Fabrication - It Started With A Great IdeaMake a Thicker Solid

FabricationWritten by Gordon Shell
Welcome to the world of Welcome to the world of EOSEOS™™
3cm Solid Surface3cm Solid Surface
““The only The only ““SolidSolid””
Solid SurfaceSolid Surface””
Click on title
Introduction
• It started with a great idea... Make a thicker solid surface – Eos Solid Surface bridges the gap between seamless
solid surface and high-end laminate. Our patent pending 3cm (1 1/4") material offers all the advantages of premium solid surface, in a thicker, more durable material at a surprisingly low price.
– By eliminating up to 75% of the labor required for traditional 1/2" solid surface, Eos combines the massive look of granite with a lower price point and faster delivery. The end result is a true value in the classic sense a higher quality product at a competitive price, offering you the flexibility to create the countertop you have always wanted.
– In addition, 2cm (3/4”) EOS™ sheet goods offer a great, low cost, low labor alternative to laminate, cultured marble, and other materials in the bath, window sill, hospitality, medical, retail, etc. market.
Introduction
• Eos offers you: – The massive look of natural stone without conspicuous seams. – A food safe, non-porous surface that is easy to clean and maintain. – Seamless integrated bowls and backsplashes. – Greater heat resistance. – A 10-year transferable product warranty. – A surface that is renewable and repairable. – All the advantages of premium solid surface, at a surprisingly low
price. • Eos Solid Surface is ideal for both residential and commercial
applications. With a large color palette to choose from, unlimited designer options, enhanced durability backed by a 10-year product warranty, Eos is changing the solid surface industry.
• We welcome you aboard the ever growing network of Eos Solid Surface Fabricators. What you will find contained in this fabrication manual is basic guidelines for the purpose of reference consisting of proper use and handling of Eos materials to ensure a long-lasting beauty and ultimate satisfaction for your customers.
Introduction
• FLEXIBILITY – Custom Sheet sizes, thickness, and color Regardless of the size, thickness, or color of your
project EOS™ Surfaces llc. can provide material to fit your specification; our plant has the ability to create sheets with custom length, width, thickness, and/or color.
EOS™ Surfaces llc. has helped fabricators and contractors save money by reducing labor, reducing waste, and fulfilling color specifications by providing custom material.
If you have a project that EOS™ Surfaces can custom build to your spec contact your regional
manager ASAP, contact info is available @ www.eos-surfaces.com
Preface
• This manual is supplied as a reference guide to the EOS™ fabricator/ craftsman.
• EOS™ 2cm and 3cm sheet goods are intended for fabrication by experienced solid surface fabricators and/or experienced woodworkers.
• The tools required to fabricate EOS™ are both powerful and sharp and can be dangerous in the hands of inexperienced individual(s).
• For your safety and the safety of those around you, read and understand the instruction manual and precautions for each tool used in fabrication.
• EOS Surfaces LLC assumes no responsibility for injuries that occur during the fabrication of EOS™ sheet or shape products.
Table of
Contents • Chapter 1 Material handling, safety, storage, and inspection • Chapter 2 Tools and accessories for EOS™ • Chapter 3 Cutting EOS™ 3cm Solid Surface • Chapter 4 Seaming EOS™ • Chapter 5 Under-mounting bowls in EOS™ • Chapter 6 Finishing EOS™ • Chapter 7 Installing EOS™ • Chapter 8 Food Service and special applications
• Chapter 9 Specifications EOS™ Spec Web Page • Chapter 10 Product Non-conformity guide • Chapter 11 EOS™ warranty
To go directly to any chapter click on the desired chapter.
Return to this page at anytime by clicking on the EOS logo in the upper corner or the page
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• Inspection of Material In order to ensure shipments arrive from your Regional Distribution Center in good condition, it is the responsibility of the fabricator to conduct a visual inspection of the material being received. Any visible damages must be notated on the carrier’s paperwork upon delivery. Carrier damage along with any concealed damage for example color match, scratches or any other problem must be immediately reported to EOS™ Solid Surface Customer Service Department 1-800-719-3671 ext. 4.
Material inspection, Material inspection,
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• Damaged or defective material If it is determined that a shipment contains damaged or defective material, a
report should be filed with both the carrier and EOS™ Surfaces. Digital pictures of the damage or defect can be sent to [email protected] or [email protected]
Claims can also be called into EOS™Surfaces @ 1-800-719-EOS1
Upon receipt of claim, EOS™ Surfaces will offer either replacement materials or credit for material to resolve claim.
Please refer to Chapter 10 for product non-conformity specifications.
INSPECT SHEETS AND SHAPE PRODUCTS CAREFULLY BEFORE BEGINNING FABRICATION. EOS™ REPLACEMENT POLICY DOES NOT ALLOW FOR
REIMBURSMENT FOR LABOR COSTS ON DEFECTIVE MATERIAL.
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• Handling 2cm and 3cm EOS™ Palleted Sheets
EOS™ Sheet goods are shipped flat on wooden or steel pallets, 3cm sheets will be stacked to a maximum of 12 sheets per pallet, 2cm sheets will be stacked to a maximum of 18 sheets per pallet. A forklift with a minimum lifting capacity of 5000lbs and fork extensions are recommended for moving complete pallets.
