richlite fabrication guide

Transcription

R I C H L I T E FA B R I C AT I O N G U I D E
CIRQUE DISTRIBUTION
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TABLE OF CONTENTS
FABRICATION GUIDE and OVERVIEW.. . . . . . . . . 4
TROUBLESHOOTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DELIVERY, HANDLING and STORAGE.. . . . . . . . . 5
CANTILEVER GUIDELINES.. . . . . . . . . . . . . . . . . . . . . 27
PLANNING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PROPERTIES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MSDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ROUTING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARRANTY.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DRILLING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IMPORTANT LINKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CNC MACHINING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SEAMING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLIES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SURFACE FINISHING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
APPLIED FINAL FINISHES.. . . . . . . . . . . . . . . . . . . . . . 22
CARE and MAINTENANCE.. . . . . . . . . . . . . . . . . . . . . . 24
RICHLITE
FABRICATION GUIDE
The following document describes how Richlite paper composite is received,
handled, and fabricated. These guidelines should ensure that your experience
with Richlite is informed and positive. Richlite is not like any other material available and by following the instructions below, it is not difficult to fabricate and
the results are tremendously rewarding.
Please note, these are general guidelines and it is recommended that any fabrication techniques be tested by the individual fabricator as each situation may
have differeing parameters that will affect performance. These guidelines do not
imply any warranty of work provided by independent companies and are superseded by the Richlite® material warranty.
FA B R I C AT I O N G U I D E
3
FABRICATION OVERVIEW
Richlite® is a versatile material that can be used in numerous
applications and multiple fabrication settings.
Provided only as a sheet-good with factory surfaces and factory rough
edge cuts, Richlite is a laminate made from paper saturated with a phenolic resin and is used in a number of applications including: wainscoting, flooring, shelving, window sills, industrial parts, countertops and
exterior rainscreens. Its structure behaves and wears like ultra hard
wood and is considered structurally superior to stone and solid surface. Woodworking tools and solid surface tools with sharp carbide bits are
preferred but wet tools will work. Richlite doesn’t melt/burn away like
plastic or burn away like wood. It is not a heat sink like metal and heat
can build up quickly and ruin tooling like metal blades and bits. Be careful with feeds and speeds from hand drilling (push hard and spin slow)
to CNC.
Countertops work best at full thickness at 1/2”, 3/4”, 1”, 1.25”. You can
stack or mitre an edge but generally it is more cost effective and easier
to fabricate with a full thickness countertop. The material is through
body color and seams are visible but should not be felt. It is extremely
important to get the deck seams as level as possible and use plastic
biscuits or splines made from Richlite. You can double stack an edge. Typical solid surface adhesive will NOT work on Richlite.
Richlite can be sanded down but it will alter the initial quality and
look of the brand new product. Sand the edges as much as you please
but sanding the deck or surface should be kept to a minimum and NO
SANDING should be done on any surface exposed to the elements. “Less is more” when it comes to sanding.
The most durable finish we have is a completely unsanded mill finish
material with Richlite Color Enhancer applied. The worst mistake you
can make while fabricating the material is oversanding. The second
worst is not wiping off the color enhancer in a timely fashion..
4
ORDERING, DELIVERY,
HANDLING and STORAGE
DELIVERY
Richlite is drop-shipped from the Richlite factory (Tacoma, WA).
• Richlite material is shipped on heat treated pallets, covered in plywood and/or Cor-X.
• A forklift will most likely be required at the receiving location. Full
pallets are approximately 3,000 Lbs. Single sheets are heavy; 400
pounds for a 1”x 5'x12'. Pallets are banded with metal strapping and require tin snips to open.
• Consider accessibility to site or shop, including hours of operation as
there will be additional charges for Limited Access Deliveries, Lift Gate,
Residential Delivery, Notification/Appointment Required. If not notified
prior to shipping, additional charges will be incurred from the freight
company.
HANDLING
• Although they are impact resistant, when sheets rub across one another they can get “rubs” or dry/slick looking areas. A wipe down with
a clean soft cloth and water will take care of most rubs or dry looking
areas. Grit between the panels is to be avoided at all costs and don’t allow the corners to drag across the surface of the panels below. • Be careful of the factory edges as they are quite sharp.
INSPECTION
Every effort has been made to provide high quality material, free of defects. However, you, the fabricator, must:
• Inspect material immediately upon receipt. • Conduct a final (pre-cutting) inspection prior to fabrication.
• List of what to look for: Color: Color, shade and grain of the panel may vary from samples.
Patina and oxidation will affect product color (lighter colors in particular). See product details document for more details.
Striations: Striations are normal in the product. Striations appear
as mottling running in a grain pattern following the length of the panel..
5
INSPECTION (continued)
Striations (continued): Occasionally, slightly darker straight lines
will appear running the length of the panel. These are normal lines initiated from the paper making process (unfortunately, there is very little
Richlite can do with these lines).
Wrinkles: These will generally appear as a very dark jagged line
running diagonally across the panel. This is not normal and should be
returned as warranty.
Surface Conditions: Most marring or light scratches can easily be
cleaned up with a wet rag. Please contact your distributor if you see
bigger bumps or divots.
Thickness: Tolerance is +/- 4%.
REPLACEMENT
If the material is defective or flawed you can either avoid flaws via part
placement on sheet or order replacement material and initiate a request
for credit. Do not notify the factory. Notify your Richlite distributor via
e-mail and include:
• Photos of the material in question.
• A copy of the invoice for the effected material (PO#, SO#, Invoice#,
Etc.) should be listed on the invoice.
