Compact Laminate Fabrication Manual

Installation Guide
Wilsonart Compact Laminate
®
Wilsonart® Compact Laminate
Fabrication Guide
Contents
Contents
Introduction 2
Safety/Precautions 3
General Information (Handling/Storage, Tooling) 5
Fabrication (Machining, Joining, Finishing) 6
Installation - Partitions 9
Installation - Wall Systems 11
Installations - Protective Panels (Hospital Headboards, Kick-plates) 15
Molding Suppliers Wilsonart® Compact Laminate
16
INTRODUCTION
Introduction
The product information and fabrication techniques contained within the Compact
Fabrication Guide are provided to promote “best practice” when using the product.
Like standard laminates, this product is composed primarily of wood fiber and
installations should be engineered to accommodate these characteristics. Other
fabrication/installation techniques that are not covered in this manual may be
employed providing sufficient engineering considerations are used.
Wilsonart® Compact Laminate
2
SAFETY/PRECAUTIONS
Safety/Precautions
General, Adhesive, Tooling
General Safety
Safety is a critical concern for any shop and a key part of a successful
business. The following safety rules should be incorporated into your safety
program to help prevent an accident. Safety training, knowledge, product
use, and environment are the responsibility of the facility owner and the shop
employees.
CAUTION: Always follow product, equipment and/or tools manufacturer’s
recommendations and instructions carefully.
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Read directions carefully before fabricating/installing
Wilsonart Compact laminate.
Read and follow instruction manual before operating the different tools.
Keep all guards in place and in working order.
Insure all tools are properly grounded. Never remove the third prong.
Keep work area clean, uncluttered and well lit.
Don’t use electric power tools in a damp or wet work area.
Keep visitors at a safe distance from the work area.
Use the right tools. Don’t force a tool or attachment to do a job it was not
designed to perform.
Always use safety glasses or approved eye protection and/or face shield,
ear/noise protectors and safety shoes. (Fig 3A & 3B)
Wear the proper apparel, no loose clothing or jewelry.
Secure all work with the proper clamp or vise to a stable work surface.
Don’t overreach. Keep proper footing and balance at all times.
Maintain tools in top condition. Disconnect tools before servicing and when
changing accessories such as blades, bits, cutters, etc.
Keep and use solvents, adhesives, and other materials in a safe, ventilated
place.
Dust collection should be utilized when cutting, routing, and sanding.
Dust collection should be utilized when cutting, routing, and sanding. Tools
should be used with dust collection at all times.
Figure 3A
Figure 3B
Adhesive Safety
A variety of different adhesive types can be used effectively with Wilsonart
Compact laminate. These different “families” of adhesive require different
types/levels of protection and/or precautions. ALWAYS refer to the specific
Technical Data Sheet AND Material Safety Data Sheet for usage instructions
and health/safety concerns, respectively.
For information concerning Wilsonart Adhesives, contact
www.wilsonartadhesives.com or the Wilsonart Hotline at
1-800-433-3222.
Wilsonart® Compact Laminate
3
SAFETY/PRECAUTIONS
Safety/Precautions
Fabrication
Fabrication WARNING
Drilling, sawing, sanding, or machining wood products generates wood dust, a
substance known to the State of California to cause cancer. Avoid inhaling wood
dust or use a dust mask or other safeguards for personal protection.
California Health and Safety Code Section 25249.6
Wilsonart® Compact Laminate
4
GENERAL INFORMATION
General Information
Handling/Storage
Handling:
Wilsonart Compact laminates are very heavy and care should be taken when handling to protect employees
and the decorative surface of the product. Large panels should be transported by pallet/fork-truck or rolling
table. Vacuum lifts are also recommended for handling large (thick) panels. Additional tips for working with
Compact laminate includes:
• Place padding (slip-sheet or protective cardboard strips) between panels when stacking
• Carry thinner types vertically to limit flex and possible breakage.
Storage
As with any laminate product, Wilsonart Compact laminate should be stored in a controlled moderate
climate. Avoid storing in excessive heat/humidity extremes. All materials should be acclimated for a
minimum of 72 hours before fabrication/installation. Material should not be stored near exterior doors that
may result in exposure to rain or temperature/humidity variations.
Store adhesive as recommended by the adhesive manufacturer’s suggestions.
Wilsonart® Compact Laminate
5
Fabrication
FA B R I C AT I O N
Machining
Although Wilsonart Compact laminate is composed of the same materials as a standard
laminate product, the mass and density of product requires some differences in how you
process the panels. While surface wear inhibitors can be a factor in tool life, the enemy in
any machining process is heat. Cutting rates and feed speeds play a major role in both the
practical life of tooling as well as the quality of cuts during machining. As in any machining
process, specific machines and tool types will vary and specific parameters will have to be
established on site. The following information should be considered as a “starting-point” for
establishing best practice.
Sawing
When working with Wilsonart Compact laminate, slower feed-speeds should be expected
due to the density of the material (as compared to HPL on particleboard/MDF). It is
always appropriate to contact your tooling suppler for specific recommendations for feed,
speed, and tool geometry. The following parameters have been used successfully in field
situations:
While good quality carbide proves effective for small projects, diamond cutting tips may be
more durable and cost effective.
• Rate of advance of the cutter (“chip load”) should be .001”- .002”.
• Triple chip designs have shown to provide good cut quality.
• Hook— +15°
• Panel saws with a “scoring-saw” option can minimize chipping on the exit side of the
panel.
Routing/Milling
Routing/Milling is the preferred method for final machining of panels. The process can be
performed by both hand routers, and automated CNC machines.
Hand Routing—For best results, finished edges of Wilsonart Compact laminate should be
routed/milled. Rough cut panels to approximately 1/16” before finish routing. Due to the
panels density, it is best to use cutters with larger diameter shanks (1/2”) however, smaller
tools may be used with minimal feed rates and trim amounts. Two-flute carbide straight
cutting bits work well for trimming double-sided panels.
