueing, and polishing procedures to determine suitability of Lumicor, and fabrication procedures, for all purposes before adopting Lumicor on a commercial scale. In no case is Lumicor, Inc. liable for direct, consequential, economic, or other damages. Lumicor disclaims all other warranties, expressed or implied, including the warranty of merchantability and fitness for a particular purpose.

Latest Revision-2/1/05

Table of Contents

The Lumicor Product 1 Safety 3 Storage &Handling 3 Fabrication 4 EDGE SEALING CUTTING DRILLING ROUTING LASER CUTTING SCRAPING SANDING POLISHING EDGE FLAME POLISHING COLD FORMING THERMOFORMING VACUUM FORMING FASTENING SEAMING / GLUEING / CEMENT Care 20 CLEANING REFINISHING Specifications 22 PANEL DIMENSIONS TEST RESULTS CHEMICAL RESISTANCE

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The Lumicor Product Lumicor is an innovative translucent material encapsulating textiles, metals, papers, foliage, and plastic films using a proprietary, patent pending, manufacturing process. Lumicor is available in thickness from 1/8” to 1”, appropriate for use in a wide variety of vertical and horizontal applications including furniture, wall partitions, countertops, cabinet doors, retail display fixtures, signage, light diffusion panels, shelving, among many others. Lumicor blends the versatile strength, flexibility, formability, UV resistance, and refinishing characteristics of acrylic sheet with a vast world of décor and texture. Lumicor may be fabricated using conventional woodworking power tools, creating unlimited design opportunities. Safety Lumicor sheet is a hard material with sharp edges and corners that may cause lacerations to unprotected skin. It is recommended that users wear protective cotton, canvas, or leather gloves to avoid injury when handling Lumicor sheet. Adequate eye protection should always be worn when machining Lumicor sheet to protect eyes from flying particles, and avoid injury. Tools should be kept clean, sharp, and in good working order. Work environment should be kept clean and well ventilated with extraction of dust and fumes. Laser cutting Lumicor will cause the material to de-polymerize, creating fumes that may cause irritation to the eyes, nose, and respiratory system. Adequate ventilation at the cutting head must be installed to ensure complete evacuation of toxic fumes from the work environment. Consult ventilation experts for recommended ventilation systems. Prolonged exposure of Lumicor to open flames or excessive heat may cause material to de-polymerize, releasing methyl methacrylate gas that is highly flammable and toxic. The flash point temperature of Lumicor is 630° F, and the self-ignition temp is 820° F. Should Lumicor ignite, it is easily extinguished with water. Concentrations of methyl methacrylate between 2.1% and 12.5% by volume in air at 77° F form explosive mixtures. The Critical Oxygen Index of Lumicor is 17.5%, similar to other polymers such as polyethylene, polypropylene, and polystyrene, and below most types of wood. When thermoforming Lumicor, ovens should be equipped with proper ventilation, temperature controls, and fail-safe thermal cutout features operating in the event of temperature control failure. Care must be taken to ensure that Lumicor material is not overheated to the point of de-polymerization or ignition. Under normal conditions, Lumicor may be stored and fabricated with the same fire precautions as would be used for wood or lumber. Care should be taken to avoid exposing Lumicor sheet, material edges, and saw dust to open flames or heat sources. The fabrication and storage environments should be kept clean and free of Lumicor scrap, sawdust, and excess polyethylene masking. Ventilation systems are recommended for the safe extraction of Lumicor dust and fumes from the work environment. It is important to note that Lumicor dust and air may create explosive mixtures. All ducting of ventilation equipment must be grounded to avoid ignition of dust particles from static electricity discharge. Accumulation of Lumicor dust from machining operations may also pose a fire hazard and should be removed from the work environment. Storage & Handling Lumicor is shipped with a polyethylene protective masking on both top and bottom surfaces to prevent damage and scratching of material surface during shipping and handling. It is recommended that the polyethylene protective masking remain attached to

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the Lumicor sheet during fabrication and thermoforming operations to prevent accidental scratching of material surface. Lumicor should be stored in an environment where atmospheric conditions are controlled, eliminating extreme temperature, direct sunlight, and exposure to rain and snow. The storage area should be separate from areas storing solvents where vapors may be present. Lumicor is best stored on edge at a 10° angle from vertical. “A” or “L” frame racks (Fig. 3A & 3B) are the preferred storage method providing full surface support to eliminate bow, reducing pressure on the masking, and minimizing imprinting of foreign particles into the material surface between sheets. Horizontal storage or long- term storage of Lumicor on pallets is NOT recommended.

Fabrication Lumicor can be fabricated in much the same manner as acrylic sheet or aluminum using conventional power and hand tools. The following practices should always be observed when fabricating Lumicor: 1. Keep cutting tools sharp, clean, and free of damage. 2. Tungsten carbide tipped tools are recommended for fabricating Lumicor (Use

diamond tipped blades and wet saw equipment for Stoneworks & Glassworks products).

3. Cutting edges should produce a scraping rather than a shearing action. 4. Lumicor material and cutting tools should be firmly and securely supported to

prevent chatter and chipping of material. 5. During fabrication operations, Lumicor may soften when excessive heat builds in

material. A continuous supply of air blast cooling may dissipate excessive heat build up preventing softening of material. (Use a continuous supply of water when cutting Glassworks and Stoneworks products on diamond blade wet saw equipment).

6. Keep material, work surface, and tools free of dust, chips and dirt that may scratch or damage material surface during fabrication.