• A written description of the defect.
• Any other pertinent information.
Your distributor will respond with either a return authorization and/or
approval or denial of a credit. Credit memos will typically include the
original cost, plus freight for the replacement material and freight for
the returned material (if applicable). The credit memo will be issued
upon confirmation the warranty material was returned.
IMPORTANT NOTE: Richlite does not supply credits for fabrication
or material handling costs. Pre-fabrication inspection is critical to insure
that defective material is not fabricated.
STORAGE
• Do not store Richlite uncovered. Place a piece of 7mm plastic or the
Cor-x® that came with the shipment on top of the Richlite.
• Store between 40-80 degrees Fahrenheit.
• Do not over stack. Richlite weighs 6.5 lbs per square foot at 1” thick.
• Store flat, do not store on edge.
6
PLANNING
SELECTING THE "A" SIDE
There is no “A” or “B” side to Richlite. Evaluate both sides of the sheet
to determine which side is more desirable to use. Small voids and
bumps may occasionally occur on the surface of the panels. Those that
cannot be avoided will require extra care when sanding.
COLORS
Different colors have different attributes during fabrication. Black is
the most forgiving in all aspects. The dark colors will stack/seam with
a less noticeable line. The pattern, striations and mottling are more
noticeable in the lighter colors and the seam will be more noticeable. Also, keep in mind that the surface color is not the same as the edge.
GRAIN DIRECTION
Richlite has a mottled appearance, which patterns in a striated effect
lengthwise. This feature is most apparent in the lighter tones, but can
be seen in darker colors including black. Consider the effect of grain
direction when planning cuts.
SEAM PLACEMENT
Seams will show and will look similar to those of wood or veneers and
should be incorporated into design layout. For both structural and
aesthetic reasons, seams should be placed at natural positions such as
corners or midpoints. Structurally, the seams may be placed exactly at a
90 degree (perpendicular) corner. Consider the impact of the striations
when determining seam placement.
EDGE DESIGN
Any edge treatment or design can be applied to Richlite. All common
profiles available to fabricators in both wood and stone tooling can be
applied to Richlite countertop edges.
THICKNESS
The minimum recommended thickness for horizontal use is 3/4”. 1/2”
can be used only with proper engineering and fastening to insure material stability. Material thickness less than 3/4” is typically suitable for
vertical use only, such as in back splashes or wainscoting. A double .
7
PLANNING (continued)
THICKNESS (continued)
stacked edge requires a special technique different than solid surface. A
mitered edge will not look exactly the same as solid full thickness material or a stacked edge. The miter joint is also weaker when using 1/2”
Richlite versus solid surface.
STACKED EDGE
There is a residue on the surface of Richlite that doesn’t interfere with
finish but it WILL cause epoxy to fail. When stacking an edge versus
gluing a seam, the surface material is taking epoxy. This surface, the
underside of the deck and the top of the stack edge, need to be sanded
by hand or with an orbital with anything between 80 and 150 grit before
gluing.
CANTILEVERS and SPANS
Richlite is extremely strong, and due to the engineering of the product,
can be cantilevered in many applications. Generally, 3/4” will remain
stable with a 12” overhang, 1” with an 18” overhang, 1 1/2” up to 24”. See
General Guidelines (page 31) for exact information on strength when
designing to maximize span or cantilever.
IMPORTANT NOTE: Richlite only provides general guidelines and specific applications and designs are the responsibility of the architect and
structural engineer.
.
8
CUTTING
ROUGH CUTTING
Rough cutting Richlite is a quick way to process panels that do not require a finished edge. Some examples include exterior paneling, nonvisible fabricated edges, mating assemblies and industrial applications.
Due to the weight of the material, stationary cutting with a circular saw,
panel saw or CNC router is preferred over table saws. While CNC routers are a good tool for certain operations as noted below, rough cutting
and routing by hand is a very efficient way to process Richlite. The factory rough cut edge is to exact stated dimension and not oversized.
• Festool® track saw is the preferred cutting setup.
• Standard circular saws can be used but will often leave saw marks due
to less stable nature and lower rpm motors.
• Single pass cutting can be achieved if the proper blades are used. Appropriate feed speeds are critical in this situation and will be a function
of thickness, and even in some cases color.
FINISH CUTTING
Finish cuts can be made with a high quality circular saw like a Festool®
track saw or worm drive high horsepower unit. Feed speeds and high
rpm’s will ensure a clean cut. Making a pass with the appropriate feed
speed, using a sharp proper blade with high rpm's can provide a cut
that need to be minimally sanded to achieve a quality edge treatment. • An even rate of speed will prevent burn marks which if present, can be
routed off with some difficulty.
• For mated seams, routing or finish cutting will result in a tighter seam.
• Sliding table saw speeds suggested between 3,450 RPMs and 4,000
RPMs.
• Jig saws and hole saws are not recommended as a tool for Richlite as
the blades tend to wear out very quickly.
9
CUTTING (continued)
SUGGESTED EQUIPMENT
Saws
• Festool® model TS 75 or TS 55
• Worm drive circular saw
• Sliding table saw
• Panel saw
Saw Blades • carbide, 60 - 80 tooth, low to negative degree hook.
• For curves, jigsaw cobalt steel blades
.
10
ROUTING
Routing is recommended as saw marks can be very difficult to remove
with a palm sander and a proper routing setup can often provide a high
quality finish that minimizes sanding and finish work. Rough cuts to
be routed should be made as close as possible to finished dimensions,
leaving only enough material to make a final pass or to finish with a
router or sander.