CNC Routing—The appropriate cutting sequence is largely determined by the type of
machining required. For example, large panel sizing may be completely different than
cutting out nested parts. In any case, the specific panels thickness, cutting sequence, and
type/condition of the machine will require that you “tune” adjustments for your particular
process. A good starting point for machining is:
• Spindle speed—16,000—18,000 RPM’s
• Feed-rate—200—900 in/min
Wilsonart® Compact Laminate
6
Compact
Compact Fabrication
Guide
Machining
Fabrication
Fabrication—Machining
Drilling
Drilling
Drilling should be done with twist-style bits. Specialty bits
Drilling
with a tip angle of 60°-80° tend to show better results. These Drilling should be done with twist-style bits. Specialty bits with a tip
Drilling bits
should
be done with
withatwist-style
with to
a tip
angle
of 60°-80°
show
better
results. These specialty bits are designed with
specialty
are designed
large pitch bits.
(steepSpecialty
twist) andbitstend
tendlarger
to show
results.
These
are designed
with
large pitch
twist)
anda utilize
larger(steep
chip channels (grooves). To minimize “chiputilize
chipbetter
channels
(grooves).
Tospecialty
minimize bits
“chip-out”
and
utilize
channels
(grooves).
To minimize
on the
exit
of the panel,
a “spoiler”
board of MDF may be used to reinforc
ontwist)
the exit
side
of thelarger
panel,chip
a “spoiler”
board
of MDF may
be side“chip-out”
sidetoofreinforce
the panel,
“spoiler”
board
of MDF
may
be into
used toWhen
reinforce
theblind
backholes
face. into the surface (holes that do not
drilling
used
the aback
face. When
drilling
blind
holes
When
drilling
holes
the surface
that do not
penetrate through the entire panel), you should leave a minithe
surface
(holesblind
that do
not into
penetrate
through(holes
the entire
penetrate
through
the
entire panel),
leave a minimum 1/16” from the bottom of the hole to the back decorative
panel),
you should
leave
a minimum
1/16”you
fromshould
the bottom
1/16”
from
the
bottom of
the hole
to the
surface (Figure 7A). When edge drilling, a minimum of 1/8” of
ofmum
the hole
to Drilling
the
back
decorative
surface
(Figure
7A).back
Whendecorative
surface
(Figure
7A).should
When
edge
drilling,
a minimum
of 1/8”
ofmaterial
the
should
between
edge
drilling,
a minimum
of 1/8”
of
the
material
should remain
Drilling
be
done
with
twist-style
bits.
Specialty
bits with
a tipremain
angle of
60°-80°the edge of the hole and
the material
should
remain
between
the
edge
of theface.
hole
and
between
the edge
of
holebetter
and
the
adjacent
decorative
decorative
face
(Figure
7 B).
tend
tothe
show
results.
These
specialty
bitsthe
areadjacent
designed
with a large
pitch
(steep
the adjacent
decorative
facelarger
(Figure
7 B).
twist)
and utilize
chip
channels (grooves). To minimize
“chip-out”
on
the
exit
Figure 7 A&B
Shaping
side of the panel, a “spoiler” board of MDF mayEdge
be used
to reinforce the back face.
Edge Shaping
Edge Shaping
When
drilling
blind
holes into
surface (holesExposed
that doedges
not can be shaped to enhance the appearance and
Exposed
edges
can be
shaped
to enhance
the the
appearance
Exposed
edges
can
be
shaped
to
enhance
the
appearance
and
of the installation. This is especially true for compact u
penetrate
through the
panel),true
youforshouldergonomics
leave a miniand ergonomics
of the installation.
Thisentire
is especially
Figure 7A
ergonomics
of
the
installation.
This
is
especially
true
for
compact
used
as a work-Typical shapes include:
surface
or
countertop.
mum
1/16”
from
the
bottom
of
the
hole
to
the
back
decorative
compact used as a work-surface or countertop. Typical shapes
surface
or
countertop.
Typical
shapes
include:
include (Figuresurface
7 B): (Figure 7A). When edge drilling, a minimum of 1/8” of
Chamfer
Fille
the material should remain between the edge of the hole and
Chamfer
Fillet
*Radius should
beadjacent
limited atdecorative
the transition
to the
face 7inB).
order
the
face
(Figure
Figure 7 A&B
to minimize the “feathering” of the decorative surface.
Edge Shaping
Thumbnail
Bullno
Exposed
edges can be shaped to enhance the appearance
and
Thumbnail
Build-Downs
Bullnose*
ergonomics
of the
installation.
To increase the
apparent mass
of the
front edgeThis
of a is especially true for compact used as a worksurface
or
countertop.
Typical
shapes
countertop, a “build-down”, or stacked edge, may be include: *Radius should be limited at the transition to the face in order to minimize the “fea
fabricated.
Edgebestrips
should
oriented
“grain”
decorative
surface. of the
*Radius should
limited
at thebe
transition
to in
thethe
facesame
in order
to minimize
the “feathering”
Chamfershould be aggressively
Fillet
direction.
The
two bonding surfaces
decorative
surface.
sanded and bonded with a suitable catalyzed (2-part epoxy or Build-Downs
urethane)
adhesive.
Build-Downs
To increase to apparent mass of the front edge of a countertop, a “
To increase to apparentThumbnail
mass of the front edge of a countertop,
“build-down”,
or
stackeda edge,
may
be fabricated.
Edge strips should be oriented in
Bullnose*
stacked edge, may be fabricated. Edge strips should be oriented
in the
“grain” surfaces should be aggressively sanded
direction.
Thesame
two bonding
Finishing
direction.edges
The two
bondingresult
surfaces
should be aggressively
sandedcatalyzed
and bonded
with
a or urethane) adhesive.
suitable
(2-part
epoxy
Machining
will normally
in slight-to-moderate
suitable catalyzed
(2-part
orfinished
urethane)
adhesive.
cutter/kerf
marks.
These
edges
can be
by sanding
*Radius
should
be epoxy
limited
at
the
transition
to
the face in order to minimize the “feathering” of the
Finishing
Figure 7B
using a random
orbital sander
decorative
surface. to a smooth attractive
Finishing
Machining edges will normally result in slight-to-moderate cutter/k
appearance. Edge finishing is a multi-step sanding process
Machining
edges
willofnormally
resultgrit.
in slight-to-moderate
cutter/kerf
These
can bemarks.
finished
by sanding using a random orbital sander to a
that
utilizes aBuild-Downs
sequence
large-to-small
Similar to Solid edges
edges
can
be
finished
by
sanding
using
a
random
orbital
sander
to
a
smooth
attractive
appearance.
Edge
finishing
is a multi-step
sanding process that utili
Surface finishing,
the final to
finish
can be achieved
using
the edge of a countertop, a “build-down”,
To increase
apparent
mass of the
front
or
appearance.
Edge
finishing
is
a
multi-step
sanding
process
that
utilizes
a
sequence
of
large-to-small
grit.
Similar
to
Solid
Surface
finishing, the final finish
following sanding
steps:
stacked
edge, may be fabricated. Edge strips should be oriented in the same “grain”
large-to-small
grit.
Similar
to
Solid
Surface