Material is shipped from EOS™ Distribution warehouse with steel banding to safely secure the sheets to the pallet, Do not attempt to move un-banded pallets. Always secure the sheets to the pallet with “tie-down straps”, if the steel banding is not in place.
• Handling individual EOS™ 2cm and 3cm sheets
• EOS™ sheets are heavy and should never be carried by no less than 2 adults
• 3cm sheets 30”x121” weigh 285lbs each • 2cm sheets 30”x121” weigh 195lbs each • Because of the weight and the sharp edges on EOS™ sheets, proper
shoes and gloves should be worn. • The use of mechanical slab lifters is highly recommended (see
pictures and descriptions on following pages for suggestions), these lifters are available thru stone and solid surface suppliers.
• Hand cups provide a quick and convenient way to handle EOS™ sheets, confirm with the supplier that the cups that you purchase are rated for the weight of each sheet. Always follow the instructions provided, carefully.
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• Pinch lifters can be used to lift individual sheets with overhead crane systems or can be adapted to fit most fork lifts.
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• Vacuum lifting systems are a great way to lift slabs directly from the pallet to the saw or work table.
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• When moving slabs or completed projects long distances the use of panel carts or dollies is highly recommended
• It is recommended that EOS™ sheets are stored on flat horizontal racks with proper support not exceeding 48” span between supports.
• A good racking system optimizes the storage area and efficiency of your operation, providing many years of reliable service.
• Racks should meet local OSHA safety standards (see following slides for guidelines)
• In order to easily verify material, EOS™ should be stored by color and LOT number.
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• EOS™ Sheets should NEVER be stored in direct sunlight.
• EOS™ Sheets should be stored in a dry, temperature controlled environment, storage area temperatures should not fall below 40° F (3°C).
EOS™ materials that are
stored out-doors are void
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• General Recommendations “as written by OSHA on the safe handling of heavy slab material” “
• Employers who are engaged in the handling and storage of slabs must prevent caught-by, struck-by, and/or crushed-by hazards in their workplace. The following are general recommendations:
• Pre-plan work to identify the hazards, safe work practices, and the equipment that will be used to perform the work safely.
• Develop and implement heavy stone slab handling procedures for transporting, loading and unloading slabs from containers and storage areas.
• Provide mechanical handling equipment appropriate to the task.
• Inspect material handling equipment before use to assure that it is in good condition. Defective equipment must be immediately reported and repaired or replaced before use.
• Instruct and train employees on the proper material handling procedures.
• Ensure that employees follow safe stone slab handing procedures.
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The following recommendations will minimize the potential hazards associated with “Slab racks" and other storage racks for storing heavy slabs:
• Design storage racks to withstand the loads and forces imposed on them.
• Design a storage rack system to secure slabs from shifting, sliding and collapsing, or provide secondary bracing or a restraint system to secure slabs from shifting, sliding and collapsing.
• Ensure that the "slab racks" are properly installed. Inspect each component to ensure that poles can be inserted into the holes.
• Maintain the rack, ensuring that no debris or other objects interfere with the insertion of the poles used with "slab racks."
• Develop and implement procedures for the placement and removal of slabs from the racks, keeping employees out of danger zones.
• Do not allow employees to use damaged storage racks.
• Inspect the storage racks prior to loading. Ensure that the racks are properly installed. Look for:
•
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for for
Stationary power tools
Table saw- A good quality 3 HP to 5 HP, 10” to 12” blade diameter table saw with an accurate fence is essential. The Table Saw is undoubtedly the most versatile machine in any shop, and should be the woodworker's first machine purchase. A good table saw becomes the centerpiece of the workshop, as the woodworker uses it to rip, square, miter, groove, shape and join pieces. A quality table saw will make completing nearly any project easier. The table saw should have a cut width of 24” to 36” and an out feed table to support 10’ lengths.
Panel Saw- Many shops have added a good quality vertical panel saw such as a Streibig or Holtz – Her. A panel saw does not replace a table saw, it compliments it. Panel saws make very accurate vertical and horizontal cuts, they take up very little space on a shop floor and handle large slabs easier than a table saw.
tools
10”-12” Power Miter Saw- A miter saw will make quick work of cutting backsplashes and smaller work pieces to length. A heavy duty model with dust collection port and all safety guards intact is highly recommended.
All saw blades used on the previously listed tools should be:
• Rated “heavy duty” • Triple-chip Carbide tipped • Have hook angled blades with a pitch of -5° to +10° • Minimum of 6 teeth per 1” diameter.
Tools and accessories Tools and accessories
for for
for for
Solid Surface CNC Routers- While CNC routers do produce very fast, accurate, and intricate cuts in EOS™, they are not required to cut EOS™.
If your shop uses a CNC for cutting solid surface then EOS™Surfaces makes the following recommendations:
1. Make sure that your machine is balanced and in good working condition. 2. The use of pods over the use of spoil-
boards is recommended to hold EOS™ in place during cutting.
3. Using a carbide, 3/8”-1/2” diameter, single flute, up-spiral router bit gives the fastest cleanest cut.
4. Spindle speed of 18,000 rpm 5. Cut rate of 70-80 ipm (depending on machine,
see mfg for their recommendations)
Tools and accessories for Tools and accessories for
EOSEOS™™
SOLID SURFACESOLID SURFACE
• Recommended Router bits for CNC Model 63-735 Onsrud, single flute, up-
spiral, solid carbide, O-flute, 3/8” Collet.
