FABRICATION GUIDELINES
Version 4.0
About IceStone
IceStone has been crafting its premium durable surfaces in the historic Brooklyn Navy Yard since 2003. Made from 100% recycled glass, portland cement, and non-toxic pigment, IceStone® durable surfaces are the sustainable surface material of choice for fabricators, contractors, designers and homeowners nationwide.
We believe that quality craftsmanship, social responsibility, and environmental stewardship are equally essential to the success of our business and yours. To learn more about IceStone’s mission and certifications, please visit www.icestoneusa.com.
Sincerely,
The IceStone Team
TABLE OF CONTENTS
SECTION 1: 4 Disclaimer5 Applications5 StandardSlabSizeandWeight6 TechnicalSpecificationsandCertifications7 DustInhalationExposure7 CertifiedFabricator&WarrantyProgram8 ProperHandling&InventoryStorage12 LoadingLooseSlabs14 IndoorStorageOnly14 Transportation
SECTION 2: 15 FabricationInstructions15 FabricationTools&SafetyEquipment16 MarbleInstituteofAmericaStandards16 ColorMatching,BatchNumbering,andSlabIdentification18 RemovingBowFromWarpedSlabsviaRewetting19 BasicFabrication20 CutoutsandReinforcingRodSupports21 SoapDispenserPlacement22 RadiusCorners22 EdgeProfiles23 ApronsandBuiltUpEdges23 RecommendedEdgePolishingSequence23 StructuralSupport24 DishwasherSupport24 CantileversandOverhangs24 InstallationOverview25 Seaming26 Sealing26 HeatTolerance27 SurfaceRepair28 PopOuts29 Microporosity
SECTION 3: 31 ForYourCustomer32 CareandMaintenance34 WarrantyRegistrationForm35 ContactInformation
4ICESTONE
FABRICATIONGUIDELINESREVISEDJUNE2015
Disclaimer
IceStonedurablesurfacesareonlysoldtoCertifiedFabricators.PleasecontactCustomer
ServiceifyouareinterestedinbecomingaCertifiedFabricator.Thefabricationandinstallation
ofIceStoneslabsissimilartoquarriedstone,buthasuniquerequirementsthatmustbefollowed
foroptimumperformance.
IceStone,LLCisnotresponsibleforvariationbetweensamplesorprintedmaterialsandslabs
receivedupondelivery.Pleaseensurethatyouandyourclientshaveuptodatesamples
thataccuratelyreflectIceStone’scurrentpaletteandproduction.Allsamplesaredatedfor
yourconvenience.
AllslabsmustbeinspecteduponreceiptaccordingtoIceStone’sTerms&Conditions.
Variationinglasssize,shape,color,andgaugeareinherenttoIceStoneslabs,whicharehand
craftedusingrecycledmaterials.Projectlayoutandthefinalquantityofslabsneededshouldbe
determinedbeforeslabsarriveatthefabricationshop.Slabsmustalsobeinspectedforcolor
matchingpriortofabrication,andexaminedagainforoverallqualitywhiledry-fittingatthejob
site.AnydefectiveareasintheslabmustbereportedtoIceStone,LLCimmediatelywithpanel
IDnumber,color,shipmentdate,nonconformitydetailsanddigitalphotos.IceStonewillnot
reimburselaborormaterialcostswhendefectiveslabsarecutandinstalledwithoutadequate
inspection.
Afterinstallation,pleaseaskthecustomertoinspectthejobtoensuresatisfaction.Provide
thecustomerwiththemostrecentIceStoneCareandMaintenanceGuidelines,whichcanbe
obtainedbyvisitingIceStone’swebsiteorbycontactingCustomerService.
ThismanualispublishedbyIceStone,LLCandsupersedesallpreviousmanuals.Contentis
subjecttochange.ForthemostrecentversionofFabricationGuidelines,pleasevisitIceStone’s
website:www.icestoneusa.com.
IceStone®isaregisteredtrademarkofIceStone,LLCofBrooklyn,NY.
5SECTION1 ABOUTICESTONEDURABLESURFACES
Applications
IceStonesurfacescanbeusedas:
• Kitchencountertops
• Bathroomvanities
• Backsplashes
• Receptionareas
• Conferencetables
• Cashtransactionareas
• Windowsills,desktops,andmore
Commercial Food Service CountertopsDO NOT installIceStonesurfacesunderheatlampsorareaswherethesurfacewillbeexposed
toextendedperiodsofdirectheat.Heattrays,heatsinks,soupwarmers,etc.,shouldnotbe
installedinIceStonesurfaces.
Standard Slab Size and Weight
Width x Length 52.5inchesx96.5inches(approx.35squarefeet)
Thickness 1.25inches
Weight 16.3pounds/squarefoot(approx.570lbs/slab)
* Please note that the slab dimensions are nominal and are only to be used for storage and transportation purposes. Actual usable slab surface will be slightly less per side, and varies from slab to slab. Please inspect the perimeter before cutting.
Pre-cuthalfslabsareavailableinselectareas.ContactyourIceStonedistributorforavailability.