finishing,
the
final
finish
can
be
achieved
using
the
following
sanding
steps:
direction. The two bonding surfaces should be aggressively sanded and bonded with a
using the following
sanding steps:
suitable catalyzed
(2-part epoxy or urethane) adhesive.
Compact Fabrication Guide
Fabrication—Machining
Fabrication
Fabrication
FA B R I C AT I O N
Fabrication
Fabrication
*
*
Matte Finish
Semi-gloss Finish
100µ
Machining edges will normally result in slight-to-moderate cutter/kerf marks. These
100µ
100µ
100µ
80µ
Finishing
Matte
Finish
Satin Finish
Satin Finish
S
100µ
edges can be finished by sanding using a random orbital sander to a smooth attractive 80µ
80µ
80µ
80µutilizes a sequence of
appearance.
Edge finishing is a multi-step
sanding process that
60µ
60µ
large-to-small
grit. Similar to Solid
60µ
60µSurface finishing, the final finish
60µ can be achieved1000 Mirka Abralon
using the following sanding
steps:
1000
Mirka Abralon
1000 Mirka Abralon
20
2000 Mirka Abralon
Semi-gloss Finish
Matte Finish
Satin Finish
100µ
100µ
100µ
80µ
80µ
80µ
60µ
60µ
60µ
1000 Mirka Abralon
1000 Mirka Abralon
Wilsonart Compact Laminate
®
10
2000 Mirka Abralon
7
8
Fabrication
Fabrication
Joining—There are a variety of techniques for jo
Joining/Finishing
pact assembly. The following illustrations includ
Compact
Fabrication Guide
ods:
Fabrication—Joining/Finishing
Compact laminates have many desirable physical properties
Butt Joined—Mechanical Fasteners
and excellent performance properties. This is especially true
as it relates to moisture and impact resistance. Depending
on the intended application, it may be desirable to fabricate
casework made partially or fully from compact panels. When
joining panels, it is important to remember that as with any
laminate, compact is primarily composed of wood fiber. This
will result in slight dimensional change as the composite is
exposed to changes in humidity. Design and construction of
the casework should allowCasework
for this dimensional
movement.
Construction—Compact
laminates have many desirable physical properties
1/8” mini
thickness
and excellent performance properties. This is especially true as it relates to moisture
and impact resistance. Depending on the intended application, it may be desirable to
Joining
Lock Shoulder—Adhesive Bond
fabricate
made
or fully from compact panels. When joining panels,
There are a variety of techniques
for casework
joining panels
thatpartially
are
suitable for compact assembly.
The following
illustrations that as with any laminate, compact is primarily composed
it is important
to remember
include some of the more prevalent
of wood methods:
fiber. This will result in slight dimensional change as the composite is exposed
to changes in humidity. Design and construction of the casework should allow for this
dimensional movement.
Fabrication
FA B R I C AT I O N
Casework Construction
fabricate casework made partially or fully from
it is important to remember that as with any lam
of wood fiber. This will result in slight dimensio
to changes in humidity. Design and construction
dimensional movement.
Joining—There are a variety of techniques for joining panels that are suitable for compact assembly. The following illustrations include some of the more prevalent methods:
Butt Joined—Mechanical Fasteners
Lap Joined—Mechanical Fasteners
1/8” minimum
thickness
Lock Shoulder—Adhesive Bond
Wilsonart® Compact Laminate
Splined Miter—Adhesive Bond
8
Installation Guide
Compact Fabrication
Partitions
Installation—Partitions
Installation
INS
TA L L AT I O N
Hardware
PartitionsHardware—
typically involve
visible hardware
becomes
integral part
of becomes an integral
Partitions
typicallywhich
involve
visiblean
hardware
which
the overallpart
appearance.
As
a
result
of
this
contribution
to
the
finished
design,
of the overall appearance. As a result of this contribution to the finished design,
hardwarehardware
styles and styles
configurations
vary greatly. vary
Somegreatly
of the most
common
and configurations
. Some
of the most common elements
elements in
in constructing
constructing aapartition
system
include:
partition system include:
Headrails
Headrail
Brackets
Latches
Keepers /
Doorstrikes
Wall Brackets
(Double-ear)
Wall Brackets
(Single-ear)
U Brackets
Hinges
Pilaster
Shoes
Due to the number of different manufacturers for these moldings, a product listing is
Due to thenot
number
of different
included
in this manufacturers
publication. for these moldings, a product
listing is not included in this publication.
Regardless of the type of hardware selected, the attachment system must be capable
Regardless
the type ofthe
hardware
the attachment
system
must mechanical strain from
of of
supporting
weightselected,
of the panels
as well as
anticipated
be capable
of
supporting
the
weight
of
the
panels
as
well
as
anticipated
dimensional change and application/use.
mechanical strain from dimensional change and application/use.
Wilsonart® Compact Laminate
10
9
Most partition systems involve using “Thick Panel” compact (1/2” or thicker). The following guidelines may be helpful in determining the necessary hardware:
Divider Panels— (supported on two ends)
Installation
The maximum distance between bracket/fasteners is influenced by panel thickness
and size (span). When fastening on opposing ends of a panel, always allow a minimum
6” distance from the upper/lower edge unless 3 or more fasteners are used. (see illustrationinvolve
11A) using “Thick Panel”
Most partition systems
compact (1/2” or thicker). The following guidelines
may be helpful
in determining the necessary
Product
Type 568
Type 575+
hardware: Type
Most partition systems involve using “Thick Panel” compact (1/2” or thicker). The folPanel
Divider
Panels—
(supported
on two
ends)
Most
partition
systems
involve
using
“Thick
Panel”
compact
(1/2”
thicker).
The
≤60”
≤48”
≤60”
Most
partition
systems
using
“Thick
Panel”
compact
(1/2”
or or
thicker).
The
fol-following
guidelines
may
be≤48”
helpful
ininvolve
determining
the
necessary
hardware:
Height
lowing
guidelines
may
be
helpful
in
determining
the
necessary
hardware:
lowing guidelines may be helpful in determining the necessary hardware:
The maximum
distance
between
bracket/fasteners
is
Divider
Panels—
(supported
on two
ends)
Brackets
/
2 per (supported
3+
per
2 perends) 3+ per
Divider
Panels—
on
two
influenced
by
panel
thickness
and
size
(span).
When
Divider
Edge Panels— (supported on two ends)
Thefastening
maximum
bracket/fasteners
on distance
opposing between
ends of a panel,
always allow is influenced by panel thickness
The
maximum
distance
between
bracket/fasteners
is influenced
by
panel
thickness
Minimum
The
distance
between
bracket/fasteners
is influenced
panel
thickness
minimum
6”maximum
distance
from
theon
upper/lower
