Max-Top Quartz Installation Kit
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 • • • • • • • • • • • • 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.