96.5” 1.25”
52.5
”
Halfslabs=26”x96.5”x1.25”
6 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Technical Specifications and Certifications
Property Test Standard IceStone Results
CompressiveStrength ASTMC–109 13,000psi-16,000psi
FlexuralStrength ASTMC–203 890psi
SpecificGravity ASTMC–97 2.31g/cm3
Porosity/Absorption ASTMC–642 0.18%unsealed
ChemicalDurabilityASTMC–1260forASRreactibility
0.49%300cycles
FreezeThaw ASTMC–666 0.05%
StainResistance ASTME–84Yes,whenusedwithrecommendedsealers
FireRating ASTME–84
Class1(A)Flamespreadindex0Fuelcontribution0Smokedensityindex0
CoefficientofStaticFriction ASTMC–1028
0.69Polisheddry0.61Polishedwet0.71Honeddry0.62Honedwet0.85Sandblasteddry0.77Sandblastedwet
FoodEquipmentMaterials NSF–51 Certified
Published HPD
Health ProductDeclaration TM
Collaborative
7SECTION1 ABOUTICESTONEDURABLESURFACES
Dust Inhalation Exposure
Tominimizedustconcentrationsinbreathingzones,IceStonerequiresusingeitherwetdiamond
toolsorwaterjetswhencuttingandpolishingIceStoneslabs,aswellasproperlocalventilation
andcollectionequipment.FineparticlesthatmaybegeneratedwhilefabricatingIceStone
surfaceswithwetdiamondtoolsorwaterjetsfallwithinthecategoryofnuisancedusts.If
ventilationmethodsareinadequatetokeepdustlevelsbelowspecifiedlimits,wearaproperly
fittedparticulaterespiratorapprovedbytheNationalInstituteforOccupationalSafetyand
Health.PleasereviewIceStone’sSafetyDataSheetformoreinformation.
Certified Fabricator & Warranty Program
IceStoneoffersfreecertificationtrainingstofabricators.OnlyCertifiedFabricatorscanpurchase
IceStoneandbenefitfromexclusivediscountsandadditionaltraining.CertifiedFabricatorsmust
followallprocedureslistedinthemostrecentversionoftheIceStoneFabricationGuidelinesand
Care&MaintenanceGuidelines.TobecomeaCertifiedFabricator,pleasevisitourwebsiteor
contactCustomerService.
OnlyinstallationsbyCertifiedFabricatorsareeligibleforIceStone’sCommercial10-Year
andResidential10-YearLimitedWarranties.Thehomeorbuildingownermustregistertheir
installationonIceStone’swebsitewithin30daysofinstallation.
8 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Proper Handling & Inventory Storage
IceStoneslabsweighapproximately570lbs,andafullcrateoftwelveslabscanweighasmuch
as7,100lbsincludingtheA–framecrate.Besureforkliftscanhandlethisweightbeforemoving
anycratesormaterial.
SLAB STORAGE PROCEDURE
AthoroughmaterialinspectionisrecommendedbeforesecurelystoringIceStoneslabs;inspect
yourdeliveryuponreceiptandsubmitanydamageclaimsimmediately.
1. Unloaddeliverycratefromtheflatbedor
LTLboxtruckusingaforklift.Alwaysmove
crateswithaforklift.Donotpush,pullor
dragcrates.IceStonecratesarefordelivery
purposeonly.DonotstoreIceStoneslabs
ondeliverycrates.
2. Movecratestodesignatedindoorareafor
slabinspectionandrelocationtopiperacks
orA-Frames.
3. Followtheprocedureforopeningsmalland
largecrates(pages10to11).
4. Placethefirstslabonthepiperackor
A-Framewiththepolishedfaceagainst
theframeorrack.
5. Placethesecondslabwiththepolished
sidefacingout(thebackofthesecondslab
shouldbeagainstthebackofthefirstslab).
9SECTION1 ABOUTICESTONEDURABLESURFACES
6. Placethethirdslabwiththepolishedface
againstthepolishedfaceofthesecond
slab.Theunpolishedfaceofthethirdslab
willfaceout.Ensurethatthebottomedges
ofslabsaretouching.Unloadalltheslabs
followingthisprocedure.
7. Whenstoredonpiperacks,slabshould
notbevertical;instead,positiontheslab
atanapproximately20degreeanglefrom
verticalposition.
11.Whenaddingorremovingslabs
frominventory,alwaysfollowthe
aboveprocedure.
8. Afterunloading,inspectionandrelocation,
beginclampingprocess.
9. Usetwobarclampsspaced24”fromtop
righthandandtoplefthandedgesofthe
slab.Tightentheclampstofirstresistance.
Donotovertighten.
10.Usetwobarclampsspaced24”from
bottomrighthandandbottomlefthand
edgesofthesameslab.Tightentofirst
resistance.Donotovertighten.
10 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
UNLOADING A SMALL CRATE
1. Unscrewandremovetopplank.
2. PullupflapofTyvekprotectivewrapand
drapeoverbackside.
3. Attachfirstclamparoundallslabs.
4. Attachsecondclamparoundsideofcrate
andallslabsexceptslabtobeunloaded.
5. Unscrewandremovesupportsandgate
fromonesideofcrate. To remove gate,
use specially marked screws.
6. Lowerclamparoundslabandengage.
7. Removefirstclampexposingslabto
beremoved.
8. Carefullyliftslab. 9. Toremovemoreslabs,attachclamp
aroundsideofcrateandallslabsexcept
slabtobeunloaded.Repeatsteps6-9.
Clamp#2
Clamp#1
11SECTION1 ABOUTICESTONEDURABLESURFACES
UNLOADING A LARGE CRATE
This crate is outfitted with a safety device designed to keep IceStone slabs from falling and causing injury.
Attention:
Active PositionTransit Position Inactive Position
1 - 2
4
5 - 6
3
4
2
13
5
6
1. FoldbacktheprotectiveTyvekwrap
2. Rotatesafetybarfromtransittoactiveposition
3. Pushawedgeinbetweentheslabstocreateaspacefortheclamp
4. Positiontheclampatcenterofslabandengageclampswitch
5. Rotatesafetybartoinactiveposition(usecautionaroundslab)
6. Liftslab
7. Repeatsteps2-6tounloadtherestoftheslabs
wedge
12 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Loading Loose Slabs
Slabsthatarenotinacratecanbeloadedonto:
• AmetalA-framethatismechanicallysecuredtotheflatbedofatruck,
• AmetalorwoodenA-framesecuredtothebedofapickuptruck,or
• AportableA-framethatcanberemovedfromaboxtruck,loaded,andthenplacedbackinthe
boxtruckandsecured
Inallofthesecases,atleasttwoverticalstrapsarerequiredtosecuretheslabstotheA-frame.