edge
andasize
(span).
When
fastening
opposing
ends
of a panel, always
allow aby
minimum
6”
4”
6”
4”
Distance
P upper/lower
and
size
(span).
When
fastening
opposing
ends
aare
panel,
always
allow
a minimum
unless 3 and
or
more
fasteners
are
used.
size
(span).
When
fastening
onon
of of
a panel,
always
a minimum
6” distance
from
the
edge
unless
3opposing
or
moreends
fasteners
used.
(seeallow
illus(see illustration
10A)
distance
from
upper/lower
edge
unless
3 or
more
fasteners
used.
(see
illusdistance
from
thethe
upper/lower
edge
unless
3 or
more
fasteners
areare
used.
(see
illustration 11A)6” 6”
Figure
10A
tration
11A)
brackets should be at or near the minimum distance P. On 3+ bracket contrationTop/bottom
11A)
Installation
I NInstallation
S TA L L AT I O N
Installation
Installation
Compact Fabrication
Guide
Partitions
CompactFabrication
FabricationGuide
Guide
Compact
Installation—Partitions
Installation—Partitions
Installation—Partitions
Product
Type
Panel
Height
figurations, middle bracket(s) should be spaced equidistant.
Type 568
Type 575+
Type
568
Type
575+
Type 568
575+
Screens—
(supported onType
one
edge)
Product
Product
Type
Type
Panel
Width
Panel
Height
Brackets
Minimum
Distance P
≤60”
P P
≤60”
≤48” ≤60”
≤60”
≤48”
Brackets /
Type 568+
2 Brackets
per Type
3+ per
2 per
3+ per
Edge
Brackets
/ /
2 per 3+3+
2 per 3+3+
perper 2 per
perper
EdgePanel2 per
Edge
≤16”
≤18”
Minimum
Width 4”
6”
6”
4”
Minimum
Distance P
Minimum
6”
4” 4”
6” 6”
4” 4”
Distance
P 6”
Distance
PPanel
≤20”
21-30”
31-36”
>36”
Height
Top/bottom
at or
ornear
nearthe
the minimum distance P. On 3+ bracket conTop/bottombrackets
bracketsshould
should be at
Top/bottom
brackets
should
be
or
near
minimum
distance
bracket
conminimumTop/bottom
distance
P. On
3+
bracket
configurations,
brackets
should
at at
orequidistant.
near
thethe
minimum
distance
P. P.
OnOn
3+3+
bracket
configurations,
middle
bracket(s)
should
be be
spaced
Brackets
2be spaced
2
3 be spaced
4 equidistant.
figurations,
middle
bracket(s)
should
middle bracket(s)
should
equidistant.
figurations, middle bracket(s) should be spaced equidistant.
Screens— (supported on one edge)
Screens—
(supported
one edge)
Minimum
Screens—
(supported
onon
one
Screens—
(supported
on
3”one edge)
4” edge)
6”
Product
Type
≤48”
Panel
P
P
Panel
≤48”
≤48”
Height
Height
Product
≤48”
≤60”
≤60”
P
Distance P
Product
Product
Type
Type
Type 568+
Type
568+
Type
568+
P
Hardware materials and designs vary. The recommendations above are suggestions
≤16”
≤18”
solely based
on the compact and does not assure that the specific hardware used will
Panel
Panel
≤16”
≤18”
≤16”
≤18”
Width
support the load and applicable
stresses from daily use.
Width
≤20”
21-30”
31-36”
>36”
Panel
Panel
≤20” 21-30”
21-30” 31-36”
31-36” >36”
>36”
≤20”
P P
Height
Height
2
2
2 2
3
2 2
3”
4”
3” 3”
4” 4”
Brackets
Brackets
Minimum
Minimum
Distance
Distance
P P
4
3 3
6”
4 4
6” 6”
11
Hardware materials and designs vary. The recommendations above are suggestions
Hardware materials and designs vary. The
Hardware
materials
and
designs
vary.
The
recommendations
above
suggestions
materials
and
designs
vary.
The
recommendations
above
areare
suggestions
solely
basedHardware
on
the above
compact
and
does
not
assure
that
the
specific hardware
used
will
recommendations
are suggestions
solely
solely
based
on
the
compact
and
does
not
assure
that
the
specific
hardware
used
based
on the
and
does
assure that the specific hardware used
willwill
support
load
and
applicable
stresses
from
daily
use.
based the
on solely
the
compact
and
doescompact
not
assure
that
the not
support
load
and
applicable
stresses
from
daily
use.
specific hardware
used
will
support
the load and
support
thethe
load
and
applicable
stresses
from
daily
use.
applicable stresses from daily use.
Wilsonart® Compact Laminate
10
11
11
Installation
I N S TA L L AT I O N
The principles for installing HPL laminated panels will
generally apply to the installation of Wilsonart Compact
Laminate as well. However, due to the large range of product
thicknesses available, the most appropriate method may be
specific to accommodate the weight and mass.
Wall Systems
There are two basic styles of Wilsonart Compact Laminate.
Product types 114 and 117 are sanded on one side to
facilitate bonding to a substrate. The other product types
are manufactured double-faced or with a decorative surface
on both sides of the panel in order to promote balance
construction and minimize warping. Regardless of the style of
Wilsonart Compact, some common suggestions apply to both,
which includes:
Sanded one-side
These products are designed to be fabricated and installed like
standard HPL products. The recommended substrate include
particleboard & MDF. Other substrates may be used however;
special considerations should be made to compensate for
differences in dimensional characteristics. Please see the
“Technical Bulletin—Substrate Selection” for more details on
substrates. As with substrates, suitable adhesive types are
typical of those recommended for laminates. These adhesive
types include contact adhesive, PVA, polyurethane (PUR),
epoxy, and various types of resins. For a complete list of
adhesive types, refer to ANSI/NEMA LD 3-2005. Always refer
to the adhesive manufacturers recommendations for proper
application parameters for the specific adhesive selection.
Note: Wilsonart Compact panels are primarily composed
of wood fiber. Therefore, dimensional characteristics
are influenced by humidity change. These dimensional
characteristics should be accounted for when planning an
installation.
Double-faced
As indicated above, this group of product is manufactured
with a decorative surface on both sides of the panel. This is
necessary for balance in the composition and in many cases,
allows the panel to be functional on both sides. These panels
are normally installed by mechanical fastening in various
ways.
Thin Panels (Compact panels up-to 1/4” nominal) - Can be
perimeter fastened with edge moldings. The most common
selections would include aluminum extrusions (see molding
supplier list for source details on page 16). Because this
system only involves restraining the edges, it is recommended
to design the system with smaller panels so that dimensional
change is limited. Some of the moldings that can be employed
for this system include:
•
J-Channel—This aluminum extrusion is designed to
“cap” the unfinished edge of a panel were the system
ends (examples: top edge, bottom edge, end of run).
The molding is designed with a single flange that can
be mechanically fastened making the flange/fasteners
hidden behind the panel system. The low profile design of
this molding makes it possible to cover lower edges with
commercial vinyl base.
Wilsonart® Compact Laminate
11
Installation