EOSEOS™™
Wet Stone CNC machinery- “Quote from respected stone machinery manufacturer after running EOS™” We have always been able to machine solid surface material on a
stone machine with the same diamond wheels and water that we use for granite. The problem has been that the 1/2" thick material was not rigid enough to machine with a typical pod set-up. The new EOS™ 3cm material is very rigid and that allows us to use the same pod set- ups that we use for stone.
The same tooling is also used with exception of the polishers (which are not used at all). Feed rates, except for the finger bit, are approximately twice those for granite (based on the tool manufacturer's recommended feed rates). For instance, the tooling manufacturer recommends 59.1 ipm for both the medium and fine diamond wheels. I would run both at 120 ipm in EOS 3cm. On finger bits you will only be able to run about 25% faster than stone. You can, however, substitute a collet style tool holder and use traditional routerbits. Feedrates of 200 ipm should be reasonable, but it will produce "chips" rather than fine dust that gets removed with the water.
Overall, EOS™ 3cm requires about 1/4 of the machine time that the same parts in granite require, assuming you take the granite all of the way through polish. The edges produced by the last diamond wheel (fine) very closely match the surface of the material. Also, unlike granite, the solid surface material can be sanded on the top surface.
Cover of Surface Fabrication magazine showing EOS™ on stone machinery.
EOSEOS™™
Portable power tools
Heavy duty Circular or worm-drive saw- A good quality circular saw with a solid surface blade will be used quite often in the shop and on the job site for trimming, and ripping EOS™ to size. A good quality “worm saw” works well on long cuts. A saw with a dust-collection port works very well for indoor, on-site work.
Regardless of the type of circular saw that you choose, always use the proper saw blade. Never use Jig saws, Hacksaws, ripping or combination blades when cutting EOS™ Solid Surfaces.
EOSEOS™™
• Circular saw blades- – Tungsten Carbide – Triple-Chip – -5° to +10° hook angle – Minimum 6 teeth per inch – Described as “used for cutting hard plastic”
Blades and Bits for Blades and Bits for
EOSEOS™™
• Diamond saw blades – Diamond blades can be used to cut EOS. – Diamond Blades must be run wet with clean
water.
EOSEOS™™
• Router bits for EOS™ 3cm Solid Surface
Because of the bold thickness of EOS™ Surfaces the following specialty bits are recommended:
• For flush-cuts off of straight edges
• For bowl cut-outs with over-hang
• For Full Bull-nose Edge Treatment
• For Bevel-edge into Solid Surface Bowl
• For Radius into Solid Surface Bowl
•Bits are available from many tool suppliers, bits pictured
can be found at www.wesleytools.com .
EOSEOS™™
• Drill bits for EOS™ 3cm Solid Surface – The only acceptable tools for boring holes in
EOS™ 3cm Solid Surface are: • Drill bits- Modified paddle-
• Hole Saws- Diamond hole saw (wet)-
• Paddle bits-
• Hand Routers – Plunge Router (Minimum 3 hp)…used for
plunge cuts of sinks, faucet holes, etc. – Fixed Base Router (Minimum of 3hp)…Used
for creating seams, edge treatments, and cutting shape.
– Trim Router (3/4 hp)…used for simple round over of cut-outs, works well as a router on skis for glue removal
EOSEOS™™
EOSEOS™™
not PSA.) (preferably with Dust collection)
– Polisher (11-13” pad)- (preferably with Dust collection)
Cutting EOSCutting EOS™™ 3cm 3cm
Solid SurfaceSolid Surface
• Cutting EOS™ to “rough size” can be done easily with any of the following tools- – Panel Saw – Table Saw – Circular Saw – CNC – Water Jet
Cutting EOSCutting EOS™™ 3cm 3cm
Solid SurfaceSolid Surface
• Cutting EOS™ 3cm to “Finished size” or for seaming the following tools are the only tools recommended- – Router – CNC – Heavy Duty- calibrated Panel saw with very
sharp blade.
Seaming EOSSeaming EOS™™
• Tools and Supplies needed- – 3 hp router – Double fluted ½” router bit – C-clamps – Straight edge (s) – Solid Surfaces Adhesive and dispenser – Router on skis or low angle block plane – Clean white rags or white paper towel – Denatured Alcohol – Seam Clamps – Random orbit sander and sand paper
• Seam Placement – Inside Corners- seams near an inside corner must be offset
by 3X the radius of the corner Example: If you use the minimum inside radius if ½” then your seam should be at least 1.5” from the inside corner. (See 1-A and 1-B on following pages)
– Butt Seams and/or square inside corners are not acceptable in Solid Surface (see diagram 1-C following pages)
– Try to avoid seaming over Dishwashers and thru Cook-top Cut-outs. If your design does not allow this contact EOS™ tech support for guidance. (See Diagram 1-D on following pages)
• Seam Placement – Diagram
• Preparing your seams- – Edges to be seamed must be cut with a
clean sharp router bit. 1. Secure sheets to work table or horses so that clamps will not impede the path of
the router. 2. Securely clamp straight edge to the edge to be routed, adjust straight edge so that
router bit cuts approximately ¼” off edge to insure a clean straight cut. (allow the router to do the cutting, do not force the router thru the cut; applying baby powder to the sheet and straight edge will reduce friction and allow the router to slide more freely)
3. Inspect edge for router chatter, divots, etc. If any imperfections in the cut are found re-route the sheet until the edge is perfect.
