Guidelines for Workshop Practice
PLEXICOR®
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Preparation FabricationGuidelines 4 Packaging/Transportation/Storage 5
Fabrication Sawing/Routing 6 Drilling/ScrewUnions/Thermoforming 7 Bonding/Sanding/Finish 8 EdgesandWallConnection/Undermounting 10 Undermounting/InstallationofFormedProducts 11 InstallationofFormedProducts:Undermounting 12 InstallationofFormedProducts:IntegratedInstallation 13 Installingcookerhobs/hotplates 14
CareInstructions 15
PLEXICOR®Contents
3
CareInstructions
PLEXICOR®isahigh-qualityacrylicmaterialwhosemainconsti-tuentisthenaturalmineralaluminumhydroxide Itoffersagelessbeauty,feelswarmtothetouchandcanbeshapedlikewood PLEXICOR®isasolid,perfectlysmoothandhomogenousmaterialwhoseregenerablesurfacealwayslooksbrand-new
DesigningwithPLEXICOR®means:EndlessCreativityPLEXICOR®canbesawn,routed,drilled,sandeddown,formedandseamlesslybonded,thusenablingevencomplexdesigns PLEXICOR®iseasytomachineusingcarbidetools
Beingbasedonacrylic,PLEXICOR®isbiologicallyinoffensiveandenvironmentallyfriendly PLEXICOR®scrapiseasytodisposeoforcanbedirectlyrecycled
Uponreception,thematerialshouldbeexaminedforanydamageduetotransportationorvisibledefects Ifdefectivematerialhasobviouslybeenused,weassumenocompensationforhigherfabricationcostsorguaranteesintheeventofsubsequentdamagetothefinishedproduct
Themaskingfilmorpackagingmayneedtoberemovedforexamination
Examine sheets before cutting to size for:
exteriordamage,e g crackingornotches•surfacedamage•warpage•colorconsistency(thisshouldbeexamined•innormallightingconditions,notinbrightsunlight!)sheetsfromthesamebatch •Whenplanninghowtocutthesheetstosize,•careshouldbetakennottobondsheetsectionswithpronouncedpatternswithsectionsthatcontainlesspatternedzones
Examine formed products for:planarityofedges•edgerouting•damageduetoincorrectshipmentorhandling•colorconsistency(thisshouldbeexamined•innormallightingconditions,notinbrightsunlight!)formedproductsfromthesamebatch•
Examine adhesives for:minimumstorageperiod•adhesivecolorthatmatchessheetmaterialor•formedproducts
Batch numberMakeanoteofthebatchnumberandproduc-•tiondateofthesheetandformedproductsonyourorderdocuments
Checklist
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PLEXICOR®
FabricationGuidelines
Beforecommencingwork,allPLEXICOR®components,includ-ingadhesives,shouldhaveroomtemperature Atemperatureofatleast18°Cisrecommended
PLEXICOR®issubjecttotemperature-relatedchangesinlength Attemperatureincreasesofabout30°C,PLEXICOR®expandsbyapprox 1mmpermeterofinstallationlength,orcontractsbythesamemeasureattemperaturesthatare30°Clower Thismustbetakenintoaccountforinstallation
AdditionalinsulationisrequiredbetweentheheatsourceandPLEXICOR®forstovecutoutsandareasexposedtohigherheatlevels
PLEXICOR®elementsshouldalwaysbeinstalledstress-free OnlypermanentlyelasticadhesivesmaybeusedforbondingPLEXICOR®toundermountingstructures
Powerful,high-qualitymachinesandsharpcarbidetoolsmakeworkmucheasier Jigsawsandhand-heldcircularsawsarenotsuitable Alltheinnerandouteredgesmustberoundedbecausesharpedgesandcornersmayhaveanotcheffect Cutoutsandcut-to-lengthsectionsareproducedusingahand-heldoverheadrouterwithcorrespondingcarbide-tippedcutters
PLEXICOR®hastheappearanceofnaturalstone,whichproducesinterestinglightandcoloreffects
Thesurfacemaskingfilmmustberemovedbeforeplanningthecut-to-sizesections
