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

4

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

5

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

6

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