4. Repeat steps 1-3 for the second sheet to be seamed 5. Dry fit the seam (push the sheets together with out adhesive). The seam should be
inconspicuous with no voids; if the seam looks good then proceed to next step, if not repeat step 1-3.
Dry fit seam
• Creating an inconspicuous hard seam – **Always use the term “INCONSPICOUOS” when referring to solid surface seams, calling
the seams invisible can set false expectations and can be misleading. – Only proceed with these steps if you have an inconspicuous dry fit! – The following steps are used in the shop to create a shop seam, please see the chapter
on installation for additional precautions taken when field seaming.
1. Using Denatured Alcohol and a clean white rag or white paper towel, thoroughly clean the seam and the surrounding areas, making sure to remove any ink, pencil, or dust from the seam and surrounding areas. (do not use paper towel with print or colored rags as there is risk of the ink bleeding into the adhesive)
2. Pre-set your seam clamps so that they are easily accessible and ready to apply to your seam.
3. Select to proper adhesive color to match the EOS™ color that you are seaming a. Remove the cartridge cap and set it aside for replacement later b. Insert cartridge into applicator gun and push plunger forward
Continued in next slide……..
• Creating an inconspicuous hard seam (cont.) 3. continued….
c. On a clean rag or paper towel, purge a small amount of adhesive, out of cartridge to insure that both adhesive and activator are flowing freely. d. Insert the mixing tip and secure with threaded ring. e. Squeeze approximately a glue tip’s length of adhesive out to make sure that adhesive and applicator have time to mix. f. With the sheets approximately ¼” apart begin applying the adhesive in a continuous full bead, rest the tip on the top edge of the sheet to allow the adhesive to flow down the seam surface.
4. Manually push the sheets together, looking for adhesive squeeze-out along the entire length of the seam, no voids or dry spots. (do not remove excess adhesive, doing so could contaminate the seam and starve the seam)
5. Following the mfg instructions apply your seam clamps (in this application we are using “Gorilla Grips”)
6. Check that your sheets are level and flat at the seam (this can be done by running a clean razor blade or tile shim through the adhesive to check levels, once you are satisfied with seam tighten your clamps.
7. Allow adhesive to cure for 35-45 min
• Creating an inconspicuous hard seam (cont.) 4. After 35-45 minutes check to see that adhesive has cured, you
can check this by pushing your thumbnail into adhesive, your thumbnail should not leave an imprint if the adhesive is properly cured.
5. Remove the seam clamps. 6. Using a low angle block plane, direct drive rotary sander or
router on skis remove the excess glue bead (do not use a belt sander! Belt sanders are overkill and can heat the adhesive up leading to seam failure and poor appearance.)
Low angle block planeDo not use Belt Sander!
• Finishing the seam 1. Using a random orbit sander with 100 micron abrasive remove the left over
excess adhesive from the seam and level any differences between the sheets, be sure to feather out the seam area being careful not to create low spots on the seam.
2. Once the seam has been leveled and adhesive removed, change to either a 60 micron or Green Trizact pad (wet), making sure to clean the surface thoroughly
between grits. 3. Finally finish the seam area to match the
rest of the counter by proceeding to either a blue Trizact pad (wet) or a maroon Scotch- Brite® pad on a 12 inch sander. (continue to the Finishing EOS section)
UnderUnder--mounting mounting
bowls in EOSbowls in EOS™™
• This Chapter will cover the installation of the two most common bowl applications with EOS™Solid Surfaces:
– Integrated Solid Surface Bowls
• Installing an integrated Solid Surface Bowl:
1. Using a CNC or Plunge-cut router, cut the proper sized opening for your bowl.
(save the bowl cut-out to be used as cutting board or the required scrap piece to be left with customer)
2. Check bowl fit before proceeding to next step.
• Installing an integrated Solid Surface Bowl:
3. With the bowl dry fit in place, hot-melt glue wood blocks into place around the bowl to keep it from shifting after adhesive is placed on bowl.
4. With denatured alcohol and a clean white rag or white paper towel thoroughly clean the entire bowl area, making sure to remove all ink, pencil lines, dirt, oil, etc
5. With Denatured Alcohol and a clean white rag or paper towel, thoroughly clean the entire bowl flange, making sure that it is free of dust, ink, pencil, oil etc. If necessary use a clean Scotchbrite® pad to remove stubborn material from the flange.
(during the cleaning process, be sure to inspect the entire flange for defects)
6. Apply a single, generous bead of adhesive around the entire perimeter of the bowl flange.
Do not apply a second bead of adhesive, this can act like a gasket and trap air
possibly leading to air bubbles or air pockets in your seam.
Use the adhesive that is a match to your bowl color as opposed to the color of the deck surface.
Simple bowl clamp that can be created from plywood, threaded rod, nuts and washers.
(see next page for image of clamp in use)
7. Carefully place the bowl onto the sheet, between your glue blocks.
8. Place threaded rod of clamp thru the drain hole and tighten the wing-nut to secure the clamp and bowl into place.
9. Allow Adhesive to cure for 35-45 minutes or as specified by the adhesive mfg.
10. Once adhesive has fully cured spay the hot-melt glue that is securing the wooden blocks with Denatured Alcohol, allow to soak for approx 30-60 seconds, remove block with chisel and wipe area dry.
