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Solid Surface WorktopInstallation Manual
MAKING SPACE MORE VALUABLE
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Contents
1. Introduction page 32. Tools Required page 53. Unpacking and Preparation page 74. Cutting page 85. Joining page 96. Inset Sink Installation page 128. Hob Installation page 139. Upstand Installation page 1411. Undermount Sink page 1512. Undermount Sink - Cutting/Finishing page 1613. Drainer Grooves page 1714. Creating Curves page 1815. Sanding and Finishing page 1913. Care and Maintenance page 20
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Introduction
This Installation Manual will provide step by step instructions on how to use and install the Getacore solid surface worktop products. It will also provide tips on how to make the installation run as smoothly as possible, along with providing useful information on how to get the most out of the Getacore worktop products.
The range includes - 3m Worktop - 1.5m Worktop - 2m Breakfast Bar - Upstand
Using similar techniques used for standard timber worktops the Getacore Solid Surface Worktop products are easy to install. It can be milled, sanded and joined to give a seamless joint.
Benefits: - Easy to clean and maintain - Resistant to most household chemicals - Heat resistant to up to 160°C - Fully compatible with all Howden’s sinks and hobs - A perfect compliment to a modern or traditional kitchen
Please note: The colours of solid surface available may vary. Images used in the installation manual are for fitting reference only.
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Introduction
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Howdens offer Getacore kits that are recommended to be used for specific stages of installation.
01 Care and Maintenance Kit02 Worktop Adhesive Kit03 Adhesive Applicator Kit04 Sanding and Finishing Kit.05. Additional Nozzles (Pack of 10)
Always refer to the instructions on the product before using them.
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To install the Solid Surface products, the following equipment will be required to achieve a quality finish.
Tools Required
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01 Circular Saw.02 Router with 30mm copying ring.03 Edge Trimmer.04 Random Orbital Sander with 150mm Pad.05 Drill.06 Chop Saw.
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Tools Required
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07 Horizontal clamps08 Vertical clamps09 Worktop Mitre Jig10 MDF or HDF to be used for a template.11 Worktop Connecting Bolts (GIR0029)12 Biscuit Cutter13 Tape Measure and Pencil14 Masking Tape, to be used when cutting to prevent scratches on the worktop surface15 Square16 Straight Edge17 Methylated Spirits18 PU Adhesive19 Silicone Sealant20 Solvent Free Gap Filling Adhesive21 Wooden or Plastic Spatula22 Cleaning Cloths23 Dust Mask24 Eye Protection25 Worktop Biscuits26 Drainer Groove Jig
Note: Ensure you wear items 23 & 24 when cutting or sanding the Getacore product
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It is recommended that two people are required to carry worktops and upstands
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Unpacking and Preparation
Treat the product with care when removing its packaging. The worktop should be removed from its outer case in a dry and stable environment where the humidity is constant before commencing installation. If the product is required to be stored, remember to lay it flat and fully supported in its original packaging.
Please ensure that the packaging is disposed of in a safe environmentally way.
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Cutting
The following equipment is required to complete this stage:
- Circular Saw - Straight Edge- Router - Masking Tape - Clamps - Tape Measure and Pencil- Square - Dusk Mask
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After clamping the worktop down use a circular saw to make the cut in the worktop, at a steady controllable pace.
It is advisable to use extraction where possible to reduce the amount of dust that is being generated.
Once the cut has been completed, use a router to remove the remaining 2mm to leave a smooth surface edge, using a three depth cutting process to avoid overloading the router.
Note: Please take into account the tool size variables when finishing to ensure the dimensions are correct.
Place the worktop on the work bench ensuring there is plenty of room to work around the product. Using a tape and a pencil, mark the worktop at the required length. Oversize the measurement by 2mm to allow for trimming with a router. Clamp the worktop down securely ensuring the worktop is stable.
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Joining
The following equipment is required to complete this stage:
- Worktop Mitre Jig - Wooden or Plastic Spatula - Random Orbital Sander- Clamps - Joining Kit - Sanding and Finishing Kit- Router - Worktop Joining Bolts - Methylated Spirit- Straight Cutter - Worktop Adhesive Kit - Biscuit Cutter - Masking Tape - Adhesive Applicator - Worktop Biscuits
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With the worktop jig in place, use a router to create the male and female mitred edges, using a three depth cutting process. Once the edges have been cut, use the jig to create the worktop connecting bolt recesses in the substrate.
Note: It is recommended that three bolts are used per joint.
With the edges and connecting bolt recesses complete, the next stage is to cut slots in the substrate for the three biscuits using a router with a biscuit cutter tool.
Note: Location for the biscuit joints should be taken from the top face down to ensure a consistent level is achieved.
Once the worktops have been cut to size and are clean from dust, secure the worktop mitre jig to the worktop using clamps.
Note: When using the Howdens Joinery worktop jig, a 1mm spacer is required between the peg and the rear edge of the worktop.
