Max-Top Quartz Installation Kit

Max-Top Quartz.
Installation Care and
Maintenance Guide.
Max-Top Quartz is a modular, lightweight
engineered quartz product which does not
require templating or specialist fabrication,
facilitating ease of handling and installation.
The following guide deals with the
fabrication, installation and care and
maintenance of Max-Top Quartz worktops to
comply with and obtain the 25 year warranty.
Installers of Max-Top Quartz should carefully
read the instructions and contact their MaxTop Quartz Distributor if in any doubt
regarding procedures.
Simple, swift, stunning
Eliminating inconvenient lead times, Max-Top
Quartz is fitted at the same time as the
cabinets, so handover is completed more
quickly compared to templated products.
Due to its installation simplicity and
lightweight handling properties, the installed
cost of Max-Top Quartz lies between
laminate and traditional stone.
Max-Top Quartz is prolific in major
apartment and student accommodation
projects where performance and longevity
are vital. Max-Top will retain its good looks
for many years compared to other solid
surface products. All materials used in the
production of Max-Top Quartz are 100%
waterproof.
5 Minute Installation
Video
Discover how Max-Top Quartz is simpler to
install than laminate surfaces!
Installers new to Max-Top should view the
short video prior to fabrication procedures.
Please go to:-
www.maxtopquartz.co.uk
Engineered
Construction
8mm quartz surface with 40mm square edge
profile (pre-finished on all four sides)
Glass fibre reinforcement to underside of
quartz surface for enhanced impact
resistance compared to traditional slabs.
Lightweight honeycomb polypropylene core
(waterproof) for strength & weight reduction
Lightweight quartz beams for strength and
rigidity to both long sides.
PVC balancer for stability
Factory pre-finishing reduces installation
time compared to other solid surface brands
Max-Top Components
• Worktops:• 3000x600x40mm (61kg) contains free
3000x40x8mm and 600x40x8mm matching
acrylic upstands in pack
• 2400x600x40mm (49kg) contains free
2400x40x8mm and 600x40x8mm matching
acrylic upstands in pack
• 1500x600x40mm (31kg) contains free
1500x40x8mm and 600x40x8mm matching
acrylic upstands in pack
• 2400x900x40mm (71kg)
• All worktop components come with a (free)
matching acrylic (rebated) end cap solution
600x42x8mm
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Optional accessories:3000x100x8mm matching acrylic upstand
2400x100x8mm matching acrylic upstand
3000x600x8mm matching acrylic splashback
2400x42x8mm matching acrylic edging strip
(none-rebated)
Acrylic adhesive (50ml twin pack for end cap)
800 grit smooth sanding block
50 grit coarse sanding block
Twin Pack Glue Gun
Suction jointing clamps
Installation Kit
Universal Drill Guide
Max-Top Quartz
Installation Kit and
Universal Drill Guide
Electroplated diamond hand pads 50 & 800 grit
(underneath flap):For sanding edge after cutting or
applying glue.
Vacuum brazed hole saws 12mm and 35mm: For
starting hob/sink cut outs and tap holes. NB. Should
be used with Max-Top universal drill guide
150mm fine turbo diamond blade: For all straight
cuts to quartz.
Bevel cutting diamond cone 6.35mm diameter: For
recreating bevel edge on quartz (not acrylic)
Straight router 70/80 grit 12.7mm shaft: For
removing quartz factory fitted edge and squaring
worktops prior to edging.
Vacuum brazed jigsaw blades 30/40: Gold (coarse)
for general use, Black (fine) for tighter radius
Important Fabrication Rules
• Only use diamond coated tools when working with MaxTop Quartz. Installation Kits are available from your
Max-Top Quartz Distributor and individual router bits or
saw blades can be sourced from specialist tool suppliers.
• Work slowly and let the blade do the work for best
results.
• Regularly vacuum away quartz dust and debris when
working to avoid damage. Quartz grated on quartz can
scratch your surface!
• The tops of the cabinets must be flat and true within
2mm of a flat surface for every 3m length.
• Allow 3mm clearance for expansion between worktops
and walls.
• Never install mechanical fasteners (screws, nails etc.)
directly into the Max-Top surface.