7. Masking should remain on material to minimize the risk of scratching of the sheet surface.

8. Always wear adequate personal protective equipment when operating power tools. Consult power tool manufacturers guide for further details.

9. To counteract electrostatic charges that might attract dust and fine particles, an antistatic spray product is recommended. Please see the Lumicor website for more information.

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EDGE SEALING If your Lumicor application will be exposed to moisture, it is important to seal the edges after cutting or fabrication to prevent wicking. The core materials embedded in Lumicor may wick moisture into the sheets leaving a permanent watermark. Do not use alcohol to clean edges! Alcohol is easily wicked into Lumicor material and will permanently damage the material. It is important to seal the cut Lumicor edge sufficient to prevent moisture from wicking into the sheet. Sealing may be accomplished by the following methods. 1. Silicone:

• For framed edges, route Lumicor edge smooth with flush cut router bit. For applications using exposed Lumicor edges, a groove or cove may be routed at the core level along the edge creating a well to be filled with the acid free silicone sealer (use diamond router bits for Stoneworks & Glassworks products).

• Mask off material with blue masking tape, exposing only the area to be sealed, and allowing for the easy removal of masking tape after silicone is cured.

• For framed edges, apply clear acid free silicone into bottom of frame channel that will receive the Lumicor material, effectively sealing the fabric layer from moisture. Avoid air bubbles and voids in the silicone sealant.

• For exposed edges, use a putty knife to spread clear silicone sealant into routed groove, and scrape off excess silicone.

• Allow to cure. • Remove masking. • An acid-free (non-corrosive) silicone is recommended. The following

products are acid free: DAP – Titanium RTV Loctite – Superflex non-corrosive RTV Dow Corning – Silastic 1080 RTV

2. Bonded Acrylic Substrate:

• Using 2” blue masking tape, mask off the top and bottom surfaces of both Lumicor and acrylic based material to be bonded, leaving the edge surfaces to be bonded exposed.

• Apply 2-part clear, or colored, West System Epoxy 105 resin / 207 hardener adhesive to both surfaces. Apply mating acrylic substrate to Lumicor edge using light clamping pressure (40 psi), ensuring adhesive is squeezed from the bond along entire seam. Avoid air bubbles and voids within the seam.

• Allow to cure. • Remove excess cured epoxy adhesive with razor knife. • Remove masking. • Sand excess adhesive with 60 micron discs using a random orbital sander.

Finish with 3M Trizact following manufacturers instruction for achieving desired gloss level.

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3. 3M VHB (Very High Bond) two-sided tape: • Rout Lumicor edge smooth using flush cut router bit (diamond flush cut router

bit for Stoneworks & Glassworks products). • Apply a strip of 3M VHB tape to all exposed edges. Following manufacturers

instructions for product suggestions and application directions. • Apply very firm pressure to ensure the tape has adhered to entire edge

surface. • Trim off excess tape with razor knife. • Peel the masking from back side of tape to expose the second adhesive

surface. • Apply a decorative finish material as desired.

4. Epoxy / Polyurethane Seal: • Rough cut material using a table saw equipped with modified triple chip blade

(diamond blade for Stoneworks & Glassworks products). • Rout material edge smooth using flush cut router bit (diamond flush cut router

bit for Stoneworks & Glassworks products). • Using 120 grit sandpaper, sand edge of Lumicor. Clean edge using a damp

lint-free cloth. Avoid any wicking of moisture into the Lumicor edge. • Using 2” blue masking tape, mask off top and bottom surfaces of Lumicor

material. • Apply 2-part clear West System Epoxy 105 resin / 207 hardener adhesive, or

Minwax clear polyurethane and allow to cure according to adhesive manufacturers instructions.

CUTTING Stoneworks & Glassworks Products -Crystal -Sapphire -Pebble Beach -Pacific Beach Due to the nature of embedded glass and stone, conventional woodworking tools are not appropriate for cutting Lumicor Stoneworks and Glassworks products. All Lumicor products containing glass and stone must be cut and fabricated using conventional stone cutting equipment, or water-jet equipment. Stone cutting equipment using water cooled circular diamond blades may be used for cutting Lumicor products to squared dimensions requiring straight cuts. CNC controlled water-jet equipment may be used to cut Lumicor products to squared dimensions, and radius shapes that are not possible with circular saw cutting methods. Consult your Lumicor representative with any questions or comments you may have. Products that do not contain stone or glass Circular Saw Cutting Circular saws may be used for long, straight cuts through single or multiple stacked sheets. Blade selection will be dependent on the sheet thickness. Table II outlines recommended blade selections.

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Stationary and traveling table saws are most commonly used for production runs of long straight cuts. Travelling saws are recommended when cutting unmasked sheets, as the material remains stationary during cutting operations reducing the risk of scratching sheet surface. When using portable circular saws, the material and guide strips should be securely clamped to a fixed supporting work surface for best results. To prevent binding, and to minimize frictional heat, the use of hollow ground circular saw blades are recommended. Large diameter blades should receive expansion slots to minimize warping and whipping of the blade. All teeth should be of uniform height with 7° positive rake angle. A tungsten carbide tipped blade with alternate teeth beveled 45°, commonly known as a modified triple chip blade, is recommended for cutting Lumicor. See Fig 4B for recommended saw blade detail. The recommended rim speed of the circular saw blades is 8,000- 12,000 peripheral surface feet per minute (PSFPM). The following formula should be used in determining the proper rpm per saw diameter, where d= saw blade diameter. RPM = 144,000 / 3.14(d) When using table saws, the blade should extend slightly higher than the thickness of material, to reduce ship loading and allow chips to clear saw tooth gullet. Chipping of material may occur if blade extends too far above material thickness. The throat gap should not exceed the width of the cut to reduce vibration and chipping. A separator blade should be installed directly behind the saw blade to prevent the re-welding of material following the heat build-up generated during the cutting operation. A steady even feed speed of 75 in. / min is recommended for best results. Feed speed may need to vary based on thickness of material being cut. Refer to Table IIA for troubleshooting. Table IIA TROUBLESHOOTING CIRCULAR SAW CUTTING Problem Possible Solution Melting or Gumming of Edges - Increase blade tooth size