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Joining - continued
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Once the slots have been cut, carefully hand sand both edges to ensure that both top surfaces come together perfectly.
When using worktop adhesive, squeeze out the first few inches of bead on to a waste cloth before applying, this will ensure a consistent mix of the two parts of the adhesive.
Clean the solid surface edges using methylated spirit. Apply the worktop adhesive edges and spread with a spatula, then apply the adhesive to the biscuits and insert them into the slots.
Bring the worktop edges close together and apply worktop adhesive to the top of the front edge of the worktop.
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Joining - continued
Once the worktop adhesive has been applied, bring the worktops together by tightening the connecting bolts, ensuring that the excess adhesive oozes out and creates a bead on the worktop surface.
It is important to ensure any air bubbles that appear in the adhesive are pierced. As it will be difficult to get a sander right into the corner of the worktop joint, it is recommended that the excess adhesive bead from the front edge is removed with a spatula before the adhesive becomes solid. Once this is complete, allow the worktop adhesive to cure for 45 minutes to 1 hour, dependant upon environmental conditions.
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Once the adhesive has cured, sand away the excess adhesive bead from the worktop surface using the Sanding and Finishing Kit. Please refer to the Sanding and Finishing section for more information.
To join two worktops together using a butt joint, use the same process as corner joining, using straight cuts rather than mitre cuts.
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Inset Sink InstallationThe following equipment is required to complete this stage:
- MDF or HDF sink cut out template - PU Adhesive- Clamps - Tape Measure and Pencil- Router - Methylated Spirit- Plunge Cutter
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To ensure an accurate cut out for the inset sink, it is recommended to have a sink template made from MDF or HDF. Ensure that the template creates internal corners with a minimum radius of 10mm, this will reduce the likelihood of any stress cracks in the worktop.
Allow at least 45mm from the front edge of the worktop to the edge of the cut out to maintain rigidity. Clamp the worktop and template down securely ensuring that they are stable.
Use a router with 30mm copying ring attached and start to cut out the hole. To avoid overloading the router, it is recommended to make the cut in 3 depth stages. Again, ensure that internal corners have a minimum radius of 10mm. All edges should be rounded after cutting using a router and cutter with 3mm or 5mm radius.Note: Use a straight cutter with plunge.
Once the cut has been completed, wipe down the surface to ensure it is clean and free from dust. Next, seal the inside of the cut out using PU adhesive. Once this is completed, the sink can then be installed as per a normal laminate worktop, using the clips and tape provided with the sink.
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Hob Installation
The following equipment is required to complete this stage:
- MDF or HDF Hob cut out template- Router- Plunge Cutter- Clamps- Aluminium Tape
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To ensure an accurate cut out for the hob, it is recommended to have a hob cut out template made from MDF or HDF. Please allow at least 45mm from the front edge of the worktop to the edge of the cut out to maintain rigidity. Clamp the worktop and template down securely ensuring that they are stable. Ensure that the template creates internal corners with a minimum radius of 10mm; this will reduce the likelihood of any stress cracks in the worktop.
With the template securely clamped in place, use a router with a 30mm copying ring attached to start to cut out the hole. To avoid overloading the router, it is recommended to make the cut in 3 depth stages. Again, ensure that internal corners have a minimum radius of 10mm. All edges should be rounded after cutting using a router and cutter with 3mm or 5mm radius.
With the cut out complete, the next stage is to line the inside of the cut out with the aluminium tape. This should then be applied to the inside edge, over the first layer of aluminium tape. Please ensure that the aluminium tape overlaps the top and bottom surfaces of the cut out, this is to protect the substrate from heat.
With the tapes in place, the hob can then be installed as per a normal laminate worktop, using the clips and tape provided with the hob.
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Use a pencil and tape measure to mark where the upstand needs to be cut. Then use a square and straight edge to make the line across the upstand.
Cut the upstand using a chop saw. Once the is completed, use the Sanding and Finishing Kit to smooth the edges of the upstand. Corner pieces may require additional machining to mitre the edges.
The following equipment is required to complete this stage:
- Chop Saw - Silicone Sealant - Router - Sanding and Finishing Kit - Random Orbital Sander - Methylated Spirit- Clamps - Tape Measure and Pencil- Solvent Free Gap Filling Adhesive - Square
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Upstand Installation
If joining two sections of upstand together, it is important that the edges are cleaned using methylated spirit before joining. Apply a small bead of worktop adhesive to both edges and push the upstands together until excess adhesive oozes out of the joint. It is important to ensure any air bubbles that appear in the adhesive are pierced. Leave the worktop adhesive to cure for 45 minutes to 1 hour, dependant upon environmental conditions.
Once the worktop adhesive has cured, use the Random Orbital Sander and Sanding and Finishing Kit to remove the excess adhesive, and then blend the joint in with the rest of the upstand.
The entire upstand will need to be fully sanded for a uniform finish. Please see the Sanding and Finishing section for further information.