H-Molding—This molding is designed to restrain the edges of butt-jointed panels and provide expansion/
Wall
• H-Molding
—This allowances.
molding is designed
to restrain
the edges
contraction
There
are many
style/color/
of butt-jointed panels and provide expansion/contraction
materialThere
options
to help
with the aesthetics
allowances.
are many
style/color/material
options to on the installation.
Theaesthetics
base flange
is typically
than the exposed
help
with the
on the installation.
Thewider
base flange
isflange
typicallywhich
wider than
the exposed
flange which fastening.
allows for When inallows
for mechanical
mechanical
When
be certain tofor
allow
stalling, fastening.
be certain
toinstalling,
allow clearance
dimensional
clearance for dimensional change in the Compact.
change in the Compact.
 Inside
Inside
Corner
Molding—This
moldingto is
designed
to fasten and
•
Corner
Molding
—This molding is designed
fasten
and
maintain
alignment
where
panels
meet
at
an
inside
corner.
maintain alignment where panels meet at an inside corner. These
These can allow dimensional change to occur in the panel
can allow dimensional change to occur in the panel while covering
while covering the required expansion.
the required expansion.
•
Corner
MoldingMolding—This
—This aluminum extrusion
is designed
 Outside
Outside
Corner
aluminum
extrusion is designed to
toreceive
receive two
panels
at
an
outside
corner.
In
most
cases,
two panels at an outside corner.
In the
most cases, the outside
outside corner is chamfered to eliminate the sharp corner.
corner
is chamfered
to to
eliminate
the panels
sharpand
corner. Some variations
Some
variations
involve splines
restrain thicker
involve
spline to
restrain
thicker panels and utilize an aluminum
utilize
an aluminum
“bead”
at the corner.
“bead” at the corner.
Systems
Thick Panels (Compact panels > 1/4” nominal) - Thick compact
can also be perimeter fastened with edge moldings. In addition to
Thick Panels (Compact panels > 1/4” nominal) - Thick compact can also be perimeter
the moldings listed for thin panels, additional options are available
fastened
with edge
moldings.
In addition
the moldings listed for thin panels, addito provide additional
support
and/or different
aesthetics.toThese
tional options
moldings
include: are available to provide additional support and/or different aesthetics.
These moldings include:
•