- Reduce saw speed - Increase feed rate - Use compressed air to cool blade - Use a blade lubricant compatible with sheet - Inspect blade for sharpness - Check fence/blade alignment

Chipping of Edges - Decrease blade tooth size - Increase saw speed - Provide better clamping and/or support for the sheet stock- Reduce feed rate - Check blade and arbor for wobble - Inspect blade for sharpness

TABLE II Blade Characteristics Blade Teeth Lumicor® Thickness (inch) Per Inch

.040 - 0.80

.080 - .156

.156 - .375

1/16 2-5

2–5

2-5

3/32

1/8

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Band Saw Cutting When cutting large diameter curves, band saw cutting with soft metal-cutting blades may be recommended. Please see Table III for blade selection guide. Materials up to .125” in thickness require band saw blades with 16 – 20 teeth per inch. Thickness greater than .125” require band saw blades with 10-12 teeth per inch. Continuous air blast cooling will dissipate heat build up during cutting and may prevent material from re-welding behind saw blade. Material accumulation on saw blade should be removed periodically. TABLE III Blade Selection Radius to be Cut Blade Blade (inch) Width (inch) Thickness (inch) 1/2 – 1-1/2 3/16 – 3/8 0.028 2 – 3 1/2 – 5/8 0.032 4 – 8 3/4 – 1 0.032 – 0.035 10 – 20 1-1/4 – 1-1/2 0.035

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DRILLING When drilling Lumicor sheet, slow helix angle jobber drill bits, commonly used for brass or hard plastics, provide the best finish while reducing chipping and shattering of material. Tubular hole saws may be used for drilling large diameter holes. Fly cutters may also be used for large diameter holes. Frequent cleaning of drill bits may be required to prevent chips from thermally fusing to material. A drill point angle of 130° is recommended when drilling Lumicor that is fully supported (see Fig. 4D). The cutting edge should have zero rake. It is important that drill flights penetrate the top surface of material prior to the drill point exiting bottom side of sheet (see Fig 4E). Drill point angle of 60° should be used when drilling unsupported Lumicor sheet (see Fig 4E).

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ROUTING Lumicor may be routed using standard power routing tools commonly used in woodworking operations. For safety, always use sharp, high quality bits that maintain sharp cutting edges. Recommended spindle rpm should fall between 18,000- 24,000 to facilitate bits with 2-3 cutting edges. The spindle rpm and linear feed rate should accommodate .001” of material being removed with each pass of a blade. Two flute 3/8” – ½” carbide tipped bits are recommended when using table and portable routers (see Fig 4C). LASER CUTTING Lumicor sheet is suitable for laser cutting operations. Laser cutting yields a gloss polished edge quality desired for some applications. Polyethylene masking may remain attached to the material during laser cutting. Laser cutting facilities should be equipped with adequate ventilation at the cutting head to exhaust toxic vapors. Laser cutting produces a stressed heat affected zone up to 1/8” into Lumicor sheet. To eliminate the possibility of stress crazing, it is important to anneal the Lumicor material after laser cutting. Exposure of edges to solvents, inks, paint, or radius forming without proper heat will cause stress crazing in un-annealed laser cut Lumicor. SCRAPING / FILING Saw cutting operations may produce uneven edge quality, chips, or chatter marks. Scraping of Lumicor edge may remove uneven surface, improving edge quality. Using tool steel with edge ground to a sharp 90° angle, a scraper drawn towards the operator with firm pressure over a securely fixed Lumicor edge will remove uneven edge height. Care should be taken to angle the scraper to remove only the high points of the edge surface. Aligning the scraper parallel with saw marks may only recreate the uneven edge quality. Edge filing may also improve edge quality. Files drawn over the Lumicor edge towards the operator in a smooth steady motion will improve edge quality. Round, half-round, and triangular files may be used to accomplish alternative edge profiles. Files may need to be cleaned periodically with a wire brush to remove Lumicor cuttings.