11.Flip the countertop to the upright position and use a combination Router Bit with a Teflon bearing, mounted in a fixed base router to complete the opening.
12. Using a 5” Random Orbit palm sander and 100 micron sand paper, sand the seam and radius until smooth.
13. Continue to finer pads to achieve desired finish.
• Installing a Stainless Steel bowl under EOS™
• Installing a Stainless Steel bowl under EOS™
1. Using a CNC or Plunge-cut router, cut the proper sized opening for your bowl.
(save the bowl cut-out to be used as cutting board or the required scrap piece to be left with customer)
2. Route the desired bevel or radius around the perimeter of the bowl opening.
3. Using a 5” Random Orbit palm sander and 100 micron sand paper, sand the bowl opening smooth.
4. Apply a bead of clear silicone to the entire flange of the bowl.
3cm Solid Surface3cm Solid Surface 3. Press bowl into place and use under-mount sink hardware to secure the bowl in place.
(Hardware shown below is available at www.integra-adhesives.com )
Apply epoxy to surface Press base of stud into epoxy
Smooth epoxy and allow to cure Secure bowl to stud with clip and wing nut
• Under-mount sink optional hardware
PEEL'N STICK* UNDERMOUNT SINK
CLIP Epoxy mounted studs
and clips
There are many systems available on the market, search the web, tradeshows, and workshops often for the best system for
you.
The following slides will offer finishing processes that many fabricators and
the EOS™ Tech Team have found to be the most efficient, there are many
different processes available on the market today; regardless of the
process that you choose, the final project should have a uniform finish
free of scratches.
Finishing EOSFinishing EOS™™
• Tools and supplies needed- 1. 6” random orbit sander with papers (see following pages)
2. 11” or 13” Polisher with pads (see following pages)
3. Spray bottle with water 4. Dish soap 5. Clean rags or paper towels 6. Water Bucket 7. Window Squeegee 8. Low angle lighting
• Getting started- – Fill spray bottle with clean water and add 2-3 drops of dish soap
and shake; you will use this water during the damp sanding steps in the process, and also to clean our tops between grits (the soap in the water keeps the water “wet” longer by slowing evaporation, it also adds slight lubrication to the abrasives)
– Fill your water bucket with clean water and place your squeegee in it; you will use this to squeegee the used water from the top between grits (the water in the bucket is to rinse the squeegee; change when water becomes to dirty)
– Because we are using wet sanding steps, be sure that your sanders are powered by GFI protected outlets.
– Proceed to next page.
– 3M™ Trizact™ discs
• Finishing basics- – Your sander should run at least 6000 OPM (orbits per Min) and a stroke of at least
3/16”. – move the sander “east and west” along the length of the project overlapping each
path by a few inches. – move the sander “north and south” along the width of the project overlapping each
path by a few inches – You MUST clean the top thoroughly between each grit change otherwise you may end
up continuing to grind leftover grits into your top, never achieving a perfect finish – Placing lighting at a low angle, close to the height of the Countertop will produce more
natural lighting and highlight imperfections and swirls in your finish, do not trust overhead shop lighting as your only light source; natural lighting at the consumers location can highlight problems, its better to see and fix this in a controlled environment . See next slide for example of using low angle lighting.
– Allow the sander to do the work, do not apply to much pressure to the sander it will impede the orbital action, slowing the finishing process and possibly creating an inconsistent finish. (See trick of the trade on following pages)
– Hook and Loop papers and discs are recommended over the use of Peel and Stick (psa). Hook and loop pads will stay on your sander during damp sanding, they are reusable, and they give a more consistent finish.
• Using low angle lighting
• Random orbit sander “trick of the trade”
Place 4 marks on the pads of your random orbital sanders. If you have light colored pads, use a black magic marker, if you have dark colored pads, use the old “white out” correction fluid you can still get at office supply areas.
The marks should be placed evenly at north, south, east, and west on the pad.
When using the sander with the correct amount of “arm pressure”, you should see a strobe light effect from the marks.
With too much “arm pressure”, you will be able to see the 4 individual marks.
You will not be getting the true random orbital effect!
• Different finishes- – The following pages will outline the steps needed
to achieve the following finishes: • Matte Finish- Standard finish in most lighter colors of
EOS™ Solid Surface, preferred finish for high traffic/use surfaces.
• Semi-Gloss/Satin- Slight gloss that can be seen in low angle lighting, this finish helps bring depth to darker colors of EOS™
• High-Gloss- Very sensitive finish that requires constant maintenance, not recommended for high traffic/use areas such as Kitchens or reception area (if consumer insists on this finish it is advised that you educate them thoroughly and have them sign an acknowledgement that they know the maintenance required to maintain the finish)
Regardless of the desired finish always clean the project thoroughly between each grit change!!!