U-Channel (or Omega profile)—This aluminum extrusion may
be with or without flanges. It is designed to overlap the edge of
U-Channel
Omega
profile)—This
aluminum
adjacent
panels (or
leaving
a recessed
area between the
compact extrusion
which
is
also
where
the
molding
is
fastened.
A
decorative
insert
may be with or without flanges. It is designed
to overlap the
isedge
sometimes
used
to
cover
the
visible
fasteners.
of adjacent panels leaving a recessed area between
the compact which is also where the molding is fastened. A
insertpairs.
is sometimes
isdecorative
installed in multiple
While primarilyused to cover the visible fasused
on thick panels installed with mechanical
teners.
it is plausible to bond strips to the
 fasteners,
Z-clips—This
extrusion is used behind the panel and usually is inback of thinner compact if a suitable adhesive
stalled
in
multiple
pairs. While
is used. A Z-clip system involves
installingprimarily used on thick panels installed
with mechanical
fasteners,
rows
of moldings
on the wall structure
(lip-up) it is plausible
and
strips/clips
on
the
back
of
the
panel
(lip
to bond strips to the back of thinner
compact if a
down).
Once
the
panel
is
”dropped”
into
place,
suitable adhesive is used. A Z-clip system inblocking at the top of the panel keeps the
volvesfrom
installing
rows of moldings on the wall
compact
being removed.
structure (lip-up) and strips/clips on the back of
• Specialty
Outside/Inside
Corners
—There
severalisvariations
the panel
(lip down).
Once
thearepanel
of”dropped”
corner moldings
that
allow
panels
to
be
splined
an of the
into place, blocking at the totop
aluminum extrusion to finish an outside corner. Since the edge
panel keeps the compact from being removed.
of the Compact is visible at the spline, chamfering and finishing
 isSpecialty
Outside/Inside
Corners—There
are
necessary when
using this type of
molding.
several variations of corner moldings that allow panels to be
splined to an aluminum extrusion to finish an outside corner. Since the edge of the Compact is visible at the spline,
chamfering and finishing is necessary when using this type
of molding.
•
Z-clips—This extrusion is used behind the panel and usually
Wilsonart® Compact Laminate
Wall Structure
Installation
I N S TA L L AT I O N
Installation—Wall systems
12
Installation
Installation
I N S TA L L AT I O N
Wall Preparation:
Compact Fabrication
Guide
Wall Systems
Installation—Wall systems
• Preparation:
Walls should be pre-inspected to determine if it is flat
Wall
enough for direct clip installation.
In cases
of extreme
deviation from
plane, 1” X if4”it is flat
 • Walls
should
be pre-inspected
to determine
lathe
and
shims
may
be
necessary.
enough for direct clip installation.
• If sufficiently flat, install inside corners (optional) and
at base deviation
of wall. from plane, 1” X 4”
 In J-channels
cases of extreme
lathe and shims may be necessary.
Z-clip installation:
 • If sufficiently
flat,
insidelay-out
corners
(optional)
Using a scope
or install
laser leveler,
and
attach and
Z-clip strips
on wall
J-channels
at base
ofusing
wall. appropriate mechanical
fasteners .
•
Vertical spacing is typically 16” - 24” depending on
Z-clip installation:
the thickness of compact and/or panel size.
 • Using
a scope
or laserin leveler,
lay-out
andstrips
attach
For slight
variations
plane, directly
shim
to z-clip
plumb.
strips on wall using appropriate mechanical fasteners .
• Top and bottom rows of Z-clips/strips should be
 Vertical
spacing
is 6”
typically
- 24” depending
on the
positioned
within
of their16”
respective
edge.
• thickness
Allow space
at top of and/or
wall for panel
furringsize.
strip. This
of compact
strip limits vertical lift of the panels and allows top
 Formolding
slight variations
installation.in plane, directly shim strips to
plumb.