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SANDING Please be advised that the removal of Lumicor surface imperfections through sanding will result in optical distortion of the material. It is recommended that Lumicor sheet be hand or machine sanded beginning with 100-120 grit sandpaper, and progressing to 220 grit, and 400-600 grit as needed. Be sure that the sanding operation does not produce scratches greater than the original imperfection. For best results, use 60, 30, and 15-micron sandpaper beginning with the coarsest grit first. Each progressive grit should reduce the severity of the scratch pattern, while expanding the area of work, effectively feathering the repair. Dust and residual abrasive should be removed with air or damp rags before proceeding to the next grit. Do not flush Lumicor with water, as moisture may wick into the sheet from the edge, possibly leaving a permanent watermark. Hand sanding should be performed using rubber-sanding blocks, periodically altering sanding direction 30° producing a diamond pattern in the material. Power sanding equipment should follow the same procedures. Belt, orbital oscillating, and vibrating finish sanders may be used to sand flat surfaces. Disc sanders may be used for removing material from edges. Machine sanders may generate excessive heat during sanding operations. It is recommended to provide continuous air blasts over material being sanded to aid in heat dissipation. When sanding Lumicor sheet, machine sanders should be run at lower speeds than would otherwise be used for wood or metal materials. POLISHING Following the sanding operations, Lumicor can be restored to a high gloss finish using traditional buffing wheels and polishing compounds, or 3M Trizact products. See the “Refinishing” section of this guide for details. EDGE FLAME POLISHING The edge and surface of Lumicor sheet may be polished using a flame process. Fabricators experienced with gas torch use only should perform flame-polishing operations. Flame polished edges must be annealed to avoid the possibility of crazing when exposed to solvents, cements, paints, inks, water, water vapor, and cleaning aerosols. Screen-printing may cause crazing if printing within ¼” from a flame polished edge. Crazing may occur on the material surface at the hot/cold boundary point near flame polished edges. Results from flame polishing are based largely on adequate machining and preparation of the surface to be polished. High quality routed, and sanded surfaces will yield the best results. Prepared surface must be free of detergents, oils, fingerprints, and contaminants to achieve best results. Sanding, and /or scraping is the recommended method for removing contaminants from prepared surfaces to be flame polished. Ensure that material to be worked is well illuminated, and accessible on all sides to the gas torch. The flame should be adjusted until blue in color, and large enough to polish material in one pass. Areas requiring multiple passes of the flame must be allowed to cool between passes. The flame should be passed across the material rapidly providing enough heat to accomplish desired polish and gloss level. CAUTION. Lumicor sheet will ignite if flame is concentrated in one area for a short duration. Prolonged heating at temperatures in excess of 390° F will cause the sheet to de-polymerize, producing a flammable gas. Flammability precautions must be exercised when flame polishing Lumicor sheet. Travel speed of the flame must exceed that which may cause the material to burn (carbonize) or boil (de-polymerize). Should Lumicor ignite, it is easily extinguished with water. Never perform flame-polishing procedures in the presence of flammable materials.

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COLD FORMING Lumicor may be mechanically cold formed into simple curves by bending the sheet while being held by physical stops, such as a frame system. A minimum radius of 300 times the sheet thickness is required for cold forming. Attempts to achieve radii below this requirement may result in crazing, damage, or fracture of the material. THERMOFORMING Lumicor is manufactured using thermoplastic resin allowing the possible forming of complex shapes in a heated state. The degree to which Lumicor may be formed, and the possible depth of draw, rely heavily on the elasticity of the core material embedded in the resin. It is important to note that Lumicor sheet should be free from moisture before use in thermoforming operations. It is possible for Lumicor to absorb moisture when exposed to humid environments. Lumicor exposed to moisture for prolonged periods should be dried at 175° for 12 hours prior to thermoforming. Strip Heating It is possible to form Lumicor in straight line bends by applying localized heat using strip heaters, bending part with hand pressure, and mechanically holding part in desired position until cool. Strip heat bending should be performed at the lowest possible temperature required to achieve desired form, approximately 290° F, to minimize stress built up in the sheet. Lumicor must be heated uniformly along the bend line and throughout the thickness of the sheet for best results. The polyethylene masking may be left on the sheet, but if heated too long may bubble and transfer this texture to sheet surface. For best results, the bend line should be perpendicular to the length of the original Lumicor sheet. Inconsistent, or insufficient heating of the sheet may cause stress crazing if bend line is exposed to solvents or chemicals. The bend should always be made away from the heated side. For thickness greater than .125” it is recommended that the sheet be heated from both sides alternately. As thickness increases, it may be required to heat both side of material simultaneously using two strip heaters. Once material has been sufficiently heated, formed, and mechanically held in position, it is recommended that air flow be allowed to pass over both sides of the heated area to facilitate cooling for a period equal to the heating cycle length. Table V below offers helpful troubleshooting information for strip heating operations.

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Blistering a. Overheating b. High moisture level in sheet

a. Reduce heater temperature and/or cycle b. Pre-dry sheet at 175°F (80°C) (for 3mm sheet, at least 12 hours drying time required)

Poor Surface Finish a. Contact with hot surface

a. Do not allow sheet to contact heater surface

Wrinkles a. Sheet too hot b. Sheet too cold c. Radius too tight

a-1. Reduce surface temperatures a-2. Have hottest surface on outside of bend b. Longer heating cycle c. Use larger radius

Warpage a. Non-uniform

b. Part removed from bending fixture while hot

a. Provide uniform output from heater heating/cooling

b-1. Limit area heating b-2. Increase cooling time in bending fixture b-3. Machine a radius or “V” groove at bend

Distortion a. Non-uniform heating

b. Part removed from fixture while hot

c. Sheet bend angle too

a. Provide uniform heater output and spacing from sheet

b-1. Keep support surfaces uniformly cool b-2. Increase fixture cooling time c-1. Increase bend angle shallow c-2. Use counter bowed tool

Oven Heating It is recommended that Lumicor be heated in circulating air ovens providing the greatest temperature control and uniform heating throughout the sheet (see Fig. 7C). Table VI outlines recommended heating times per thickness. Exceeding these recommended times may imprint shelf texture into the sheet when heated horizontally, or cause unwanted elongation of sheet if heated in a vertical position. Oven shelves should be made of a milled or sandblasted aluminum material for best results. Textured, or perforated shelves may transfer texture into material surface during the heating operation. To avoid the material stretching during vertical heating operations, strict temperature control and adequate clamping is required. Material should be clamped on all sides, or along the longest dimension using continuous clamps. Remove the polyethylene masking on the sheet prior to the heating cycle. Parts must be cooled to room temperature before removing masking. TABLE VI Maximum Times and Temperatures Thickness Heating Time (minutes) at: (mm.) 280°F 2 13.0 2.5 13.5 3 15.0