FINISH EDGE ROUTING
After cutting with a saw, a finished edge can be cut with a router.
• 1/32” of material or less for finish pass.
• Large diameter bits and larger horsepower routers will provide a
smoother finish cut.
• Smooth and consistent feed speeds without hesitation will avoid burning the edge.
PLUNGE ROUTING
For inside shapes and large holes, plunge routing is the best solution. • Large shapes and interior cutouts can be cut using templates.
• Use a stepped cut and do not plunge all the way through the material.
A good rule of thumb is to use no more than the diameter of the bit as
your depth of cut per pass. • When cutting out a small hole make multiple passes and use a jig to
ensure a safe operation.
Routing Drainboards: Do not rout any area deeper than what would
leave 1/2” minimum thickness.
PROFILE ROUTING
Any standard wood or stone decorative, round-over, or chamfer router
bit profile can be cut into Richlite. Use a sharp carbide bit and an even
rate of speed to prevent burning. Multiple passes may be required for
removing large amounts of material and deep profile shapes. Sand the
edge detail with a random orbital sander, by hand or with sponge sanding blocks. You can not oversand the edge like you can the surface and
finishing the edge doesn’t take the same caution as the surface.
11
PROFILE ROUTING (continued)
You need to be careful sanding a full bullnose or generous roundover.
Don’t allow the orbital to walk up onto the deck or cause a scalloped
edge between the end of the deck and the start of the round edge.
Due to the way Richlite is manufactured, sharp square edges can be
achieved but are prone to impact damage. At minimum, a 1/16” chamfer
or radius is suggested.
SUGGESTED EQUIPMENT
Routers
• 2 - 3 1/4 Horsepower, Variable speed
• Solid carbide straight flute bits
• Standard carbide profile bits
.
12
DRILLING
THROUGH HOLE DRILLING
Through-hole drilling is very similar to drilling into wood or MDF. Speed
rate should be set to avoid burning or polishing the inside of the hole.
Holes drilled completely through Richlite® should consider tolerances
of overall parts being fabricated. Part assemblies that are casework
construction, attached to metal or wood, or exterior applications such
as cladding should have oversized holes to accommodate the expansion
and contraction of the materials. Richlite® is very stable and strong and
the other materials can be damaged if not considered for movement.
PILOT HOLE WITH NO TAPPING
Drill a pilot hole that is slightly smaller than the screw thread. Because
of its density, Richlite® is nearly impossible to screw into without a
pilot hole. The pilot hole should be slightly longer than the screw. You
may not be able to penetrate the hole further after your screw reaches
the end of the pilot hole. Richlite® is VERY dense and will snap screws
if you are not careful.
PILOT HOLE FOR TAPPING
Richlite is able to be drilled and tapped and has very good screw holding ability with this process. Plastic expansion inserts are not recommended as they tend to be engineered for soft compressible material
and will not grip properly in Richlite®. Standard tap drill specifications
for metals can be used on Richlite®.
EQUIPMENT
• For small holes use titanium or cobalt bits if possible
• Step drilling up from smaller sizes to larger will insure accurate hole
dimensions and location accuracy.
• Hole saws are not recommended for use on Richlite® due to its density and heat retention. However, for larger holes a bi-metal hole saw or
carbide-tipped hole saw can be used but may tend to wear out quickly
due to heat buildup. Routing is preferable to hole saws for thicker material and larger holes.
13
CNC MACHINING
CNC machining is an excellent way to fabricate curves and cut undermounted sink cutouts. Richlite® is a very dense product so it is very
important to have a specific router bit for cutting it to protect the machine, the router bit and the safety of the operator. Feed rates with CNC
routers and machining centers vary depending on the tool. Please consult your machine tool sales person for more information regarding the
specific application of cutting cellulose sheet phenolic resin panels.
CUTTING
• To rout any Richlite material thicker than 1/4", use a step cut process
in increments of 1/4" to 3/8" at a time.
• Consider leaving a small “onion skin” (about 0.02” thick) at the bottom to help hold pieces in place.
• Remove dust from groove after each pass. • Rough cut to 1/64” over-sized from final dimensions. Final pass to cut
the remaining 1/64” at full depth in a single cut to clean and polish the
edge and reduce the amount of finish sanding needed.
• Do not come straight down at the starting point, always lead in and
out of cuts at a 45 degree angle with a lead in of twice the material
thickness.
• If the material is smaller than what the machine can safely hold down,
use an onion skin technique and leave 1/16" short from the table so you
can route the piece off with a bearing router. • When cutting out holes, use a pocketing program to avoid projectiles.
• Due to slight inconsistencies in panel thickness edge profiles are best
put on with a hand router.
• Spraying bits with Bostik DRICOTE will lengthen tool life consideraby. FA B R I C AT I O N G U I D E
14
FEED and SPEED RECOMMENDATIONS
Materials 3/4" and thicker
Rotation speed 16,000RPM, working speed 4400mm/min (175ipm),
lowering speed 8000mm/min (315ipm). Recommended to use a down
cut spiral for rough cutting and finish cut with a 1/2" compression 2
flute bit. Cutter lengths should be 1/4" longer than the material thickness.
Materials thinner than 3/4"
Rotation speed 18,000RPM, working speed 5000mm/min
(200ipm), lowering speed 2000mm/min (75ipm). Recommended to use
a 3/8" down cut spiral for rough cutting and finish cut with a 3/8" diameter straight flute bit. Cutter lengths should be 1/4" longer than the
material thickness.