Whenplanninghowtocutthesheetstosize,careshouldbetakennottobondsheetsectionswithpronouncedpatternswithsectionsthatcontainlesspatternedzones
ThedarkdesignercolorsfromthePLEXICOR®rangehaveaverynoble,high-classlook Aswithalldarksurfaces,tracesofweararemoreobviousthanonpalecolors Suchshadesarethere-foremoresuitableforlessheavy-dutyitems,e g washstands,consolesandpanels
Preparation
ReadtheDirectivesforWorkshopPractice•withPLEXICOR®carefullybeforecommenc-ingwork ThesameappliestoadhesivesandPLEXICOR®formedproducts
Inparticular,bearinmindtheapplicable•officialsafetyregulations(wearsafetygoggles,respiratoryprotectiveequipment,earmuffs,safetyshoes,protectivegloves) Extractorsmustbeusedduringmachining
Checklist
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Packaging/Transportation/Storage
TransportationTheedgesandsheetsurfacesofmachineditemsmadefromPLEXICOR®mustbeprotected Suit-ablematerialforsurfaceprotectionarecorrugatedcardboardorblisterfilm Foamblocksorthickcardboardcanbeusedfortheedgesandcorners
Toavoiddamageduringtransportation,itisadvisabletomarkthepackagingwithappropri-atewarningsthatspecifycarefulhandlingoftheconsignment
PLEXICOR®sheetsmustalwaysbecarefullytrans-portedinaverticalposition Astandard-sizedsheetweighsover40kg Handlingaidssuchasvacuumliftingdevices,liftingclampsandsheettransportersshouldbeused Whencarryingthesheet,cutoutsandinsetformedproductsshouldbeprotectedfromheavyloads PLEXICOR®sheetcanbestoredflatorupright,butdeflectionshouldbeavoided
PLEXICOR®adhesivesshouldbestoredinadark,dryplaceat10–15°C
PLEXICOR• ®ismorebrittleatlowtemperaturesthanatroomtemperature Thisshouldbeborneinmindduringtransportationandfabrication
Checklist
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Sawing/Routing
SawingHigh-qualitymachinesandtoolsprovideoptimal,cleansawnedgesthatrequirenofurthertreatment
Sawpanelsaws/horizontalsaws/verticalpanelsaws
Suitablesawbladesarecarbide-tipped(trapezoidalflattooth)bladeswithatleast8teethper2 5cmdiameterandacuttingangleof8–10°
Thesawbladeshouldbesharpandprotrude25mmbeyondthematerialtobecut
Therecommendedspeedforapanelsawis4,000–4,500rpmwithasawbladediameterof300mmwithnegativerake
RoutingRoutingisoneofthemostimportantmachiningmethodsforPLEXICOR® ItisnormallyperformedusingpowerfulCNCcuttersandtable-mountedrout-ers Hand-heldoverheadroutersshouldhaveapowerinputofatleast900Wandatleast1,600Wformoreintensivework
Theemployedroutingcuttersmustbeofhigh-quality,carbide-tippedandhaveashaftdiameterofatleast12mm
Thedepthstopsshouldbesheathedinplastic
PLEXICOR®supplierscanprovidealistofsourcesforcuttersthatarespe-ciallyequippedformachiningthemineral-filledmaterialPLEXICOR®
Recommended sawblades:
Diameter Bladewidth Bore No ofteeth
250mm 3,3mm 30mm 80
300mm 3,5mm 30mm 96
350mm 3,5mm 30mm 92
PLEXICOR®Fabrication
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Drilling/ScrewUnions/Thermoforming
DrillingPLEXICOR®iseasytodrillwithuprightdrills HSStitaniumdrillsareidealforholesupto10mm,whereascarbide-tippedForstnerdrillsaresuitableforlargerdrillholes
Theedgesofthedrillholesmustbechamferedorbroken,sincedrillholeswithsharpedgesmayhaveanotcheffect Itisparticu-larlyimportanttochamfertheholesmadetoaccommodatetapsinkitchencountertopsorlaboratoryworksurfaces
PLEXICOR®elementscanbescrew-fastened Threadscanbeincorporatedviathreadedinserts Weadviseagainstusingself-tappingscrewsandcuttingthreadsdirectlyintoPLEXICOR®,sincethismaydamagethematerial Holesdrilledforscrewunionswithothermaterialsmustbeatleast2mmlargerindiameterthanthescrewdiameter