• All sink and hob apertures, rebates, notches or other cutouts with 90 degree or sharp internal corners within the
Max-Top surface must be radiused to a minimum of
12mm to avoid potential stress cracking through normal
expansion and contraction.
• No worktop joint should be within 150mm of a sink or
hob cut-out or positioned over a dish washer.
• Always use aluminium heat reflective tape to prevent
heat damage at hob cut-outs with a 3mm clearance gap
all round to allow for heat expansion and contraction.
• Splashbacks and upstands must be a minimum of 130mm
from the heat source of a gas hob.
• Support overhangs exceeding 300mm with cantilevered
brackets or legs. It is the installer’s responsibility to
ensure adequate and safe support.
• Drainer grooves should not exceed 5mm maximum depth
• Use only PU, silicone, acrylic or 2-part epoxy adhesives
• Always use a protective metal plate to the worktop edge
over dish washer locations.
Inspection!
Please check your surfaces before installing
• Max-Top Quartz worktops and matching acrylic accessories are supplied wrapped in foam and
packaged in strong cardboard for protection. The factory finish on the worktop surface may have
dusting from the foam wrapping following the lines of the cardboard corrugations due to
compression from storage. This is normal and is easily cleaned off with a soap and water solution.
It will be more noticeable on black designs.
• Quartz is a natural material and slight variations in pigment, colour and pattern density are
inherent in the manufacturing process. The installer should report any abnormal defects to their
Max-Top Quartz supplier prior to fitting, including colour incompatibility. It is the responsibility
of the installer to conduct a visual inspection for defects on the worktops once unwrapped. If
unsure regarding quality of material, always contact your Max-Top Quartz supplier for advice.
• Never stack or slide unprotected Max-Top Quartz worktops directly on top of each other. Whilst
quartz is highly scratch resistant to everyday household materials, quartz on quartz will cause
scratching.
• Max-Top Quartz Limited will replace any of their worktops that do not meet with the product
specification. However, Max-Top Quartz Limited will not be responsible for any labour charges or
any associated charges incurred for fabrication done on defective materials, or any costs
whatsoever for any faulty worktops fitted or any cost associated with refitting.
Health and Safety Guidelines
• Silica dust is created during sawing, drilling, routering and sweeping Max-Top Quartz worktops and
overexposure may cause silicosis. Therefore simple precautions should be taken during fabrication and
cleaning procedures by ensuring use of personal protective equipment.
• Respiratory face masks (type FFP3) should be worn during dry fabrication to avoid inhalation of silica dust
and impact resistant safety goggles to protect eyes against dust and debris.
• Use portable vacuum dust extraction with plunge saws and router equipment and remove dust in sealed
bags for disposal.
• The amount of dust from fabrication may be relatively low, but it is better to perform fabrication processes
outside domestic premises where possible in a sheltered open area. When fabricating inside, ensure as
much ventilation as possible through window and door openings.
• Whilst Max-Top Quartz is substantially lighter than traditional slab quartz, it is recommend that two
experienced and trained persons lift the product at all times.
• Only use quality diamond coated saw blades, router and drill bits which are suitable for cutting stone
products. Standard woodworking tooling will not cut Max-Top Quartz and could be dangerous if attempted.
• Always use a drill guide or jig when drilling Max-top Quartz
Cutting Max-Top
Quartz
All cutting work should be undertaken with a
diamond coated circular saw blade from the
Max-Top Installation Kit or specialist tool
supplier.
Always use a plunge saw with guide rail for
the best results.
Work slowly for an efficient cut and quality
finish.
Cut end will normally be into a wall leaving
factory finished end exposed or forming a
butt joint.
Allow 3mm expansion gap all round.
150mm Turbo Fine blade (available in Max-Top Quartz Installation Kit)
Standard 22.23mm bore (suits Festool TS55R) fitted with a 22.23mm
to 20mm reducing ring for various brands
Drilling Max-Top
Quartz
12mm or 32mm diameter diamond hole saw
available in the Max-Top Quartz Installation
Kit. (Minimum 12mm radius to all apertures
in Max-Top Quartz).