1. Use the 100 Micron pads to remove all scratches and excess adhesive. (this disc is ran dry preferably with a vacuum attachment)
2. The Green Trizact™ disc is used to produce a uniform Matte Finish. (keep this pad damp using the spray bottle with soap and water)
3. The Blue Trizact™ disc is used to create a Matte Finish on darker colors. (keep this pad damp using the spray bottle with soap and water) (For light colors of EOS™ you can proceed to step #4)
4. The Maroon Scotch Brite™ pad is the final step in the Matte Finish process (keep this pad damp using the spray bottle with soap and water) (for a swirl free finish an 11”-13” Buffer is the preferred tool)
3. The Blue Trizact™ disc is used to create a Matte Finish on darker colors. (keep this pad damp using the spray bottle with soap and water)
4. The Orange Scotch-Brite™ disc will increase the finish from a Matte to a Semi-Gloss. (keep this pad damp using the spray bottle with soap and water)
5. The Grey Scotch Brite™ pad is the final step in the Semi-Gloss Finish process (keep this pad damp using the spray bottle with soap and water) (for a swirl free finish an 11”-13” Buffer is the preferred tool)
3. The Blue Trizact™ disc is used to create a Matte Finish on darker colors. (keep this pad damp using the spray bottle with soap and water)
4. The Orange Trizact™ disc will increase the finish from a Matte to a Semi-Gloss. (keep this pad damp using the spray bottle with soap and water)
5. The White Trizact™ disc is the final step in the High-Gloss Finish process (keep this pad damp using the spray bottle with soap and water) (for a swirl free finish an 11”-13” Buffer is the preferred tool)
• Alternate Finishing systems- – Abranet® andAbralon® Finishing pads Some EOS™ customers have reported very positive results With this system, you will find many systems on the market Today, choose the one that gives you the best finish. The Vacuum sander pictured and the Abranet System have Preformed well in many shops.
Step One Finish seams or level repair areas with Abranet®.
Use Abranet® P120 grit (125 micron) abrasive (dry) to remove surface defects or repair areas.
• Alternate Finishing systems- – Abranet® andAbralon® Finishing pads
Step Two Surface preparation with Abranet®.
Use Abranet P180 grit (82 micron) to P240 grit (60 micron) abrasive (dry) to remove scratches and
prepare for final surface finishing. Step Three
Final finishing with Abralon®. Use Abralon 360 grit for matte finish.
For a satin finish, continue with 1000 grit. For a gloss finish, continue with 2000 grit.
• Solid Surface Sanders – Random orbit sanders are the only sanders that are acceptable for
finishing EOS™ Solid Surface. Below are many versions of R/O Sanders available on the market.
• Conclusion- – Finishing EOS™ Surfaces properly is one of the most
important steps in fabrication, great care should be taken in the shop to ensure that the finish is perfect before presenting to the consumer.
– It is good practice to pack the finished tops properly for transport, protecting the finish, wrapping the tops with cardboard, moving pads, foam wrap, etc will protect the finish.
– EOS™ Surfaces llc. Does not warranty finishes, it is the responsibility of the fabricator to provide a proper finish to the consumer. Unless a problem is determined to be defective material, ALL finish issues will be referred back to the original installer.
Installing EOSInstalling EOS™™
• Installation requirements- – The tops of all cabinets or structures must be true within 1/8” of flat surface. – Cabinets or structure must be strong enough to support the weight of EOS™ 3cm
(11.4lbs per sqft) – A minimum inside radius of ½ inch is required on all inside corners. – Aluminum “Heat Conductive” tape must be used around all “Hot” openings i.e. Cook-
tops, Buffet warmers, pasta boilers, insta-hots, etc. – All “Hot” openings require a minimum inside radius of ½ inch and the top and bottom
edge of opening must be rounded over and sanded smooth. – A color matched piece of EOS™ must be left on the job site for the consumer,
minimum size of piece is 10”x10”. – Use dabs of flexible adhesive, such as silicone, to fasten EOS™ to the structure.
Never rigidly adhere EOS™ to structure. – Never screw directly into EOS™, Brass inserts or surface mounted anchors are
acceptable. – Maximum unsupported overhang is 12”. – Maximum unsupported span is 24”. – An EOS™Care Kit with registration card inside must be left with
the consumer on every install. – EOS™Care Kits are available from EOS Surfaces.
• The installation of EOS™ – As with the fabrication, the simplicity and
thickness of EOS™ 3cm makes the installation very simple and efficient. By eliminating a lot of the requirements of ½” solid surface, such as seam plates, additional substrate, etc, we have made the process very simple.
– The following slides will give you some pointers on installation.
– For additional installation guidelines contact EOS™ Tech Support
• The installation of EOS™ – Adhering EOS™ to the cabinets-
• Using dabs of flexible adhesive to fasten EOS™
• The installation of EOS™ • Field Seams
– Extra care taken in field
Food Service and Food Service and
Special Special
Special Special
ApplicationsApplications
• Food Service – Hot and Cold service area and Cut-out guide lines: – All openings must be sanded smooth, free of all cuts, kerf marks, router chatter, etc. – All inside corners must have a min. of a ½” radius – All top and bottom edges must be rounded over with a min. of 1/8” radius – All openings must be covered with Heat Conductive tape. – Food heating trays must not be in direct contact with or supported by EOS™ (contact tech
support for detailed drawings) – Food heating trays and or heating elements must not be in direct contact with EOS™
surface. – Heat trivets are recommended during the change-out of hot trays by buffet staff, do not
place hot pans directly on the surface of EOS™ – The surface temperature of EOS™ surfaces should never be allowed to exceed
150 degrees Fahrenheit (66 degrees Celsius). See Heat lamp bulletin on next page.
– Because of the unlimited food service applications, technical drawings for food service will be provided by EOS™ tech support upon request.