Drilling
Rotation 4000RPM, lowering speed for 5mm bit is 1500mm/min
(60ipm), slower for larger bits. FA B R I C AT I O N G U I D E
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SEAMING
Seams should be level, flat and very tight revealing a hairline mark that
can be seen but not felt on the surface. Structurally, seams should run
the entire depth of a counter to be considered sound. Because Richlite
is pressed and is not cast or extruded, the thicknesses may vary from
sheet to sheet or even within a sheet. Therefore, the surface on either
side of a seam must always be indexed from the top and the difference
sanded on the underside. Whenever using epoxy, make sure that the
joint gluing surfaces are roughed-up, 100 grit or less, for better glue
adhesion.
SEAMING TECHNIQUES
Biscuits with epoxy
• Do not use traditional wood biscuits as they will not expand nor
provide a mechanical advantage. Place Lamello K20 biscuits every 6”
starting with the first biscuit 3” from the edge. It is important to do a
dry fit because if it is not a tight fit during the dry fit it will not be a
tight fit once epoxy is used. Cut slots in the center of the material, indexing from the top. Biscuits are engineered with a directional “tooth”
that will be difficult to remove in the direction opposite the tooth. To
remove the biscuit after dry fit, grab the point end of the biscuit and
pull in an arc away from the opposite end.
Splines with epoxy
• An excellent choice for strength. Cut so that when installed in
the slot, the grain (paper layers) in the spline follows the same direction
as the grain in the sheet. Dry-fit all seams prior to applying any epoxy.
Tight Joint Fastener or “Dog Bones” with or without epoxy
• Use in non-structural situations only. Ideal for field installations
by out-of-house installers or subcontractors. With CNC tooling the fit
may be good enough in some instances to not use any filler or epoxy.
Epoxy Only
• Make sure that the joint gluing surfaces are roughed-up, 100 grit
or less, for better glue adhesion. Do not over-tighten clamps to keep
enough glue in the seam. Vacuum clamp fixtures are ideal to hold the
surface seam flat due to the lack of a spline or biscuit.
16
SEAMING (continued)
EQUIPMENT
• Biscuit Joiner - Minimum power- 6.5 amps. Don’t try to plunge all the
way in on the first push. Cut 20% of the way in and let the material and
blade cool for a second or two with the machine running; repeat. Hold
the cutter onto the material TIGHTLY !
• Use plastic biscuits only like Lamello K20. Do not use standard #20
biscuits as lack of water in epoxy does not expand biscuit.
• 3/4” Richlite splines
• Mechanical joint fasteners (Knape & Vogt “Tite Joint Fastener”, “Dog
Bones”)
17
BUILT UP ASSEMBLIES
Richlite is currently being specified in applications where stack laminations are required. Examples include mold and die units, part assemblies, extra thick design elements, and countertop or casework built up
edges.
• It is critical for this application to have the mating surfaces of the material abraded before gluing. This applies to both stack laminations as
well as mitered or butt-joined fabrications. If the surface is not abraded
sufficiently with 100 grit sandpaper prior to glue up, there will most
likely be failure in the joint at some point as the mill finish and machine
cut edge are both highly resistant to proper adhesion regardless of adhesive used due to the low porosity of the material.
• The built up edge needs to be at least 1-1/2” deep to insure enough
surface area for the mating parts to adhere and not create an imbalance
on the front edge of the material. Any edge less than this will be prone
to movement and instability.
• Mitered edges are acceptable and require the same abrasion technique on all mating surfaces. Any mitered should be backed by a support block of Richlite.
• The edge of Richlite is not the same as the face of the panel and a
built up / stacked edge will not look the same as a mitered edge.
• Built-up or mitered material must be 1/2” thick or more. There are no
maximum build-up dimensions.
• Two part water resistant epoxies formulated for thermoset resins or
phenolics are recommended for this application. Most other countertop
adhesives WILL NOT be appropriate for use with Richlite.
• Screw clamps must be used to set the built-up edge to ensure a good
bond with structural epoxies. SPRING CLAMPS WILL NOT WORK.
EQUIPMENT
Two-Part Epoxies
• Industrial Epoxy formulated for Thermoset Resin or Phenolic Resin
• Suggested for Best Performance: System Three T-88, 12-24 hour cure
• 5 Minute General Purpose Epoxy: Devcon DEV-20845
• Loctite E-120HP, Hysol
18
SURFACE FINISHING
MATERIAL SURFACE OPTIONS
The most durable finish we have is a completely unsanded mill finish
with Richlite Color Enhancer applied. However, there are other options
for how the surface of the product can be finished. OPTION 1: MILL SURFACE
Richlite ® is shipped from the factory with a Mill Surface. This finish has
a slight texture that is created in the manufacturing process and acts
like a light skin over the faces of the panel. No finish is applied as a surface treatment. For exterior applications, a dry factory finish is recommended. Sanded surfaces, when placed in an exterior environment, will
oxidize more rapidly and appear chalky and dry.
Pros: more durable, no additional work for surface preparation or
finishing; scratching and wear are less apparent over time.
Cons: material that has been handled may have slight abrasions,
not repairable or restorable to exact finish from factory.
Example applications: industrial parts and sub-assemblies, exterior
cladding, interior wall panels, benches and seating, high wear areas, assemblies, furniture and industrial work surfaces.
OPTION 2: LEATHERED
Richlite ® Leathered requires the addition of any of the finishes listed in
the Final Finishes section. The final surface remains more durable as
the skin from pressing has not been removed or altered.