Drilling process is best undertaken with our
Max-Top Quartz Universal Drill Guide for
accuracy and to avoid any damage to the
surface of the Quartz.
Diamond Hole Saws
Bevelling
wheel
Sanding pads (coarse and
finishing)
Jointing Max-Top
Quartz
Pre-finished (all round) quartz edges are simply
butted together form a neat “V” groove and are
bonded with matching silicone or PU adhesive.
Suction jointing clamps are optional for fast and
accurate fit. Use plastic window packers to “fine
tune” levelling procedure.
Clean out excess adhesive to form a neat v-groove
joint. Use masking tape to edges of bevel or soapy
water on surrounding surface so excess adhesive
can be easily removed.
Cut pieces can be sanded with a 50 grit and 800 grit
sanding blocks or routered with a diamond coated
beveling wheel (in laminate trimmer) to form new
bevel. (Sanding blocks and beveling wheel available
in the Max-Top Quartz Installation Kit).
Worktops should be screwed to the carcass through
the PVC balancer (use pilot hole). Always allow
3mm all round against walls and abutments for
expansion.
Colour matched PU adhesive
provides a smart and effective seal
Suction clamps
provide accuracy
Forming Bevelled Edge
With Diamond Coated
Sanding Blocks and/or
bevelling tool
Remove bulk with 50 grit pad
Finish with 800 grit pad and a little water for
a smooth professional finish
Take care not to sand surface of quartz
Process takes no more than 5 minutes
(Sanding pads and bevelling wheel
available in the Max-Top Quartz
Installation Kit)
Inset Sink Installation
Mark out sink position on masking tape on surface
of quartz
Drill corners (minimum 12mm diameter diamond
coated hole saw or drill bit) and cut out aperture
with a circular plunge saw with guide rail using a
diamond coated saw blade, connecting the holes.
The last part of the cut can be done with a diamond
coated jig saw blade if required for control. Start
from the center of the cut to avoid over stressing
the material.
Minimum 12mm radius to all apertures to avoid
stress cracking
Seal sink in place with silicone or PU adhesive to
protect the kitchen carcass
Use aluminum heat reflective tape to prevent heat
damage at hob cut out’s, leaving a 3mm clearance
gap all around to ensure adequate and safe support
Matching Acrylic End
Cap
Rebated end cap (600x42x8mm) comes in prefinished colour matched acrylic material for ease of
site application.
Primarily required for an island unit due to factory
finishing on 4 edges as standard.
Router cut end of quartz and sand for a true square
finish.
1
Trim down core and backing material with router
between concrete beams to house male section of
rebate. (1)
Remove dust and debris and thoroughly clean end
cap and core area with alcohol wipes and apply
matching acrylic adhesive. (50ml-2 part). (2)
Clamp and clean off excess adhesive. Use ‘A’ clamps
to hold edging securely in place during adhesion.
Allow up to one hour to dry and trim edging with
laminate trimmer or orbital sander to form bevel.
2
Polish as appropriate with orbital sander to match
luster of quartz. (3)
3
Matching Acrylic
Upstands and
splashbacks
Acrylic upstands and splashbacks are best lightly
polished to match the lustre of the quartz
before installation
Use PU adhesive or silicone to for fixing to wall
or surface of worktop
40mm upstands (1no. 3000x8 and 1no. 600x8)
are free in every worktop pack
100mm upstands are available to order
separately from stock
Please note that mirror chips are not included in
acrylic accessories which affects three designs.
This has no detrimental aesthetic effect on the
finish of the upstand which blends in beautifully
with the quartz surface. It may be more
noticeable on a splashback and this should be
stated at the point of sale. Please see brochure.
Undermount Sink
Installation
Max-Top quartz is primarily used with inset
sink applications for simplicity and optimum
installation speed, however, undermount
applications can also be achieved.
Installers with experience of undermount
applications in solid surface (acrylic) work
surfaces already have the skill base and
tooling for the task.
We ask all new installers to ensure they view
the installation video before commencement
of work. www.maxtopquartz.co.uk
Additional coarse diamond router bit and
polishing drainer groove router bit are
available from www.atsdiamondtools.co.uk
or other specialist tooling supplier.