Once the upstand is ready to be installed onto the wall, ensure that the rear of the upstand and the wall are clean and free from dust. Apply solvent free gap filling adhesive to the rear of the upstand and fit into place.
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cabinet following the information below.
Measure the cabinet area which will house the undermount sink as shown.
Cut a piece of MDF to the appropriate size and secure in place
Use the undermount sink template to mark the cut-out in the MDF panel for the bowl.
Note: The lip of the undermount sink needs to be recessed into the top of the MDF panel.
Fit the undermount sink to the MDF top and silicone the rim to secure.
the top rim of the sink. The cut solid surface worktop can now be placed onto the units.
the information in sections 7 & 9.
Note: Thermal protection tape to be used in all areas in direct contact with heat.
The following equipment is required to complete this stage:
- Jigsaw- Tape Measure & Pencil- Router- Silicone- Thermal Protection Tape (Sink Installation)
Undermount Sink
MDF Panel
Router rebate into MDF
Worktop
Fixing Blocks
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Using the undermount sink template as a guide, cut the worktop section using a router.
Note: When cutting the worktop, cut just inside the pencil line to allow enough material to clean the inside edge. We recommend the use of a jig made from a piece of MDF to ensure the top is cut correctly.
information.
Note: Thermal protection tape to be used in all areas in direct contact with heat.
The following equipment is required to complete this stage:
MDF or HDF sink cut out template- Clamps - Tape Measure and Pencil- Router - Methylated Spirit- Plunge Cutter - PU Adhesive
Undermount Sink - Cutting/Finishing
20/30Grit
80/100Grit
To create drainer grooves for your undermount sink, follow the information below and the instruction sheet supplied with the jig.
of the worktop. Never lay tools onto the worktop during sanding and polishing.
Before applying drainer grooves ensure the sink cut-out is
Decide on the location of the drainer grooves, i.e equal spacing from the front to back of the sink cut-out, or positioned towards the front, and the required length of the drainer grooves.
Clamp the drainer groove jig to the worktop making sure it is
the jig for positioning & setting up information.
Note: Check the position of the jig is in exactly the right place before applying the grooves.
information.
The following equipment is required to complete this stage:
- Drainer Groove Jig- Router
Drainer Grooves
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of the worktop. Never lay tools onto the worktop during installation.
Use the curved worktop jig placing it against the corner of the
the worktop using a router pushing the router towards the front edge of the jig
edge of the jig to achieve a smooth cut.
information.
The following equipment is required to complete this stage:
- Curved Worktop Jig- Clamps
Creating Curves
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The Sanding and Finishing Kit, comprises of 6 sanding discs of varying grades.
01 The P-120 disc is used for removing the adhesive bead on joints, as well as on severe scratches.02 The P-180 disc is used after the P-120 for the second stage of sanding off adhesive bead. Application over the whole surface will remove light scratches.03 The P320 disc is used for normal sanding across large areas04 The VF-360 (Red) disc is to be used for normal sanding across larger areas.05 The S-400 (Black) disc is to be used after the VF-360 to finish the sanding process.06 The STS-150 finishing disc brings out the colour of the work surface and completes the process.
Sanding and Finishing
The following equipment is required to complete this stage:
- Random Orbital Sander- Sanding and Finishing Kit
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Whilst sanding, please bear in mind the following points:
• Apply even pressure throughout the sanding process and move the sander in circular motion to ensure the best results.
• At each stage of sanding, it is required that the work surface is consistently sanded. Failure to do so may result in blotching/clouding once the work surface is finished.
• Do not start and stop the sander on the work surface. This might result in swirls appearing on the surface.
• Do not over-sand any particular area as this will cause the work surface to warm up and soften, making sanding much more difficult.
• Sanding should be carried out in a circular motion, working backwards and forwards and diagonally in all directions.
Note: If surface results are not satisfying, repeat the sanding process.
Whilst sanding the solid surface with a Random Orbital Sander, it is advisable that extraction is used in order to minimise dust.
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Care and Maintenance
Getacore solid surface worktops can cope with the rigours of a busy kitchen environment. The worktops are easy to clean and maintain, offering long lasting appearance and performance for the lifetime of the kitchen. To keep the Getacore Solid Surface worktop in the best possible condition, it is recommended that Getacore Care and Maintenance Kit is used. This kit comprises of:
- Microfibre Cloth - Sanding Block - P-320 Sanding Pad - P-800 Sanding Pad- S-400 Sanding Pad - STS150 Dust Pad- Finishing Sponge
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Normal everyday spills can be wiped away using a damp cloth and a mild detergent. The worktop is resistant to most household chemicals; however solvent based products should be avoided.
Should any stubborn stains or marks become evident, these can be sanded away using the sanding pad and disc supplied within the maintenance kit.
As with all solid surface products, it is recommended to use a chopping board when cutting food on the surface and use worktop savers or trivets when placing hot pots or pans on the worktop.
Notes
HD712092 HJS9772