ThermoformingThepossibilityofthermoformingPLEXICOR®opensupmanydifferentconstructionanddesignoptions
Theoptimumformingtemperatureisapprox 150°C Themate-rialmustbeheatedthroughandthrough
Heatingplatesareespeciallysuitableforthree-dimensionalforming TheseheatPLEXICOR®throughmorerapidlyandenableamoreeffectiveworkprocess Givenreliabletempera-turecontrol,overheatingofthematerialisprevented Hot-airovensorpresseswithplatesthatcanbeheatedtoatleast150°Caresuitablefortwo-dimensionalforming
Theworkpiececanonlybecuttoitsfinalsizeaftercompletecooling
Alaser-guidedinfraredthermometerisrecom-•mendedfortemperaturecontrol Theheatingtimeandsmallestpossiblebendingradiusalsodependonthemachinepower,heattransferandsheetcolorandmustbedeterminedbytests
Checklist
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PLEXICOR®Fabrication
Standardjoint
Reinforcedstandardjoint
Bonding/Sanding/Finish
BondingPLEXICOR®canbebondedwithoutapparentjointsbymeansofspecialPLEXICOR®adhesives ThismeansthatPLEXICOR®itemsofalmostanysize,andamultitudeofshapes,canbeassembledasdesired
ItisessentialtouseoriginalPLEXICOR®two-componentadhesivesystems Theseareavailableincartridgesizesof50and250mL ThereisasuitablycoloredadhesivesystemforeveryavailablehueofPLEXICOR®sheet Thecolormatchmustbeexaminedbeforestartingwork Iftheadhesivetemperatureiscorrectlyadjustedto18–23°C,theadhesivecurescompletelyafteraslittleas30to45minutes
Chooseadhesiveofmatchingcolor•Checkshelflife•Temperatureatleast18̊ C•Cleansurfacestobebonded:•
withcleanwhitenon-lintingcloths•onlywithalcoholoracetone•
Firmlyfixpartstobebonded-donotexertpressure•Leaveadhesivetocurecompletely(shrinkage)•Makesuretoobservethesafetyinstructionswhenprocessingthe•adhesivesystem
Checklist
Priortobonding,anypencilmarks,greaseorothersoilingmustberemovedfromtheadherendsusingmethylatedspiritandacleanwhitenon-lintingcloth Afterinsertingtheadhesivecar-tridgeinthegun,thesafetydiscatthetipofthecartridgemustberemovedandtheplasticcapunscrewed Themixernozzle,whichisdisposableandmustnotbeshortened,isthenattached Thefirst10to15cmofthemixedadhesivefromanewcartridgeareunsuitableforbonding Adhesivejointsdonothavethesamestrengthassheetsorformedproducts Certainconstructiondetailsthereforehavetobeborneinmind Noadhesivejointsshouldbeplannedinareasexposedtohightemperatures Thisincludesstovecutouts,surfacesabovedishwashersornearradiators
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Thepartsarepreferablybondedinplacesexposedtothelowestmechanicalloads Adhesivejointscanbestabilizedbyreinforc-ingstripsbondedtotheunderside Makesuretoobtainclean,straightandunchippedcutedges Undernocircumstancesshouldcutedgesforbondingbebroken Toperformbonding,thepreparedsheetsareplacedonaflatandevensurface Acopi-ousamountofadhesiveisappliedinadhesivejointsofapprox 3mm Thepartsarethenpushedtogetherandfixedinpositionusingscrewclamps Presstogetheronlylightly,donotexerthighpressure Foredgebonding,adhesiveisonlyappliedtoonesideandbothpartsareclampedinplaceevery8to10cm Excessadhesiveisonlyremovedaftercompletecuring(approx 45minutes),byroutingorsanding
Sanding/FinishThecorrectfinishofaPLEXICOR®surfacehasacrucialinfluenceontheappearanceandservicevalueofaninstalleditem Sandingprovidesaclean,smoothandeasy-caresurface
Hand-heldsanderswithadustextractionportarerecommendedforthispurpose,particularlypowerfulrandomorbitsanders
Givenmoderateholdingpressureandfreshmedium-gritabrasivesheet,optimumresultsareobtainedandoverheatingofthePLEXICOR®surfaceisavoided