IceStonewillnotloadlooseslabsontoaboxtruckthatdoesnothavearemovableA-frame,
astheheightofboxtruckspreventsloadingwithaboomoroverheadcrane.Whethera
truck,A-frame,orstrapmeetstherequirementsforcarryingand/ortransportingourslabsis
completelyatthediscretionofIceStone,LLC.
1. Atleasttwopeoplemustguidetheslab
tothedesignatedtruck.Iftheslabisbeing
movedwithanoverheadcrane,oneworker
shouldoperatethecrane,whiletheother
steadiestheslabastoreduceextraneous
movementswhichcouldresultincracking.
Iftheslabisbeingmovedviaaboom,one
workershouldoperatetheforklift,whilethe
otherworkersteadiestheslab.
2. Whenmaneuveringtheslabontothetruck,
atleastoneworkermusthelpthedriverrest
theslabontheA-frameorbackerslabinorder
tomakesuretheslabremainslevelthroughout
theprocess.
13SECTION1 ABOUTICESTONEDURABLESURFACES
3. Oncetheslabisonthetruck,thedriver
shouldsecuretheslabusingatleasttwo
verticalstrapstohelpevenlydistribute
thepressurealongtheslab.Tightenthe
strapsjustenoughtorestrictmovementof
theslabduringtransportation.Anyexcess
tighteningmayleadtocracks.
4. Addpaddingwherethestrapmeetsthe
slabatthetopandatthebottom.The
paddingwillreducethetensionontheslab
duringtransit.
5. ThispictureillustratesanIceStoneslabon
aA-framesecuredtothetruckagainsta
backerslab.Slabsshouldbeloadedface
toface,backtoback.Alllooseslabsof
IceStonemustbeloadedonaA-frame
thatissecuredtoatruck.Whilebacker
slabsarenotmandatory,itdoesoffermore
protectionthanaslabbeingflushagainsta
metalorwoodenA-frame.
14 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Indoor Storage Only
IceStonemustbestoredindoors.Eventarpedslabscanstain,etch,warp,orcrackwhen
exposedtoweatherelements.Theslabshownin FIGURE 1 wasstoredoutsideanddamagedby
acidicrainfallcondensationunderatarp.
VEHICLE LOADSItistheresponsibilityofthedrivertoensurethattheloadiswithinthelegalcarryingcapacity
ofthevehicle.Allowapproximately570lbsperIceStoneslab,plustheweightofanyotheritems
alreadyloadedonthevehicle.
SECURING THE LOADItistheresponsibilityofthedrivertoensurethattheloadisfullysupportedandsafelysecured
tothevehiclepriortoleavingIceStone’spremises.IceStonewillnotsecuretheloadtoyour
vehicle.AlltransportingA-framesmustbesecuredtothetruck.IceStonereservestherightto
refuseloadingmaterialonatruckinwhichA-framesarenotsecuredtothebedofthetruck.
AnytimeIceStonematerialisbeingtransportedwhenexposedtooutdoorelements,thematerial
mustbetarped.
FIGURE 1 Example of a slab that was etched from condensation
15SECTION2 FABRICATIONINSTRUCTIONS
• Stone (pony) Clamps
• Fabrication Stands
• Air Compressor
• Seaming Clamps
• Water Source
• Reinforcing Rods and Adhesives
• Forklift Truck with Boom and Lifting Clamp
• Bridge Saw
• Electric/Pneumatic Polisher (variable speed
preferred)
• Diamond Grinding Wheel
• Diamond Polishing Pads
• Grinding Stone
• Core Bits
• Diamond Contour Blade
• Wet Profiling Machine (edge router)
• Stone Carts/Dollies
• A–Frame Storage Racks
WhenmachiningIceStoneslabsonCNCs,takethefollowingprecautionstoreducethepossibilityofdiscoloration:• Removepiecesassoonastheyarecompleted
• Avoidleavingvacuumpodsengagedovernightorforprolongedperiodsoftime
• Cleanvacuumpodsroutinely
• Replacewornordeterioratingvacuumpods
Fabrication Instructions
Fabrication Tools & Safety EquipmentBelowisalistofcriticaltoolsandsafetyequipmentneededtofabricateIceStoneefficiently:
Basic Tools
Advanced Tools Basic Safety Equipment
• First–Aid Kit
• Safety Glasses
• Steel–Toe Footwear
• Respiratory Protection
• Work Gloves
• Aprons
• Ear Plugs
• Face Masks
• Water Jet
• CNC
• Automated Profiler
• Diamond Jig Saw
• Radial Arm Polisher
16 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Marble Institute of America Standards
IceStonerecommendsfollowingtheFabricationandInstallationGuidelinesoftheMarble
InstituteofAmerica(http://www.marble-institute.com)andtheConcreteCountertopInstitute
(http://www.concretecountertopinstitute.com)asapplicabletoquarriedstone.Traditional
stonefabricationequipment,suchasCNCmachines,bridgesaws,routers,andpolishers(with
diamondpadsandbits)shouldbeusedwithwater.Avarietyoffabricationmachineryisused
ineveryshop,soitisimportanttoexploretoolingandfabricationtechniquestoidentifythebest
practicesforyourshop’sequipment.Forbestresults,IceStonerecommendsusinghighquality
diamondbladesandtoolingsuitableforusewithhardgranite.