4 17.0 5 20.0

TABLE V Troubleshooting the Thermoforming Process Defect Causes Corrective Action

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Infrared Ovens While infrared, or radiant, ovens may heat Lumicor sheet faster than circulating air ovens, uniform heating is more difficult to achieve. Users and fabricators are encouraged to perform their own tests on individual heating devices to determine adequate heating cycles. Double-sided heating is recommended for best results with material thickness exceeding .125”. It is important to ensure that material is evenly and adequately heated throughout the entire thickness of the sheet, and that one side does not become overheated. To facilitate even heating, it is possible to install expanded metal wire faced with aluminum window screening between the heating elements and the material to diffuse heat. Vacuum Forming Lumicor may be heated and draped over thermoforming molds and subject to a vacuum forming process. The degree to which Lumicor may be molded, and the depth of the possible draws, is heavily dependent on the elasticity of the core material embedded in the Lumicor sheet. Fabricators and users should perform their own tests on selected Lumicor materials to determine each individual product’s suitability for the intended purpose. It is recommended that vacuum form molds be made of aluminum with incorporated temperature control capability. The optimum mold temperature range is from 170° - 200° F. The mold surface should be machined smooth to reduce mold texture from transferring to material surface. Critical to achieving the best result is the determination of the correct cooling cycle. Excessive cooling times will cause the part to shrink back on the mold, possibly fracturing the part in weak areas. Insufficient cooling may cause the part to distort beyond the desired part shape. Fabricators should perform testing to determine adequate heating and cooling cycle times based on mold temperature, sheet thickness, and ambient temperature. Best results are achieved when molder parts are removed when mold temperatures are between 170° - 180° F, and cooled slowly in a jig to prevent distortion. It is not recommended to cool molded parts with forced air as this may induce stress into the material and cause warping. Single Curve Thermoforming Lumicor can be easily shaped into simple single curve shapes along a single axis with minimal pressure upon heating the material to a temperature not exceeding 300°F.

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FASTENING It is not recommended to use mechanical fasteners for load-bearing Lumicor applications. The rough edges, and heat-stress build up caused during drilling operations may cause the material to fracture under load. Through bolting methods may be used to fasten two Lumicor sheets that have been formed into “L” or “U” shapes along the sheet periphery (see Fig 8A). The mating surfaces created can be through bolted provided the bolt holes are sized to accommodate movement during thermal expansion of the panels. Always use rubber or nylon grommets and washers to insulate material from fastener. Do not over-tighten fasteners as fracturing may occur. Joining two “U” end panels can also be achieved by sliding the appropriately sized metal “C” channel extrusion over the panel edges as seen in Fig 8B, thus eliminating fracture and thermal expansion issues associated with through bolting. SEAMING / GLUING / CEMENT Lumicor sheet may be joined together using a number of commercially available transparent adhesives typically used with acrylic or solid surface materials. The strength and aesthetic appearance of the seams depends largely on the shape of the seam, the preparation of the edges to be joined, and the skill and care of the fabricator. Prior to joining, properly prepared edge surfaces should be free of detergents, oils, fingerprints, and foreign particles. Best seaming results are achieved when edge surfaces have been planed, joined, routed, or saw cut producing a clean smooth edge quality. Rough cuts should be sanded or machined until a smooth, flat, square edge is achieved. Properly prepared and fabricated seams may approach or even exceed the strength of the original material. It is important to note that heat generated during machining of the material may induce heat stress affected zones. Solvents in adhesives may cause crazing in heat affected stress zones, but can be eliminated by annealing material prior to the seaming procedure.

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Glazing Lumicor sheet may be used in safety glazing applications such as doors, windows, and interior wall panels. Lumicor meets the safety requirements of ANSI Z97 and CPSC 16 CFR 1201 for plastic safety glazing materials. Lumicor also good sound reduction values over a wide range of frequencies as outlined in table XI below. It is important to note that Lumicor will expand and contract with temperature and humidity changes at a rate higher than glass. It is strongly recommended to cut Lumicor panels 1/16” per foot less than the window frame opening to accommodate expansion and contraction during temperature change (see Fig 11A). Glazing thickness is dependent on sash width and anticipated wind loads. Fig. 11B outlines thickness recommendations per load. Rabbet depth will need to accommodate the movement of Lumicor glazing under thermal expansion and wind loads. Table X provides appropriate rabbet depth data per glazing panel size. Numerous sealants may be used with Lumicor including non-hardening elastic glazing compound, non-oily filler tapes, and non-acetic silicone and polysulfide sealants. Sealant products should be used as directed by product manufacturers. Mechanical fastening of Lumicor with screws and/or bolts is not recommended.