GlossDependingontheselectedabrasivesandpolishingagents,amattetoglossysurfacecanbeobtainedonPLEXICOR® Forcountertopsandworksurfaces,amattetosatinsurfaceshouldbechosen,whereasaglossorhigh-glosssurfaceispossiblefordecorativesurfacesorthosesubjecttolessheavywear(e g washstands)
Abrasives and Polishing Agents
SupplierProductSeries
Gloss 3M®IMFF Mirka MirkaABRANET®
Matte
10060
7447
P150P320
VFMIRLONP240
VFMIRLON
Satinmatte
1006030
7448
P150P320
360ABRALON®
P240P400
360ABRALON®
High-gloss
1006030159
AbrasivepastePol-ishingagentwithfelt
orfoampad
P150P320P500
P10004000ABRALON®
AbrasivepastePol-ishingagentwithfelt
orfoampad
P240P400P600
ABRALON®4000
Polishseeleft
Performcross-sanding •
Checklist
UndermountingTheundermountingstructuredependsontheapplicationforPLEXICOR® Inmostcases,afull-surfaceundermountwithchipboardcoatedonbothsidesispreferred Whereverpossible,usewood-coreplywoodorMultiplexboardsforundermountframework
Sinceundermountingstructuresmayexpanddiffer-entlytoPLEXICOR®,itisimportanttouseperma-nentlyelasticbonding,e g pointwisebondingwithsiliconeorareabondingwithaneoprene-containingcontactadhesive
Bonding with other materials
Adhesive
PLEXICOR® PLEXICOR®2Kadhesive
Acrylic PLEXICOR®2Kadhesiveor2-comp acrylicadhesive
Wood permanentlyelasticadhesive
Laminate permanentlyelasticadhesive
Woodveneerstrip permanentlyelasticadhesive
Metalinserts permanentlyelasticadhesive
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EdgesandWallConnection/Undermounting
Ingeneral,edgesarefabricatedbybondingstripsofmaterialtotheunderside Owingtothehighpropor-tionofnaturalmineral,finedifferencesinpatternandcolorcannotbeexcludedinbondededges Itisthereforerecommendedtorebatetheedges Theadhesivejointisarrangedsoastolieinthepartoftheradiusthatissubsequentlyrouted Owingtothechangedincidenceoflightintheedgeregions,anyslightdeviationincolorandtextureisthennolongernoticed
Examplesofedgeconfiguration
WallConnectionProfilePLEXICOR®covingistheidealformofwallconnec-tion Sinceitisintegrated,thecountertoplooks„allofapiece “Theabsenceofsharpedgesandcornersmakesiteasy-care,particularlyhygienicandmakesitimpossibleforsoilingtoadhere
PLEXICOR®Fabrication
Changesinlengthof±1mmpermetermay•occurinPLEXICOR®owingtotemperaturefluctuations Itisthereforerecommendedtousepermanentlyelasticadhesiveforareabondingwithothermaterials(e g wood/metal) Surfacestobebondedmustbethoroughly•cleanedbeforeapplyingtheadhesive Noemulsion-basedadhesivesmaybeused •PLEXICOR• ®ispreferablybondedtoothermaterialspointwiseorstripwise Forsmallerparts,rapidlycuringreactionadhe-•sivesthatcurewithoutpressuremaybeusedinadditiontopermanentlyelasticones
Checklist
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Undermounting/InstallationofFormedProducts:Undermounting
IntegratedInstallationofFormedProductsPrefabricatedpartscanbebondedwithPLEXICOR®sheettoformauniformwhole Theadhesivejointshouldbesituatedintheroundedpartthatistoberouted,sothatminorcolordevia-tionsarenotnoticed
Therearetwodifferenttypesofinstallation:Undermounting:formedproductmarked„U“•Integratedinstallation:formedproductmarked„I“•
UndermountingAhand-heldoverheadrouterwithapowerinputofatleast1,600Wisrequiredforcuttingout Thecarbide-tippedcuttersshouldhavea12mmshaft
Furtherrequirements:30mmcopyring•10mmslottingcutter•10mmconicalcutterwithplastic-sheatheddepthstop•chamferingcutterwithplastic-sheatheddepthstop•radialcutterwithplastic-sheatheddepthstop•AsuitableinstallationtemplateisrequiredforthePLEXICOR• ®formedproduct Itisdesignedforusewitha30mmcopyring