Special Special
ApplicationsApplications
• Heat lamps • Heat lamps can generate extremely high surface temperatures and should
never be used to heat EOS™ surfaces. Most health authorities require food to be kept a temperature of at least 165 degrees Fahrenheit (74 degrees Celsius). This should be accomplished by positioning infrared bulb, rod or wire heat lamps directly over and aimed towards the food. The lamp should be a minimum distance of 20” (508mm) from the EOS™ surface, both in 2cm and 3cm applications.
• In no case should a heat lamp be placed over a seam in EOS™. • The surface temperature of EOS™ surfaces should never be allowed to
exceed 150 degrees Fahrenheit (66 degrees Celsius). • The use of lamps that produce UV (ultraviolet light) should never be used
over the surface of EOS™ Surfaces. • Due to the thermal expansion that can be caused, under prolonged use heat
lamps, EOS™ surfaces should be given a minimum expansion gap of at least 1/8” on all sides (for aesthetics, this gap may be filled with a flexible silicone).
• Random testing of the surface should be performed to ensure that the surface never exceeds the specified temperature of 150 degrees; if testing proves that the surface is exceeding 150 degrees then the heat source should be adjusted accordingly.
Special Special
• Coved splash – EOS™3cm solid surface can
be easily converted into Coved applications thru the use of many shapers, coving routers, and techniques in the market.
– The easiest method is to glue a ½”x ½” piece of EOS™into the corner and use a Coving router to mill out the radius. Finish the process with some hand sanding or a cove sander.
Coving RouterCove Sander
Special Special
suited for window sill applications. • Adhere the sills using flexible
silicone adhesive. • Because of the extreme
temperature ranges in window sills it is required to leave an expansion gap of at least 1/8” for sills that are trapped between walls, this gap can be filled with color matched silicone.
• Leave a minimum of 1/16” gap between EOS™ and metal window frames due to the extreme transfer of temperature thru these frames.
Special Special
• Inlays – Thru the use of templates and
colored adhesive, you can create unlimited designs to fit your customers needs.
– Many aftermarket inlay kits are available, be sure to follow the mfg directions for each kit.
Special Special
Solid Surface allows you easily create drain-boards that actually drain.
– Use a template tapered to the sink edge and a fluting bit to create the drain-board, finish by hand, softening all sharp edges.
– Drain-boards should not exceed ½ the depth of EOS™
Product Product
• The following pages will cover the product specification, always visit
www.eos-surfaces.com for updated product specifications and details.
If you are specifying EOS™ on a project please click here to go directly to a Word
Document with Product specs. Spec Document
EOS™ Spec Web Page
SpecificationsSpecifications
• Sheets
– 3cm x 121”x 30” …..286 lbs – 2cm x 121” x 30”…..195 lbs – Custom sizes and thickness available, call
representative for details.
insulation – Sound pad under
Product Product
expectationsexpectations
• Document Purpose – EOS Surfaces is fully committed to the quality of its products.
This document will identify the difference between defective and usable material. This document can be used by manufactures, fabricators, and installers to inspect slabs prior to fabrication as required by the General Terms page of the EOS Fabricator Agreement. In addition this document will be used as a resource for field inspections as a part of any warranty claim or dispute resolution.
– This document identifies non-conformities that may appear in EOS products when received from our manufacturing facilities. This document is a reference document only and is not indicative of the normal quality or consistency of EOS products.
Product NonProduct Non--
blended solid surface material sold to material converters/fabricators for use in the construction of but not limited to countertops.
• Slab sizes and usable area expectations • EOS Solid Surfaces are currently available in the
following sizes; • 3 CM Slabs 2 CM Slabs
30”x 121” 30”x 121”
• Though EOS Surfaces produces slabs to be 100% usable the are some unforeseen and uncontrollable events that can occur during the loading, shipping and offloading process.
• EOS 3 cm slabs can exceed 280lbs each, special care must be used during the offloading process to prevent the slabs from colliding with nearby pallets or other objects that may cause chipping and breakage of the slabs.
• The following are guidelines used to determine the difference between acceptable material damage and material which would require attention from EOS management
• The following described damage must be documented and photographed before the sheets are off loaded by fabricator personnel. If it is obvious that damage occurred during shipping please file appropriate paper work with truck driver and forward to EOS Surfaces for processing.
• Chips – Chips from the outer, factory saw-cut, edge should
not exceed 1 inch into the width of the sheet. – Chips from the outer, factory saw-cut, edge should
not exceed 1.75 inches into the length of the sheet. • Cracked/broken sheets
– Sheets that are broken thru the width of the sheet will be credited based on the remaining usable area of the sheet. Digital photos must be submitted for credit.
• Thickness – EOS slabs are classified as a nominal Thickness of 2.0cm or
3.0cm. EOS slabs do have a tolerance range for each thickness classification as follows:
• Nominal Thickness Tolerance 2.0cm 19.5-20.5mm 3.0cm 29.5-30.5mm
• Sheet Contamination/Foreign material – Materials found in EOS slabs that are determined to be not an
acrylic/polyester solid surface such as; Metal, rubber, wood, etc. are considered foreign material. If the foreign material cannot be safely removed and repaired during fabrication it must be photographed and reported immediately to EOS Surfaces management.
• Off colored particulate contamination – Off colored particulate found in the sheet i.e.; black particulate in white
EOS™ should be drilled and filled with corresponding adhesive color during fabrication.