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TABLE IX Noise Reduction Values Frequency

(H2) Lumicor® Acrylic Sheet

Thickness (inch)

.118” .236” .315” 100 9.4 15.0 16.6

125 11.9 16.6 19.9 160 13.3 18.4 20.5 200 16.3 21.1 23.3 250 18.8 24.9 26.5 315 22.2 28.2 30.6 400 21.1 26.6 29.1 500 22.8 28.4 30.8 630 21.8 27.9 30.0 800 24.8 30.7 32.9

1.000 24.9 31.2 33.3 1,250 27.0 32.4 34.6 1,600 28.9 35.2 37.8 2,000 30.0 36.3 37.9 2,500 32.5 37.8 38.2 3,150 34.0 38.2 35.5 4,000 34.3 35.7 29.6 5,000 34.9 29.9 31.9

Mean SRI 22.5 28.4 29.8

Weighted Mean SRI 28.0 32.0 34.0

TABLE X Rabbet Depth Sheet Size Rabbet Depth 24” x 36” 1/2” x 5/8” 36” x 48” 5/8” x 3/4” 48” x 72” 3/4” x 1” 60” x 84” 1” to 1-1/4” 72” x 96” 1-1/8” to 1-3/8”

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WIND VELOCITY (PSF) 20 PSF = 73 mph wind velocity 30 PSF = 90 mph wind velocity 40 PSF = 103 mph wind velocity 50 PSF = 131 mph wind velocity

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Care CLEANING Lumicor decorative panels should be treated just like acrylic sheet. Care should be used to observe the following guidelines when cleaning Lumicor. • For all cleaning methods, always ensure that edges of material are sealed, or taped to

prevent exposure of material edge to moisture. Some Lumicor products may wick moisture into the sheet at the edge discoloring the core.

• Use plenty of warm water, mild detergent, and a soft scratch free sponge, cloth, or chamois to remove most stains with light gentle pressure so as not to scratch surface.

• More stubborn stains can be removed using 3M Finesse-It compound according to instructions. Also, surface contamination may be cleaned using kerosene, hexane, or aliphatic naphtha. Always follow solvent and cleaning solution manufacturers recommended use and safety procedures.

• Do not use window or glass cleaning products, acetone, alcohol, gasoline, benzene, lacquer thinner, chlorinated solvents, gritty abrasive scouring compounds, or alkaline cleaners to clean Lumicor sheet as damage to the sheet will occur.

• Remove oily residue from solvent cleaning immediately with a detergent water wash. • Do not use squeegee, scraper, or synthetic rags that may scratch surface. • Never scrub Lumicor sheet surface. Gently pat or wipe surface with a soft scratch free cloth

to reduce scratching material surface. • To counteract electrostatic charges that might attract dust and fine particles, an antistatic

spray product is recommended. Please see the Lumicor website for more information. • For cleaning and polishing light scratches, the following products may be used:

Novus Plastic Polish Systems www.novuspolish.com Janvil Plastic Restore and Polish www.scratchpolish.com 3M Finesse-It

For refinishing, please see REFINISHING instructions using 3M trizact system. REFINISHING

3M™ Acrylic Solid Surface Finishing with 3M™ Trizact™ Film Abrasives Finishing acrylic based solid surfaces with 3M™ Trizact™ Hookit™ II film abrasives is quick and easy. Just follow these simple instructions for matte, semi-gloss, high gloss finishes. Tools You Will Need

• Random orbital disc sander (10,000 – 12,000 rpm) • Spray bottle

Accessories: Description 5” Diameter Part Number 3M™ Hookit™ II Disc Pad PN 05245-1 Hookit™ to Hookit™ II Conversion Pad* PN 02327 *Converts a standard Hookit or other hook-type disc pad to a Hookit II disc pad Tips and Techniques

• Do not use Trizact™ abrasives dry. • Start and stop the sander while resting flat on the surface to eliminated swirls • While sanding, follow a “North, South, East, and West” pattern. (See diagram below) To ensure

previous scratches are removed and a uniform finish is achieved, two “patterns” per step are recommended.

• Note: If a sanding pattern is visible on the surface of your material after sanding in this pattern, move the sander in a small circular motion, while following the “North, South, East, and West” pattern.

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Keep it clean! Rinse debris from the Trizact disc after each use, and wipe surface clean following each step to minimize contamination scratches.

Finishing Steps – Matte Finish

1. Apply 3M™ Microfinishing film – 366L, 100-micron (brown) to your Hookit™ II backup pad. Begin sanding your solid surface material in the pattern above. (This step is done dry. Do not spray the surface with water.) This step is intended to remove any defects in the surface of the material and to level the surface. Defects will be highlighted while sanding. Sand until all defects are removed and the surface is level. After you’ve sanded the entire surface, wipe the surface clean. If all previous scratches and irregularities have been removed, and the surface appears flat and uniform, proceed to Step 2. If defects remain, repeat Step 1. (Be sure to rinse all debris from your work surface and abrasive disc.)

2. Replace the 100 micron (brown) disc with 3M™ Trizact™ Hookit™ II disc – 268XA, A35 (green). Spray the work surface till it is damp, not flooded. Begin sanding in the same pattern and at the same rate as the previous step. Spray with water as necessary to keep the surface damp. Repeat the pattern twice OR sand at a rate of 1 minute per square foot of material. Rinse the debris from the Trizact disc and your work surface. Wipe the surface clean and inspect your work. For many materials and colors, you will now have a satisfactory, matte finish. If not proceed to Step 3.

3. Repeat the procedure using 3M™ Trizact™ Hookit™ II – 268XA, A10 (blue). Rinse the debris from the Trizact disc and your work surface. Wipe the surface clean and inspect your work. You should now have a uniform matte finish. (Gloss level 12 – 15.) Option: When generating a matte finish, Scotch-Brite™ hand pad 7447 (maroon) can be used instead of the Trizact A10 disc. On some solid surfaces, Scotch-Brite pads can “draw the color out” of the material better than Trizact film. The Scotch-Brite pad can be used by hand or trimmed to fit your sander. Can be used wet or dry.