Pros: high durability, only additional work is application of final
finish, scratching and wear are less apparent over time.
Cons: material that has been handled may have slight abrasions,
not repairable or restorable to exact finish from factory.
Example applications: interior wall panels, seating, high wear area
assemblies and furniture, work surfaces and countertops.
When used with Osmo® finish, very good for high water use areas. Enhancer is more appropriate for dry applications. See applied finish application for detailed instructions. FA B R I C AT I O N G U I D E
19
LEATHERED TECHNIQUE
1. Sand with Scotch-Brite™ Maroon pad on a random orbital sander in 12” circular motion to mildly abrade the mill finish and to remove
marring or surface imperfections.
2. Leave any scratches alone as most will disappear with finish and
aggressive machining will make a more polished spot in your final overall surface.
3. Clean with soap and water.
4. Apply finish of choice (see next section for options).
OPTION 3: HONED
Any of the finishes in the Applied Finishes section can be applied to a
Richlite Honed finish which will have light 150 grit sandpaper swirls evident. The Honed finish is a more “satin” finish that is very nice for millwork and countertop applications. It is not recommended for exterior
applications and does require an applied finish to be put on after sanding to achieve proper performance. If sanded with no applied finish,
the surface will start to appear “chalky” and will also pick up oils from
fingerprints, food, etc. While Richlite can be polished to a high finish,
this is not recommended as it will show scratches and wear very quickly
from use.
Pros: more polished and satin finished look and feel, good abrasion and wear resistance, paper patterns and natural look more pronounced, can be refinished and surface repairs are easy. Cons: slightly less durable surface finish prone to abrasions and
hard material wear. Example applications: interior wall panels, seating, high wear area
assemblies and furniture, work surfaces and countertops.
When used with Osmo® finish, very good for high water use areas. Enhancer is more appropriate for dry applications. See applied finish application for detailed instructions below.
20
HONED TECHNIQUE
It is not recommended to sand on job site due to the high amount
of dust generated when sanding Richlite. As mentioned before, an unsanded surface wears the best, but if interested in doing the full sand
and seal technique, use a random orbital sander with 150 grit sandpaper, applying light and even pressure. The worst mistake you can
make in fabricating the material is oversanding. Remember, Richlite is
made with layers of paper and if you sand too aggressively you will create something to the effect of a “topography” map by burning through
a layer of paper and certainly a more burnished area that will have a different sheen.
1. Using a random orbital sander with 150 grit sandpaper, sand the
length of the sheet moving lightly and evenly. There is no need to apply
pressure, just enough to keep the sander on the surface.
2. Turn 90 degrees and sand perpendicular to the initial pass.
3. Wipe sanding grit from the panel and follow with Scotch-Brite™
Maroon pad in 12” circular motions to even out linear sanding pattern. The Scotch-Brite is not nearly as aggressive as sandpaper and can be
used more liberally.
4. Clean with soap and water, or wipe down with a solvent.
5. Let dry and apply finish (see next section for options).
EQUIPMENT
• 150 Grit Sanding Discs. This is very important as higher or lower grit
will not provide the finish to match the manufacturer provided samples
in the specifier boxes.
• Maroon Dynabrade® or Scotch-Brite™ Maroon Pad Sanders
• Random Orbit Sander 5”
• Pneumatic sanders must be turned down or feathered to reduce power.
• Belt sanders are not recommended! Heat retention will burn Richlite
edge surfaces. FA B R I C AT I O N G U I D E
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APPLIED FINAL FINISHES
APPLIED FINAL FINISH OPTIONS
RICHLITE COLOR ENHANCER
Richlite Color Enhancer is a food safe gel polyurethane finish. It is recommended
for both residential and commercial projects and should be applied in a shop
environment. The Enhancer will mechanically wear off in a matter of months or
years depending on use and it can be reapplied in the field. When selecting to
finish the surface with Richlite Color Enhancer, either sand the surface as detailed above or apply to an unsanded surface. Although not recommended, if
the surface is being finished in the field, it is important to mask adjacent edges
and walls to protect them from the finish. The Enhancer flashes VERY quickly. It
flashes even faster: in the hot sun; on hot material; under warm or circulating air
or under blowing AC. It will create a HORRIBLE mess if too much is left on the
surface of the material for more than a few moments. Also it can’t be feathered
too well or pushed into dry areas which may result in lap marks and streaks similar to an incorrectly applied dye based wood stain.
APPLICATION TECHNIQUE
1. Using clean white rags, apply the finish liberally across the entire surface,
including the edges. Work quickly to avoid streaking.
2. Follow with clean dry rags, wiping in a large circular motion to remove
excess finish. Move quickly with lots of clean rags and when the rag becomes
saturated, use a fresh rag to avoid streaking. If streaks are visible, let the surface
dry and Scotch-Brite™ again to attain an even surface.
3. Buff to an even, matte finish.
4. Apply one to three coats, allowing 20 minutes between coats. Sanding
is not required between coats. The second coat is more forgiving.
5. Clean with soap and water after dry.
22
OTHER FINISHES (continued)
OSMO POLY-X
The easiest finish to apply is OSMO Polyx. It is an acceptable substitute
and recommended for many DIY projects. PolyX, PolyX Professional, or
Top Oil from Osmo ® is a great choice for all around applications. The
finish is a hard wax-oil combination that is highly refined so that it does
not separate. It performs like an air cured wood finish and does not stay
waxy or soft like most oil-wax products. It also acts as a better repellent
to water marks, stains, etc. This is the preferred finish for residential use
as it has low VOCs and can be field applied. It is compatible with the
Richlite enhancer and can be used to spot repair on top of both enhancer and itself. The cure times are longer than a solvent-based product
but will set up to the hardness of such finishes at full cure.