– Off colored particulate that is determined to be un-repairable should be photographed and reported to EOS™ management immediately.
– Off colored particulate exceeding the proximity standard of five pieces per five linear Ft. should be reported to EOS™ management immediately.
• Slab Warp – Though we take every precaution to avoid slab warp, warping can
occur during shipping and if slabs are stored improperly. – Slab warp must be reported immediately after it is found during
delivery inspection. – The following chart outlines the limits of slab warp.
• Warping caused by improper storage of material in fabricator facility is not covered by EOS Surfaces.
• NOTE: – Because of the fact that EOS is a solid surface
material most minor warp can be removed by placing the slabs on a flat surface in a warm area, the slabs should go back to tolerance level that can be easily fabricated and installed.
• Factory Finish
– The EOS manufacturing facility uses state of the art machinery to create a consistent finish on the slabs. The finish delivered to the fabricator is a “Factory finish” it is not a final finish. The fabricator is required to use standard solid surface finishing steps to create the desired final finish for their end customer.
– Because of the weight of EOS, slabs can easily be damaged by foreign material between the sheets. The fabricator should take care in material handling. The use of vacuum lifters are recommended to minimize dragging of sheets over one another.
– The machinery used by EOS manufacturing can sometimes cause a swirling finish effect, this is merely a by-product of the finishing process and is easily removed by using standard solid surface finishing techniques.
WarrantyWarranty
• Residential 10-year Warranty – Eos warrants through the fabricator to the original owners of
installed Eos products for a period of ten (10) years from the date of installation that the Eos material will be free from manufacturing defects. If a manufacturing defect occurs during the warranty period, Eos will, at its option, replace the defective Eos products at no cost to the end user. The fabricator of the countertops reserves the right to repair the defect in a workmanlike manner should they judge that the material is repairable.
• What this Limited Warranty Covers – Eos obligation under the 10-year warranty covers only the
provision of replacement material for the failed product. – This limited warranty covers Eos solid surfaces that have been
permanently installed in your residence. – This limited warranty covers products that have been maintained
according to the Eos surfaces care and maintenance guide provided free of charge at the time of installation, or upon request, by the Eos installer or by Eos.
WarrantyWarranty
• What this Limited Warranty DOES NOT Cover – This limited warranty does not cover thermal shock, chemical abuse or
defects by fabrication, misuse or improper fabrication. – This limited warranty does not cover any additional or supplemental
repairs or modifications, such as tile or wall surface modifications, that may be necessary to repair or replace the Eos product covered under this limited warranty; such other repairs and modifications shall be the responsibility of the customer.
– This limited warranty does not cover products that have not been paid for in full.
– This limited warranty does not cover uses for products exposed to outside weather and climate conditions, abnormal use or conditions, or abuse in any way. “Abnormal use or conditions” includes, but is not limited to, damage from mishandling or misuse, damage from excessive heat or uneven exposure to weather conditions, exposure to ultraviolet light, physical or chemical abuse, and damage from improper care and maintenance.
– Eos is not responsible for damage or injury caused in whole or in part by acts of God, job site conditions, architectural and engineering design, structural movement, acts of vandalism or accidents.
WarrantyWarranty
• Warranty Registration – To register for this limited warranty, you or the Eos Authorized
Installer must fill out the warranty registration card or call or write Eos at the phone number or address below to obtain a registration form. Or you may register right now.
• To Obtain Service Under this Warranty – To obtain the best service under this limited warranty, contact
the source from whom you purchased Eos. For more information about this warranty, please contact Eos directly by writing or calling:
• Eos Surfaces P.O. Box 4146 Portsmouth, VA 23701 Attn: Warranty Department 800-719-3671
Warranty Registration cards can be found in the EOS™Care kit
Available from EOS Surfaces
WarrantyWarranty
• In order to obtain service under this limited warranty, you must permit your Eos Authorized Installer or Eos authorized agents to inspect your Eos product at your residence. Also, you must reasonably cooperate with your installer and Eos’ agents in the efforts to service this limited warranty.
• Except as provided in this limited warranty, Eos shall not be liable in either tort or contract for any loss of direct, consequential or incidental damages arising out of the use or inability to use the product in residential applications covered by this warranty. Some states do not allow the exclusion or limitation of incidental damages, so the above limitation or exclusion may not apply to you.
• Eos makes no other warranty, representation or guarantee, express or implied, with respect to its products, except as expressly stated herein. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.
• This warranty gives you specific legal rights, and you may also have other rights which may vary from state to state or, in Canada, from province to province.
• This is the only warranty offered by Eos. No one other than Eos is authorized to make any warranty promise with respect to Eos solid surfaces.
Thank You!Thank You!
FabricationManual
Welcome to the world of EOS™ 3cm Solid Surface“The only “Solid” Solid Surface”
Slide Number 3
Tools and accessories for EOS™SOLID SURFACE
Blades and Bits for EOS™
Cutting EOS™ 3cm Solid Surface
Cutting EOS™ 3cm Solid Surface
Seaming EOS™3cm Solid Surface
Under-mounting bowls in EOS™3cm Solid Surface
Finishing EOS™3cm Solid Surface
Installing EOS™3cm Solid Surface
Food Service and Special Applications
Product Specifications

Documents

Fabrication - It Started With A Great IdeaMake a Thicker Solid