Color Matching, Batch Numbering, and Slab Identification
VISUAL SLAB INSPECTION
Fabricatorsareresponsibleforimmediatelydeterminingiftheslabsarefitforuse.Iftheslabis
defective,contactCustomerServiceimmediatelyand DO NOT cutormodifyslabsinanyway
beforeexchangingthematerialwithIceStone,LLC.Onceaslabhasbeencutand/orinstalled,it
cannotbereturnedtoIceStone,LLCforcreditorrefund.
AvisualinspectionforimperfectionsandcolormatchingisessentialwhenworkingwithIceStone
surfacesandshouldbestandardpracticebeforecutting.Inspectinlightingconditionssimilarto
thoseattheinstallationsite.Usethefollowingasachecklistduringinspection:
• Cracks
• Slab–to–slabcolormatch
• Colorinconsistencywithintheslab
• Warping/bowing
• Consistentglosslevels
• Glasssegregationontheedges (seeFIGURE 2)
17SECTION2 FABRICATIONINSTRUCTIONS
COLOR MATCHING
Duetotheuniquenatureofrecycledglass,notwoIceStoneslabsareexactlyalike,andwillexhibit
variationsincolor,shade,glasssizeandglassparticledistribution.Thesevariationsarenotstructural,
andarepartoftheinherentcharacterofthematerial.
Beforefabricating,alwaysvisuallyinspectslabstoensurethatanacceptablecolormatchis
achieved.Wheninspectingslabsforcolor,usesimilarlightingconditionsaswillbefoundatthe
jobsite.Slabsthatarebeingseamedtogethermustbefromthesamebatchdate.
BATCH NUMBERING AND SLAB IDENTIFICATION
Thebatchnumberisstampedonthetwoshortsidesofeachslab.IceStone,LLCreferstothebatch
numberasthe“PanelID”,whichisan8digitcodethatrepresentsthedateandsequenceinwhicha
particularslabwascast.Forinstance,apanelIDof04180942meansthattheslabwasbatchedon
April18th,2009,andtheslabwastheforty-secondmadethatday.RecordPanelIDsforwarranty
registrationandincaseissuesariseduringthetransportation,fabrication,installation,anduseof
thematerial.
FIGURE 3Each IceStone slab has a Panel ID number, circular quality control inspection stamp, color name, thickness measurement (1.25” or 3cm), and Made in USA stamp.
FIGURE 2Example of acceptable glass segregation on the left and unacceptable glass segregation on the right.
18 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Removing A Bow From Warped Slabs by Rewetting
BowingoccurswhenanIceStoneslabbecomeswarpedorcurvedandisnolongerflat.Bowing
canoccurwhentheslabisnotclampedproperly.Measurebowbyusinga96”straightedgeand
acaliper.Holdthestraightedgesteadyalongthetopofthebackside(unpolishedface)ofthe
slab.Measurethebowalongthetopoftheslab,atthemidpointofthelongside
(seeFIGURE 4).
Slabsthathavebowedbeyondtheacceptablelevelof3.0mm(onthelengthoftheslab)needto
beremovedfromtheinventoryandrewettedfollowingoneoftheproceduresbelow:
REWETTING OPTION 1
1. Placebowedslabonabridgesawtable.
2. Saturatetheslabwithrunningwaterfor10minutes.
3. Leaveslabonbridgesawtableforonehour.
4. Afteranhour,measurethebowagain.Iftheslabstillmeasuresabowgreaterthan3.0mm,
repeatthefirstthreesteps.
REWETTING OPTION 2
1. PlacebowedslabonanA-frameagainstaflatslabofgranite,withtheunpolishedfaceofthe
IceStoneslabfacingout.
2. Useahosetocontinuouslysaturatetheslabwithrunningwaterfor10minutes.
3. Turntheslabaroundsothatthepolishedsideisfacingout,clampittoanotherslabof
IceStoneorgranitewithC-clampsfollowingourclampingprocedures.
4. Afteranhour,measurethebowagain.Ifthebowisstillgreaterthan3.0mm,repeatthefirst
threesteps.
Afterthebowontheslabiseliminated(orreducedtoanacceptablelevel),wipethefaceofthe
slabdrybeforemovingbacktoinventoryandclamping.
Figure 7: Demonstration on how to properly measure a slab for bowing.
FIGURE 4Use a caliper to properly measure slabs for bowing.
19SECTION2 FABRICATIONINSTRUCTIONS
Basic Fabrication
Traversetheslabnofasterthan4linearfeetperminute(see FIGURE 5),ashigherfeedrateswill
resultinexcessiveedgeorglasschipping.
WhenroutingIceStonesinkopeningsoredgeprofiles,donotusesegmentedbits,asthey
increasetheriskofchipping(seeFIGURE 6).
HAZING
Duringthefabricationprocess,slurrymaydryonthesurfaceoftheslabcausingavisualhaze.
Toavoidtheeffectsofhazing,saturatethesurfaceoftenduringfabrication.Thishazecanalso
beremovedafterfabricationusinganon-scratchScotch-Britepador000steelwool.
FIGURE 5Run blades and tooling at a high RPM and flood slab with water at all times.
Figure 9: Proper process to route a sink opening.
FIGURE 6Routing IceStone sink openings
20 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Cutouts and Reinforcing Rod Supports
IceStone,LLCrequiresthatallroughandfinishedopeningsbesupportedwithreinforcingrods
atboththefrontandbackbridgestospanaminimumof6.0inchesbeyondeithersideofthe
opening.Openingsincludebutarenotlimitedtocooktops,surfacemountsinks,undermount
sinks,downdraftvents,etc.
IceStone,LLCrecommendsthatreinforcingrodsbe1/8inchx1/2inchFiberglassRodderstock
(orapprovedequivalent)setverticallyina3/16inchwidex5/8inchdeepbladekerf(orspaceleft
bythesawbladeaftercutting)coveredinTenaxMicto2PartEpoxy.IceStone,LLCrecommends
fiberglassratherthanmetalroddingbecausefiberglasswillnotoxidizeovertimeandwillphysically
bondtotheadhesive(seeFIGURE 7 AND 8).