APPLICATION TECHNIQUE
DO NOT USE THE INSTRUCTIONS ON THE OSMO ® can as these instructions are for the floor application of the product and not for Richlite.
1. First sand or abrade the surface as detailed above. Apply the
finish as desired, including the edges. The Osmo has a much longer dry
time so you can work at a normal speed compared to the Richlite Enhancer product.
2. Follow with clean dry rags, wiping in a large circular motion to
remove excess finish.
3. Buff to an even, matte finish. When the rag becomes saturated,
use a fresh rag to avoid streaking.
Osmo ® will blend into previous coats and can be used as spot repair
for both itself and Richlite Enhancer in the field. Apply one coat, allowing 12-48 hours for curing. It can be put into use sooner but it is best to
leave it as long as possible.
Full cure takes 48-72 hours. A second coat can be applied for a slightly
higher sheen but is not required.
TEAK OIL / MINERAL OIL
Many finishes have been used successfully by fabricators and installers. Richlite
can be painted or finished with most wood or stone finishes. Teak oil, urethanes,
and stone finish products have been used by customers with success in the field.
Mineral oil can be used as a “finish” but requires frequent maintenance. Because
Richlite is non-porous the oil does not penetrate the surface and water marks
may appear from glasses and tableware. Paper products left on a desk surface
will pull oil from the surface and leave dry areas. If you are using soap and water
to clean your countertops, be aware the soap will expedite the removal of oil
and the countertops will start to appear dry and chalky.
23
CARE and MAINTENANCE
INTERIOR GENERAL PRECAUTIONS
Paper composite countertops are pretty low maintenance. Nonporous,
they’re stain resistant and easy to clean. However, it is VERY IMPORTANT to note the counter will develop a patina over time. This is especially true around the sink where soap is used.
• For day-to-day cleaning, use a damp cloth or sponge to wipe the surface. Skip the soap—alkaline soap, such as regular dish soap will gradually dull the surface.
• Avoid using bleach products or abrasive powdered cleaners. It is good
to avoid using the abrasive side of sponges as this may also scratch the
surface of a Richlite countertop.
• Richlite is stain resistant to most common substances on interior applications. As with most any material however, there is a potential for
some staining. With stubborn stains, try a nonabrasive household cleaner (avoid using bleach products). A unique stain remover is plain yogurt,
applied only on the stain area. Let sit over night for 3-4 applications,
wiping away in the mornings, to lighten stains.
• In residential applications, some raw meat juice (such as liver), highalkaline fruit or vegetables (such as papaya and red beets), red wine
and high-alkaline soaps (such as automatic dishwasher powder and
oven cleaners) may cause staining when left in contact for a prolonged
time. • The lighter colors in the Richlite color range will show stains more
than the darker colors. Additionally, grout (high alkaline) will lighten
darker-colored Richlite counters and darken the lighter tones.
• Paper composite counters are only heat resistant to 350 degrees: Hot
pads or trivets are a must to avoid burning the surface. That said, surface nicks, scratches, and scorch marks can be sanded out of the top
with an abrasive pad and then finished with food-safe mineral oil.
24
CARE and MAINTENANCE (continued)
Mill Surface Maintenance
• Often requires very little maintenance due to textured surface.
• Warm water and sponge for daily cleaning. Mild soap can be used if
needed.
• Cleaning agents may affect the surface which is not protected by an
applied finish.
• Repairs – very difficult to repair as the textured surface will show any
changes and cannot be reproduced.
Leathered Surface Maintenance
needed. • Howard Naturals Wood Cleaner and Polish or mineral oil can be used
to renew the look and feel of the finish.
• Repairs – OSMO ® PolyX is a very good spot repair product that can be
applied by the end user. Wipe on a small amount and buff into adjacent
areas. Allow to dry 24-48 hours before full use. It is compatible with
Richlite enhancer and blends very well to a similar finish.
• Do not sand the surface as it will disturb the Factory Surface which
cannot be reproduced. Minimal Scotch-Brite™ work can be done prior to
applied finishes.
Honed Surface Maintenance
needed. • Howard Naturals Wood Cleaner and Polish or mineral oil can be used
to renew the look and feel of the finish.
EXTERIOR GENERAL PRECAUTIONS
• For exterior applications, flashing and proximity to metal or water may
require additional attention or maintenance. • Graffiti/Spray Paint: paint and graffiti removal products can be used.
Pressure Washing can be used for extreme situations but may alter the
factory surface slightly. A more matte finish will be left by this process.
Over time the variation will blend with the natural oxidation process.
• Applied finishes or sealers are not recommended as they will tend to
flake and deteriorate from UV exposure.
• Normal wear and tear due to elements will change the surface over
time and oxidize in a similar way to cedar siding.
25
TROUBLESHOOTING
FIELD VERSUS SHOP WORK
Richlite can be a dusty fabrication process and fabricating or finishing
in the field is not recommended. Both the dust created and the Richlite
Color Enhancer in a home can create air quality issues that can pose a
problem for end-users.
OVERSANDING
Richlite is made with cellulose fibers (layers of paper). If you sand too
aggressively in one area for too long, you will create something to the
effect of a “topography” map by burning through a layer of paper. It is
most noticeable in darker colors. Be cautious with seams and uneven
surface areas (bumps or divots). After applying finish, these may even
out, but the lines will never disappear. The contouring is especially noticeable in the Slate Black product and is less so in the Black Diamond.