Undermountingwithrebate
Untermountingin„fullsheetthickness“
Aperturerouting Anglerouting
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UndermountingwithRebateThisundermountingmethodisrecommendedwhenthesheetisofthesamecolorastheformedproduct Thatminimizesanyvisiblecolorvariationbetweenthesheetandthepart Sandingtoprovideaflushconnectiontakeslesstimethanundermountinginfullsheetthickness
InstallationofFormedProducts:Undermounting
Undermounting„FullSheetThickness“Recommendedmethodwhensheetandformedproductareofdifferentcolor
PLEXICOR®Fabrication
ChecklisteMakeacutoutinthesheetthatroughlycorrespondstothe•formedproduct,usingaself-madetemplate Checktheplanarityoftheformedproductandthe•undersideofthesheetusingaspiritlevelandifnecessary,correctitbysandingorrouting Theinneredgeofthebasinmustbe„sharp “•Theformedproductisthenalignedandpossiblyfixed•usingshims(andhot-meltadhesive) Thesurfacesofsheetandformedproductthataretobe•bondedmustbecleanedwithmethylatedspiritoracetone ApplyathickbeadofPLEXICOR• ®adhesive5mmfromtheinneredgeofthebasin PositionthebasinonthePLEXICOR• ®sheet Preciseadjustmentismadebypushinglightly Theformed•productsshouldnotbeliftedupagain Theadhesivemustexudeuniformlyontheinsideofthe•basin Theformedproductisthenpresseddownandfixedby•meansofclampsorathreadedbarconstructionuntilthePLEXICOR®adhesivehasfullycured Releasetheclamps/fixingsystem,andturnoverthesheet•andformedproduct Removeprotrudingsheetmaterialwithabevelcutteruntil•flush,andpolishanyremainingprotrusionuntilflush
ProceduresameasPoint1„fullsheetthickness,“butwith•additionalroutingsteptocreatearebate Dependingonformedproduct,differentprecisiontem-•platesareavailableforthistypeofinstallation
Checklist
Checklist
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InstallationofFormedProducts:IntegratedInstallation
IntegratedInstallationAhand-heldrouterwithapowerinputofatleast1,600Wisrequiredforcuttingout Thecarbidecuttersshouldhavea12mmshaft Furtherrequire-mentsare:
30mmcopyring•10mslottingcutter•15°conicalcutter•stepcutter •
AsuitableinstallationtemplateisrequiredforthePLEXICOR®formedproduct Itisdesignedforusewitha30mmcopyring
Flush-FitIntegrationThisisrecommendedwhenthesheetandtheformedproductareofdifferentcolor
ChecklisteFixthetemplatetothesurfaceofthe•PLEXICOR®sheet Mountthe30mmcopyringonthecutter •Cutoutthecontourwiththe10mmslotting•cutter Cutdeeperstepbystepwiththe15°conical•cutteruntiltheformedproductisalmostflushwiththesheet Removethetemplateandfreethesheetfrom•dust Stickcrepetapeontotheundersideofthe•cutout(thispreventsadhesivefromdripping) Cleantheadherendsurfacesofsheetand•formedproductwithmethylatedspiritoracetone Applyadhesivefirsttotheformedproduct,•thentothecutout Placethebasincarefullyinthecutoutandalign•itwithcautiouspressureortapping Important:Adhesivemustexudeallalongthe•joint Nofurtherfixationisnecessary •Lettheadhesivecurecompletely,thensand•thejointuntilflat
ChecklisteUsingthetemplatefortheformedproduct,•routingisperformedwiththe30mmcopyring Inthefirstpass,thecutoutismadestepwiseusingthe10mmslottingcutter Inthesecondpass,thecutoutisenlargedstep-wisewiththeconicalcuttertofittheformedproduct
Checklist
Checklist
Smooththesurfacesandedges
Stepcutter