Under Counter Sink Mounting Specifications
Stainlesssteelsinkbasinsdesignedforundercounterapplicationshouldbemechanically
anchoredtotheundersideoftheIceStonecountertopusing3/8”x5/8”diametercaulk-in-anchors
with10-24machinescrews(FIGURE 9) orwithadhesivetypehardware (FIGURE 10)orwithapproved
equivalent.Heaviercastironenamelandquartzcompositesinkbasinsrequirebuilt-incabinet
supportaspermanufacturer’sinstallationinstructionsandshouldnotbemechanicallyattachedto
theIceStonecountertop.
FIGURE 7Fiberglass rod and roll.
FIGURE 8Saw kerfs for rodding.
FIGURE 10Peel and stick sink mounting clip.
FIGURE 9Undermount sink mounted with mechanical anchors.
Figure 12: Caulking anchors are installed on the underside of a countertop.
Figure 13: Image of an adhesive type mounting hardware supporting an undermount sink.
21SECTION2 FABRICATIONINSTRUCTIONS
Allundermountsinksshouldbeadheredtotheundersideofthecountertopusing
100%silicone.Donotusesolvent–basedadhesivesorplumbers’putty;theywillstain
IceStonesurfaces.
Allsinkbasinsshouldbeinstalledfollowingmanufacturer’sinstructionsandbyusing
manufacturer’ssuppliedmountinghardwarewheneverpossible.
Alwaysfollowmanufacturer’sspecificationsforsinkbasinroughopeningandfixturedrilling
diametersandlocations.Usemanufacturer’sprovidedtemplateswheneverpossible.
AllundercountersinkbowlcutoutsmusthavetheinsideedgepolishedtomatchtheIceStone
surface.
Soap Dispenser Placement
Handpumpsoapandlotiondispensersshouldbeplacedsothatthespoutdripsintoasink
bowlorbasinandnotonthecountertop.Avoidusingswiveldispensers.Foamsoapsare
recommended.
FIGURE 11Soap dispenser should drip directly into sink bowl.
22 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Radius Corners
IceStonesurfacesrequireradiuscornersonallcutouts.TheinsidecornersofIceStonecutouts
andcountertopsmustbeshapedtoaminimumof1/4inchradiustorelievecornerstresses.
Miteredor90degreecornerseamsdonotneedaradius.AlloutsidecornersofIceStone
surfacesmustbetooledtoaminimumof1/8inchradius.
Edge Profiles
AlwaysavoidinstallingIceStonewith90ºedges,asthismayleadtoglasschippingand
pop–outs.EdgeprofilesrecommendedbytheMarbleInstituteofAmericaareappropriatefor
IceStonesurfaces,includingtheonesshownbelow.
Glasssegregationinsomeedgeprofilesmaybepronounced.Thiscanbeaddressedusingafull
bullnose,radiusorplatneredge.
RadiusEdge HalfBullnoseEdge OgeeEdge
PencilEdge FullBullnoseEdge PlatnerEdge
23SECTION2 FABRICATIONINSTRUCTIONS
Aprons and Built Up Edges
Toavoidthevisualeffectofglasssegregation,allbuiltupedgesshouldbemitred.IceStoneslabs
shouldnotbestacklaminatedatvisibleedges.Laminatingmaycreateanundesiredlookifthere
isglasssegregationintheslabedge.Thejointshouldbeclean,flushandparallel.
Recommended Edge Polishing Sequence
Edgepolishingshouldbeperformedwithsufficientpressure.Onlyusepolishersthathavea
speedof2,000rpmorhigher,andhighqualityindustrialdiamondabrasivepolishingpads.Polish
usingasequenceofincreasinglyfinerpadstoachieveasmooth,highquality,highglossfinish:
#50,#100,#200,#500,#1000,#2000,#3000andbuffingpad.
Structural Support
FOUR SIDED PERIMETER SUPPORT
IceStonesurfacesarestrongenoughthattheydonotrequireadditionalsubstratesupportifa
foursidedperimeterframeexistsforacountertopinstallation.However,fronttobacksupportis
requiredforevery36inches.
THREE SIDED PERIMETER SUPPORT
Additionalsupportisrequiredforstructuresthathaveperimetersupportonthreesides,suchas
vanitybases,desksandframelesscabinets.Installationswithdepthslessthan26inchesrequire
supportsevery24inches.Installationswithdepthsover26inchesrequiresupportsevery18
inches.
FIGURE 12Example of properly built up edge (left), and improper stack lamination (right).
24 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Dishwasher Support
DishwashersshouldnotbeattacheddirectlytoIceStonesurfaces.Reviewthedishwasher
manufacturer’sspecificationsforthepropersidemountinginstallationprocedure.You
canalsoattachthedishwashertothecabinetsbyusingadishwashermountingbracket.
Cantilevers and Overhangs
Cantileversandoverhangs9inchesorlessdonotrequireadditionalsupport.
Cantileverslargerthan9inchesrequireadditionalsupportat24inchintervals.Supportscanbe
korbels,legs,columnsorreinforcingrods.