Finishing Steps – Semi-Gloss Finish

1 2 3 Follow the matte instructions above. (Using 366L 100 micron, and Trizact 268CA, A35, and A10.)

4. With 3M™ Trizact™ Hookit™ II – 268XAm A5 (orange) on your sander, spray the surface and sand in the usual “North, South, East, West” pattern. Repeat the pattern twice. Wipe the surface clean and inspect your work. You should now have a uniform semi-gloss finish. (Gloss level approx. 45.)

Option: When generating a semi-gloss finish, Scotch-Brite™ hand pad 7448 (gray) can be used instead of the Trizact™ A5 disc. On some solid surfaces, Scotch-Brite pads can “draw the color out” of the material better than Trizact film. The Scotch-Brite pad can be used by hand or trimmed to fit your sander. Can be used wet or dry.

Finishing Steps – High Gloss Finish 1 2 3 4 Follow the procedure for semi-gloss finishes through the Trizact film A5 (orange) step.

(Abrasives used so far are 366L 100 micron, and Trizact 268XA – A35, A10, and A5.) 5. Using Trizact™ Hookit™ II – 568XA (white), spray the surface and polish in the usual

sanding pattern. Two to four passes may be necessary.

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Rinse the debris from the Trizact disc and your work surface. Wipe the surface clean and inspect your work. You should now have a rich looking, high gloss finish. (Gloss level approx. 80.) Alternate Step 5. If you desire a very high gloss (level higher than 80), or encounter swirl marks using the standard sequence, use 3M™ Wetordry™ Polishing Paper – 286Q, 9 micron (blue) instead of Trizact 568XA (white). Buff with Finesse-it™ Finishing Material – Easy Clean up (PN 83483-9). 3M™ Imperial™ Polishing Film discs – 968M can be used as carrier for this compound using your random orbital sander. (These are sold separately – NOT included in the standard kit.) For faster buffing time, use a rotary buffing tool and a wool buff pad.

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Specifications RESIN COMPARISON CHART Test Results Flammability Properties Test Method Cross-Linked Acrylic Acrylic PETG Fire Rating ASTM D 635 PASS, CC2 PASS, CC2 PASS, CC1 Self-Ignition Temperature ASTM D 1929 PASS, 960F PASS, 960F PASS, 800F Smoke Density ASTM D 2843 PASS, <75% PASS, <75% PASS, < 75% Flame Spread ASTM E 84/UL 723 PASS, < 150 PASS, < 150 CLASS II, < 75% Smoke Developed ASTM E 84/UL 723 > 450 > 450 PASS, < 120* Horizontal / Vertical Burn ASTM UL 94 PASS, UL 94-HB PASS, UL 94-HB PASS, UL 94-V2 * Note: this data was collected while the sheet samples remained in the original test fixture position and do not include the material that ignited on the furnace floor. Furthermore, a Class II material can be used in place of a Class I material when installed with an approved automatic fire suppression system. Mechanical Properties Test Method Cross-Linked Acrylic Acrylic PETG Specific Gravity ASTM D 792 1.19 1.19 1.27 Water Absorption (24 hr immersion)

ASTM D 570 0.25% 0.22% 0.20%

Impact Resistance Notched

ASTM D 256 0.3 ft – lbs/in .45 ft – lbs/in 1.7 ft – lbs/in

Rockwell Hardness ASTM D 785 M-95 M-95 M-115 Stain / Chemical Resistance

Excellent, PASS ANSI Z 124

Good Good

Microbial Resistance Excellent Excellent Excellent Formability Excellent Good Excellent Bonding Fair Good Fair Renewable Surface Excellent Excellent Fair Optical / Audio Properties

Test Method Cross-Linked Acrylic Acrylic PETG

UV Absorption Excellent Excellent Fair Weather Resistance Excellent Excellent Fair Light Transmittance ASTM D 1003 93% 93% 86% Optical Refractive Index ASTM D 542 1.49 1.49 1.57 Sound Absorption Good Good Good Thermal Properties Test Method Cross-Linked Acrylic Acrylic PETG Maximum Continuous Service Temperature

180F 180F 155F

Softening Temperature 210-220F 210-220F 180-190F Melting Temperature 320-380F 300-315F 220-240F Thermoforming Temperature

340-380F 280-350F 280-320F

Deflection Temperature (264 psi)

ASTM D 648 190F 190F 157F

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TABLE XI Chemical Resistance of Lumicor® Acrylic Sheet Compound Common Name Type Concentration Chemical Class Resistance At 72°F Acids Acetic Acid Glacial 100% NR Acetic Acid 5 E Chromic Acid 40 F Citric Acid 10 E Hydrochloric Acid Concentrated 38 E Hydrochloric Acid 10 E Nitric Acid Concentrated 70 F Nitric Acid 40 G Nitric Acid 10 E Oleicic Acid E Sulfuric Acid Concentrated 98 NR Sulfuric Acid 30 E Sulfuric Acid 3 E Bases Ammonia Solution .88 SG E Ammonia 28 % E Ammonia 10 E Sodium Carbonate 20 G Sodium Carbonate 2 G Sodium Hydroxide 60 E Sodium Hydroxide 10 E Sodium Hydroxide 1 E Hydrogen Peroxide 10 E Commercial Cottonseed Oil Edible Grade E Products Detergent Solution Heavy Grade .025 % E Kerosene No.2 Fuel Oil G ASTM D-396 Gasoline 100 octane F Lacquer Thinner NR Mineral Oil White, USP F Olive Oil Edible Grade 1 E Soap Solution White Flakes G Transformer Oil ASTM D-1040 G Turpentine Distilled Spirit NR ASTM D-13 Isopropyl Alcohol 10 F Ethyl Alcohol 10 F LEGEND: NR - Not Recommended E – Excellent G - Good F - Fair

*This information is based on tests performed on small unstressed samples. The actual performance of the article will depend on the presence of internal and external stresses and orientation in the manufactured article.