REPAIR
• Use router dust mixed with epoxy in thick paste form to do small spot
repairs. Depth of repair may need to be made deeper for repair to take.
• Use melamine or laminate patch for very small spot repairs.
• Sealing will require the use of blue tape on seams to ensure that overflow of adhesive does not compromise the surface finish.
• Refinishing should be advised by the fabricator who installed the
counter. In most cases, it is preferable if the trained installer refinishes
the surface.
• Light scratch marks and burn marks can be refinished using a ScotchBrite™ Maroon pad on a random orbital sander.
• It is important to note, the refinished area will noticeably lighten compared to the surrounding surface area. Richlite surfaces are made of
paper which, like wood, patinas – or darkens – over time, especially in
the lighter colors other than Black. The area will eventually patina and
match the remainder of the counter surrounding it. In order to avoid
affecting one spot, a full sanding and refinishing the entire counter is
required, but this is an intensive and not an inexpensive process versus
spot treatment.
26
CANTILEVER and SPAN
GENERAL GUIDELINES
CANTILEVER SPAN
l=length
(overhang)
d=thickness
F=Force#
y = max
deflection
b=12"
b=18"
b=breadth (width of countertop)
b=25"
b=30"
b=36"
b=42"
b=48"
b=60"
l=12"
d=.75"
F=100 lbs
y=
.070"
.047"
.033"
.028"
.023"
.020"
.017"
.014"
l=18"
l=18"
l=18"
l=18"
d=.75"
d=1.0"
d=1.25"
d=1.5"
F=150 lbs
F=150 lbs
F=150 lbs
F=150 lbs
y=
y=
y=
y=
.356"
.150"
.076"
.044"
.244"
.100"
.050"
.029"
.171"
.072"
.037"
.021"
.142"
.060"
.030"
.018"
.118"
.050"
.025"
.015"
.101"
.043"
.022"
.013"
.089"
.037"
.019"
.011"
.071"
.030"
.015"
.009"
l=24"
l=24"
l=24"
d=1.0"
d=1.25"
d=1.5"
F=150 lbs
F=150 lbs
F=150 lbs
y=
y=
y=
.356"
.181"
.105"
.244"
.120"
.070"
.171"
.087"
.050"
.142"
.072"
.042"
.118"
.060"
.035"
.101"
.051"
.030"
.089"
.045"
.026"
.071"
.036"
.021"
SIMPLE SPAN
l=length
(the span)
d=thickness
F=Force#
y = max
deflection
b=12"
b=18"
b=breadth (width of countertop)
b=25"
b=30"
b=36"
b=42"
b=48"
b=60"
l=24"
d=.75"
F=100 lbs
y=
.035"
.023"
.017"
.014"
.012"
.010"
.008"
.007"
l=36"
l=36"
d=1.0"
d=1.25"
F=150 lbs
F=150 lbs
y=
y=
.075"
.038"
.050"
.025"
.036"
.018"
.030"
.015"
.025"
.012"
.021"
.010"
.018"
.009"
.015"
.007"
l=48"
l=48"
d=1.5"
d=1.75"
F=200 lbs
F=200 lbs
y=
y=
.070"
.044"
.046"
.029"
.033"
.021"
.028"
.017"
.023"
.014"
.020"
.012"
.017"
.011"
.014"
.008"
Most Acceptable
Acceptable
Not Acceptable
Least Acceptable
IMPORTANT NOTE: Calculating spans and cantilever's incorporate numerous variables;
including thickness of material, the length of the overhang, the breadth (or width of the
countertop), and of course the abount of weight it needs to support. Because all these different
variables and the fact that different areas of the country have different code regulations, it is
important that the specifier appropriately calculate the specifications based off Richlite properties
defined in the properties section.
27
21
RICHLITE ® PROPERTIES
Properties of Richlite‚ Natural Fiber Composite
Electrical Properties
Dielectric Strength (Volts/mil)………………………………………………………………………..…...150
Dielectric Constant…………………………………………………………………………………….….9.24
Disipation Facto…………………………………………………………………………………….….….0.29
Thermal Properties
Coeff. Of Thermal Expansion In X Dir (min/in.∞F)…………………………………………………….….5.2
Coeff of Thermal Expansion In Y Dir (min/in.∞F)………………………………………………………..12.8
Coeff of Thermal Expansion In Z Dir (min/in.∞F)…………………………………………………..45.9/73.5”
Thermal Conductivity (Cal cm/cm2 sec ∞C)………………………………………………………….0.00051
Tensile Strength
X Direction(psi)………………………………………………………………………………………..19,200
Y Direction (psi)……………………………………………………………………………………….13,100
Compressive Strength
X Direction (psi)……………………………………………………………………………………….18,400
Strain @ Failure………………………………………………………………………………………...7.09%
Y Direction (psi)……………………………………………………………………………………….15,900
Strain @ Failure………………………………………………………………………………………..7.15%
Z Direction (psi)……………………………………………………………………………………….30,000
Strain @ Failure………………………………………………………………………………………...ª20%
Flexural Strength (Face In Tension)
X Direction (psi)……………………………………………………………………………………….22,000
Y Direction (psi)……………………………………………………………………………………….17,300
Flexural Strength (Edge In Tension)
X Direction (psi)……………………………………………………………………………………….20,400
Y Direction (psi)……………………………………………………………………………………….16,100
Izod Impact (Face Impact)
X Direction (ft. lb. Per Inch of width)……………………………………………………………………2.48
Y Direction (ft. lb. Per Inch of width)……………………………………………………………………1.46
Izod Impact (Edge Impact)
X Direction (ft. lb. Per Inch of width)……………………………………………………………………0.68
Y Direction (ft. lb. Per Inch of width)……………………………………………………………………0.62
Abrasion Resistance – Taber Abraser (CS-17) (1/4x”x4”x4”)
Weight Loss per 1000 revs…………………………………………………………………………..0.0112%
Wear per 1000 revs (Inches)…………………………………………………………………………0.00011
Coefficient of Friction (Unpolished)……………………………………………………………………...0.2
Burning Rate………………………………………………………………………………………………....Very Slow
Aging………………………………………………………………….Improves Mechanical and Electrical Properties
Sunlight………………………………………………………………………………………………..Darkens Surface
Clarity…………………………………………………………………………………………………………..Opaque
Weak Acids…………………………………………………………………………None to slight depending on Acid
Strong Acids…………………………………………………………………..None to slight for reducing and organic
Decomposed by oxidizing acids
Weak Alkali…………………………………………………………………Slight to marked depending on alkalinity
Strong Alkali………………………………………………………………………………………………Decomposes
Organic Solvents………………………………………………………………………………………………….None
Metal Inserts……………………………………………………………………………………………………….Inert
“The two values for C.O.L.T.E. represent coefficients below and above glass transition temperature (130∞F)
respectively.