Installation Overview
IceStonesurfaceshaveasimilarstructuralstabilitytoquarriedstone.Werecommendthe
installationguidelinesspecifiedintheMarbleInstituteofAmerica’sDimensionStoneDesign
Manual(http://www.marble-institute.com).Therecommendationsbelowwillofferadditional
guidanceasyouinstallIceStonedurablesurfaces:
• UsequalitytransportA–frames
• AlwayscarryIceStoneslabsontheverticaledgetoavoidflexing
• Aminimumoftwoinstallersarerequiredforallprojects
• Installonlyonlevelandplumbbasecabinetry
• Topsurfacesofthecabinetsmustbewithin1/8”(3mm)offlatandlevelwhenmeasured
acrossadistanceof10’-0”(3m)
• Useshimswhennecessary
• Use100%siliconecaulking(orapprovedsubstitute)toadherecountertopstoallsubstrates
FIGURE 13Use a dishwasher mounting bracket to attach the dishwasher.
25SECTION2 FABRICATIONINSTRUCTIONS
ToensureaccuracybeforeinstallingIceStonedurablesurfaces,useatemplatejustasyouwould
withquarriedstoneorquartzproducts.Whentemplating,usetraditional‘stick’templatesor
digitaltemplatingsystemstoensureaccuratefabrication.
1. Alwaysremoveexistingsurfacetopspriortotemplate.
2. Checkallwallsandbasecabinetrytoensureeverythingisplumbandlevel.Scribetothewall
whenthebackedgeisnotsquare.
3. Markallcenterlinesonthetemplatewheretherewillbesinkcutouts,cook-toprough
openings,fixturedrillingsorelectricaloutlets.
4. Notethedimensionsfromcabinettocabinetthroughoutthekitchen.
5. Doublecheckallmeasurementsandmarkings.
6. WhennestingtemplatespriortocuttingDONOTmarkIceStoneslabswithinkpens
orgreasepencils.
Seaming
Inordertoachieveaminimallyvisibleseam,IceStonesurfacesshouldbeseamedwithacolor
matchedtwo–partpolyester,epoxyoracrylicjointadhesive.Theadhesivemustbepigmented
tomatchtheslabbeinginstalled.Seamsshouldbenomorethan1/16inchinwidth.Useseam
setterstoachievebestresults.TenaxRivo50A&Bpartknifegradeepoxycanbetintedtocolor
matchwithTenaxTepoxEpoxycolors.TenaxRivo50A&BareVOCcompliantunderCalifornia
regulation.
Priortoinstallation,makesurethat:
• Seamsaresupportedtoassuredurabilityovertime.Unsupportedseamsmaybuckleorsag.
• IceStonesurfacesareproperlysealedandwaxed.
• Basecabinetsarepermanentlyanchoredinplaceandareonatrueplanecompletelyleveled
acrossallplanes.
• Aspaceof1/8inchexistsbetweenwallswheretheslabwillbeinstalledandthematerial
(installationsrequireatleast1/16”ateachwall).
• Surfacesareplacedlevelontopofcabinetsorbase;shimifnecessarytoensurefit.
• Reviewallsafetyinstructionsandwarningsbeforeusinganyseamingproducts.
Alwaysuse100%siliconeadhesivetosecuretheslabtocabinetryorbases.Donotuse
cementitiousgroutbetweenIceStonecountertopsandbacksplashes.
26 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Sealing
IceStone,LLCrequiresthatfabricatorssealthesurfacebeforeoratthetimeofinstallation.
Applyoneoftherecommendedsealersbelowaccordingtothemanufacturer’sinstructions.If
thesurfacewaseversealedwithasolvent-basedsealer,youcannotuseawater-basedsealerfor
subsequentapplications.Ifthesurfacewassealedwithawater-basedsealer,consistentlyusea
water-basedsealerforsubsequentapplications,oruseasolvent-basedsealer.
RECOMMENDED SEALER COMPARISONRecommended Sealers Tenax ProtexStoneTech BulletProof
Water Based •Solvent Based •Penetrating Sealer • •Minimal Odor •Low Volatile Organic Compounds (VOCs) •Staining Protection • •Etching Protection none; wax after sealing none; wax after sealing
Manufacturer Tenax/Tenax USA Dupont
Telephone Number 1-800-341-0432 1-877-786-6383
Website www.tenaxusa.com www.dupont.com
Youcanapply CHENG Concrete Countertop Wax aftersealingforaddedprotection.
Heat Tolerance
IceStonesurfacescanwithstandincidentalheatcontactupto450°F.However,pleasenotethat
thesealerandwaxappliedtothesurfacemightnotbeheatresistent,sohotplatesortrivets
shouldbeusedunderpotsandpansrecentlyremovedfromaheatsource.Cooktopappliances
thataresurfacemountedrequireadequateinsulationtopreventthermalconductivitybetween
theappliancesandtheIceStonesurface.Followmanufacturersinstructionsregardinginsulation
forfreestandingrangesandovens.Under-counterovensshouldnotbeinstalledunderIceStone.
Watch how to seal on IceStone’s YouTube channel:
youtube.com/user/IceStoneLLC
27SECTION2 FABRICATIONINSTRUCTIONS
Surface Repair
Scratches and Etch Marks
Minorscratchesandmarkscanbebuffedoutofthesurfaceusingapowderedmixtureand
cottoncloth.BrandsofpowderedbuffingmixtureincludeDia-GloorAkemiLiquidPolish.
Rubvigorouslyinsmallcirclesuntiltheareaissmooth.
Greaterdamagewillrequireuseofalowrpmelectricpolisheranddrypolishingdiamondpads.
BecausetheglassintheIceStonesurfaceisharderthanthecement,startwiththehighest
abrasive(3000g)andworkdown(2000g,1000g)untilthedamageisgone,thenreversethe
steps(1000g,2000g,3000g)untilthemarksaregone.Sealthesurfaceafterremovingthe
marks.
YoucanapplyCHENGConcreteCountertopWaxaftersealingforaddedprotectionandtohelp
minimizetheappearanceofminorsurfacemarks.
Removing Stains
UsingapoulticeisaneffectivemethodofremovingstainsfromIceStone.Makesuretotestthe
poulticeonaninconspicuousareatoensuretherewillbenodiscolorationfromtheprocedure.