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PETG Chemical Resistance Users of Spectar copolyester should make and be guided by their own tests under conditions equivalent to or representative of those to which the plastic will be subjected in service.

% Changea Reagent Weight Thickness Appearance of Plastic After Exposure

Acetic Acid, 5% <1 <1 Very slight yellowing

Acetic Acid, conc. 19 18 Discolored, swollen

Acetone 16 23 Discolored (brown), swollen, rubber-like

Ammonium Hydroxide, conc. –29 –20 Turned white, outside crumbling off

Ammonium Hydroxide, 10% 4 4 Discolored (pink), surface has blisters

Antifreeze, Automotive Ethylene Glycol Type <1 <1 No change

Benzene 34 43 Discolored, rubber-like

Brake Fluid, DOT3 2 2 No change

Brake Fluid 6 6 Turned yellow, surface attacked, flaking off

Carbon Tetrachloride 27 18 Discolored, swollen

Chromic Acid, 40% <1 <1 Slightly discolored

Citric Acid, 10% <1 <1 Slight yellowing

Cottonseed Oil <1 <1 Very slight yellowing

Deionized Water <1 <1 Slight yellowing

Detergent, Alconox (0.25%) <1 <1 Slight yellowing

Di(2-Ethylhexyl)Phthalate <1 <1 Very slight yellowing

Dibutyl Sebacate <1 1 Slight yellowing

Diesel Fuel <1 2 Discolored

Dimethyl Formamide 22 39 Badly discolored and distorted

Ethanol, 50% <1 <1 Slight yellowing

Ethanol, 100% <1 <1 Very slight yellowing

Ethyl Acetate 20 24 Badly discolored and swollen, softened

Ethylene Dichloride — — Completely deteriorated after 1 week

Gasohol, 10% Ethanol 9 8 Cloudy, slight yellowing

Gasohol, 10% Methanol 11 10 Cloudy, yellowed

Gasoline, Base for Gasohol 6 6 Slight yellowing

Gasoline, Premium Unleaded 2 3 Discolored

Gasoline, Regular <1 <1 Slight yellowing

Gasoline, Regular Unleaded 2 2 Discolored

Grease, Automotive <1 <1 No change

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Hand Cleaner, Waterless Jergens SBS30 <1 2 No change

Hexane <1 <1 Slight yellowing

Hydrochloric Acid, conc. 1 <1 Badly discolored, blisters under surface

Hydrochloric Acid, 10% <1 <1 Slight yellowing

Hydrogen Peroxide, 3% <1 <1 Slight yellowing

Hydrogen Peroxide, 28% <1 <1 Slight yellowing

Isooctane <1 <1 Very slight yellowing

Kerosene <1 <1 Very slight yellowing

Lacquer Thinner 7 6 Cloudy, white

Methyl Alcohol <1 <1 Very slight yellowing, crazing

Mineral Oil <1 <1 Very slight yellowing

Motor Oil <1 <1 No change

Nitric Acid, conc. — — Completely deteriorated after 1 week

Nitric Acid, 10% <1 <1 Slight yellowing

Nitric Acid, 40% 1 <1 Turned white

Oleic Acid, 83% <1 <1 Very slight yellowing

Olive Oil <1 <1 Very slight yellowing

Penetrating Oil, Liquid Wrench #1 10 11 Discolored

Phenol, 5% 13 14 Turned black

Silicone Spray Lubricant 67 34 White, swollen

Soap Solution, 1% <1 <1 Slight yellowing

Sodium Carbonate, 2% <1 <1 Slight yellowing

Sodium Carbonate, 20% <1 <1 Slight yellowing

Sodium Chloride, 10% <1 <1 Slight yellowing

Sodium Hydroxide, 1% <1 <1 Slight yellowing

Sodium Hydroxide, 10% 8 6 Slight yellowing

Sodium Hypochlorite, 3.5% <1 <1 Slight yellowing

Sulfuric Acid, conc. — — Completely deteriorated after 1 week

Sulfuric Acid, 3% <1 <1 Slight yellowing

Sulfuric Acid, 30% <1 <1 Slight yellowing

Tapping Oil <1 1 No change

Toluene 26 31 Turned white, softened

Transformer Oil <1 <1 Very slight yellowing

Transmission Fluid, Auto <1 <1 No change

Turpentine <1 <1 Slight yellowing aChanges shown are increases unless the figure is preceded by a negative sign.

Publication TRS-211B (November 2003)

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Material Safety Data Sheets providing safety precautions that should be observed in handling and storing Eastman products are available online or on request. You should obtain and review the available material safety information before handling any of these products. If any materials mentioned are not Eastman products, appropriate industrial hygiene and other safety precautions recommended by their manufacturers should be observed.

Neither Eastman Chemical Company nor its marketing affiliates shall be responsible for the use of this information, or of any product, method, or apparatus mentioned, and you must make your own determination of its suitability and completeness for your own use, for the protection of the environment, and for the health and safety of your employees and purchasers of your products. No warranty is made of the merchantability or fitness of any product, and nothing herein waives any of the Seller's conditions of sale.

Eastman, Eastar and Spectar are trademarks of Eastman Chemical Company.

© Eastman Chemical Company, 2003.