Panel installation:
•
Top and bottom rows of Z-clips/strips should be posiMachined panels should be fitted with clips
tioned
within 6”toofthe
their
respective
corresponding
desired
vertical edge.
spacing
(see page 14).
Allow space at top of wall for furring strip. This strip
Horizontal spacing of clips is typically 16” (max) with
limits
verticaloflift2 of
and allows
top molding
a minimum
perthe
rowpanels
(dependent
on width
installation.
of panel).
• Edge/reveal designs vary greatly and will determine
the specific sequence for panel installation.
• installation:
For multi-row installations, lower rows are installed
Panel
first in order to allow panel clips to “drop” into strips.
 Machined panels should be fitted with clips corresponding tocompletion:
the desired vertical spacing (see page 15).
Installation
• Once panels are installed, install furring strip.
 Horizontal spacing of clips is typically 16” (max) with a
• Install applicable moldings.
of 2 per
row
widthupper
of panel).
• minimum
In some cases
such
as (dependent
wainscoting, on
a slotted

•

J-channel may be used to finish the upper edge.
Edge/reveal designs vary greatly and will determine
the specific sequence for panel installation.

For multi-row installations, lower rows are installed
first in order to allow panel clips to “drop” into strips.
Installation completion:

Once panels are installed, install furring strip.

Install applicable moldings.

In some cases such as wainscoting, a slotted upper Jchannel may be used to finish the upper edge.
Wilsonart® Compact Laminate
13
14
Panel Preparation:
Installation Guide
Compact Fabrication
Wall Systems
Installation—Wall
systems
INS
TA L L AT I O N
Installation
• Panel
PanelsPreparation:
should be cut to size with allowance for profiled edges or
edge finishing.
 Panels should be cut to size with allowance for profiled
finishing.laminates have the same
• Since
bothedges
sidesor
of edge
most compact
decorative face, inspect both surfaces and confirm visual quality.
 Since both sides of most compact laminates have the
samefinal
decorative
• Perform
machiningface,
and inspect
finishing.both surfaces and confirm visual quality.
• Lap stile joints should be paired appropriately on adjacent edge.
(reference
Perform
final
andillustration
finishing. below)
A, A,
B, Bmachining
and Lap Joint

B
A
B
A
Lap stile joints should be paired appropriately on adja-
Z-clip installation:
cent edge. (reference A, A, B, B and Lap Joint illustration below)
• Lay-out and install Z-clips.
Z-clip installation:
• Mechanical
should
not penetrate beyond
Lay-outFasteners
and install
Z-clips.
1/8” of the outer (opposite) face. Pilot drilling can be
1/16” of outer
face. should not penetrate beyond
within
Mechanical
Fasteners
1/8” of the outer (opposite) face. Pilot drilling can be
• When
using suitable adhesives, belt sand (with 50-80
within 1/16” of outer face.
grit) the bonding location to create an aggressive
pattern.
This adhesives,
method should
be used
scratch
When
using Note:
suitable
beltonly
sand
(withwith
50-80
thinner,
smaller
panels
at
the
lower
portion
of
the
walls.
Insure that
grit) the bonding location to create an aggressive
the Z clips are secure before installation, to prevent the panel from
scratch
pattern.
Do not
directly
todelamination
a factory finish
falling.
Do not
bond directly
to abond
factory
finish as
delamination may occur.
mayas
occur.
..
Joint
optionsfor
for wall
wall panels
Joint
options
panelsinclude:
include:

Lap Joint (Rabbeted)
• Lap Joint (Rabbeted)
Z-clips
A
(Expansion/Contraction requirements
must
be
(Expansion/Contraction
requirements
must
observed
for
each
panel)
be observed for each panel)
Splined
Reveal
one side)
• Splined
Reveal
(fixed(fixed
one side)
Z-clips
B
Z-clips
Z-clips
Z-clips
Z-clips
Z-clips
Z-clips
(Expansion/Contraction requirements
must
(Expansion/Contraction
requirements
must
be observed for each panel)
be observed for each panel)

H-molding (fixed one side)
• H-molding (fixed one side)
(Expansion/Contraction requirements
must
be
(Expansion/Contraction
requirements
must
observed
for
each
panel)
be observed for each panel)

H-molding Reveal (fixed one side)
• H-molding Reveal (fixed one side)
(Expansion/Contraction requirements
must
be be
(Expansion/Contraction
requirements
must
observed
for
each
panel)
observed for each panel)
Wilsonart® Compact Laminate
15
14
Compact Fabrication Guide
Installation
Installation—Protective
Panels
Installation
I N S TA L L AT I O N
Protective Panels
Some special applications (small, single-panel
configurations) require specifically placed protective
panels such as hospital headboards, gurney (kick)
panels, and cafeteria tray-guards.
Some special applications (small, single-panel configuraFor these
applications
where
a partial
panel is to
be such as
tions)
require
specifically
placed
protective
panels
installed
with
limited
exposed
fasteners,
the
following
hospital headboards, gurney (kick) panels, and cafeteria
method may be used:
tray-guards.
Section View
• these
Machine
recess intowhere
back-side
of panel
to is to be inFor
applications
a partial
panel
accommodate Z-clips and strips. Recesses should
stalled with limited exposed fasteners, the following methbe limited to small pockets sufficient to mount
od may
be used:
panels.
Do not extend recess across the length of
the panel as slight warpage may result.
Machine recess into back-side of panel to accommoZ-clips
and strips.
Recesses
should
to
• date
Fasteners
should
not penetrate
beyond
1/8”beoflimited
the
small
outer pockets
surface. sufficient to mount panels. Do not extend recess across the length of the panel as slight
• warpage
Wall/structure
may surface
result. should be flat within the
installation area. If shimming is required, the
recessed area
should
for the overall
 Fasteners
should
notcompensate
penetrate beyond
1/8” of the
thickness
of
clips/shims.
outer surface.

Once the panel issurface
“dropped”
into be
place,
single the
re- instal• Wall/structure
should
flatawithin
straining
fastener
can
be
placed
to
keep
the
panel
lation area. If shimming is required, the recessed area
from lifting off of the clip system.
should compensate for the overall thickness of clips/
This shims.
method is only suitable for thick panel (≥ 1/2”)
to the
rigidity of theinto
panels,
it isa single reapplications.
Once theDue
panel
is “dropped”
place,
extremely important that panel size be limited and
straining fastener can be placed to keep the panel
subsurface
be flat.
from lifting off of the clip system.
This method is only suitable for thick panel (≥
1/2”) applications. Due to the rigidity of the panels, it is extremely important that panel size be
limited and sub-surface be flat.
16
Wilsonart® Compact Laminate
15
Suppliers for aluminum and plastic extrusions include:

Suppliers
for aluminum and plastic extrusions include:
Brunner
Enterprises—877.299.2622—www.brunnerent.com

 ABrunner
Enterprises—877.299.2622—www.brunnerent.com
Extrude
Trim—888.557.0883—www.extrude-a-trim.com

 Industries—800.824.2049—www.futuraind.com
Extrude A Trim—888.557.0883—www.extrude-a-trim.com
Futura

 Futura
Industries—800.824.2049—www.futuraind.com
Outwater
Plastics—800.631.8375—www.outwater.com
Molding Suppliers
Outwater Plastics—800.631.8375—www.outwater.com
•Brunner Enterprises—877.299.2622—www.brunnerent.com
•Extrude A Trim—888.557.0883—www.extrude-a-trim.com
•Futura Industries—800.824.2049—www.futuraind.com
Z-Clips
Z-Clips
•Outwater Plastics—800.631.8375—www.outwater.com
The molding suppliers listed above are for reference only
and are not exclusive to Wilsonart Compact Laminate. Other
manufacturers of suitable moldings may be available in your
H Molding
H Molding
area.
Compact Fabrication Guide
Compact Fabrication Guide
Molding Suppliers
Molding Suppliers
17
J Channel
J Channel
Installation
Installation
I N S TA L L AT I O N
Suppliers for aluminum and plastic
extrusions include:
Installation
Installation

Inside Corner
Inside Corner
Outside Corner
Outside Corner
The molding suppliers listed above are for reference only and are not
The molding suppliers listed above are for reference only and are not
exclusive to Wilsonart Compact. Other manufacturers of suitable
exclusive to Wilsonart Compact. Other manufacturers of suitable
moldings may be available in your area.
moldings may be available in your area.
Wilsonart® Compact Laminate
16
18