Toremovestains,youwillneedthefollowing:
• Acetone
• Water
• PlasticWrap
• Painter’stape
• DryTreatHannafinnOxy-Klenza(fororganicstains)
• RecommendedSealer
• *Optional:CHENGConcreteCountertopWax
Watch how to remove stains on IceStone’s YouTube channel:
youtube.com/user/IceStoneLLC
Watch how to remove etching on IceStone’s YouTube channel:
youtube.com/user/IceStoneLLC
1. Removeresidualsealerandwaxfromthesurfacewithacetone.
2. Identifythestainingagent.
3. Selecttheappropriatepoulticeforthestain.DryTreatHanafinnOxy-Klenza™workswell
formostorganicstains.Ifyouhavequestionsaboutaparticularstainingagent,contact
IceStoneCustomerService.
4. WhenusingOxyKlenza,mixwithwaterintoathickpasteandapplytothestain.Coverwith
withplasticwrap,usingpainter’stapetoholdinplace.Letsitfor24hours,thenremoveand
rinsewithcleanwater;airdry.
5. Ifthestainstillpersists,repeatinstructionsinstep4.
6. Alwayssealthesurfaceafterremovingstaining.YoucanapplyCHENGConcreteCountertop
Waxaftersealingforaddedprotection.
28 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
Pop Outs
Shellaccanbeusedtofillanylargevoidsover2.0mmintheIceStonesurface.ContactIceStone
toordershellacpiecesthatmatchthecoloroftheIceStonesurface.
Tofillpopouts,youwillneedthefollowingmaterials:
• Shellacpiecesthatmatchthematrixcolor
• Smallmetalspatula
• Razorblade
• Electricburnerorheatgun
1. Heatthemetalspatulabyrestingtheblade
ontheelectricburner.
2. Usehotmetalspatulatopressshellacinto
thevoid.Ifthepopoutisparticularlylarge,
breakoffsmallpiecesofshellacsothat
thecavityisfilled.Usethemetalspatula
tomeltmoreshellacuntilthevoidisfull.
Thereshouldbenoairbubbles.
3. Wait1minuteuntiltheshellachascooled
andhardened.Useasharprazorbladeto
scrapeoffexcessshellacfromthesurface
oftheslab.Voidshouldbefilled,leveled
withtherestofthesurface,andsmooth.
4. Ifthevoidwasnotsuccessfullyfilled,usea
razortoremovetheshellacfromthevoid
andtryagain.
5. Wipesurfacearoundshellacwithaclean
ragandacetone.
Watch how to fill in pop-outs on IceStone’s YouTube channel:
youtube.com/user/IceStoneLLC
29SECTION2 FABRICATIONINSTRUCTIONS
1. Mixthedrypatchingkitinthemetalbowl
toensurepigmentsaredispersedevenly.
2. Add40gramsofcleancoldwaterto
themixture.
3. Stiruntilthemixtureissmooth.The
mixtureshouldbethickerthanpancake
batterbutnotasthickaspeanut
butter.Addmorewater(5gatatime)
ifnecessary.Thelesswaterused,the
strongertheconcretewillset.
4. Wetthewholesurfacewithaspraybottle
ofwater.Emptyhalfofthemixtureinone
lineinthemiddleoftheIceStone.Onebag
ofpatchingpowdermakesenoughslurry
for2slabs.
5. Withcircularmotionsspreadtheslurry
evenlyoverthefaceoftheslabwiththe
groutfloat,makingsurethewholesurface
iscovered.
Microporosity
IceStone,LLChasdevelopedapatchingmethodthatisrecommendedforanysmallsurface
problemslikepinholesorslightdiscoloration.Thepatchingkitisavailablebyorderfrom
IceStone,LLC.Iftherearelargevoidsinthesurface(largerthan2.0mm),followthePopouts
procedurelistedonpage28.
Youwillneedthefollowingmaterialsandtools:
• Patchingkit(acolormatchedcementitiousmixprovidedbyIceStone)
• Plasticspatulaorspoonforstirring
• Metalmixingbowl
• Water
• Groutfloat
• Cleanrag
Watch how to fill microporosity on IceStone’s YouTube channel:
youtube.com/user/IceStoneLLC
30 ICESTONEFABRICATIONGUIDELINES
REVISEDJUNE2015
6. Scrapeexcessslurryintothemixing
bowl.Makesurethepatchdriesina
consistentlythinlayer.Areaswithtoo
muchpatchwillappeardiscoloredand
willrequirereworking.
7. Waituntilthepatchhascompletelydried.
Oncedry,wipeoffallthedriedmaterial
fromthesurfacewithacleancottoncloth.
Theporesshouldbefilledandlevel.
31SECTION3 FORYOURCUSTOMER
For Your Customer
Thenextfewpagesincludetheinformationyouwillneedtoprovide to your end user upon installation.Makeacopy,downloadonourwebsiteaticestoneusa.com,[email protected].
• Care & Maintenance Guidelines• Warranty Registration Form
32
ABOUT YOUR ICESTONE SURFACEIceStoneismanufacturedwithoutanypetrochemicalsorresins,makingitanenvironmentallyresponsible
choiceforcountertopsinthehomeoroffice.CareofIceStoneissimilartothatofnaturalstone.Likeall
surfaces,IceStonewillshowsignsofwearandtearovertime.Withsensiblecare,youcanmaintainthebeautyand
qualityofyourIceStonesurface.
CARING FOR YOUR ICESTONEGENERAL CLEANING
Usetheproductsrecommendedinthese
guidelines.Cleaningproductsshouldbefree
ofchlorinebleach,ammonia,acidand
citrusscents.