28
MATERIAL SAFETY DATA SHEET
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 
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

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


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















































 


29
Richlite® Surface material
Lifetime Limited Warranty for
Interior Residential Use
Richlite Company
624 E. 15th St.
Tacoma, WA 98421
888 383 5533
www.richlite.com
Richlite Company warrants to the owner of the original installation that its Richlite®
Surface material will be free from material defects for a lifetime. This warranty applies
only to the original owner and is not transferable.
The obligation of Richlite Company and its distributors is limited, at their option, to
repair or replace material found to be defective and excludes shipping charges and
costs of removal and reinstallation. This is a product only warranty, not a fabrication
and/or installation warranty.
Richlite Company makes no express or implied warranty, including the fitness for a
particular purpose even if that purpose is known to Richlite Company. It excludes implied warranty of merchantability. Richlite Company shall assume no risk or liability for
results obtained by the use of products covered by this warranty, whether used singly
or in combination with other materials. This warranty does not cover any damage
to Richlite® surfaces caused by improperly installed, used or maintained appliances
which are either built into Richlite® or placed or stored on Richlite® surfaces.
Laws and building safety codes governing the design, engineering and construction
of installations vary widely. Richlite Company assumes no responsibility or obligations
with respect to the selection of product for the installation or the design, engineering
and construction of the installation. Architects, engineers, and designers alike need to
review technical specifications of Richlite® surfaces to determine if Richlite® surfaces
suit the intended purpose.
This warranty does not cover any conditions or damages resulting from accidents,
alterations, misuse, abuse, acts of God, excessive humidity, excessive heat and temperature, fading, patina, or discoloration over time. Richlite® surfaces are a papercomposite material and will patina over time. “Patina” is a natural occurrence in the
product and Richlite Company makes no express or implied warranty covering the
extent of the patina in the Richlite® surface. This warranty also does not cover any
condition or damage resulting from removal of the product or reinstallation in the
same or different application.
This warranty does not apply to conditions caused by normal wear and tear upon the
product.
To obtain warranty service, contact the dealer from whom you purchased the product.
Your dealer will work with their regional distributor and Richlite Company to promptly repair or replace any defective pieces. Warranty claims must be accompanied by
proof of purchase, as well as details regarding the nature of the problem, location of
the product, etc.
This warranty is exclusive and in lieu of all other obligations, liabilities or warranties.
In no event shall Richlite Company or its distributors be liable or responsible for
incidental or consequential damages or for any other direct or indirect damage,
loss, cost, expense or fee. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so this exclusion or limitation may not apply to
you. This warranty gives you specific legal rights, and you may also have other rights
that vary from state to state.
30
20 Year Limited Warranty for
Interior Commercial Use
Richlite Company
624 E. 15th St.
Tacoma, WA 98421
888 383 5533
www.richlite.com
Surface material will be free from material defects for 20 years. This warranty applies
product.
the product, etc.
31
10 Year Limited Warranty for
Exterior Residential and Commercial Use
Richlite Company
624 E. 15th St.
Tacoma, WA 98421
888 383 5533
www.richlite.com
Surface material will be free from material defects for 10 years. This warranty applies
product.
the product, etc.
32
IMPORTANT LINKS
Scotch-Brite Pads
http://www.shop3m.com/scotch-brite-hookit-production-clean-and-finish-disc-5-in-x-nh-a-vfn.html
Fasteners
https://www.fastenal.com/products?term=thread+rolling+screws&r=~|sat
tr03:^%22Indented%20Hex%20Washer%22$|~%20~|sattr04:^%22Hex%20
-%20Unslotted%22$|~
Osmo
http://www.osmona.com/interior/Original_polyx.shtml
System Three Epoxy
http://www.systemthree.com/store/pc/T-88-c27.htm
Howard Wood Cleaner
http://www.howardproducts.com/prod-wood-cleaner-polish.php
33

richlite fabrication guide

Transcription

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