Undermount Sink Fabrication Procedures
• Using a sink jig, firstly router bulk of cut out with a coarse
(10.0mm diameter) router taking two passes (maximum
5mm depth of first cut). Only cut through the quartz
surface material as the larger underside aperture in the
core is a separate process using a conventional twin
fluted router.
• Remove approx. last 2mm of quartz aperture with
polishing router (12.7mm diameter) and finish with
beveling tool in laminate trimmer or diamond sanding
blocks for the optimum finish. (1/4)
• Router larger sink profile cut out on reverse side by
removing PVC balancer and polypropylene core with a
standard twin fluted router and scrape off the fiber glass
reinforcement to the underside of the quartz. The quartz
is now exposed to take the sink flange and support clips.
(2)
• Treat the quartz surface cut out and core material cut out
as two separate jobs. Do not use the diamond router on
the polypropylene core as it could get contaminated with
the heat generated and require cleaning when cool.
• Sink flange should always be adhered to the underside of the
quartz with silicone or PU adhesive
• Screw fix sink clips through pilot hole in PVC backing or use a 2
part epoxy adhesive.
• Use portable vacuum equipment during routering and ensure
that you vacuum away residual quartz dust and debris from the
surface of Max-Top as you proceed. (3)
• Make sure your MDF or plywood jig is sanded to a good standard
as its contours will be mirrored in the sink aperture when cut.
• Use sharp diamond blades. Work clean. Take your time.
Coarse diamond router for cut out
(10mm diameter)
Polishing diamond router for finishing
(12.7mm diameter)
Bevelling tool for final finish (optional)
Undermount Sink Fabrication
Finishing aperture
with polishing router
Scrape off fibre glass webbing from exposed
quartz to take sink flange
)
Vacuum all debris (work clean)
Use sanding blocks for the
optimum final finish
Drainer Grooves
• Cut straight drainer grooves using a jig to a
maximum of 5mm depth. It is better to utilise a
polishing router blade only with one single pass
towards the sink and then reverse the pass for
the best result. Polish grooves using 200 grit
diamond hand polishing sheet (with a little
water) or alternatively silicone carbide sheet.
Take care not to sand surface of quartz. When
routering darker colours, the final finish is
lighter than the face which is normal.
• Tap hole should be cut with a standard 35mm
diamond coated hole saw with a Max-Top
Universal Drill Guide or jig.
• Tools and polishing sheet available from
www.atsdiamondtools.co.uk or from other
specialist supplier
Polishing router bit
Care and maintenance
Max-Top Quartz is resistant to stains,
scratches and cracks and also highly heatresistant. It has high resistance to most
common household chemicals.
Max-Top Quartz is non-porous, so stain and
odour causing bacteria, mold, and mildew
can't penetrate the surface.
Max-Top Quartz is low maintenance and no
sealing, waxing or special polishing is
required compared to granite, timber or
acrylic based solid surface materials.
Do not use Max-Top Quartz outdoors.
25 year manufacturers warranty subject to
fair wear and tear
Cleaning Max-Top
Quartz
Simply clean with warm water and mild
detergent to keep Max-Top Quartz surfaces
looking their best.
To remove adhered material such as food,
gum, nail polish or even dried paint, first
scrape away excess material with a plastic
putty knife and then use a damp cloth to
remove any marks or residual dirt.
Chemicals can damage Max-Top Quartz.
Never clean with products that contain
Trichlorethane, Methylene or Dimetil
Chlorine such as paint removers or strippers.
Do not use abrasive cleaning agents such as
bleach or oven cleaner.
Protect from high
temperatures and
sharp utensils
Max-Top Quartz is both heat resistant and
durable; however, even quartz needs protection
from very high temperatures. Always use a
counter saver or trivet placed between your
Max-Top Quartz surface and the heat source.
Quartz products should not be subjected to
temperatures above 150 degrees Celsius.
Sustained heat from casserole dishes or oil
based cooking utensils could cause the surface
to crack from the sudden temperature change,
especially near the edges. Therefore hot utensils
and pans should never be directly placed on the
surface as a precaution.
Quartz is scratch resistant, however, it is
recommended that surfaces are protected by a
cutting board when using knives.