WIPE UP SPILLS
Beespeciallyattentivetospillssuchascoffee,
wine,fruitjuicesandotheracidicliquids,wiping
themuppromptlywithadampclothandwater.
USE TRIVETS AND CUTTING BOARDS
Placeatrayundercoffeemachines,soap,
andsoapdispensers—aswithallsurfaces,
usetrivetsandcuttingboardstohelpprotect
thesealerandthesurface.
PROTECT YOUR SURFACEIceStoneisverydense,butstillporous,so
surfacesmustbesealed.IceStonerequires
thatthefabricatorsealsbeforeoratthe
timeofinstallation.
AtypicalIceStoneinstallationrequiresannual
resealing.Todetermineifitistimetoreseal
yourIceStone,dabacottonballinwaterand
evenlywipethesurfaceinastraightline.
Sealingissimple!Whileyoucancertainlycall
inaprofessional,mosthomeownersopttodo
itthemselves.Wehavemadeiteveneasier
byprovidingavideotutorialonsealingonthe
IceStoneYouTubechannel:
www.youtube.com/user/IceStoneLLC
YoucanapplyCHENG® Concrete Countertop
Waxaftersealingforaddedprotection.
TIME TO RESEAL Ifthewatermarkiswideandflat.
SEALER IS INTACTIfthewatermarkisraisedandhasirregularedges.
IceStone Care & Maintenance Guidelines 1/2
33SECTION3 FORYOURCUSTOMER
CONTACT USThankyouforselectingIceStonesurfaces.Wearecontinuouslyresearchingnewproductsthatmakeiteasierforyou
tocareforyoursurface.Pleasevisitourwebsiteorcallusforthelatestinformationaboutcareandmaintenance.
REPAIRSREMOVING TOUGH STAINSStainingiscausedbyliquidsthathavepenetrated
anddiscoloredthesurface.Moststainscan
beremovedbyusingapoultice.Refertoour
videoillustratingstainremovalonourYouTube
channel:www.youtube.com/user/IceStoneLLC
REMOVING SURFACE MARKS/ETCHINGEtchingiscausedbyacidicliquidsthathave
discolored,dulled,and/orerodedthesurface.
Ifetchingoccurs,contactIceStoneCustomer
Service:[email protected]
WARRANTYIceStoneoffersaResidential10-yearLimited
WarrantyandaCommercial5-yearLimited
Warrantyforinstallationsthatarefabricated
andinstalledbyanIceStoneCertifiedFabricator.
Registeryourwarrantyonourwebsiteand
receivee-mailremindersaboutmaintainingyour
IceStone.
RECOMMENDED PRODUCTSYoucanpurchaserecommendedproducts
atourwebstoreatwww.icestoneusa.com
* Usingproductsotherthanthoserecommendedon
IceStonecanresultinlessthanoptimalperformance
ofthematerial.
CLEANERSSeventh Generation®All-Purpose Cleaner | Free & Clear
Method®All-Purpose Natural Surface Cleaner | Lavender
Method®Daily Granite Cleaner
SEALERSIceStonerecommendsStoneTech® Bulletproof,®
ahigh-performancewater-basedsealant.Ifyour
IceStonesurfacewassealedwithasolvent-based
product,werecommendTenax® Protex
whenresealing.
IceStone,LLC|BrooklynNavyYard|63FlushingAve,Building12|Brooklyn,NY11205|icestoneusa.com
[email protected]|718.624.4900
IceStone Care & Maintenance Guidelines 2/2
34
IceStone Warranty Registration Form
Building/Homeowner Name:
Type of Installation: Commercial Residential
If Commercial, Project Name:
Project address:
Building/Homeowner Phone Number: ( ) -
Building/Homeowner Email Address:
IceStone Color(s) Installed:
Type of Construction: NewConstruction Remodel
Estimated Square Footage Installed:
Usage (ie.KitchenCountertop,bathroomvanity,outdoorapplication,receptiondesk,etc)
Did you receive the Care and Maintenance Guidelines? (circle one) : Yes/No
Fabricator Company Name:
Installer Company Name:
Purchase Date: / /
Installation Date: / /
Panel ID Number(s):
Brand of Sealer Used:
Brand of Wax Used:
Would you like to receive email updated on IceStone Care & Maintenance Guidelines? Yes/No(Choose“Yes”forreminderstodoawatertesttodetermineifitistimetoresealyoursurface)
Please go to icestoneusa.com/customer-service/warranty to register your warranty. Alternatively, complete the form below and send via email to [email protected] or fax to 718.624.4002. Your warranty must be registered within 30 days of installation.
Street Apt/Suite
City State/Province Zip/PostalCode
Country
IceStone,LLC|BrooklynNavyYard|63FlushingAve,Building12|Brooklyn,NY11205|icestoneusa.com
[email protected]|718.624.4900
Thank You & Contact Us
Westrivetodesignsurfacesolutionsthatwon’tcompromisehumanorenvironmentalhealth.
Tothatend,everyIceStoneslabisfreeoftoxicpigmentsandharmfulcarcinogens,andcontains
justthreecoreingredients:pigment,cement,and100%recycledglass.Safeforouremployees
andsafeforourcustomers.
IceStone,LLCwasfoundedonthebeliefthatmanufacturingsustainable,highdesignproducts
couldrevitalizeandrevolutionizeAmericanmanufacturingandhaveapositiveimpactonthe
environment.IceStonehasdivertedover10millionpoundsofglassfromlandfillssince2003,
andwethankyouforhelpingussavetheworld,onecountertopatatime.
IceStone Customer [email protected]
718.624.4900ext.0
T7186244900| F7186244002|[email protected]
BrooklynNavyYard,63FlushingAve,Building12,Brooklyn,NY11205
©June2015IceStone
www.icestoneusa.com