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InsertingaCeramicHobInsulationmustbeprovidedwheninstallingequipmentthatemitsheatorcold Noadhesivejointsshouldbeincludedinsuchzoneswithfluctuatingtemperatures Thecontouroftheappliancemustbecutoutwitharouter,neverwithasaw Alledges,alsoontheinside,mustberounded(>3mm)andsmoothed
InsulationMaterial1 onelayerofself-adhesiveceramicfibertape,
(seePLEXICOR®SalesRange)2 twolayersofself-adhesivealuminumtapeofatleast0 08mm
(seePLEXICOR®SalesRange)A3mmairgapmustbeleftbetweentheapplianceandtheinsulation
InstallationofFormedProducts:IntegratedInstallation
IntegrationwithStep-downRebateThisisrecommendedwhenthesheetisthesamecolorastheformedproduct
Standardroutedcutoutsforcookerhobs/hotplates(forprivatehouseholdappliances,notforprofessionaluse)
PLEXICOR®Fabrication
Theprocessisbasicallythesameasthatofflush-fitintegration,but•theformedproductshouldbeinstalledabout1 5mmbelowsheetlevel Thetemplateshouldonlyberemovedafterthebasincontourhas•beencutroundwithasuitablestepcutter Theadhesiveedgeisthensandedandthesurfacepolished
Checklist
Onlyroutecutouts,donotsaw•RoundnessofinsideedgesatleastR=6mm•Roundalledges>3mm•Leave3mmspacebetweenedgeandcookerhob/hotplate•
•
Insertaninsulatinglayerwithceramicfibertape•Applytwolayersofpurealuminumtape•DONOTFLUSH-MOUNTcookerhobs/hotplates•Installcookerhob/hotplatewithoutgeneratinginternal•stress
Checklist
Stainlesssteelrodsin-sertedinPLEXICOR®makeausefulstandforhotsaucepans
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CareInstructions
ExtremelyEasyCareRegularwipingwithaspongecloth,waterandagrease-dissolv-ingcleaningagentordishwashingliquid(e g Pril,methylatedspiritorceramichobcleaner)isquitesufficient
Stubbornsoilingshouldberemovedwithascouringpadandwater Toremovescale,werecommendusingascouringpadandvinegar,vinegar-basedcleaningagentorcitricacid Wipethesinkdryafteruse
Hard-WearingPLEXICOR®withstandsheatbetterthanmanyothermaterials Short-termexposuretoheatsources,e g burningcigaretteash,matches,hotoiletc donotdamagePLEXICOR® However,hotsaucepansorfryingpansshouldalwaysbeplacedoncorrespond-ingstands(e g stainlesssteelrods)
ResistanttoChemicalsandHygienicPLEXICOR®isinsensitivetothechemicalsgenerallyusedinthehousehold Itssuperiorhygienicpropertiesmakeittheidealmaterialforhospitals,laboratoriesanddoctors‘offices
ChecklisteDonotusemoisturizingcleaningagents!•Donotuseindilutedcleaningagents!•
Checklist
®=registeredtrademark
PLEXICORandPLEXIGLASareregisteredtrademarksofEvonikRöhmGmbH,Darmstadt,Germany
CertifiedtoDINENISO9001(Quality)andDINENISO14001(Environment)
Thisinformationandallfurthertechnicaladviceisbasedonourpresentknowledgeandexperi-ence However,itimpliesnoliabilityorotherlegalresponsibilityonourpart,includingwithregardtoexistingthirdpartyintellectualpropertyrights,especiallypatentrights Inparticular,nowarranty,whetherexpressorimplied,orguaranteeofproductpropertiesinthelegalsenseisintendedorimplied Wereservetherighttomakeanychangesaccordingtotechnologicalprogressorfurtherdevelopments Thecustomerisnotreleasedfromtheobligationtoconductcarefulinspectionandtestingofincominggoods Performanceoftheproductdescribedhereinshouldbeverifiedbytesting,whichshouldbecarriedoutonlybyqualifiedexpertsinthesoleresponsibil-ityofacustomer Referencetotradenamesusedbyothercompaniesisneitherarecommendation,nordoesitimplythatsimilarproductscouldnotbeused
Ref No 361-1 August2008xx/0808/09632 (en)
Business UnitPerformance Polymers
Evonik Röhm GmbHKirschenallee64293DarmstadtGermany
info@plexiglas netwww plexiglas netwww evonik com